Power module assembly line

Abstract

The utility model discloses a power module assembly line which comprises a power module assembly line and a tray assembly line which are arranged up and down. The power module assembly line comprises a turnover on-line station, a module disassembly station, a bottom layer assembly station, a middle layer assembly station, a top layer assembly detection station, a module test station and a turnover off-line station which are arranged in sequence. Trays are mounted on the power module assembly line and are used for bearing the power modules so as to circulate among the stations; the tray assembly line is used for transporting the trays on the overturning off-line station to the overturning on-line station so as to realize backflow of the trays; the overturning online station and the overturning offline station are each provided with a hoisting module, a supporting and positioning module, a clamping module and an overturning module. The device has the advantages of simple and compact structure, high automation degree, safety, reliability and the like.

Description

Technical Field

[0001] The utility model mainly relates to the technical field of rail transportation, and in particular to a power module assembly line. Background Art

[0002] Currently, rail transit boasts a promising future, and EMUs, closely related to rail transit, will continue to experience rapid growth. Numerous rail transit applications have already been put into production both domestically and internationally. Over time, EMUs will eventually enter a maintenance phase. As one of the core components of an EMU, the traction inverter functions like the human heart, and the traction inverter power module is the heart of the traction inverter. A single traction inverter is equipped with five power modules, requiring significant maintenance and manpower. Technological advancements are driving the rail transit industry toward intelligent and automated development, and the realization of an intelligent assembly line for traction inverter power modules has become one of the company's key projects.

[0003] The project team studied the operational processes, standardization, and assemblability of traction converter power modules, and combined them with leading intelligent assembly technology solutions within the industry. Based on product production capacity, operational intensity, and bottleneck processes, the team selected traction converter modules (approximately 200 kg) as a key area for intelligent assembly. Starting with customer needs and researching advanced assembly technologies, the team implemented intelligent power module maintenance processes, focusing on operational guidance, key parameters (such as torque values), tightening solutions, process traceability, torque data analysis, and production tact control.

[0004] Each traction converter is currently equipped with two to five power modules. During power module assembly, a lifting mechanism is first used to transfer the modules to a hydraulic jacking vehicle. The vehicle then lifts the modules onto a turning table. After securing them with bolts, the hydraulic vehicle is removed and the turning table is activated to flip the modules. After flipping, the modules are disassembled and then assembled. Both the front and rear ends of the assembly process are handled, and the serial numbers of the relevant components are recorded. After the assembly is complete, the modules are flipped over and removed using a hydraulic jacking vehicle. The assembly process requires no movement, and the large number of components requires multiple sets of tools to meet production needs. Utility Model Content

[0005] In view of the technical problems existing in the prior art, the utility model provides a power module assembly line with a compact structure and a high degree of automation.

[0006] In order to solve the above technical problems, the technical solutions proposed by the present invention are as follows:

[0007] A power module assembly line includes a power module line and a tray line; the power module line and the tray line are arranged vertically;

[0008] The power module assembly line includes a flip-on line station, a module disassembly station, a bottom assembly station, a middle assembly station, a top assembly and inspection station, a module test station and a flip-off line station arranged in sequence;

[0009] The power module assembly line is equipped with a tray for carrying power modules for transfer between various workstations;

[0010] The pallet assembly line is used to transport the pallets on the flip down line station to the flip up line station to achieve the return of the pallets;

[0011] The flip up-line station and the flip down-line station are both equipped with a hoisting module, a support and positioning module, a clamping module and a flip module;

[0012] The hoisting module is used to hoist or remove the power module to the flip up-line station and the flip down-line station;

[0013] The support and positioning module is used to support and position the power module;

[0014] The clamping module is used to clamp and fix the power module on the supporting and positioning module;

[0015] The flip module is used to flip the clamped power module.

[0016] As a further improvement of the above technical solution:

[0017] The supporting and positioning module includes a carrying plate and a plurality of L-shaped blocks located around the carrying plate, wherein the top of the L-shaped block is used to carry the power module, and the side of the L-shaped block is used to position the power module.

[0018] The clamping module includes a plurality of clamping components arranged around the supporting and positioning module, and each clamping component includes a clamping block and a clamping cylinder; the clamping block is located at the movable end of the clamping cylinder.

[0019] The flip module includes a flip motor, and the flip motor is connected to the supporting plate.

[0020] The power module assembly line and the pallet assembly line are both powered roller transmission lines.

[0021] The flip-up line station and the flip-down line station are both equipped with a lifting module for lifting and lowering the pallet.

[0022] A rotating disk is provided at the bottom of the lifting module for realizing the rotation of the module in a horizontal plane.

[0023] The tray is provided with a plurality of placement slots for accommodating the placement of different types of components.

[0024] The module disassembly station is equipped with a drawer-type cabinet for placing and transporting disassembled materials.

[0025] The bottom assembly station, the middle assembly station and the top assembly and inspection station are all equipped with material and tool carts for placing materials and tools.

[0026] Compared with the prior art, the advantages of the present invention are:

[0027] This utility model realizes the reflux of modules and pallets from the line through the power module assembly line and pallet assembly line arranged vertically. The lifting module is designed at the front and rear ends of the entire line body, which can save external space and make the overall production line more compact. At the same time, it can also simplify operations and save use and maintenance costs. This utility model adopts an accumulation-type friction wheel conveyor line combined with a metal roller double-speed chain line to automatically convey modules on the assembly line, which can improve the load-bearing capacity and conveying stability; the flip-on line station, module disassembly station and flip-off line station are all equipped with KBK intelligent hoist flexible lifting equipment. The area covered by the lifting equipment is 4 stations in the front and back. The use of telescopic lifting arm can reduce the floating of the product in the process of lifting. Compared with the improvement of lifting in other areas, it reduces walking. At the same time, the lifting equipment is upgraded to ensure the safety and reliability of the lifting process. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a three-dimensional structural diagram of a power module assembly line in an embodiment of the present utility model.

[0029] Figure 2 This is a front structural diagram of a power module assembly line in an embodiment of the present utility model.

[0030] Figure 3 This is one of the module layout structural diagrams at the flip-up line station of the present invention.

[0031] Figure 4 This is the second module layout structure diagram at the flip-up line station of the present invention.

[0032] Figure 5 This is a structural diagram of a tray in an embodiment of the present invention.

[0033] Legend: 1. Flipping on-line station; 2. Module disassembly station; 3. Bottom-level assembly station; 4. Bottom-level wiring station; 5. Bottom-level inspection station; 6. First-middle-level assembly station; 7. Middle-level wiring station; 8. Second-middle-level assembly station; 9. Middle-level inspection station; 10. Top-level assembly and inspection station; 11. Module testing station; 12. Flipping off-line station; 13. Power module assembly line; 14. Pallet assembly line; 15. Pallet; 16. Hoisting module; 17. Support and positioning module; 171. Loading plate; 172. L-shaped block; 18. Clamping module; 181. Clamping assembly; 1811. Clamping block; 1812. Clamping cylinder; 19. Flipping module; 191. Flipping motor; 20. Lifting module; 21. Rotating disk. DETAILED DESCRIPTION

[0034] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0035] like Figure 1 As shown, the power module assembly line of the embodiment of the present utility model includes a power module assembly line 13 and a tray assembly line 14; the power module assembly line 13 and the tray assembly line 14 are arranged up and down;

[0036] The power module assembly line 13 includes a flip-on line station 1, a module disassembly station 2, a bottom assembly station (including a bottom assembly station 3, a bottom wiring station 4, and a bottom inspection station 5), a middle assembly station (including a first middle assembly station 6, a middle wiring station 7, a second middle assembly station 8, and a middle inspection station 9), a top assembly and inspection station 10, a module testing station 11, and a flip-off line station 12.

[0037] A tray 15 is installed on the power module assembly line 13 to carry the power modules for circulation between the various stations;

[0038] The pallet assembly line 14 is used to transport the pallet 15 on the flip down line station 12 to the flip up line station 1 to realize the return of the pallet 15, such as Figure 2 As shown; the tray assembly line 14 is arranged below the power module assembly line 13, and automatic reflow is achieved in the line body without adding additional space and operation and maintenance costs;

[0039] The flip up-line station 1 and the flip down-line station 12 are both equipped with a lifting module 16, a support and positioning module 17, a clamping module 18 and a flipping module 19; the lifting module 16 is used to lift or lift the power module to the flip up-line station 1 and the flip down-line station 12; the support and positioning module 17 is used to support and position the power module; the clamping module 18 is used to clamp and fix the power module on the support and positioning module 17; the flipping module 19 is used to realize the flipping operation of the clamped and fixed power module.

[0040] like Figure 3-Figure 4 As shown, the flip loading station 1 is the first station of the entire line, used for hoisting and flipping power modules (rectifier modules and inverter modules) onto the production line. The corresponding hoisting module 16 is a KBK flexible hoist with three-dimensional movement above this station, matched with an intelligent hoist, which can lift the module from the pallet 15 on the ground to the production line; the support and positioning module 17 includes a carrier plate 171 and multiple L-shaped blocks 172 located on the side of the carrier plate 171, wherein the top of the L-shaped block 172 is used to support the power module, and the side of the L-shaped block 172 is used to position the power module; the clamping module 18 includes multiple clamping assemblies 181 arranged around the support and positioning module 17, each clamping assembly 181 includes a clamping block 1811 and a clamping cylinder 1812; the clamping block 1811 is located at the movable end of the clamping cylinder 1812; the flipping module 19 includes a flipping motor 191, which is connected to the carrier plate 171 via a reducer. The flip motor 191 is equipped with an overload circuit protection, which stops when encountering resistance during operation, eliminating the hidden danger of obstacles. At the same time, a redundant mechanism for manual operation is designed, so if there is a problem with the electrical program or sensor, manual mode operation can be performed. The above overall structure is simple and easy to operate.

[0041] Specifically, the main work content of the module disassembly station 2 is: disassembly of the various components of the module, placing the disassembled small materials on the material rack on the right, and placing the large materials in the material cart drawer on the left; a KBK intelligent hoist flexible lifting device is installed above the station, which is used for loading the standard module and disassembling and lifting the capacitor.

[0042] Specifically, at each assembly station, modules flow into the station after cleaning, where components on the bottom, middle, and top floors are installed and inspected. Next to the corresponding station is a screw tray and tool rack with a touch button for confirming material removal.

[0043] Specifically, when the upper part of the module is assembled, it automatically flows into the test room of the module testing station 11. The entrance of the test room is equipped with an automatic door. When the module flows in, the door automatically opens and automatically closes after the module enters, and then corresponding automatic debugging is performed.

[0044] like Figure 5 Specifically, both the upstream and downstream turning stations 1 and 12 are equipped with lifting modules 20 for lifting and lowering pallets 15. When a pallet reaches the corresponding downstream turning station 12, it is clamped onto the lifting module 19, and then the lifting module 20 descends into position, delivering the pallet 15 to the pallet assembly line 14 below for reflow. Once the pallet 15 has fully entered the reflow layer, the lifting module 19 flips over, and after the flip is complete, the pallet is hoisted off the line.

[0045] Specifically, a rotating disk 21 is provided at the bottom of the lifting module 20 to enable the module to rotate in the horizontal plane. Specifically, the rotating disk 21 is evenly distributed with eight detents, which can achieve 45-degree angle positioning, making it easy to rotate the position during assembly and disassembly. This allows the operator to complete all module operations from a single side, eliminating the need for back-and-forth movement.

[0046] The tray 15 features multiple slots for accommodating various components (rectifier modules, inverter modules, and standard drive modules). The contact points between the tray 15 and the modules are made of fiberglass composite material, offering excellent pressure resistance and insulation. A powered, rubber-coated chain is installed on the lifting module 20 to facilitate the loading and unloading of the tray 15.

[0047] The utility model realizes the reflow of modules and trays 15 from the line through the power module assembly line 13 and the tray assembly line 14 arranged vertically. The lifting module 20 is designed at the front and rear ends of the entire line body, which can save external space, make the overall production line neater and more beautiful, and at the same time simplify operations and save usage and maintenance costs.

[0048] Specifically, each workstation adopts a front and rear stop mechanism design. When the pallet 15 arrives after being sensed by the sensor, the front stop extends to stop the pallet 15, and then the rear clamping and positioning mechanism is activated to prevent the pallet 15 from sliding during operation.

[0049] Each workstation is equipped with a drawer-type cabinet for disassembly, placement, and transfer of materials; a material tool cart for storing materials and tools; and a material operation guide cart for storing materials, equipped with an operation guide IO light. The entire assembly line is equipped with three sets of intelligent electric hoists, placed at the top of the line body, for module loading and unloading, as well as capacitor replacement. The line body is equipped with tool placement tools for disassembly, cleaning, assembly, inspection, and testing stations. By setting up dedicated tooling on the production line, classification management is carried out. The handy design makes it easy to pick up tools, and it has tool selection instructions and pickup prompts. The transmission part of the line body must adopt a protective safety design to prevent small materials such as tools and bolts from falling into the track. Materials and tooling are integrated into the line body. Tools are directly in front of the operator and can be picked up by raising their hand. Materials are on the right side of the operator and can be picked up by turning around. Testing stations are integrated into the assembly line to ensure safety isolation. Products are only removed from the line after passing the test.

[0050] Specifically, the accumulation type friction wheel conveyor line combined with the metal roller double-speed chain line is used to automatically convey the modules on the assembly line, which can improve the load-bearing capacity and conveying stability; the flip-up line station 1, the module disassembly station 2 and the flip-down line station 12 are all equipped with KBK intelligent hoist flexible spreaders, and the auxiliary lifting equipment covers an area of ​​4 stations in the front and back. The use of telescopic lifting arm can reduce the floating of the product up and down and left and right during the lifting process. Compared with the improvement of lifting in other areas, it reduces walking, and the lifting equipment is also upgraded to ensure the safety and reliability of the lifting process.

[0051] On the power module assembly line 13, 10 modules can operate simultaneously without interfering with each other. By rationally dividing the working procedures, the cycle time can be set to less than 45 minutes, and the production time of each module can be reduced by more than 20 minutes.

[0052] Action process: Use the sling to lift the module above the carrier plate 171, slowly approach the L-shaped block 172 on the right, and slowly place it on the L-shaped block 172, observe to ensure the accuracy of the position, then remove the sling and move it to a safe position, clamp the module with the clamping blocks 1811, and then use the reducer of the flip module 19 to flip the module 180 degrees clockwise. After flipping into place; the pallet 15 flowing back from the bottom of the loading and flipping station flows back to the lifting module 20, the lifting module 20 rises to a certain position to lift the module, the clamping block 1811 retreats, and finally the conveyor on the elevator sends the pallet 15 to the module disassembly station 2 for disassembly, and then it is assembled at different positions in the bottom assembly station, the middle assembly station and the top assembly and inspection station 10 in turn. After the assembly is completed, it enters the module testing station 11 for testing. After the test is completed, it is flipped at the flipping offline station 12 and then taken offline (the offline operation is the opposite of the online operation).

[0053] In the description of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0054] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature specified as "first" or "second" may explicitly or implicitly include one or more of such features. In the description of this utility model, "plurality" means two or more, unless otherwise specifically defined.

[0055] In this utility model, unless otherwise specified or limited, the terms "assemble," "connect," "connect," "fix," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two components or interaction between two components. For those skilled in the art, the specific meanings of the above terms in this utility model can be understood according to specific circumstances.

[0056] The above are only preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be pointed out that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A power module assembly line, characterized in that: It comprises a power module assembly line (13) and a tray assembly line (14); the power module assembly line (13) and the tray assembly line (14) are arranged vertically; The power module assembly line (13) comprises a flip-up line station (1), a module disassembly station (2), a bottom assembly station, a middle assembly station, a top assembly and inspection station (10), a module testing station (11) and a flip-down line station (12) which are arranged in sequence; The power module assembly line (13) is provided with a tray (15) for carrying the power modules for circulation between various workstations; The pallet assembly line (14) is used to transport the pallets (15) on the flip downline station (12) to the flip upline station (1) to achieve the return of the pallets (15); The flip up-line station (1) and the flip down-line station (12) are both equipped with a hoisting module (16), a supporting and positioning module (17), a clamping module (18) and a flip module (19); The hoisting module (16) is used to hoist or remove the power module to the flip-up line station (1) and the flip-down line station (12); The supporting and positioning module (17) is used to support and position the power module; The clamping module (18) is used to clamp and fix the power module on the supporting positioning module (17); The flip module (19) is used to implement a flipping operation on a clamped and fixed power module.

2. The power module assembly line according to claim 1, characterized in that: The supporting and positioning module (17) comprises a carrier plate (171) and a plurality of L-shaped blocks (172) located around the carrier plate (171), wherein the top end of the L-shaped block (172) is used to support the power module, and the side edge of the L-shaped block (172) is used to position the power module.

3. The power module assembly line according to claim 2, characterized in that: The clamping module (18) includes a plurality of clamping assemblies (181) arranged around the supporting and positioning module (17), and each clamping assembly (181) includes a clamping block (1811) and a clamping cylinder (1812); the clamping block (1811) is located at the movable end of the clamping cylinder (1812).

4. The power module assembly line according to claim 3, characterized in that: The flip module (19) includes a flip motor (191), and the flip motor (191) is connected to the supporting plate (171).

5. The power module assembly line according to claim 1, 2 or 3, characterized in that: The power module assembly line (13) and the tray assembly line (14) are both power roller transmission line bodies.

6. The power module assembly line according to claim 1, 2 or 3, characterized in that: The flip up-line station (1) and the flip down-line station (12) are both equipped with a lifting module (20) for realizing the lifting and lowering of the tray (15).

7. The power module assembly line according to claim 6, characterized in that: A rotating disk (21) is provided at the bottom of the lifting module (20) for realizing the rotation of the module in a horizontal plane.

8. The power module assembly line according to claim 6, characterized in that: The tray (15) is provided with a plurality of placement slots for accommodating the placement of components of different types.

9. The power module assembly line according to claim 1, 2 or 3, characterized in that: The module disassembly station (2) is equipped with a drawer-type cabinet for placing and transporting disassembled materials.

10. The power module assembly line according to claim 1, 2 or 3, characterized in that: The bottom assembly station, the middle assembly station and the top assembly and inspection station (10) are all equipped with material and tool carts for placing materials and tools.

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