A WPC wireless charging module whole machine assembly production line

Abstract

The present application relates to the technical field of assembly production line, and more particularly to a WPC wireless charging module whole machine assembly production line, comprising a circulating conveying device and a fan lock device, a PCBA assembly station, a cover assembly device, a filter plate installation hot riveting device, a product turnover device and a base lock device arranged in sequence along the product conveying direction; the circulating conveying device realizes the circulating conveying of the product carrier through the assembly conveying line, the carrier backflow line and the carrier lifting mechanism, and the product carrier is provided with an RFID code body and is associated with the product identification information. The present application can continuously complete multiple assembly processes of the WPC wireless charging module on the same product carrier, reduce repeated handling and re-chucking, and realize the association and tracing of assembly information, thereby improving the continuity, automation degree and assembly quality of the whole machine assembly.

Description

Technical Field

[0001] This invention relates to the technical field of assembly production lines, and more particularly to a complete assembly production line for WPC wireless charging modules. Background Technology

[0002] A wireless charging module (WPC) is a functional module used to achieve wireless power transmission. It typically integrates components such as coil assemblies, PCBA boards, fan assemblies, and filter boards, which are supported, positioned, and encapsulated by a base and a top cover. The assembly process of a WPC wireless charging module involves multiple steps, including loading the base and fan assemblies, fastening the fan assembly, assembling the PCBA assembly, assembling and pressing the top cover, installing and hot-riveting the filter board, flipping the product, and fastening the base screws. These assembly steps are closely interconnected.

[0003] Currently, the assembly of existing WPC wireless charging modules mostly relies on manual division of labor or individual, separate equipment. Material handling between processes is manual, leading to low assembly efficiency. Furthermore, the lack of a unified transport system between these individual machines occupies significant production space and hinders continuous, efficient automated assembly line operations. In addition, the existing assembly process lacks mechanisms for linking and tracing information throughout the entire assembly process. Material and processing data for each process are independent and cannot be linked to the product's own flow information. When product quality abnormalities occur, it is difficult to quickly pinpoint the problematic workstation and the source of materials, severely restricting the improvement of the production quality management system.

[0004] Therefore, there is an urgent need for a complete assembly line for WPC wireless charging modules to realize the continuous conveying and assembly of WPC wireless charging modules through multiple processes, and to achieve traceability of production information while ensuring continuous and efficient assembly, thereby improving the continuity, automation and assembly quality of the complete assembly. Summary of the Invention

[0005] To address the problems mentioned above, this invention provides a WPC wireless charging module assembly line that enables continuous multi-process conveying and assembly of WPC wireless charging modules, and allows for traceability of production information, thereby effectively improving the continuity and quality of the assembly process.

[0006] The solution adopted by this invention to solve its technical problem is: a WPC wireless charging module assembly line, comprising: The circulating conveying device includes an assembly conveyor line and a carrier return line arranged at intervals. A product carrier for carrying WPC wireless charging modules is movably arranged on the assembly conveyor line. Carrier lifting mechanisms are connected to both ends of the assembly conveyor line and both ends of the carrier return line to transfer the product carrier between the assembly conveyor line and the carrier return line. A fan locking device is provided on one side of the assembly conveyor line. The fan locking device includes a first three-axis motion mechanism mounted above the assembly conveyor line and a first locking mechanism installed on the moving end of the first three-axis motion mechanism. The locking end of the first locking mechanism corresponds to the fan locking position on the product carrier. The PCBA assembly station is located downstream of the fan locking device along the product conveying direction and is used to assemble PCBA boards. The top cover assembly device is located downstream of the PCBA assembly station. The top cover assembly device includes a top cover feeding mechanism located on one side of the assembly conveyor line, a clamping mechanism located above the assembly conveyor line, and a first handling robot located between the top cover feeding mechanism and the assembly conveyor line. The end of the first handling robot is equipped with a clamping component for picking up and handling the top cover. The clamping mechanism performs downward clamping after the first handling robot places the top cover on the product carrier. A filter plate mounting hot riveting device is located downstream of the upper cover assembly device. It includes a filter plate feeding mechanism located on one side of the assembly conveyor line, a second handling robot for acquiring filter plates located between the filter plate feeding mechanism and the assembly conveyor line, a hot riveting mechanism located above the assembly conveyor line, and a riveting point detection mechanism located behind the hot riveting mechanism along the product conveying direction. The hot riveting mechanism includes a hot riveting drive component arranged vertically, a hot riveting mold detachably connected to the output end of the hot riveting drive component, and a pressure sensor located between the hot riveting drive component and the hot riveting mold. The hot riveting mold is located above the product carrier. The riveting point detection mechanism includes a line scan detection component arranged toward the filter plate riveting position on the product carrier. The product flipping device is located downstream of the filter plate mounting hot riveting device. It includes a third handling robot and a rotating mechanism located within the picking and placing range of the third handling robot. The rotating mechanism includes a rotating drive, a flipping component connected to the output end of the rotating drive, and a clamping mechanism located on the flipping component. The clamping mechanism is used to clamp the WPC wireless charging module, and the rotating drive is used to drive the flipping component to rotate the WPC wireless charging module 180°. A base locking device is located downstream of the product flipping device. The base locking device includes a second three-axis motion mechanism mounted above the assembly conveyor line and a second locking mechanism installed on the moving end of the second three-axis motion mechanism. The locking end of the second locking mechanism corresponds to the screw locking position on the WPC wireless charging module base. The control device includes an RFID tag on the bottom of the product carrier and at least one identification device corresponding to the RFID tag along the conveying direction of the product carrier on the assembly conveyor line. The control device and the identification device are communicatively connected to associate the product identification information of the WPC wireless charging module with the RFID tag on the product carrier carrying the WPC wireless charging module.

[0007] In some optional embodiments, the product carrier includes a carrier mother plate and a positioning fixture detachably disposed above the carrier mother plate. The positioning fixture is detachably connected to the carrier mother plate via a quick-change locking device, and the RFID carrier is disposed at the bottom of the carrier mother plate.

[0008] In some optional embodiments, the vehicle lifting mechanism includes a vertically arranged lead screw assembly and a drive component that is pulsatorically connected to the lead screw assembly. The lead screw assembly is connected to a vehicle receiving part that can move between a first position corresponding to the assembly conveyor line and a second position corresponding to the vehicle return line. The vehicle receiving part is provided with a receiving and conveying component that connects to the first position of the assembly conveyor line and the second position of the vehicle return line.

[0009] In some optional embodiments, the fan locking device further includes a first screw feeder, a first vision positioning mechanism, and a first displacement detection element; The first locking mechanism includes a first electric screwdriver installed on the moving end of the first three-axis motion mechanism, and the first screw feeder is connected to the locking end of the first electric screwdriver through a screw feeding channel; The first visual positioning mechanism is positioned toward the product carrier located on the assembly conveyor line. The first displacement detection component is installed on the moving end of the first three-axis motion mechanism and located on one side of the first electric screwdriver, so that the first three-axis motion mechanism can drive the first electric screwdriver and the first displacement detection component to move to the screw fastening position and the height detection position of the fan assembly, respectively.

[0010] In some optional embodiments, the assembly conveyor line is provided with a stopping and positioning mechanism at each assembly station for stopping and positioning the product carrier. The stopping and positioning mechanism includes a stopping cylinder and a check valve arranged opposite to each other on both sides of the product carrier along the conveying direction of the product carrier, and a lifting and positioning component located below the assembly conveyor line. The output end of the stopping cylinder can extend into or out of the conveying path of the product carrier to stop or release the product carrier. The lifting and positioning component is used to lift the product carrier that has been stopped by the stop cylinder upwards, so that the product carrier is separated from the assembly conveyor line and maintained in the processing position of the corresponding workstation.

[0011] In some optional embodiments, the cover feeding mechanism includes a tray for carrying the cover and a tray loading and unloading assembly corresponding to the tray, and the first handling robot is disposed between the tray loading and unloading assembly and the assembly conveyor line. The clamping mechanism includes a pressing cylinder vertically disposed above the product carrier and a pressing mold connected to the output end of the pressing cylinder, wherein the pressing mold is adapted to the upper cover structure; The cover assembly device further includes a second visual positioning mechanism facing the product carrier and a fastening detection mechanism located downstream of the fastening mechanism. The second visual positioning mechanism is located beside the clamping member and is used to visually position the fastening position of the cover on the product carrier. The fastening detection mechanism includes a detection clamp for clamping the product and distance sensors located on both sides of the detection clamp. The distance sensors are used to detect the height of the corresponding area of ​​the cover.

[0012] In some optional embodiments, the hot riveting mold includes a mold base, a plurality of hot riveting posts spaced apart on the mold base, a heating element disposed in the mold base and thermally connected to the hot riveting posts, and a plurality of elastic holding members disposed on the side of the mold base facing the product carrier; the hot riveting posts and the elastic holding members are all disposed toward the WPC wireless charging module located on the product carrier, and the elastic holding members protrude toward the product carrier relative to the hot riveting posts. The line scan detection component is located on the rear side of the hot riveting mold along the product conveying direction, and faces the riveting point of the filter plate after hot riveting is completed.

[0013] In some optional embodiments, the rotating mechanism is disposed within the picking and placing range of the third handling robot, and the rotating mechanism further includes a mounting base fixedly disposed on one side of the assembly conveyor line, the rotating drive is mounted on the mounting base, and the flipping component is connected to the output end of the rotating drive. The rotation axis of the rotary drive extends horizontally, and the clamping mechanism includes two clamping parts disposed opposite to each other on the flipping assembly, forming a clamping space for the WPC wireless charging module between the two clamping parts.

[0014] The base locking device also includes a second screw feeder, a third vision positioning mechanism, and a second displacement detection component; The second locking mechanism includes a second electric screwdriver installed on the moving end of the second three-axis motion mechanism, and the second screw feeder is connected to the locking end of the second electric screwdriver through a screw feeding channel; The third visual positioning mechanism is positioned toward the product carrier located on the assembly conveyor line, and the second displacement detection component is installed on the moving end of the second three-axis motion mechanism and located on one side of the second electric screwdriver. The locking end of the second electric screwdriver and the detection end of the second displacement detection element are respectively facing the screw mounting position on the WPC wireless charging module base; The carrier lifting mechanism, located at the downstream end of the assembly conveyor line, is arranged adjacent to the base locking device and is located behind the base locking device along the product carrier conveying direction.

[0015] In some optional implementations, the control device includes a PLC and an industrial computer communicatively connected to the PLC; a first barcode scanning mechanism is provided at the loading position corresponding to the upstream of the fan locking device, and a second barcode scanning mechanism is provided at the PCBA assembly station; the control device associates the assembly material identification information obtained by the first barcode scanning mechanism and the PCBA identification information obtained by the second barcode scanning mechanism with the RFID tag of the product carrier carrying the corresponding WPC wireless charging module to form an assembly identification record of the corresponding WPC wireless charging module, and uploads it to the MES system.

[0016] In summary, the beneficial effects of the present invention are as follows: 1. This invention, through the establishment of a circulating conveyor device including an assembly conveyor line, a carrier return line, and a carrier lifting mechanism, enables product carriers to circulate between the upper assembly conveyor line and the lower carrier return line. The WPC wireless charging module can be carried by the same product carrier sequentially through a fan locking device, PCBA assembly station, top cover assembly device, filter board mounting hot riveting device, product flipping device, and base locking device, thereby connecting multiple assembly processes of the WPC wireless charging module into a continuous automated assembly production line. During product assembly, there is no need to repeatedly change the main carrier between stations, reducing repeated handling and re-clamping of products between different processes. Furthermore, each assembly station can establish a relatively unified positioning benchmark based on the same product carrier, thereby improving the assembly continuity and stability of the entire production line. Simultaneously, empty product carriers can return to the front end of the production line for reuse via the lower carrier return line, which helps reduce interference from carrier return to the upper product assembly and conveying process and improves the utilization rate of the production line space.

[0017] 2. This invention, by setting an RFID tag on the bottom of the product carrier and setting an identification device corresponding to the RFID tag on the assembly conveyor line, enables the control device to associate the product identification information of the WPC wireless charging module with the product carrier carrying the product. At the same time, the identification device binds the corresponding information with the RFID tag on the product carrier to form an assembly identification record, thereby enabling the WPC wireless charging module to maintain a stable identity association as it passes through multiple assembly stations with the product carrier. This achieves information correspondence between the product and the product carrier, improves the traceability of the overall assembly data, and facilitates centralized recording and management of production information.

[0018] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the production line structure in this embodiment; Figure 2 This is a front view of the production line in this embodiment; Figure 3 This is a schematic diagram of the structure of the circulating conveying device in this embodiment; Figure 4 This is a schematic diagram of the vehicle lifting mechanism in this embodiment; Figure 5 This is a schematic diagram of the fan locking device in this embodiment; Figure 6 This is a schematic diagram of the structure of the first screw feeder, the first vision positioning mechanism, and the first displacement detection element in this embodiment; Figure 7 This is a schematic diagram of the upper cover assembly device in this embodiment; Figure 8 This is a schematic diagram of the clamping mechanism in this embodiment; Figure 9 This is a schematic diagram of the structure of the heat-riveting device for mounting the filter board in this embodiment; Figure 10 This is a schematic diagram of the hot riveting mechanism in this embodiment; Figure 11 This is a schematic diagram of the hot riveting mold in this embodiment; Figure 12 This is a schematic diagram of the rivet detection mechanism and the product reversing device in this embodiment; Figure 13 This is a schematic diagram of the flipping mechanism in this embodiment; Figure 14 This is a schematic diagram of the base locking device in this embodiment; Figure 15 This is a schematic diagram of the second locking mechanism in this embodiment; Figure 16 This is a control flow diagram of the control device in this embodiment.

[0020] In the picture: 1. Circulating conveyor; 11. Assembly conveyor line; 12. Carrier return line; 13. Carrier lifting mechanism; 131. Screw assembly; 132. Lifting drive component; 133. Carrier receiving part; 134. Receiving and conveying assembly; 14. Stopping and positioning mechanism; 141. Stop cylinder; 142. Check valve; 143. Lifting and positioning component; 2. Fan locking device; 21. First three-axis motion mechanism; 22. First locking mechanism; 221. First electric screwdriver; 23. First screw feeder; 24. First vision positioning mechanism; 25. First displacement detection component; 3. PCBA assembly station; 4. Top cover assembly device; 41. Top cover feeding mechanism; 411. Material tray; 412. Material tray loading and unloading assembly; 42. First handling robot; 421. Clamping component; 43. Clamping mechanism; 431. Pressing cylinder; 432. Pressing mold; 44. Second vision positioning mechanism; 45. Clamping detection mechanism; 5. Filter plate mounting hot riveting device; 51. Filter plate feeding mechanism; 52. Second handling robot; 53. Hot riveting mechanism; 531. Hot riveting drive component; 532. Hot riveting mold; 5321. Mold base; 5322. Heating element; 5323. Elastic holding component; 54. Rivet point detection mechanism; 541. Line scan detection assembly; 6. Product flipping device; 61. Third handling robot; 62. Rotating mechanism; 621. Mounting base; 622. Rotating drive component; 623. Flipping assembly; 624. Clamping mechanism; 6241. Clamping part; 7. Base locking device; 71. Second three-axis motion mechanism; 72. Second locking mechanism; 721. Second electric screwdriver; 73. Second screw feeder; 74. Third vision positioning mechanism; 75. Second displacement detection component; 8. Control device; 81. Industrial computer; 82. Identification device; 831. First scanning mechanism; 832. Second scanning mechanism; 84. MES system. Detailed Implementation

[0021] To make the content of this invention easier to understand, the invention will be further described below with reference to specific embodiments and accompanying drawings.

[0022] It should be noted that the terms "upper," "lower," "front," "rear," "left," "right," "inner," and "outer" used herein to indicate the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings. The terms "upstream" and "downstream" are based on the conveying direction of the WPC wireless charging module on the assembly conveyor line. These terms are used only for the convenience of describing the present invention and for simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Unless otherwise stated, "a plurality of" means two or more.

[0023] Unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "setup" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections, electrical connections, or communication connections; they can refer to direct connections or indirect connections through intermediate components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0024] like Figure 1 and Figure 2 As shown, this embodiment provides a WPC wireless charging module assembly line, including a circulating conveyor 1, and a fan locking device 2, a PCBA assembly station 3, a top cover assembly device 4, a filter board mounting hot riveting device 5, a product flipping device 6, and a base locking device 7 arranged sequentially along the product conveying direction of the circulating conveyor 1. It also includes a control device 8 for coordinating the operation of each device and recording product assembly information.

[0025] The WPC wireless charging module to be assembled includes a base, a fan assembly, a PCBA, a coil assembly, a coil bracket, a top cover, and a filter board. In this embodiment, the PCBA, coil assembly, and coil bracket are already connected to form a pre-assembled assembly before entering the PCBA assembly station 3. Therefore, the PCBA assembly referred to herein means adjusting the above-mentioned pre-assembled assembly, including the PCBA, to a predetermined assembly posture and then inserting it as a whole into the base, rather than bending the rigid PCBA board body.

[0026] The entire production line uses the circulating conveyor device 1 as the basic material connection between the various assembly units, allowing the same product carrier to sequentially carry the products to be assembled through each assembly position. In this way, each assembly unit does not need to be equipped with independent product transfer fixtures, and the products can maintain the same main carrier positioning base during the process from fan locking to final base locking, thereby reducing the position reference conversion caused by repeated picking, placing, and re-clamping between different processes.

[0027] like Figure 3As shown, the circulating conveying device 1 includes an assembly conveyor line 11 and a carrier return line 12 arranged at intervals. The assembly conveyor line 11 is located above the carrier return line 12 and extends along the product assembly direction; the carrier return line 12 extends below the assembly conveyor line 11, and its conveying direction is opposite to that of the assembly conveyor line 11.

[0028] In this embodiment, both the assembly conveyor line 11 and the carrier return line 12 include two synchronous belts arranged opposite each other. The two synchronous belts form a conveying space for the product carrier. The two sides of the product carrier are respectively supported on the corresponding synchronous belts so as to move along the length of the production line when the synchronous belts are running.

[0029] Using synchronous belts on both sides to carry the product carrier allows the middle of the product carrier to remain relatively open. This facilitates the placement of lifting and positioning mechanisms, RFID identification components, and other detection components below the assembly station. Furthermore, it enables the product carrier to form stable conveying supports mainly on both sides, allowing different workstations to share a uniform conveying structure.

[0030] Of course, in other embodiments, the assembly conveyor line 11 and the carrier return line 12 may also adopt flat belts, double-speed chains or other structures that can stably and linearly transport product carriers, and are not limited to synchronous belts.

[0031] Both ends of the assembly conveyor line 11 are connected to the corresponding ends of the carrier return line 12 via carrier lifting mechanisms 14. The carrier lifting mechanism 14 located at the beginning of product assembly is used to lift the empty product carrier returned from the carrier return line 12 to the assembly conveyor line 11. The carrier lifting mechanism 14 located at the end of product assembly is used to lower the empty product carrier after product unloading from the assembly conveyor line 11 to the carrier return line 12. Thus, the assembly conveyor line 11, the carrier lifting mechanism 14 located at the end, the carrier return line 12, and the carrier lifting mechanism 14 located at the beginning are sequentially connected to form a closed-loop carrier circulation path.

[0032] like Figure 4 As shown, the vehicle lifting mechanism 14 includes a frame, a lead screw assembly 141 mounted vertically on the frame, a lifting drive component 142 that is drivenly connected to the lead screw assembly 141, and a vehicle receiving part 143 that is connected to the lead screw assembly 141.

[0033] The lead screw assembly 141 includes a vertically extending lead screw and a movable seat threadedly engaged with the lead screw. A carrier receiving part 143 is connected to the movable seat, so that when the lead screw rotates, the movable seat and the carrier receiving part 143 can move up and down along the lead screw axis. A lifting drive 142 is disposed at one end of the lead screw assembly 141, and its output end is directly connected to the lead screw or connected to the lead screw through a transmission assembly.

[0034] In this embodiment, the lifting drive component 142 is preferably a servo motor, and the lead screw is preferably a ball screw. Since the product carrier needs to repeatedly change positions between the upper and lower conveyor lines, controlling the rotation of the ball screw by the servo motor can more accurately control the carrier receiving part 143 to stop at the corresponding height of the assembly conveyor line 11 or the carrier return line 12, thereby reducing the height difference between the receiving conveyor component 144 and the corresponding conveyor line, and thus reducing the possibility of jamming when the product carrier crosses the two conveyor structures.

[0035] The carrier receiving part 143 is provided with a receiving and conveying assembly 144, the conveying direction of which corresponds to the conveying direction of the assembly conveyor line 11 and the carrier return line 12. When the carrier receiving part 143 moves to the first position above, the receiving and conveying assembly 144 connects with the end of the assembly conveyor line 11; when the carrier receiving part 143 descends to the second position, the receiving and conveying assembly 144 connects with the end of the carrier return line 12.

[0036] Taking the carrier lifting mechanism 14 at the beginning of the production line as an example, when it is working, the carrier receiving part 143 first descends to the second position, the receiving conveyor component 144 runs and receives the empty product carrier sent out by the carrier return line 12; after the product carrier has completely entered the carrier receiving part 143, the receiving conveyor component 144 stops, and the lifting drive component 142 drives the carrier receiving part 143 to move upward to the first position; then the receiving conveyor component 144 starts again and sends the product carrier into the assembly conveyor line 11.

[0037] The carrier lifting mechanism 14, located at the end of the production line, operates in the opposite sequence: it first picks up an empty product carrier from the assembly conveyor line 11 at a first position, then lowers it to a second position and sends the product carrier into the carrier return line 12. This allows for carrier circulation without the need for manual handling of the product carriers.

[0038] In one optional embodiment, a carrier cleaning component is also provided near the carrier lifting mechanism 14 at the beginning of the production line. The carrier cleaning component may include a negative pressure vacuum cleaner and a suction pipe facing the positioning fixture, which cleans foreign objects in the positioning fixture before the empty product carrier re-enters the assembly conveyor line 11. In this way, the amount of debris or dust generated in the previous assembly cycle remaining in the positioning fixture can be reduced, thus reducing its impact on the positioning status of the next product.

[0039] like Figure 3 As shown, the product carrier includes a carrier mother plate and a positioning fixture disposed above the carrier mother plate.

[0040] The carrier mother plate is a universal basic component that cooperates with the product carrier, assembly conveyor line 11, carrier return line 12, and various stopping and positioning mechanisms 15. Its outer peripheral contour dimensions remain basically consistent. The positioning fixture is set on the upper surface of the carrier mother plate, and a bearing position is formed on it that is adapted to the shape of the base of the WPC wireless charging module to be assembled, so that the base can be restricted in the horizontal direction after being placed in the positioning fixture.

[0041] The positioning fixture and the carrier mother plate are detachably connected via quick-change locking components. Specifically, the carrier mother plate has an installation area for supporting the positioning fixture. After the positioning fixture is placed in the installation area, it is pressed against the carrier mother plate by a quick-release knob located on the periphery of the positioning fixture.

[0042] When it is necessary to produce another model of WPC wireless charging module, the quick knob can be released, the original positioning fixture can be removed from the carrier mother plate, and a positioning fixture that matches the shape of the other model product can be installed. The carrier mother plate, assembly conveyor line 11 and carrier return line 12 do not need to be replaced as a whole.

[0043] Therefore, by setting the "general parts that cooperate with the production line" and the "special parts that cooperate with the specific product shape" as the carrier master plate and the positioning fixture respectively, the structural changes during product changeover can be concentrated on the positioning fixture, thereby reducing the impact of changeover on the entire carrier cycle system.

[0044] In other alternative implementations, the quick-change locking element may also be a quick-release pin, an eccentric locking element, or other structures that enable repeated disassembly and assembly of the positioning fixture.

[0045] The RFID carrier is set at the bottom of the carrier mother plate, so that it can pass along with the product carrier as it moves along the assembly conveyor line 11, passing the identification device 82 set at the corresponding position on the conveyor line.

[0046] By placing the RFID carrier on the carrier master plate instead of a replaceable positioning fixture, the carrier master plate retains its original carrier identity after the product is redesigned. This avoids the need to replace or rearrange the carrier when the positioning fixture is changed, thus making carrier identity management and product positioning fixture redesign independent of each other.

[0047] Furthermore, such as Figure 3 As shown, each assembly station on the assembly conveyor line 11 is equipped with a stop and positioning mechanism 15. The stop and positioning mechanism 15 includes a stop cylinder 151, a check valve 152, and a lifting and positioning component 153 located below the assembly conveyor line 11.

[0048] The stop cylinder 151 and the check valve 152 are arranged at intervals along the conveying direction of the product carrier, with the stop cylinder 151 located downstream of the stop position of the product carrier and the check valve 152 located upstream of the stop position. The output end of the stop cylinder 151 is provided with a stop part that can extend into the conveying path of the product carrier. When the stop cylinder 151 is activated, the stop part protrudes to the front of the product carrier and abuts against the product carrier, thereby preventing the product carrier from continuing to move downstream.

[0049] The check valve 152 has a check part that allows the product carrier to pass in the normal conveying direction while restricting its reverse movement. When the product carrier moves from upstream to the corresponding station, it can pass over the check valve 152 to enter the stop position; after the product carrier is stopped by the stop cylinder 151, the check valve 152 restricts the product carrier from retracting in the upstream direction, so that the product carrier is restricted in the forward and backward directions by the stop cylinder 151 and the check valve 152 respectively.

[0050] The lifting and positioning component 153 is located below the product carrier's stop position, with its output end facing upward and connected to a lifting part for supporting the product carrier. After the product carrier is stopped by the stop cylinder 151, the lifting and positioning component 153 drives the lifting part to move upward, and the bottom of the product carrier lifts the entire carrier, causing the product carrier to detach from the main support of the timing belt.

[0051] Thus, during operations such as screw fastening, cover pressing, and hot riveting, the product's positioning is primarily provided by the lifting and positioning mechanism, rather than directly by the synchronous belt in its conveying state. Because the synchronous belt itself has a certain degree of flexibility, if pressing or fastening is performed directly under its load, the force exerted by the equipment may cause slight displacement of the carrier. By lifting the carrier to an independent processing position, the conveying function and the processing positioning function can be separated, thereby improving the stability of the product's position during processing.

[0052] Limit switches, photoelectric sensors, or proximity sensors can also be installed near the stopping position of the product carrier on the assembly conveyor line 11 as carrier arrival detection components. After the arrival detection component detects the product carrier, the control device 8 sequentially controls the stop cylinder 151 and the lifting and positioning component 153 to operate; after processing is completed, the lifting and positioning component 153 descends, the stop cylinder 151 releases its stop, and the product carrier is again carried by the synchronous belt and transported to the next workstation.

[0053] In this embodiment, a material feeding position is set upstream of the fan locking device 2. After the product carrier is stopped and lifted into position, the operator places the base into the positioning fixture and places the fan assembly in the corresponding installation position on the base.

[0054] Furthermore, a first barcode scanning mechanism 831 and a vision inspection mechanism for detecting the base and fan assembly are set at the material loading position. The first barcode scanning mechanism 831 reads the identification information of the product to be loaded or the assembly material, while the vision inspection mechanism is set towards the product carrier and determines whether the material exists and whether the installation direction meets the set requirements by taking images of the base and fan assembly.

[0055] After passing visual inspection, the product carrier is released to the fan locking device 2.

[0056] like Figure 5 and Figure 6 As shown, the fan locking device 2 includes a first three-axis motion mechanism 21, a first locking mechanism 22, a first screw feeder 23, a first vision positioning mechanism 24, and a first displacement detection element 25.

[0057] The first three-axis motion mechanism 21 is mounted above the assembly conveyor line 11. It includes a first horizontal motion module extending laterally along the assembly conveyor line 11, a second horizontal motion module installed at the moving end of the first horizontal motion module and extending in another horizontal direction, and a vertical motion module installed at the moving end of the second horizontal motion module. This allows the final moving end of the first three-axis motion mechanism 21 to be adjusted in three coordinates above the assembly conveyor line 11.

[0058] The first locking mechanism 22 is installed on the moving end of the vertical motion module. The first locking mechanism 22 includes a first electric screwdriver 221 and a screw guide provided at the locking end of the first electric screwdriver 221. The output shaft of the first electric screwdriver 221 is vertically oriented toward the product carrier.

[0059] The first screw feeder 23 is located on one side of the assembly conveyor line 11 and is connected to the screw guide of the first electric screwdriver 221 through the screw feeding channel. The first screw feeder 23 sorts the bulk screws and feeds them one by one into the screw feeding channel, so that the screws reach the fastening end of the first electric screwdriver 221 along the screw feeding channel, thus eliminating the need for the first electric screwdriver 221 to be moved to the screw picking position separately before each fastening.

[0060] In this embodiment, the first screw feeder 23 is preferably a blow-nail feeder, that is, the airflow is used to transport the sorted screws along the screw feeding tube to the locking end.

[0061] The first visual positioning mechanism 24 includes a CCD camera facing the product carrier and a light source corresponding to the CCD camera. After the product carrier is lifted and positioned, the CCD camera captures images of the fan assembly and its screw installation positions. The control device 8 calculates the actual screw installation positions based on the preset image features and controls the first three-axis motion mechanism 21 to compensate for the deviation between the actual and theoretical positions of the product.

[0062] The first electric screwdriver 221 then moves sequentially to each screw fastening position and tightens the screws downwards, fixing the fan assembly to the base.

[0063] In this embodiment, two sets of first three-axis motion mechanisms 21 and corresponding first locking mechanisms 22 are preferably provided, so that the two first electric screwdrivers 221 can each be responsible for different screw positions. When the two sets of locking mechanisms work in parallel, multiple locking actions that originally needed to be completed sequentially by a single electric screwdriver can be distributed to the two sets of motion mechanisms, thereby shortening the time required for this station to complete the locking of all fan screws.

[0064] The first displacement detection element 25 is installed on the moving end of the first three-axis motion mechanism 21 and located on one side of the first electric screwdriver 221, with its detection end facing the product carrier. After the screws are tightened, the first three-axis motion mechanism 21 can drive the first displacement detection element 25 to move above each screw to detect the height of the screw head relative to the set reference plane.

[0065] Since a properly locked screw head has a relatively definite positional relationship with the product surface, while a screw that is not fully locked or is locked at an angle will have a large floating height, the actual height of the screw after locking can be checked a second time by the first displacement detection element 25. This can supplement the judgment of locking abnormalities that cannot be fully reflected by the torque signal of the first electric screwdriver 221 alone.

[0066] In one optional embodiment, the fan fastening device 2 is further provided with a torque checking component. The first electric screwdriver 221 moves to the torque checking component at a set cycle to check the output torque, thereby confirming the actual output state of the first electric screwdriver 221. The first fastening mechanism 22 may also be provided with a pressing mechanism, which presses down on the fan assembly during the fastening process to reduce the possibility of the fan assembly tilting during screw insertion.

[0067] After the fan assembly is secured, the product carrier is transported to the PCBA assembly station 3. In this embodiment, the PCBA assembly station 3 is located on one side of the assembly conveyor line 11 and is equipped with a second barcode scanning mechanism 832 and an auxiliary flipping fixture. The auxiliary flipping fixture is independent of the product carrier on the assembly conveyor line 11 and is mainly used to carry the pre-assembled PCBA, coil assembly, and coil bracket assembly that has been connected.

[0068] The operator first places the pre-assembled assembly on the auxiliary flipping fixture, and changes the spatial placement posture of the pre-assembled assembly by the auxiliary flipping fixture, so that the coil assembly, coil bracket and PCBA are in an assembly posture suitable for entering the base; then the second scanning mechanism 832 reads the identification code of the PCBA or pre-assembled assembly, and then the adjusted pre-assembled assembly is installed into the base carried by the product carrier.

[0069] Thus, the auxiliary flipping fixture is responsible for the posture adjustment function before the pre-assembled assembly is installed into the base. The main line carrier of the product itself does not need to be flipped or replaced, so it can continue to flow in a unified direction along the assembly conveyor line 11.

[0070] When upstream material detection or fan screw floating height detection produces an anomaly that can be manually recovered, the control device 8 can also associate the corresponding anomaly with the current product carrier. When the product arrives at the PCBA assembly station 3, it will prompt the operator through the display device, and the operator will handle the previous anomaly. After the handling is completed, it will continue to be transported downstream.

[0071] like Figure 7 and Figure 8 As shown, the top cover assembly device 4 includes a top cover feeding mechanism 41, a first handling robot 42, a fastening mechanism 43, a second vision positioning mechanism 44, and a fastening detection mechanism 45.

[0072] The cover feeding mechanism 41 is located on one side of the assembly conveyor line 11, and includes a tray 411 for carrying multiple covers and a tray loading and unloading assembly 412 corresponding to the tray 411.

[0073] The tray loading and unloading assembly 412 includes a receiving position for carrying the tray 411 and a tray 411 transporting structure capable of sending a full tray 411 into the picking position and moving an empty tray 411 out of the picking position. Multiple top covers are arranged in a predetermined posture in the tray 411, enabling the first transport robot 42 to pick up the materials one by one according to the set position.

[0074] The first handling robot 42 is positioned between the material tray loading / unloading assembly 412 and the assembly conveyor line 11, and its working range covers both the material picking position on the top cover and the product carrier on the assembly conveyor line 11.

[0075] In this embodiment, the first handling robot 42 is preferably a four-axis robot with a clamping member 421 installed at its end. The clamping member 421 includes a suction cup mounting part connected to a negative pressure air circuit and at least one vacuum suction cup mounted on the suction cup mounting part, with the suction surface of the vacuum suction cup facing the upper cover.

[0076] After the first handling robot 42 moves above the material tray 411, it makes the vacuum suction cup contact the surface of the upper cover and establishes negative pressure, thereby sucking the upper cover from the material tray 411; then the robot transports the upper cover to the assembly conveyor line 11 and places the upper cover on the base that has been equipped with the PCBA pre-assembled assembly.

[0077] The second visual positioning mechanism 44 is used to provide position correction for the above-mentioned material picking and placing process. The second visual positioning mechanism 44 may include a positioning camera set at the end of the first handling robot 42 and / or a CCD camera set near the assembly conveyor line 11, and compensate for the theoretical picking and placing coordinates of the robot by acquiring the actual position of the top cover in the material tray 411 and the actual position of the product in the carrier.

[0078] The clamping mechanism 43 is set independently of the first handling robot 42 and is mounted above the assembly conveyor line 11. The clamping mechanism 43 includes a vertically arranged pressing cylinder 431, a pressing die 432 connected to the output end of the pressing cylinder 431, and a guide structure for guiding the movement of the pressing die 432.

[0079] The pressing mold 432 is located directly above the product carrier, and its side facing the product forms a pressing surface that matches the pressure area of ​​the top cover. After the first handling robot 42 places the top cover in place and exits the pressing area, the pressing cylinder 431 drives the pressing mold 432 to descend vertically, so that the pressing mold 432 applies a downward force to the top cover until the snap-fit ​​structure around the top cover is engaged with the corresponding position of the base.

[0080] The handling of the top cover and the final fastening of the top cover are respectively handled by the first handling robot 42 and the independent fastening mechanism 43. This allows the first handling robot 42 to mainly handle the picking and placing actions that require flexible positioning, while the fastening mechanism 43 mainly handles the pressing action that has a single direction but a large force. This avoids the robot being subjected to fastening force for a long time, and the lower pressing mold 432 can apply force more evenly to the predetermined area of ​​the top cover, thereby improving the stability of the synchronous fastening of multiple buckles.

[0081] The fastening detection mechanism 45 is located downstream of the fastening mechanism 43. It includes a detection clamp and distance sensors disposed on both sides of the detection clamp. The distance sensors correspond to the top plane of the cover, thereby detecting the actual height of the corresponding area of ​​the cover after fastening, and thus realizing the recognition of the fastening result.

[0082] When a buckle at a certain position is not fully engaged, the corresponding area of ​​the top cover usually cannot be lowered to the normal height. Therefore, the control device 8 can obtain the top cover engagement detection result by comparing the detection height with the preset qualified range.

[0083] In other embodiments, the driving source for the clamping mechanism 43, in addition to the pressing cylinder 431, can also be an electric cylinder or a servo press; when using an electric cylinder or a servo press, the pressing stroke or pressing force can be further controlled in a closed loop. All of the above substitutions do not change the basic structural relationship that "the independent clamping mechanism 43 performs the pressing and clamping after the robot places the top cover."

[0084] like Figures 9 to 11As shown, the filter plate mounting hot riveting device 5 includes a filter plate feeding mechanism 51, a second handling robot 52, a hot riveting mechanism 53, and a riveting point detection mechanism 54.

[0085] The filter plate feeding mechanism 51 is located on one side of the assembly conveyor line 11. Its structure is similar to that of the cover feeding mechanism 41, including a tray 411 containing multiple filter plates and a tray loading and unloading assembly 412 for conveying the tray 411.

[0086] The second handling robot 52 is positioned between the filter plate feeding mechanism 51 and the assembly conveyor line 11. Its picking range covers the filter plate tray 411, and its unloading range covers the product carrier located at the hot riveting position.

[0087] The second handling robot 52 is equipped with a filter plate gripping unit and a vision positioning camera at its execution end. The filter plate gripping unit can grip the filter plate using a vacuum adsorption method, and the vision positioning camera is used to obtain the material picking position of the filter plate and the corresponding installation position of the top cover.

[0088] Multiple plastic rivets are pre-formed on the top cover, and multiple mounting holes are correspondingly formed on the filter plate. The second handling robot 52 places the filter plate on the top cover based on the visual positioning result, so that the multiple plastic rivets pass through the corresponding mounting holes of the filter plate, thereby giving the filter plate a preliminary positional constraint before hot riveting.

[0089] The hot riveting mechanism 53 is located above the assembly conveyor line 11 and includes a hot riveting drive 531, a pressure sensor and a hot riveting mold 532. The hot riveting drive 531 is arranged vertically, the hot riveting mold 532 is located directly above the product carrier, and the pressure sensor is located between the hot riveting drive 531 and the hot riveting mold 532.

[0090] In this embodiment, the hot riveting drive component 531 is an electric cylinder. The output end of the electric cylinder is set downward and connected to the upper part of the hot riveting mold 532 through a pressure sensor. When the electric cylinder drives the hot riveting mold 532 to move downward and contact the product, the reaction force on the hot riveting mold 532 is transmitted to the pressure sensor along the connection path, and the actual riveting pressure is obtained by the pressure sensor.

[0091] Therefore, the control device 8 can not only control the position of the hot riveting die 532 according to the displacement or stroke of the electric cylinder, but also obtain the actual pressure exerted by the hot riveting die 532 on the product according to the pressure sensor. When the pressure does not reach the set range, it can indicate that the hot riveting die 532 has not been pressed into the corresponding position normally; when the pressure is abnormally high, it can also indicate that there is an abnormality in the product position, the state of the rivet, or the state of the die, thereby improving the reliability of the state judgment of the hot riveting process.

[0092] The hot riveting mold 532 and the hot riveting drive component 531 are detachably connected, allowing the hot riveting mold 532 to be replaced as a whole according to different product models.

[0093] Specifically, the hot riveting mold 532 includes a mold base 5321, multiple hot riveting pillars, a heating element 5322, a heat insulation element, and multiple elastic holding elements 5323.

[0094] The mold base 5321 serves as the mounting base for multiple hot riveting pillars and elastic retaining members 5323. A quick-locking structure is installed on it and connected to the mounting part of the hot riveting mechanism 53 through the quick-locking structure. The quick-locking structure can be a quick-knob lock, which allows the mold base 5321 to be completely removed when changing molds by releasing the quick-knob.

[0095] The heating element 5322 is disposed inside the mold base 5321. In this embodiment, a heating tube extending along the inside of the mold base 5321 is preferably used. Multiple hot riveting posts are respectively installed on the side of the mold base 5321 facing the product carrier and form a thermally conductive connection with the heating element 5322, so that the heat generated by the heating tube can be transferred to each hot riveting post through the mold base 5321 or directly.

[0096] The heat insulation component is placed between the heat-generating area and other connecting parts of the hot riveting mold 532 to reduce the transfer of heat to the hot riveting drive component 531 and the surrounding mounting structure.

[0097] The positions of the multiple hot riveting posts correspond to the multiple plastic riveting posts on the upper cover. Each hot riveting post can be adjusted in position relative to the mold base 5321 along its own axis.

[0098] In this embodiment, an axial adjustment component is provided at the rear end of the hot riveting post, and the extension length of the hot riveting post in the product direction is changed by adjusting the axial adjustment component; a lateral locking component is provided on the side of the hot riveting post, and after being adjusted to the required position, the hot riveting post is clamped and fixed from the side by the lateral locking component.

[0099] Therefore, even if there are design differences in the height of different plastic rivet pillars on the same product, or if there are changes in the height of rivet pillars between different product models, the extension amount of the corresponding hot rivet pillars can be adjusted separately without reprocessing the entire mold base 5321.

[0100] Multiple elastic retaining members 5323 are also installed on the side of the mold base 5321 facing the product carrier and are distributed near the hot riveting post. The elastic retaining member 5323 includes a retaining post and an elastic member that applies a spring force to the retaining post in the product direction. In this embodiment, a spring retaining post structure is preferably adopted.

[0101] When the hot riveting die 532 is not in contact with the product, the lower end of the elastic holding member 5323 is closer to the product than the working end of the hot riveting post, that is, the elastic holding member 5323 protrudes from the hot riveting post along the product direction.

[0102] Therefore, when the hot riveting mold 532 descends, the elastic holding member 5323 first contacts the filter plate. As the hot riveting mold 532 continues to descend, the elastic holding member 5323 elastically retracts and forms a continuous downward elastic clamping force on the filter plate, thereby causing the filter plate to adhere to the upper cover; then the hot riveting post contacts the plastic riveting post that passes through the mounting hole of the filter plate.

[0103] The hot riveting post maintains a set temperature under the action of the heating element 5322, and the end of the plastic riveting post is softened and deformed by the pressure of the hot riveting drive element 531, so that the end of the plastic riveting post that originally passed through the mounting hole of the filter plate forms a rivet joint with a size larger than the mounting hole, thereby fixing the filter plate to the top cover.

[0104] This embodiment sets up an action relationship where the elastic holding member 5323 first presses down on the filter plate and then acts on the plastic rivet post. This ensures that the filter plate is in a stable and fitted state before the rivet post begins to undergo thermoplastic deformation. Therefore, it can reduce the possibility of the filter plate shifting laterally or lifting up locally when the hot rivet post is in action.

[0105] The rivet detection mechanism 54 is located on the rear side of the hot riveting mechanism 53 along the product conveying direction, so that after the product is hot riveted, it can continue to move with the product carrier to the rivet detection position without leaving the current assembly conveyor line 11.

[0106] The rivet detection mechanism 54 includes a line scan detection component 541 and a detection motion mechanism for causing the line scan detection component 541 to perform relative scanning motion with the product. The line scan detection component 541 faces multiple rivet positions on the filter plate; in this embodiment, a 3D line scan detection component 541 is preferably used.

[0107] After the product carrier is stopped and lifted into position, the line scan detection component 541 moves relative to the product to perform a three-dimensional contour scan on the rivet joint after hot riveting, thereby obtaining the height and contour information of the rivet point, and judging whether there are any missing rivets, abnormal rivet point heights, or incomplete forming.

[0108] By placing the riveting detection mechanism 54 directly downstream of the hot riveting mechanism 53, the hot riveting process and the hot riveting result detection can be completed continuously within the same assembly module. This allows for timely identification of hot riveting abnormalities before the product continues to undergo subsequent flipping and fastening, reducing the need for defective products to continue occupying subsequent processing resources.

[0109] In one embodiment, the filter plate mounting hot riveting device 5 is further equipped with an NG unloading robot and an NG unloading conveyor line. The NG unloading robot's picking range covers the product carrier on the assembly conveyor line 11, and its unloading range covers the NG unloading conveyor line.

[0110] When the line scan detection component 541 determines that the product hot riveting is unqualified, the control device 8 controls the NG unloading robot to take the product out of the product carrier and transfer it to the NG unloading conveyor line.

[0111] Furthermore, if the fastening detection mechanism 45 of the cover assembly device 4 has determined that the fastening of the cover of a certain product is abnormal, the control device 8 can establish an internal association between the abnormal state and the corresponding product carrier number. When the product carrier moves to the filter plate installation hot riveting device 5, the filter plate loading and hot riveting actions are no longer performed, but are directly taken out by the NG unloading robot.

[0112] This avoids wasting filter boards and hot riveting time on products where the cover fastening is already confirmed to have abnormalities.

[0113] like Figure 12 and Figure 13 As shown, the product flipping device 6 includes a third handling robot 61 and a rotating mechanism 62. The rotating mechanism 62 is located on one side of the assembly conveyor line 11 and within the picking and placing range of the third handling robot 61, enabling the third handling robot 61 to move products back and forth between the product carrier and the rotating mechanism 62.

[0114] The third handling robot 61 is preferably a four-axis robot with a product gripping component installed at its end and a vision positioning mechanism for determining the actual position of the product in the product carrier.

[0115] The rotating mechanism 62 includes a mounting base 621, a rotating drive 622, a tilting assembly 623, and a clamping mechanism 624. The mounting base 621 is fixed to one side of the assembly conveyor line 11, and the rotating drive 622 is fixedly mounted on the mounting base 621, with its output shaft extending horizontally.

[0116] The flipping component 623 is connected to the output end of the rotary drive 622, so that when the rotary drive 622 is working, it can drive the flipping component 623 to rotate around the horizontal axis.

[0117] The clamping mechanism 624 is mounted on the flipping assembly 623 and includes two clamping portions 6241 disposed opposite each other, forming a clamping space between the two clamping portions 6241 for placing the WPC wireless charging module. At least one clamping portion 6241 is movable relative to the other clamping portion 6241 to change the width of the clamping space.

[0118] During the flipping process, the third handling robot 61 first removes the WPC wireless charging module from the product carrier and places it between the two clamping parts 6241; the clamping mechanism 624 drives the two clamping parts 6241 to move closer to each other, so that the product is fixed on the flipping assembly 623; then the rotation drive 622 drives the flipping assembly 623 to rotate 180° around the horizontal axis.

[0119] After rotation, the product's upward-facing side turns downward, while the base side turns upward. The clamping mechanism 624 releases, and the third handling robot 61 retrieves the product again and places it back into the same product carrier that carried the product before the rotation.

[0120] Instead of flipping the entire product carrier along with the product, by setting up an independent rotating mechanism 62, the product carrier can maintain the same posture throughout the entire assembly conveyor line 11. This eliminates the need to design the RFID carrier, the bottom positioning surface of the carrier, and the conveying mating surface into a complex structure that can be flipped as a whole. At the same time, after the product is flipped, it is put back into the original product carrier, so that the information association between the product and the carrier can continue to be maintained.

[0121] In other alternative embodiments, the rotary drive 622 may be a rotary cylinder, a servo motor with a reduction gear, or other drive structure capable of driving the flipping component 623 to rotate around a horizontal axis.

[0122] like Figure 14 and Figure 15 As shown, the base locking device 7 is located downstream of the product flipping device 6, and includes a second three-axis motion mechanism 71, a second locking mechanism 72, a second screw feeder 73, a third vision positioning mechanism 74, and a second displacement detection element 75.

[0123] The second three-axis motion mechanism 71 is mounted above the assembly conveyor line 11. Its structure is basically the same as that of the first three-axis motion mechanism 21. It includes two horizontal motion modules and one vertical motion module. The combined motion in the three directions drives the second locking mechanism 72 to move to different screw installation positions on the base.

[0124] The second locking mechanism 72 includes a second electric screwdriver 721, the output shaft of which faces vertically toward the product carrier. Since the product has been rotated 180° before entering the base locking device 7, the base side of the WPC wireless charging module is facing upwards, allowing the second electric screwdriver 721 to directly access the multiple screw mounting positions on the base from above the product.

[0125] The second screw feeder 73 is located on one side of the base fastening device 7 and is connected to the fastening end of the second electric screwdriver 721 through the screw feeding channel to supply screws to the second electric screwdriver 721 one by one.

[0126] The third visual positioning mechanism 74 is positioned toward the WPC wireless charging module in the product carrier to obtain the actual position of the base and the installation position of each screw; the control device 8 controls the movement of the second three-axis motion mechanism 71 according to the position result obtained by the third visual positioning mechanism 74, so that the second electric screwdriver 721 is aligned with each screw hole and the screw is fastened.

[0127] In this embodiment, it is also preferable to set two sets of second three-axis motion mechanisms 71 and corresponding second electric screwdrivers 721, so that the two sets of locking mechanisms can perform screw locking at different positions respectively, thereby shortening the time required for final base locking.

[0128] The second displacement detection element 75 is installed on the moving end of the second three-axis motion mechanism 71 and located on one side of the second electric screwdriver 721, with its detection end corresponding to the mounting position of the base screw. After the screw is tightened, the second three-axis motion mechanism 71 drives the second displacement detection element 75 to move above the corresponding screw to detect the floating height of the screw head, thereby providing a secondary confirmation of the final tightening state of the base.

[0129] Furthermore, at the end of the assembly conveyor line 11 along the assembly direction, a carrier lifting mechanism 14 is provided for transferring empty product carriers from the assembly conveyor line 11 to the carrier return line 12. In this embodiment, the carrier lifting mechanism 14 is located on the rear side of the base locking device 7 along the product conveying direction. After the WPC wireless charging module is removed from the product carrier after the base locking is completed, the empty product carrier continues to enter the carrier lifting mechanism 14 and is lowered by the carrier lifting mechanism 14 to the carrier return line 12.

[0130] This embodiment does not limit the specific unloading method for the product after the complete machine assembly. It can be set up to automatically remove the product from the product carrier by an independent unloading robot, or it can be removed by a handling mechanism connected to the subsequent equipment of the production line, or it can be unloaded manually. As long as the product is separated from the carrier before entering the carrier lifting mechanism 14, the subsequent empty carrier return can be completed.

[0131] like Figure 16 As shown, the control device 8 includes a PLC and an industrial computer 81 that is communicatively connected to the PLC, and may further include a motion control card, a robot controller, a servo driver, and input / output modules for connecting to various sensors and actuators.

[0132] The PLC is connected or communicates with the circulating conveyor 1, the lifting mechanism 14 of each carrier, the stopping and positioning mechanism 15, the first three-axis motion mechanism 21, the clamping mechanism 43, the hot riveting mechanism 53, the product flipping device 6, and the second three-axis motion mechanism 71, respectively, to coordinate the conveying of product carriers and the operation of each assembly device according to the preset production rhythm.

[0133] Industrial computer 81 stores product information, production process parameters, and assembly records, and communicates with MES system 84. First scanning mechanism 831 is located upstream of the fan mounting device 2 at the material loading position, and second scanning mechanism 832 is located at PCBA assembly station 3. When a product first enters the assembly process, the first scanning mechanism 831 acquires the identification information of the assembly material corresponding to the base, fan, or product, and the identification device 82 located at the conveyor line reads the RFID tag on the bottom of the product carrier.

[0134] The control device 8 associates the aforementioned product identification information with the RFID carrier of the current product carrier.

[0135] When the product moves further to PCBA assembly station 3, the second scanning mechanism 832 reads the identification information of the PCBA or PCBA pre-assembled assembly, and the control device 8 adds the PCBA identification information to the product assembly record that is already associated with the current RFID carrier.

[0136] Since the product moves with the same product carrier during the processes of fan mounting, PCBA assembly, cover pressing, filter board hot riveting, flipping, and base mounting, the control device 8 can use the carrier identity as an intermediate link to identify the current product between different workstations.

[0137] The final assembly record may include at least product identification information, material identification information, PCBA identification information and corresponding product carrier information, and is uploaded by industrial computer 81 to MES system 84 for subsequent query and production traceability.

[0138] RFID carriers are primarily used for product-product identification and assembly record management, and do not require all processing equipment to directly rely on RFID data for real-time motion control. The real-time processing status of each workstation can be managed by a PLC based on the current workstation location of the product carrier and internal queue information.

[0139] Based on the above structure, the specific workflow of this embodiment is as follows.

[0140] After production begins, the empty product carrier returns to the starting end of the production line via the carrier return line 12. The first carrier lifting mechanism 14 descends to the height of the carrier return line 12 and receives the empty product carrier via the receiving conveyor assembly 144. Subsequently, the first carrier lifting mechanism 14 is raised to the height of the assembly conveyor line 11 and sends the product carrier into the assembly conveyor line 11.

[0141] After the product carrier enters the material loading position, it is stopped and lifted for positioning. The first scanning mechanism 831 obtains the assembly material information and establishes an association between the information and the RFID carrier at the bottom of the carrier mother plate. Then, the base and fan assembly are installed into the positioning fixture, and the visual inspection mechanism confirms the existence status and installation direction of the materials.

[0142] After the product carrier enters the fan mounting device 2, the first visual positioning mechanism 24 obtains the actual position of the fan assembly, the first screw feeder 23 continuously feeds screws to the first electric screwdriver 221, the first three-axis motion mechanism 21 drives the first electric screwdriver 221 to complete the screw mounting between the fan assembly and the base in sequence or in parallel, and then the first displacement detection element 25 detects the screw floating height.

[0143] Subsequently, the product carrier enters PCBA assembly station 3. The PCBA, coil assembly and coil bracket pre-assembled assembly are first adjusted on the auxiliary flipping fixture, and the PCBA identification information is read by the second scanning mechanism 832 before being installed into the base as a whole.

[0144] The product continues to enter the top cover assembly device 4. The first handling robot 42 picks up the top cover from the top cover tray 411 and corrects the pick-up and placement position through the second vision positioning mechanism 44, placing the top cover on the base. After the first handling robot 42 exits, the clamping mechanism 43 drives the lower pressing mold 432 to move downward, so that the top cover is snapped together with the base. The clamping detection mechanism 45 then detects the clamping height.

[0145] After the product enters the filter plate installation hot riveting device 5, the second handling robot 52 takes the filter plate from the filter plate tray 411 and sets it on the plastic rivet column of the upper cover; the hot riveting drive component 531 drives the hot riveting mold 532 to descend, the elastic holding component 5323 first presses the filter plate, and then the hot riveting column heats and rivets the corresponding plastic rivet column, and the pressure sensor synchronously detects the actual riveting pressure.

[0146] After hot riveting is completed, the product moves with the product carrier to the line scan detection position, where the line scan detection component 541 checks the three-dimensional forming status of each hot riveting point. Qualified products continue to enter the product flipping device 6, while unqualified products can be removed by the NG unloading mechanism.

[0147] After entering the product flipping device 6, the third handling robot 61 takes the product out of the original product carrier and puts it into the flipping component 623. The clamping mechanism 624 clamps the product, and the rotation drive 622 drives the flipping component 623 to rotate 180°. Then the third handling robot 61 puts the product back into the original product carrier, so that the base faces the second locking mechanism 72.

[0148] After the product enters the base locking device 7, the third vision positioning mechanism 74 determines the position of the base screw, the second screw feeder 73 feeds screws to the second electric screwdriver 721, the second three-axis motion mechanism 71 drives the second electric screwdriver 721 to complete the base screw locking, and then the second displacement detection element 75 detects the screw floating height.

[0149] The WPC wireless charging module, after being fully locked, is removed from the product carrier. The empty product carrier is lowered by the second carrier lifting mechanism 14 to the carrier return line 12, and then returns to the first carrier lifting mechanism 14 along the carrier return line 12, thus starting the next carrier cycle.

[0150] Through the structural coordination of the above-mentioned devices, this embodiment enables the product carrier to form a complete closed loop in the assembly and conveying stage, the empty return stage, and the upper and lower layer conversion stage, and uses the same product carrier to carry the product to complete multiple assembly processes in sequence; at the same time, each processing station uses a combination of blocking and lifting to convert the product carrier from the conveying state to the stable processing state, so that the conveying function and the processing positioning function are separated from each other.

[0151] Based on this, the fan locking device 2 and the base locking device 7 form a continuous action of "positioning-locking-detection" through visual positioning, three-axis motion locking, and screw floating height detection, respectively; the top cover assembly device 4 forms a continuous action of "automatic feeding-positioning placement-independent pressing-height detection" through the cooperation of robot flexible handling and independent clamping mechanism 43; the filter plate installation hot riveting device 5 forms a continuous action of "positioning installation-stable holding-hot riveting fixation-result detection" through robot feeding, elastic pre-pressing, pressure monitoring hot riveting, and three-dimensional riveting point detection. In this way, the execution mechanisms of different processes form a structural cooperation around the corresponding assembly quality requirements, rather than simply arranging multiple independent devices on the same conveyor line.

[0152] In addition, the positioning fixture and the carrier mother plate adopt a detachable quick-change structure, and the hot riveting mold 532 also adopts a detachable structure and allows each hot riveting column to adjust its extension position. Therefore, when producing different models of WPC wireless charging modules with similar assembly processes, the model change can be completed mainly by replacing the positioning fixture and the hot riveting mold 532, adjusting the equipment program and corresponding processing parameters, without changing the basic structure of the circulating conveying device 1.

[0153] The embodiments described above are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and modifications made by those skilled in the art based on the present invention shall fall within the scope of protection of the present invention.

Claims

1. A production line for assembling a WPC wireless charging module, characterized in that, include: The circulating conveying device includes an assembly conveyor line and a carrier return line arranged at intervals. A product carrier for carrying WPC wireless charging modules is movably arranged on the assembly conveyor line. Carrier lifting mechanisms are connected to both ends of the assembly conveyor line and both ends of the carrier return line to transfer the product carrier between the assembly conveyor line and the carrier return line. A fan locking device is provided on one side of the assembly conveyor line. The fan locking device includes a first three-axis motion mechanism mounted above the assembly conveyor line and a first locking mechanism installed on the moving end of the first three-axis motion mechanism. The locking end of the first locking mechanism corresponds to the fan locking position on the product carrier. The PCBA assembly station is located downstream of the fan locking device along the product conveying direction and is used to assemble PCBA boards. The top cover assembly device is located downstream of the PCBA assembly station. The top cover assembly device includes a top cover feeding mechanism located on one side of the assembly conveyor line, a clamping mechanism located above the assembly conveyor line, and a first handling robot located between the top cover feeding mechanism and the assembly conveyor line. The end of the first handling robot is equipped with a clamping component for picking up and handling the top cover. The clamping mechanism performs downward clamping after the first handling robot places the top cover on the product carrier. A filter plate mounting hot riveting device is located downstream of the upper cover assembly device. It includes a filter plate feeding mechanism located on one side of the assembly conveyor line, a second handling robot for acquiring filter plates located between the filter plate feeding mechanism and the assembly conveyor line, a hot riveting mechanism located above the assembly conveyor line, and a riveting point detection mechanism located behind the hot riveting mechanism along the product conveying direction. The hot riveting mechanism includes a hot riveting drive component arranged vertically, a hot riveting mold detachably connected to the output end of the hot riveting drive component, and a pressure sensor located between the hot riveting drive component and the hot riveting mold. The hot riveting mold is located above the product carrier. The riveting point detection mechanism includes a line scan detection component arranged toward the filter plate riveting position on the product carrier. The product flipping device is located downstream of the filter plate mounting hot riveting device. It includes a third handling robot and a rotating mechanism located within the picking and placing range of the third handling robot. The rotating mechanism includes a rotating drive, a flipping component connected to the output end of the rotating drive, and a clamping mechanism located on the flipping component. The clamping mechanism is used to clamp the WPC wireless charging module, and the rotating drive is used to drive the flipping component to rotate the WPC wireless charging module 180°. A base locking device is located downstream of the product flipping device. The base locking device includes a second three-axis motion mechanism mounted above the assembly conveyor line and a second locking mechanism installed on the moving end of the second three-axis motion mechanism. The locking end of the second locking mechanism corresponds to the screw locking position on the WPC wireless charging module base. The control device includes an RFID tag on the bottom of the product carrier and at least one identification device corresponding to the RFID tag along the conveying direction of the product carrier on the assembly conveyor line. The control device and the identification device are communicatively connected to associate the product identification information of the WPC wireless charging module with the RFID tag on the product carrier carrying the WPC wireless charging module.

2. The WPC wireless charging module assembly line according to claim 1, characterized in that, The product carrier includes a carrier mother plate and a positioning fixture detachably mounted on top of the carrier mother plate. The positioning fixture is detachably connected to the carrier mother plate via a quick-change locking device. The RFID carrier is located at the bottom of the carrier mother plate.

3. The WPC wireless charging module assembly line according to claim 1, characterized in that, The vehicle lifting mechanism includes a vertically arranged lead screw assembly and a drive component that is pulsatorically connected to the lead screw assembly. The lead screw assembly is connected to a vehicle receiving part that can move between a first position corresponding to the assembly conveyor line and a second position corresponding to the vehicle return line. The vehicle receiving part is provided with a receiving and conveying component that connects to the first position of the assembly conveyor line and the second position of the vehicle return line.

4. The WPC wireless charging module assembly line according to claim 1, characterized in that, The fan fastening device also includes a first screw feeder, a first vision positioning mechanism, and a first displacement detection component; The first locking mechanism includes a first electric screwdriver installed on the moving end of the first three-axis motion mechanism, and the first screw feeder is connected to the locking end of the first electric screwdriver through a screw feeding channel; The first visual positioning mechanism is positioned toward the product carrier located on the assembly conveyor line. The first displacement detection component is installed on the moving end of the first three-axis motion mechanism and located on one side of the first electric screwdriver, so that the first three-axis motion mechanism can drive the first electric screwdriver and the first displacement detection component to move to the screw fastening position and the height detection position of the fan assembly, respectively.

5. The WPC wireless charging module assembly line according to claim 1, characterized in that, The assembly conveyor line is equipped with a stopping and positioning mechanism at each assembly station for stopping and positioning the product carrier. The stopping and positioning mechanism includes a stopping cylinder and a check valve arranged opposite to each other on both sides of the product carrier along the conveying direction of the product carrier, and a lifting and positioning component located below the assembly conveyor line. The output end of the stopping cylinder can extend into or out of the conveying path of the product carrier to stop or release the product carrier. The lifting and positioning component is used to lift the product carrier that has been stopped by the stop cylinder upwards, so that the product carrier is separated from the assembly conveyor line and maintained in the processing position of the corresponding workstation.

6. The WPC wireless charging module assembly line according to claim 1, characterized in that, The upper cover feeding mechanism includes a material tray for carrying the upper cover and a material tray loading and unloading assembly corresponding to the material tray. The first handling robot is located between the material tray loading and unloading assembly and the assembly conveyor line. The clamping mechanism includes a pressing cylinder vertically disposed above the product carrier and a pressing mold connected to the output end of the pressing cylinder, wherein the pressing mold is adapted to the upper cover structure; The cover assembly device further includes a second visual positioning mechanism facing the product carrier and a fastening detection mechanism located downstream of the fastening mechanism. The second visual positioning mechanism is located beside the clamping member and is used to visually position the fastening position of the cover on the product carrier. The fastening detection mechanism includes a detection clamp for clamping the product and distance sensors located on both sides of the detection clamp. The distance sensors are used to detect the height of the corresponding area of ​​the cover.

7. The WPC wireless charging module assembly line according to claim 1, characterized in that, The hot riveting mold includes a mold base, a plurality of hot riveting pillars spaced apart on the mold base, a heating element disposed inside the mold base and thermally connected to the hot riveting pillars, and a plurality of elastic holding members disposed on the side of the mold base facing the product carrier; the hot riveting pillars and the elastic holding members are all disposed toward the WPC wireless charging module located on the product carrier, and the elastic holding members protrude toward the product carrier relative to the hot riveting pillars. The line scan detection component is located on the rear side of the hot riveting mold along the product conveying direction, and faces the riveting point of the filter plate after hot riveting is completed.

8. The WPC wireless charging module assembly line according to claim 1, characterized in that, The rotating mechanism is located within the picking and placing range of the third handling robot. The rotating mechanism also includes a mounting base fixedly mounted on one side of the assembly conveyor line. The rotating drive component is mounted on the mounting base, and the flipping component is connected to the output end of the rotating drive component. The rotation axis of the rotary drive extends horizontally, and the clamping mechanism includes two clamping parts disposed opposite to each other on the flipping assembly, forming a clamping space for the WPC wireless charging module between the two clamping parts.

9. The WPC wireless charging module assembly line according to claim 1, characterized in that, The base locking device also includes a second screw feeder, a third vision positioning mechanism, and a second displacement detection component; The second locking mechanism includes a second electric screwdriver installed on the moving end of the second three-axis motion mechanism, and the second screw feeder is connected to the locking end of the second electric screwdriver through a screw feeding channel; The third visual positioning mechanism is positioned toward the product carrier located on the assembly conveyor line, and the second displacement detection component is installed on the moving end of the second three-axis motion mechanism and located on one side of the second electric screwdriver. The locking end of the second electric screwdriver and the detection end of the second displacement detection element are respectively facing the screw mounting position on the WPC wireless charging module base; The carrier lifting mechanism, located at the downstream end of the assembly conveyor line, is arranged adjacent to the base locking device and is located behind the base locking device along the product carrier conveying direction.

10. A WPC wireless charging module assembly line according to any one of claims 1-9, characterized in that, The control device includes a PLC and an industrial computer that communicates with the PLC; a first barcode scanning mechanism is provided at the loading position corresponding to the upstream of the fan locking device, and a second barcode scanning mechanism is provided at the PCBA assembly station. The control device associates the assembly material identification information obtained by the first barcode scanning mechanism and the PCBA identification information obtained by the second barcode scanning mechanism with the RFID code carrier of the product carrier carrying the corresponding WPC wireless charging module to form an assembly identification record of the corresponding WPC wireless charging module and upload it to the MES system.

Images