Product quick sorter

Abstract

This invention relates to the field of automated testing equipment technology, and in particular to a rapid product sorting machine. The sorting machine includes a machine base and, sequentially arranged on the machine base, a feeding mechanism, a scanning mechanism, a heating mechanism, a first transfer station, a high-temperature dynamic and static testing station for performing static DC steady-state electrical tests and high-frequency dynamic switching condition simulation tests under controlled high-temperature conditions, a second transfer station, a cooling station, an insulation withstand voltage testing station for applying high voltage between the conductive terminals of the product and the metal substrate to test the product's insulation withstand voltage performance, and a station for applying DC test signals to the product at room temperature and collecting steady-state electrical parameters. This invention, through a transverse multi-axis robotic arm design, integrates more than ten processes, including scanning, heating, multi-environment testing, marking, testing, and unloading, into a single device, achieving true "one-line" production, reducing waiting and handling time in intermediate stages, and significantly improving production efficiency.

Description

Technical Field

[0001] This invention relates to the field of automated testing equipment technology, and in particular to a rapid product sorting machine. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the demand for charging piles has surged. As a core component of charging piles, the power switch module's electrical performance, insulation reliability, and environmental adaptability directly affect charging safety. Currently, after production, switch modules undergo a series of rigorous testing procedures, including barcode traceability, high-temperature tolerance testing, dynamic and static electrical parameter testing, insulation withstand voltage testing, room temperature calibration, marking, and appearance inspection. Existing technologies have the following shortcomings: Existing testing processes are typically completed in segments by multiple independent machines, with manual handling or simple conveyor belts connecting the machines. This not only results in slow production cycles, but also frequent loading and unloading can easily cause product damage and introduce human error.

[0003] Traditional vibratory feeders are noisy, easily damage products, and are unsuitable for fragile or delicate electronic components. The unloading end typically requires manual insertion of products one by one into the feed tube, which is labor-intensive and necessitates frequent tube replacements, severely limiting overall production capacity.

[0004] Switching modules need to be tested in various environments, including high temperature, cooling, and normal temperature. In existing technologies, the transfer time between testing stations is relatively long, leading to temperature loss or rebound, which affects the authenticity and accuracy of the test data.

[0005] Existing equipment often only allows for testing of a single item (such as testing only pressure resistance or only static parameters), lacking the ability to screen the overall performance of products in a "one-stop" manner, resulting in a high risk of defective products being released.

[0006] Therefore, there is an urgent need for a rapid sorting method and equipment that can achieve full-process automation, integrate multi-environment and multi-dimensional testing, and has efficient material supply and unloading capabilities to meet the needs of large-scale, high-quality production of charging pile power switch modules. Summary of the Invention

[0007] In order to overcome the shortcomings of the prior art described in the background section, the present invention provides a rapid product sorting machine.

[0008] The technical solution adopted by the present invention to solve its technical problem is: a product rapid sorting machine, including a machine base and a feeding mechanism, a scanning mechanism, a heating mechanism, a transfer station one, a high-temperature dynamic and static test station for performing static DC steady-state electrical tests and high-frequency dynamic switching condition simulation tests in a controllable high-temperature environment, a transfer station two, a cooling station, an insulation withstand voltage test station for applying high voltage between the conductive terminals of the product and the metal substrate to detect the insulation withstand voltage performance of the product, a room temperature static test station for applying DC test signals to the product at room temperature and collecting steady-state electrical parameters to complete the verification of the basic electrical performance of the product, a marking mechanism, a product testing mechanism, and a feeding mechanism; The sorting machine also includes a product transfer and handling mechanism that spans the feeding mechanism, scanning mechanism, heating mechanism, transfer platform one, high-temperature dynamic and static testing platform, transfer platform two, cooling platform, insulation withstand voltage testing platform, normal temperature static testing platform, marking mechanism, and product testing mechanism.

[0009] According to another embodiment of the present invention, the product transfer and handling mechanism further includes a plurality of multi-axis manipulators arranged in sequence. The multi-axis manipulators are composed of a horizontal traverse linear module and a lifting module. All horizontal traverse linear modules are connected to form a through transmission track. The cylinder of the lifting module is fixed on the slide of the horizontal traverse linear module, and a gripper is fixed on the slide of the lifting module.

[0010] According to another embodiment of the present invention, the feeding mechanism further includes a product hopper, a material carrier, a horizontal drive cylinder for the support plate, and a product clamping cylinder; the bottom of the product hopper is provided with a horizontally extendable product support plate, and the horizontal drive cylinder for the support plate drives the product support plate; the material carrier is provided with a stop block and a product clamping cylinder.

[0011] According to another embodiment of the present invention, the feeding mechanism further includes a material swing frame, a motor, and an inclined slide; The material swing frame is driven to swing by the motor, and a clamping cylinder is provided at one end. The inclined slide is connected to the outlet end of the material swing frame.

[0012] According to another embodiment of the present invention, the unloading mechanism further includes a platform, a platform lifting cylinder, a platform horizontal moving linear module, a pushing cylinder, a push rod, a product slide, a horizontal moving feeding seat, a feeding seat horizontal moving linear module, and a linear flow channel; Below the outlet of the linear flow channel, there are sequentially arranged a feeding seat horizontal moving linear module, an upper frame, a platform horizontal moving linear module, and a lower frame. The feeding seat horizontal moving linear module, the upper frame, the platform horizontal moving linear module, and the lower frame are arranged along the same inclined direction. The linear flow channel is driven by motor 2 to swing, which is used to connect the horizontal moving feeding seat and the product slide. A horizontally moving feeding seat is fixed on the slide of the horizontally moving linear module of the feeding seat, and a cylinder-driven sealing plate is installed at the discharge end of the horizontally moving feeding seat. Several product slides are distributed horizontally on the upper frame, and the product slides are parallel to the platform surface; the feeding seat moves horizontally across all the product slides; The cylinder body and the push cylinder of the platform lifting cylinder are both connected to the moving part of the platform horizontal moving linear module. The platform is fixed on the piston rod of the platform lifting cylinder, and the platform surface is inclined. Multiple push rods are distributed horizontally and hinged to the lower frame. They are driven to swing by the push cylinder, and a return spring is connected between the push rod and the frame.

[0013] According to another embodiment of the present invention, the feeding mechanism further includes a material tube carrier, wherein the material tube carrier is provided with a support plate for supporting the material tube.

[0014] According to another embodiment of the present invention, both the first and second transfer stations include a product carrier and a carrier horizontal drive linear module, wherein the product carrier is provided with a positioning groove.

[0015] According to another embodiment of the present invention, the product inspection mechanism further includes a D-line laser profile sensor and a CCD camera, wherein the D-line laser profile sensor is used to measure the product thickness and the CCD camera is used to measure the product surface dimensions and detect surface stains.

[0016] According to another embodiment of the present invention, the cooling platform is further comprising a platform with a water cooling system.

[0017] According to another embodiment of the invention, the push rod is further comprising a bent rod.

[0018] The beneficial effects of this invention are that, through the design of a transverse multi-axis robotic arm, it integrates more than ten processes such as barcode scanning, heating, multi-environment testing, marking, inspection and unloading into one device, realizing true line-of-line production, reducing waiting and handling time in intermediate links, and significantly improving production efficiency.

[0019] Employing a support plate-type micro-separation technology, the precise insertion and extraction of the product support plate enables the non-destructive single-chip separation of brittle switch modules, avoiding noise and damage caused by the vibratory feeder. Combined with a swing-type attitude conversion mechanism, gravity sliding is used instead of mechanical hard pushing, further protecting the product pins.

[0020] It integrates high-temperature dynamic and static testing, insulation withstand voltage testing, and normal-temperature static testing, covering the extreme operating conditions that switch modules may encounter in actual use; combined with 3D laser and CCD vision inspection, it achieves dual screening of the product's electrical performance and appearance quality.

[0021] The push-rod relay tube loading technology uses gravity positioning via an inclined slide and precise docking with the swing flow channel to achieve automatic tube loading and automatic tube replacement, completely replacing the heavy labor of manual tube insertion. It also has high loading accuracy and no material jamming.

[0022] The design of the transfer platform allows products to be moved in advance while waiting for testing, thus overlapping the handling and testing time; the parallel operation of the multi-axis robotic arms ensures the smooth operation of the whole machine and significantly shortens the testing cycle of a single product. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0024] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the feeding mechanism of the present invention; Figure 3 This is a schematic diagram of the feeding mechanism of the present invention; In the diagram: 1. Feeding mechanism; 10. Product hopper; 11. Material tray; 12. Product clamping cylinder; 13. Pushing cylinder; 14. Material swing frame; 15. Motor; 16. Inclined slide; 17. Clamping cylinder; 18. Product support plate; 19. Support plate horizontal drive cylinder; 2. Product transfer and handling mechanism; 3. Scanning mechanism; 4. Heating mechanism; 5. Transfer platform one; 6. High-temperature dynamic and static testing platform; 7. Transfer platform two; 8. Cooling platform; 9. Insulation withstand voltage testing platform; 10. Normal temperature static testing platform; 11. Marking mechanism; 12. Product inspection mechanism; 13. Unloading mechanism; 131. Platform; 132. Platform lifting cylinder; 133. Platform horizontal moving linear module; 134. Push cylinder; 135. Push rod; 136. Product slide; 137. Horizontal moving feeding seat; 138. Feeding seat horizontal moving linear module; 139. Linear flow channel; 140. Material tube carrier; 141. Clamping cylinder. Detailed Implementation

[0025] As attached Figure 1 As shown, the machine base and the feeding mechanism 1, scanning mechanism 3, heating mechanism 4, transfer station 1 5, high temperature dynamic and static test station 6 for performing static DC steady-state electrical tests and high frequency dynamic switching condition simulation tests in a controllable high temperature environment, transfer station 2 7, cooling station 8, insulation withstand voltage test station 9 for applying high voltage between the conductive terminals of the product and the metal substrate to test the insulation withstand voltage performance of the product, room temperature static test station 10 for applying DC test signals to the product at room temperature and collecting steady-state electrical parameters to complete the verification of the basic electrical performance of the product, marking mechanism 11, product inspection mechanism 12, and unloading mechanism 13 are arranged in sequence on the machine base; The sorting machine also includes a product transfer and handling mechanism 2 that spans the feeding mechanism 1, the scanning mechanism 3, the heating mechanism 4, the first transfer platform 5, the high-temperature dynamic and static test platform 6, the second transfer platform 7, the cooling platform 8, the insulation withstand voltage test platform 9, the normal temperature static test platform 10, the marking mechanism 11, and the product inspection mechanism 12.

[0026] As attached Figure 2 As shown, the feeding mechanism 1 includes a product hopper 10, a material carrier plate 11, a horizontal drive cylinder 19 for the support plate, and a product clamping cylinder 12; the bottom of the product hopper 10 is provided with a horizontally extendable product support plate 18, and the horizontal drive cylinder 19 for the support plate drives the product support plate 18; the material carrier plate 11 is provided with a stop block and a product clamping cylinder 12.

[0027] According to another embodiment of the present invention, the feeding mechanism 1 further includes a material swing frame 14, a motor 15, and an inclined slide 16; The material swing frame 14 is driven to swing by the motor 15, and a clamping cylinder 17 is provided at one end of it. The inclined slide 16 is connected to the outlet end of the material swing frame 14.

[0028] Inside the product hopper 10 of the feeding mechanism 1, a stack of switch modules are placed. The product hopper 10 includes two vertical hopper bodies, one at the front and one at the back. A horizontal drive cylinder 19 for the support plate is located at the bottom of the hopper. Under the drive of the horizontal drive cylinder 19, the product support plate 18 can be horizontally inserted into or pulled out of the bottom of the product hopper 10.

[0029] Initially, a stack of products is placed in the product hopper 10, with the front and rear ends of each product positioned within two vertical compartments, supported by product support plates 18. When feeding is required, the material carrier 11 moves to directly below the product hopper 10 under the drive of the horizontal drive linear module. The product support plates 18 are pulled out, and the bottom product falls onto the material carrier 11. The product clamping cylinder 12 on the material carrier 11 extends, pressing the product against the stop block. Subsequently, the product support plates 18 are inserted again between the first and last products, completing the separation. The material carrier 11 carries the product horizontally to the front of the pusher cylinder 13. At this time, the material swing frame 14 is in a horizontal position. The pusher cylinder 13 extends, pushing the product into the material swing frame 14, where the clamping cylinder 17 clamps the product. Subsequently, the motor 15 drives the material swing frame 14 to swing counterclockwise by approximately 60 degrees until it aligns with the inclined slide 16. The clamping cylinder 17 is released, and the product slides down the inclined slide 16 to the picking position.

[0030] Product transfer and handling mechanism 2: It consists of multiple multi-axis robotic arms. Each robotic arm includes a horizontal linear module (X-axis) and a lifting module (Z-axis), with a gripper at the end. All horizontal modules are connected to form a long track, allowing the robotic arm to move freely between any workstations.

[0031] Testing and processing stations: The barcode scanning mechanism 3 reads and inputs the product barcode. The heating mechanism 4 heats the product to 125℃, simulating high-temperature conditions. Transfer stations 5 and 7 are used for buffering and positioning between workstations. The high-temperature dynamic and static testing station 6 performs static parameter and dynamic switching tests in a high-temperature environment. The cooling station 8 quickly removes heat from the product through a water cooling system. The insulation withstand voltage testing station 9 applies high voltage to test insulation performance. The room-temperature static testing station 10 performs basic electrical screening at room temperature. The marking mechanism 11 laser-marks qualified products. The product inspection mechanism 12 uses a 3D line laser contour sensor to measure thickness and a CCD camera to inspect surface dimensions and stains.

[0032] Both the transfer station 5 and the transfer station 7 include a product carrier and a horizontal drive linear module for the carrier, and the product carrier is provided with a positioning groove.

[0033] As attached Figure 3 As shown, the unloading mechanism 13 includes a platform 131, a platform lifting cylinder 132, a platform horizontal moving linear module 133, a pushing cylinder 134, a push rod 135, a product slide 136, a horizontal moving feeding seat 137, a feeding seat horizontal moving linear module 138, and a linear flow channel 139. Below the outlet of the linear flow channel 139, there are sequentially arranged a feeding seat horizontal moving linear module 138, an upper frame, a platform horizontal moving linear module 133, and a lower frame. The feeding seat horizontal moving linear module 138, the upper frame, the platform horizontal moving linear module 133, and the lower frame are arranged along the same inclined direction. The linear flow channel 139 is driven by motor 2 to swing, which is used to connect the horizontal moving feeding seat 137 and the product slide 136. A horizontally moving feeding seat 137 is fixed on the slide of the horizontally moving linear module 138 of the feeding seat, and a cylinder-driven sealing plate is installed at the discharge end of the horizontally moving feeding seat 137. Several product slides 136 are distributed horizontally on the upper frame, and the product slides 136 are parallel to the table surface of the platform 131; the feeding seat horizontal moving linear module 138 spans all product slides 136. The cylinder body of the platform lifting cylinder 132 and the push cylinder 134 are both connected to the moving part of the platform horizontal moving linear module 133. The platform 131 is fixed on the piston rod of the platform lifting cylinder 132, and the platform surface of the platform 131 is inclined. A plurality of push rods 135 are distributed in the horizontal direction and hinged on the lower frame. They are driven to swing by the push cylinder 134, and a return spring is connected between the push rod 135 and the frame.

[0034] The feeding mechanism 13 also includes a material tube carrier 140, which has a support plate for supporting the material tube.

[0035] Two tube carriers 140 are fixed to the upper and lower frames respectively to support the head and tail ends of the tubes. The tubes are stacked between the two tube carriers 140, and the support plates at the bottom of the tube carriers 140 support the bottom tube. During operation, the platform 131 rises under the drive of the platform lifting cylinder 132, supporting the bottom tube. Then, the support plates inside the tube carriers 140 are pulled out, the platform 131 descends by one tube pitch, and the upper support plate re-inserts to support the remaining tubes. Driven by the platform horizontal movement linear module 133, the platform 131 transports the empty tubes to below the target product slide 136. The push cylinder 134 is activated, pushing the push rod 135 to swing. Since the push rod 135 is a bent rod, its swinging end pushes the tilted empty tubes upward along the inclined surface of the platform 131 into the bottom opening of the product slide 136. The clamping cylinder 141 then clamps the tubes.

[0036] Simultaneously, the horizontally moving feeding seat 137, driven by the horizontally moving linear module 138, moves to below the linear flow channel 139. The linear flow channel 139, driven by motor 2, swings to an inclined state, and the product slides into the feeding seat 137. Subsequently, the linear flow channel 139 resets, the feeding seat 137 moves above the corresponding fully loaded slide, opens the bottom sealing plate, and the product slides into the material tube. After the material tube is full, the clamping cylinder 141 releases, and the material tube slides back along the inclined surface to the carrier 131, awaiting the next cycle or to be removed.

[0037] Workflow: 1. Feeding mechanism 1 automatically separates and delivers products. 2. The robotic arm picks up the products and sequentially performs barcode scanning, heating, high-temperature testing, cooling, pressure resistance testing, room temperature testing, marking, and visual inspection. 3. Qualified products are picked up by the robotic arm and automatically loaded into the material tube by unloading mechanism 13. 4. Defective products are picked up by the robotic arm and placed in the waste bin.

[0038] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A product rapid sorting machine, characterized in that, The equipment includes a machine base and, in sequence, a feeding mechanism (1), a barcode scanning mechanism (3), a heating mechanism (4), a transfer station one (5), a high-temperature dynamic and static test station (6) for performing static DC steady-state electrical tests and high-frequency dynamic switching condition simulation tests in a controllable high-temperature environment, a transfer station two (7), a cooling station (8), an insulation withstand voltage test station (9) for applying high voltage between the conductive terminals of the product and the metal substrate to test the insulation withstand voltage performance of the product, a room-temperature static test station (10) for applying DC test signals to the product at room temperature and collecting steady-state electrical parameters to complete the verification of the basic electrical performance of the product, a marking mechanism (11), a product testing mechanism (12), and a feeding mechanism (13). The sorting machine also includes a product transfer and handling mechanism (2) that spans the feeding mechanism (1), the barcode scanning mechanism (3), the heating mechanism (4), the first transfer station (5), the high temperature dynamic and static test station (6), the second transfer station (7), the cooling station (8), the insulation withstand voltage test station (9), the normal temperature static test station (10), the marking mechanism (11), and the product testing mechanism (12).

2. The product rapid sorting machine according to claim 1, characterized in that, The product transfer and handling mechanism (2) includes multiple multi-axis manipulators arranged in sequence. The multi-axis manipulators are composed of horizontal transverse linear modules and lifting modules. All horizontal transverse linear modules are connected to form a continuous transmission track. The cylinder of the lifting module is fixed on the slide of the horizontal transverse linear module. The slide of the lifting module is fixed with grippers.

3. The product rapid sorting machine according to claim 1, characterized in that, The feeding mechanism (1) includes a product hopper (10), a material carrier plate (11), a horizontal drive cylinder (19) for the support plate, and a product clamping cylinder (12). The bottom of the product hopper (10) is provided with a horizontally extendable product support plate (18), and the horizontal drive cylinder (19) for the support plate drives the product support plate (18). The material carrier plate (11) is provided with a stop block and a product clamping cylinder (12).

4. The product rapid sorting machine according to claim 3, characterized in that, The feeding mechanism (1) also includes a material swing frame (14), a motor (15) and an inclined slide (16). The material swing frame (14) is driven to swing by the motor (15), and a clamping cylinder (17) is provided at one end. The inclined slide (16) is connected to the outlet end of the material swing frame (14).

5. The product rapid sorting machine according to claim 1, characterized in that, The feeding mechanism (13) includes a platform (131), a platform lifting cylinder (132), a platform horizontal moving linear module (133), a pushing cylinder (134), a push rod (135), a product slide (136), a horizontal moving feeding seat (137), a feeding seat horizontal moving linear module (138), and a linear flow channel (139). Below the outlet of the straight flow channel (139) are arranged a feeding seat horizontal moving linear module (138), an upper frame, a platform horizontal moving linear module (133), and a lower frame, which are arranged along the same inclined direction. The straight flow channel (139) is driven to swing by a motor to connect the horizontal moving feeding seat (137) and the product slide (136). A horizontally moving feeding seat (137) is fixed on the slide of the horizontally moving linear module (138), and a cylinder-driven sealing plate is installed at the discharge end of the horizontally moving feeding seat (137). Several product slides (136) are distributed horizontally on the upper frame, and the product slides (136) are parallel to the table surface of the platform (131); the feeding seat horizontal moving linear module (138) spans all product slides (136). The cylinder body of the platform lifting cylinder (132) and the push cylinder (134) are both connected to the moving part of the platform horizontal moving linear module (133). The platform (131) is fixed on the piston rod of the platform lifting cylinder (132), and the platform (131) is inclined. Multiple push rods (135) are distributed horizontally and hinged to the lower frame. They are driven to swing by the push cylinder (134), and a return spring is connected between the push rod (135) and the frame.

6. The product rapid sorting machine according to claim 5, characterized in that, The feeding mechanism (13) also includes a material tube carrier (140), which has a support plate for supporting the material tube.

7. The product rapid sorting machine according to claim 1, characterized in that, Both the first transfer station (5) and the second transfer station (7) include a product carrier and a horizontal drive linear module for the carrier, and the product carrier is provided with a positioning groove.

8. The product rapid sorting machine according to claim 1, characterized in that, The product inspection mechanism (12) includes a 3D line laser profile sensor and a CCD camera. The 3D line laser profile sensor is used to measure the product thickness, and the CCD camera is used to measure the product surface dimensions and detect surface stains.

9. The product rapid sorting machine according to claim 1, characterized in that, The cooling platform (8) is a platform with a water cooling system.

10. The product rapid sorting machine according to claim 1, characterized in that, The push rod (135) is a bent rod.

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