Planar transformer production test line

Abstract

The utility model belongs to the technical field of transformer production, and particularly relates to a plane transformer production test line which comprises an assembly jig, a front section assembly line, a middle section assembly line, a tail section test line and a width-adjustable conveying device. The front-section assembly line comprises a magnetic core assembly device, a PCB (Printed Circuit Board) mounting device, a dispensing device and a magnetic core frictioning assembly device; the middle section assembly line comprises an automatic sheath assembly work station, a body assembly work station and an upper cover assembly work station; the tail section test line comprises a test fixture, a horizontal backflow conveying device, a laser code printing and scanning device, a detection work station and a blanking device; the front section assembly line and the middle section assembly line are each provided with a width-adjustable conveying device. The width-adjustable conveying device is used for conveying the assembly jig. According to the method, the sequence of each process can be increased, deleted or adjusted according to actual requirements, so that the production process is optimized, and the production efficiency is improved. And the production line layout is compact, the production space is saved, and the production cost is reduced.

Description

Technical Field

[0001] This utility model belongs to the field of transformer manufacturing technology, and in particular relates to a planar transformer production and testing line. Background Technology

[0002] With the rapid development of electronic technology, planar transformers have been widely used in fields such as communications, medical, and aerospace due to their unique structural advantages and performance characteristics. Compared with traditional transformers, planar transformers have advantages such as small size, high power density, good heat dissipation, and high reliability, making them particularly suitable for high-frequency, high-power-density power conversion products.

[0003] In traditional planar transformer production, common steps include assembling the core, assembling the sheath, baking, and testing. These steps are typically performed in a fixed sequence, lacking flexibility. For example, certain special orders may require additional testing or specialized assembly processes, and traditional production methods struggle to respond quickly to these changes. Furthermore, a fixed production flow can lead to inefficiencies, as some steps may involve unnecessary waiting times, while other critical steps may be delayed due to improper resource allocation. Utility Model Content

[0004] The purpose of this utility model is to provide a planar transformer production and testing line, which aims to solve the technical problem that the existing transformer production methods are often fixed and singular, making it difficult to adapt to the ever-changing market demands.

[0005] To achieve the above objectives, this utility model provides a planar transformer production and testing line, comprising:

[0006] An assembly fixture, wherein the assembly fixture is provided with an installation station;

[0007] The front-end assembly line includes a magnetic core assembly device for loading magnetic cores and assembling them onto the assembly fixture to form a workpiece, a PCB mounting device for loading PCB boards and assembling them onto the workpiece, a dispensing device for applying adhesive to the workpiece, and a magnetic core scraping assembly device for scraping adhesive from the magnetic cores after dispensing. The assembly fixture passes sequentially through the magnetic core assembly device, the PCB mounting device, the dispensing device, and the magnetic core scraping assembly device.

[0008] The intermediate assembly line includes an automatic sheath assembly station for feeding and assembling sheaths onto workpieces, a body assembly station for feeding the main body and assembling it onto workpieces, and a cover assembly station for feeding the top cover and assembling it onto workpieces to form the product; the automatic sheath assembly station, the main body assembly station, and the cover assembly station are arranged in sequence.

[0009] The final testing line includes a test fixture for placing products, a horizontal return conveyor for moving the test fixture, a laser marking and scanning device for marking and scanning the products on the test fixture to generate corresponding product identification codes, a testing station for testing products, and a unloading device for sorting and unloading the tested products.

[0010] An adjustable-width conveyor is provided on both the front assembly line and the middle assembly line; the adjustable-width conveyor is used to convey assembly fixtures.

[0011] A baking device is provided between the front assembly line and the middle assembly line, and between the middle assembly line and the final test line, for drying the workpieces on the assembly fixture;

[0012] The baking feeding station is provided in both the front assembly line and the middle assembly line. The baking feeding station receives the assembly fixture conveyed by the width-adjustable conveyor and conveys the assembly fixture to the baking device.

[0013] Optionally, the width-adjustable conveying device includes a first conveying mechanism and a second conveying mechanism with opposite conveying directions, wherein the first conveying mechanism is disposed above the second conveying mechanism; the length of the first conveying mechanism is less than the length of the second conveying mechanism.

[0014] Optionally, the first conveying mechanism includes a fixed bracket, a first conveying component, a second conveying component, a driving element, and a width adjustment module; the first conveying component and the second conveying component are arranged parallel to and spaced apart on the width adjustment module, and a conveying position for conveying an assembly fixture is formed between the first conveying component and the second conveying component; the width adjustment module is disposed on the fixed bracket and is used to adjust the distance between the first conveying component and the second conveying component; the driving element is used to drive the first conveying component and the second conveying component to operate and realize conveying.

[0015] Optionally, both the front assembly line and the middle assembly line are equipped with a fixture lift, which is used to receive the assembly fixtures conveyed by the second conveying mechanism and convey them to the first conveying mechanism.

[0016] Optionally, the baking feeding station includes a docking bracket, and a leveling mechanism and a roller conveying mechanism both disposed on the docking bracket; one end of the roller conveying mechanism is connected to the width-adjustable conveying device, and the other end is connected to the baking device, and the conveying surface of the roller conveying mechanism is inclined downward in the conveying direction; the leveling mechanism is located above the roller conveying mechanism and is used to level the assembly fixture located on the roller conveying mechanism.

[0017] Optionally, the alignment mechanism includes a horizontal drive module, a vertical drive module, and an alignment plate; the horizontal drive module is disposed on the docking bracket; the vertical drive module is installed on the moving end of the horizontal drive module and can be driven to move horizontally; the alignment plate is installed on the lifting end of the vertical drive module and can be driven to move vertically, and the bottom of the alignment plate is parallel to the conveying surface of the roller conveying mechanism.

[0018] Optionally, the horizontal return conveying device includes two sets of parallel and spaced-apart horizontal conveying mechanisms, the conveying surfaces of the two sets of horizontal conveying mechanisms are located on the same horizontal plane, and the conveying directions are opposite.

[0019] Optionally, the testing station includes a high-voltage testing station, a comprehensive testing station, and a common-mode testing station arranged in sequence. The product is tested sequentially through the high-voltage testing station, the comprehensive testing station, and the common-mode testing station, and the data is transmitted to the unloading device.

[0020] Optionally, the magnetic core assembly device includes a mounting frame, and a magnetic core loading platform, a magnetic core waiting mechanism, a loading robot, and a transfer robot, all mounted on the mounting frame. The magnetic core loading platform has stacked trays containing magnetic cores. The magnetic core waiting mechanism is located beside the magnetic core loading platform. The loading robot picks up the magnetic cores from the magnetic core loading platform and places them onto the magnetic core waiting mechanism. The transfer robot picks up the magnetic cores from the magnetic core waiting mechanism and transfers them to the assembly position for assembly.

[0021] Optionally, the automatic assembly sheathing station includes a sheathing feeding mechanism, a sheathing receiving mechanism, a sheathing positioning mechanism, and a sheathing picking robot. The sheathing feeding mechanism is provided with a feeding position located beside the sheathing receiving mechanism. The sheathing receiving mechanism is used to receive the sheaths conveyed by the feeding position and rotates the received sheaths to achieve reversal. The sheathing positioning mechanism is disposed on the sheathing receiving mechanism and is used to position the sheaths after reversal. The sheathing picking robot is located above the sheathing receiving mechanism and is used to pick up the positioned sheaths and move them to the assembly position for assembly.

[0022] The planar transformer production and testing line provided in this utility model embodiment has at least one of the following technical effects: Automated assembly and testing lines reduce manual operation and human error, improving product consistency and reliability. The width-adjustable conveyor can be adjusted according to different product sizes, improving the adaptability and flexibility of the production line. Flexible adjustment of production processes adapts to different production needs, improving production efficiency and product quality. Traditional transformer production methods are often fixed and singular, making it difficult to adapt to changing market demands. This application allows for the addition, deletion, or adjustment of the sequence of processes according to actual needs, thereby optimizing the production process and improving production efficiency. The compact production line layout saves production space and reduces production costs. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the front-end assembly line provided in an embodiment of the present invention.

[0025] Figure 2 This is a schematic diagram of the structure of the mid-section assembly line provided in an embodiment of the present utility model.

[0026] Figure 3 This is a schematic diagram of the structure of the final test line provided in an embodiment of the present invention.

[0027] Figure 4 A schematic diagram of the width-adjustable conveying device provided in an embodiment of this utility model.

[0028] Figure 5 This is a schematic diagram of the lifting component provided in an embodiment of the present invention.

[0029] Figure 6 This is a schematic diagram of the baking feeding station provided in an embodiment of the present invention.

[0030] Figure 7 This is a schematic diagram of the magnetic core assembly device provided in an embodiment of the present invention.

[0031] Figure 8 A schematic diagram of the magnetic core waiting mechanism provided in an embodiment of this utility model.

[0032] Figure 9This is a structural schematic diagram of the automatic assembly sheathing station provided in an embodiment of the present utility model.

[0033] Figure 10 A schematic diagram of the sheath feeding mechanism provided in an embodiment of this utility model.

[0034] The following are the labeling elements in the figure:

[0035] Assembly fixture 10, front-end assembly line 20, magnetic core assembly device 21, PCB mounting device 22, dispensing device 23, magnetic core scraping assembly device 24, mounting frame 211, magnetic core loading platform 212, magnetic core waiting mechanism 213, loading robot 214, transfer robot 215, material tray receiving platform 216, waiting seat 2131, lateral limiting component 2132, longitudinal limiting component 2133, middle-end assembly line 30, automatic 31. Dynamic assembly station for sheath; 32. Body assembly station; 33. Top cover assembly station; 311. Sheath feeding mechanism; 312. Sheath receiving mechanism; 313. Sheath positioning mechanism; 314. Sheath picking robot; 3111. Vibration feeding assembly; 3112. Feeding guide rail; 3113. Stopping module; 40. Final test line; 41. Test fixture; 42. Horizontal return conveyor; 43. Laser marking and scanning device; 44. Inspection station; 45. Unloading device. Laser marking device 431, automatic barcode scanner 432, high voltage testing station 441, comprehensive testing station 442, common mode testing station 443, width adjustable conveying device 50, first conveying mechanism 51, second conveying mechanism 52, lifting mechanism 53, fixed bracket 511, first conveying component 512, second conveying component 513, drive element 514, width adjustment module 515, lifting component 531, detection sensor 532, stop component 533, mounting base 5151, moving plate 5152, screw 5153, turntable 5154, detection sensor 532, fixed seat 5311, lifting cylinder 5312, lifting plate 5313, baking device 60, jig lifter 70, baking feeding station 80, docking bracket 81, aligning mechanism 82, roller conveying mechanism 83, horizontal drive module 821, vertical drive module 822, aligning plate 823. Detailed Implementation

[0036] The embodiments of this utility model are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The following description is based on the accompanying drawings. Figures 1-10 The described embodiments are exemplary and intended to explain embodiments of the present invention, and should not be construed as limiting the present invention.

[0037] In the description of the embodiments of this utility model, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments of this utility model and simplifying the description, and do not 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 this utility model.

[0038] 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 indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0039] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0040] In one embodiment of this utility model, such as Figures 1-10As shown, a surface transformer production and testing line is provided, including an assembly fixture 10, a front-end assembly line 20, a middle-end assembly line 30, a final-end testing line 40, and a width-adjustable conveyor 50. The assembly fixture 10 is provided with mounting stations; the front-end assembly line 20 includes a magnetic core assembly device 21 for loading magnetic cores and assembling them onto the assembly fixture 10 to form workpieces, a PCB mounting device 22 for loading PCB boards and assembling them onto the workpieces, a dispensing device 23 for dispensing adhesive onto the workpieces, and a magnetic core scraping assembly device 24 for scraping adhesive from the dispensed magnetic cores; the assembly fixture 10 sequentially passes through the magnetic core assembly device 21, the PCB mounting device 22, the dispensing device 23, and the magnetic core scraping assembly device 24; the middle-end assembly line 30 includes an automatic sheath assembly station 31 for loading sheaths and assembling them onto workpieces, a body assembly station 32 for loading the main body and assembling it onto the workpieces, and a top cover assembly station 33 for loading and assembling the main body onto the workpieces. The top cover is assembled onto the workpiece to form the top cover assembly station 33; the automatic assembly sleeve station 31, the body assembly station 32, and the top cover assembly station 33 are arranged in sequence; the final test line 40 includes a test fixture 41 for placing the product, a horizontal return conveyor 42 for moving the test fixture 41, a laser marking and scanning device 43 for marking and scanning the product on the test fixture 41 to generate the corresponding product identification code, an inspection station 44 for inspecting the product, and a unloading device 45 for classifying and unloading the inspected products; both the front assembly line 20 and the middle assembly line 30 are equipped with width-adjustable conveyor devices 50; the width-adjustable conveyor devices 50 are used to convey the assembly fixture 10.

[0041] Specifically, the assembly fixture 10 is the core component of the production line, used to fix and support the workpieces, ensuring their stability and accuracy during assembly. The assembly fixture 10 has mounting stations for carrying and positioning the workpieces conveyed at each station. On the front assembly line 20, the assembly fixture 10 sequentially passes through the magnetic core assembly device 21, PCB mounting device 22, dispensing device 23, and magnetic core scraping assembly device 24, completing the initial assembly of the workpieces. The assembled workpieces are then conveyed sequentially through the width-adjustable conveyor 50 to the automatic assembly sleeve station 31, body assembly station 32, and top cover assembly station 33 of the middle assembly line 30, completing the final assembly of the product. The assembled products then enter the final testing line 40 via the width-adjustable conveyor 50 for testing and coding / scanning. Products that pass the tests are sorted and unloaded by the unloading device 45, completing the entire production and testing process.

[0042] In the front-end assembly line 20, the magnetic core assembly device 21 automatically loads the magnetic cores and precisely assembles them onto the assembly fixture 10, forming the basic structure of the workpiece. After the magnetic core assembly is completed, the PCB mounting device 22 automatically loads the PCB board and assembles it onto the workpiece to achieve circuit connection. The dispensing device 23 performs a dispensing operation on the assembled workpiece to fix the PCB board and other components. After dispensing, the magnetic core scraping assembly device 24 performs scraping treatment on the magnetic core to ensure uniform adhesive distribution, improve assembly quality, and enhance product sealing.

[0043] In the intermediate assembly line 30, the automatic sheath assembly station 31 automatically feeds and assembles the sheath onto the workpiece, providing additional protection and insulation. The body assembly station 32 automatically feeds and assembles the body onto the workpiece, completing the assembly of the main structure. The top cover assembly station 33 automatically feeds and assembles the top cover onto the workpiece, forming the final product.

[0044] In the final testing line 40, test fixture 41 is used to place assembled products for subsequent testing. A horizontal return conveyor 42 moves the test fixture 41 along the production line, ensuring products smoothly enter the testing stage. A laser marking and scanning device 43 marks and scans the products, generating corresponding product identification codes for easy product tracking and management. The inspection station 44 performs quality inspections to ensure products meet quality standards. The unloading device 45 sorts and unloads qualified products, preparing them for packaging or shipping.

[0045] Automated assembly and testing lines reduce manual labor, significantly improving production efficiency. Automated assembly and testing processes reduce human error, improving product consistency and reliability. The width-adjustable conveyor 50 can be adjusted to accommodate different product sizes, increasing the adaptability and flexibility of the production line. Product identification codes generated by the laser marking and scanning device 43 facilitate product tracking and management, improving production management efficiency. The compact production line layout saves production space and reduces production costs. Automated operation reduces workers' direct contact with hazardous parts, improving workplace safety.

[0046] In this example, baking devices 60 are installed between the front assembly line 20 and the middle assembly line 30, and between the middle assembly line 30 and the final testing line 40, to dry the workpieces on the assembly fixture 10. Specifically, after the workpieces are initially assembled on the front assembly line 20, they are conveyed to the baking device 60 for drying. After drying, the workpieces are conveyed to the middle assembly line 30, where all assembly steps are completed, and then they are again conveyed to the baking device 60 for drying. After drying, the workpieces are conveyed to the final testing line 40 for product quality inspection and subsequent processing such as coding and scanning. The main working principle of the baking device 60 is to use heat energy to dry the workpieces on the assembly fixture 10. During this process, the baking device 60 generates heat through heating elements, and the heat is evenly distributed through a hot air circulation system to ensure that all parts of the workpiece are thoroughly dried.

[0047] In this example, the width-adjustable conveyor 50 includes a first conveyor mechanism 51 and a second conveyor mechanism 52 with opposite conveying directions. The first conveyor mechanism 51 is positioned above the second conveyor mechanism 52; the length of the first conveyor mechanism 51 is less than the length of the second conveyor mechanism 52. Specifically, the design of the width-adjustable conveyor 50 allows it to accommodate assembly fixtures 10 and workpieces of different sizes. The device consists of two conveying mechanisms, a first conveyor mechanism 51 and a second conveyor mechanism 52, with opposite conveying directions. The first conveyor mechanism 51 is located above the second conveyor mechanism 52, which saves space and allows for a more flexible layout. The second conveyor mechanism 52 is longer than the first conveyor mechanism 51 and is used to receive (manually or with mechanical equipment) the assembly fixture 10 after it has been used by the first conveyor mechanism 51.

[0048] In this example, the first conveying mechanism 51 includes a fixed bracket 511, a first conveying assembly 512, a second conveying assembly 513, a drive element 514, and a width adjustment module 515. The first conveying assembly 512 and the second conveying assembly 513 are arranged parallel to and spaced apart on the width adjustment module 515, forming a conveying position for conveying the assembly fixture 10 between them. The width adjustment module 515 is disposed on the fixed bracket 511 and is used to adjust the distance between the first conveying assembly 512 and the second conveying assembly 513. The drive element 514 is used to drive the first conveying assembly 512 and the second conveying assembly 513 to operate and achieve conveying. Specifically, the two conveying assemblies are arranged parallel to and spaced apart on the width adjustment module 515, forming a conveying position for conveying the assembly fixture 10 between them. These conveying assemblies may consist of a series of rollers, chains, or belts, capable of carrying and moving the assembly fixture 10. This module is mounted on a fixed bracket 511, allowing adjustment of the spacing between the first conveying assembly 512 and the second conveying assembly 513 to accommodate assembly fixtures 10 of different widths. A drive element 514 (such as a motor and gear system) is used to drive the operation of the first conveying assembly 512 and the second conveying assembly 513 to achieve the conveying of the assembly fixture 10.

[0049] In this example, the width adjustment module 515 includes a mounting base 5151, a movable plate 5152, a screw 5153, and a turntable 5154. The mounting base 5151 is fixed to the bracket 5311. The first conveying assembly 512 is mounted on the mounting base 5151, and the second conveying assembly 513 is mounted on the movable plate 5152. The screw 5153 is rotatably connected to the mounting base 5151, and the movable plate 5152 is threadedly connected to the screw 5153. The turntable 5154 is connected to the screw 5153. Specifically, the mounting base 5151 is fixed to the bracket 511, providing a stable mounting foundation for the width adjustment module 515. The second conveying assembly 513 is mounted on the movable plate 5152, which can move along the thread of the screw 5153, thereby changing the distance between the second conveying assembly 513 and the first conveying assembly 512. The screw 5153 is rotatably connected to the mounting base 5151. Rotation of the screw 5153 causes the movable plate 5152 to move along the thread of the screw 5153, thereby adjusting the distance between the first conveying assembly 512 and the second conveying assembly 513. The turntable 5154 is connected to the screw 5153. The operator can drive the screw 5153 to rotate by rotating the turntable 5154, thereby controlling the position of the movable plate 5152 and adjusting the distance between the conveying assemblies. The threaded connection between the movable plate 5152 and the screw 5153 makes the adjustment mechanism compact and space-saving, suitable for production line environments with limited space. The mechanical connection between the screw 5153 and the turntable 5154 is relatively simple and durable, reducing the risk of production line downtime due to adjustment mechanism failure. Because the width adjustment module 515 has a relatively simple structure, maintenance and replacement costs are low, helping to reduce overall production costs.

[0050] In this example, the width-adjustable conveying device 50 also includes a lifting mechanism 53, which includes a lifting component 531, a detection sensor 532, and a stop component 533. The lifting component 531 is installed below the first conveying mechanism 51 and is used to separate the assembly fixture 10 from the conveying surface of the first conveying mechanism 51. The detection sensor 532 and the stop component 533 are electrically connected. After the detection sensor 532 detects the assembly fixture 10 passing by, one end of the stop component 533 moves upward and prevents the assembly fixture 10 from moving. Specifically, the detection sensor 532 is located at one end of the lifting component 531 along the conveying direction to detect the position of the assembly fixture 10 and ensure the accuracy of the lifting action. The stop component 533 is located at the other end of the detection sensor 532. When the detection sensor 532 detects the assembly fixture 10 passing by, one end of the stop component 533 moves upward to prevent further movement of the assembly fixture 10, thus preventing the subsequent conveyed fixtures from affecting the lifting of the preceding fixtures in the correct position. The lifting assembly 531 is electrically connected to the detection sensor 532 and the stop assembly 533 to form a control loop, ensuring the coordination and precision of the lifting action. The detection sensor 532 and the stop assembly 533 are sequentially arranged at both ends of the lifting assembly 531 along the conveying direction to ensure the sequential execution of the lifting action.

[0051] In this example, the lifting assembly 531 includes a fixed base 5311, a lifting cylinder 5312, and a lifting plate 5313. The fixed base 5311 is mounted on the first conveying mechanism 51, the lifting cylinder 5312 is mounted on the fixed base 5311, and the lifting plate 5313 is connected to the moving end of the lifting cylinder 5312. When the assembly fixture 10 is detected, the detection sensor 532 transmits a signal to control the lifting cylinder 5312 to start. Specifically, when the assembly fixture 10 reaches a predetermined position, the detection sensor 532 can detect it and send a signal. The lifting plate 5313 is connected to the moving end of the lifting cylinder 5312. When the lifting cylinder 5312 is started, the lifting plate 5313 rises or falls accordingly, realizing the lifting or lowering of the assembly fixture 10. The detection sensor 532 is electrically connected to the lifting cylinder 5312 and is used to control the start of the lifting cylinder 5312. The lifting cylinder 5312 is mounted on the fixed base 5311, and its moving end is mechanically connected to the lifting plate 5313 to transmit the lifting action. The fixed base 5311 is directly mounted on the first conveying mechanism 51 to provide support for the lifting assembly 531. The detection sensor 532 can accurately detect the position of the assembly fixture 10, ensuring that the lifting action is performed at the correct time and improving assembly accuracy.

[0052] In this example, both the front assembly line 20 and the middle assembly line 30 are equipped with fixture lifts 70. The fixture lifts 70 receive the assembly fixtures 10 conveyed by the second conveyor mechanism 52 and transport them to the first conveyor mechanism 51. Specifically, the fixture lift 70 first receives the assembly fixture 10 conveyed by the second conveyor mechanism 52, preparing to transfer it to the first conveyor mechanism 51. The fixture lift 70 adjusts the height of the fixture using a lifting mechanism (such as a hydraulic or pneumatic system) to match the conveying surface of the first conveyor mechanism 51. After lifting the assembly fixture 10 to the appropriate height, the fixture lift 70 moves it onto the conveying surface of the first conveyor mechanism 51, ensuring a smooth transition of the fixture to the next assembly stage. This reduces the safety risks for operators during fixture transfer and improves the safety of the production line.

[0053] In this example, both the front assembly line 20 and the middle assembly line 30 include a baking feed station 80. The baking feed station receives the assembly fixture 10 conveyed by the width-adjustable conveyor 50 and transports the assembly fixture 10 to the baking apparatus 60. Specifically, the baking feed station 80 first receives the assembly fixture 10 conveyed by the width-adjustable conveyor 50, preparing to transfer it to the baking apparatus 60. The baking feed station 80 ensures a smooth transition of the assembly fixture 10 between different production stages, reducing potential delays or damage caused by manual fixture transfer.

[0054] In this example, the baking feed station 80 includes a docking bracket 81, and a leveling mechanism 82 and a roller conveyor mechanism 83, both mounted on the docking bracket 81. One end of the roller conveyor mechanism 83 docks with the width-adjustable conveyor 50, and the other end docks with the baking device 60. The conveying surface of the roller conveyor mechanism 83 is inclined downwards in the conveying direction. The leveling mechanism 82 is located above the roller conveyor mechanism 83 and is used to level the assembly fixture 10 located on the roller conveyor mechanism 83. Specifically, the docking bracket 81 serves as the basic structure of the baking feed station 80, supporting the leveling mechanism 82 and the roller conveyor mechanism 83 and ensuring their proper docking. The roller conveyor mechanism 83 consists of a series of rollers and is responsible for conveying the assembly fixture 10 from the width-adjustable conveyor 50 to the baking device 60. The downward-inclined conveying surface of the roller conveyor mechanism 83 helps guide the assembly fixture 10 to move smoothly while reducing the risk of damage due to friction or jamming. The alignment mechanism 82 ensures the correct position and orientation of the assembly fixture 10 before it enters the baking apparatus 60, improving the quality and consistency of the baking process.

[0055] In this example, the alignment mechanism 82 includes a horizontal drive module 821, a vertical drive module 822, and an alignment plate 823. The horizontal drive module 821 is mounted on the docking bracket 81. The vertical drive module 822 is installed at the moving end of the horizontal drive module 821 and is driven to move horizontally. The alignment plate 823 is installed at the lifting end of the vertical drive module 822 and is driven to move vertically, with its bottom parallel to the conveying surface of the roller conveying mechanism 83. Specifically, the horizontal drive module 821, mounted on the docking bracket 81, is responsible for driving the alignment plate 823 to move horizontally to accommodate the assembly fixture 10 at different positions. The vertical drive module 822, mounted at the moving end of the horizontal drive module 821, is driven to move horizontally. This module is responsible for moving the alignment plate 823 to the correct position after detecting the assembly fixture 10. The alignment plate 823 is installed on the lifting end of the vertical drive module 822 and can move in the vertical direction. The bottom of the alignment plate 823 is set parallel to the conveying surface of the roller conveying mechanism 83 to ensure that the alignment plate 823 can contact the assembly fixture 10 and be aligned.

[0056] In this example, the horizontal return conveyor 42 includes two sets of parallel and spaced-apart horizontal conveying mechanisms. The conveying surfaces of the two sets of horizontal conveying mechanisms are located on the same horizontal plane, and their conveying directions are opposite. Specifically, the horizontal return conveyor 42 is designed to convey products in two directions, allowing products to be returned or diverted to different processing stations after testing. The horizontal return conveyor 42 consists of two sets of parallel and spaced-apart horizontal conveying mechanisms located on the same horizontal plane, ensuring a smooth transition of products during conveying. The two sets of conveying mechanisms have opposite conveying directions; one set is used to convey products forward, and the other set is used to convey products in reverse, realizing the return of products.

[0057] In this example, the laser marking and scanning device 43 includes a laser marking device 431 and an automatic scanning device 432 arranged sequentially. The product is marked by the laser marking device 431, and then scanned by the automatic scanning device 432 to form a corresponding product identification code. Specifically, laser technology is used to create permanent markings on the product surface, such as barcodes, QR codes, or other types of codes. The laser marking device 431 forms the desired pattern or text on the product surface by controlling the on and off of the laser beam. After laser marking is completed, the automatic scanning device 432 reads the code in the marked area and identifies and verifies it. This is typically achieved using a camera and image recognition software, enabling quick and accurate identification of codes on the product. Once the code is successfully read, the automatic scanning device 432 converts the identified information into digital form, forming the corresponding product identification code. This information can be used for product tracking, inventory management, and quality control.

[0058] In this example, the testing station 44 includes a high-voltage testing station 441, a comprehensive testing station 442, and a common-mode testing station 443 arranged sequentially. The product is tested sequentially through these stations, and the data is transmitted to the unloading device 45. Specifically, the product is first subjected to a high-voltage test to verify whether its insulation materials and structure can withstand a predetermined high voltage without breakdown or flashover. After the high-voltage test, the product enters the comprehensive testing station 442 for more comprehensive electrical performance testing, which may include, but is not limited to, insulation resistance testing, grounding resistance testing, and withstand voltage testing. Finally, the product passes through the common-mode testing station 443 to test its performance under common-mode interference to ensure that the product can resist external electromagnetic interference in actual use. Each testing station is equipped with a data acquisition system, and the test results are recorded in real time and transmitted to the unloading device 45 for subsequent processing.

[0059] In this example, the magnetic core assembly device 21 includes a mounting frame 211, and a magnetic core loading platform 212, a magnetic core waiting mechanism 213, a loading robot 214, and a transfer robot 215, all mounted on the mounting frame 211. The magnetic core loading platform 212 has stacked trays containing magnetic cores. The magnetic core waiting mechanism 213 is located beside the magnetic core loading platform 212. The loading robot 214 picks up the magnetic cores from the magnetic core loading platform 212 and places them onto the magnetic core waiting mechanism 213. The transfer robot 215 picks up the magnetic cores from the magnetic core waiting mechanism 213 and transfers them to the assembly position for assembly. Specifically, the magnetic core loading platform 212 is used to stack trays containing magnetic cores to be used. The platform is designed for automatic or manual tray replenishment. The magnetic core waiting mechanism 213 is located beside the magnetic core loading platform 212 and is used to temporarily store the magnetic cores picked up by the loading robot 214. The transfer robot 215 picks up the magnetic core from the magnetic core waiting mechanism 213 and precisely transfers it to the assembly position for assembly. The magnetic core assembly device 21 realizes automatic feeding and transfer of magnetic cores, reduces manual operation, and improves the degree of production automation.

[0060] In this example, the magnetic core waiting mechanism 213 includes a waiting base 2131, and a lateral limiting component 2132 and a longitudinal limiting component 2133, both disposed on the waiting base 2131. The waiting base 2131 has a waiting slot. The lateral limiting component 2132 and the longitudinal limiting component 2133 work together to confine the magnetic core within the waiting slot. Specifically, the waiting base 2131 has a waiting slot for placing the magnetic core. The lateral limiting component 2132, disposed on the waiting base 2131, restricts the left-right movement of the magnetic core within the waiting slot, ensuring the magnetic core's position is fixed in the horizontal direction. The longitudinal limiting component 2133, also disposed on the waiting base 2131, restricts the front-back movement of the magnetic core within the waiting slot, ensuring the magnetic core's position is fixed in the longitudinal direction. The lateral limiting component 2132 and the longitudinal limiting component 2133 work together to form a stable limiting system, precisely confining the magnetic core within the waiting slot. Through the synergistic effect of the lateral and longitudinal limiting components 2133, the magnetic core is precisely positioned in the waiting slot, providing a guarantee for subsequent transfer and assembly.

[0061] This example also includes a tray receiving platform 216, located beside the core loading platform 212. The loading robot 214 transfers empty trays to the tray receiving platform 216 for stacking. Specifically, a dedicated area is provided beside the core loading platform 212 for storing empty trays. The tray receiving platform 216 is adjacent to the core loading platform 212, allowing the loading robot 214 to easily transfer empty trays between them. By centrally storing empty trays, the tray receiving platform 216 helps optimize space utilization in the production area and reduces cluttered stacking.

[0062] In this example, the automatic sheath assembly station 31 includes a sheath feeding mechanism 311, a sheath receiving mechanism 312, a sheath positioning mechanism 313, and a sheath picking robot 314. The sheath feeding mechanism 311 has a feeding position located beside the sheath receiving mechanism 312. The sheath receiving mechanism 312 receives the sheaths conveyed from the feeding position and rotates the received sheaths to achieve reversal. The sheath positioning mechanism 313 is located on the sheath receiving mechanism 312 and is used to position the reversed sheaths. The sheath picking robot 314 is located above the sheath receiving mechanism 312 and is used to pick up the positioned sheaths and move them to the assembly position for assembly. Specifically, the sheath feeding mechanism 311 includes a feeding position for placing and conveying sheaths. The feeding position can be a position for manually or automatically replenishing sheaths. The sheath receiving mechanism 312 is located beside the sheath feeding mechanism 311 and is used to receive the sheaths conveyed from the feeding position. This mechanism also rotates the sheath to achieve reversal, ensuring the correct orientation and position of the sheath. A sheath positioning mechanism 313 is mounted on the sheath receiving mechanism 312 to precisely position the reversed sheath for subsequent picking and assembly. A sheath picking robot 314 is located above the sheath receiving mechanism 312 to pick up the positioned sheath and move it to the assembly position for assembly. The robot may be equipped with a vision system and precise gripping devices to ensure accurate operation. The sheath feeding mechanism 311, sheath receiving mechanism 312, sheath positioning mechanism 313, and sheath picking robot 314 are all connected by a mounting frame 211 or a similar structure to ensure coordinated operation. The sheath receiving mechanism 312 is connected to the feeding position of the sheath feeding mechanism 311 to receive the conveyed sheath. The sheath positioning mechanism 313 is fixed to the sheath receiving mechanism 312 to position the sheath. The sheath picking robot 314 is connected to the mounting frame 211 via its drive system (such as a servo motor and transmission mechanism) to achieve precise movement and operation. The automatic sheath assembly station 31 realizes automatic feeding, receiving, positioning and picking of sheaths, reducing manual operation and improving the degree of production automation.

[0063] In this example, the sheath feeding mechanism 311 includes a vibratory feeding assembly 3111, a feeding guide rail 3112, and a stop module 3113. The discharge port of the vibratory feeding assembly 3111 is connected to the feeding guide rail 3112, and the vibratory feeding assembly 3111 conveys the sheaths into the feeding guide rail 3112 through vibration. The discharge end of the shrinkage feeding guide rail 3112 is located close to the sheath receiving mechanism 312. The stop module 3113 is located at the discharge end of the feeding guide rail 3112 and is used to control the sheath unloading from the feeding guide rail 3112. Specifically, the vibratory feeding assembly 3111 uses the principle of vibration to convey the sheaths in the tray one by one to the discharge port. Vibration can promote the movement of the sheaths, ensuring that they can continuously enter the feeding guide rail 3112. The feeding guide rail 3112 connects to the discharge port of the vibratory feeding assembly 3111, forming a channel for conveying the sheath from the vibratory feeding assembly 3111 to the sheath receiving mechanism 312. The guide rail design helps guide and stabilize the conveying path of the sheath. A stop module 3113 is located at the discharge end of the feeding guide rail 3112 to control the unloading of the sheath. The stop module 3113 can be mechanically or electronically controlled, capable of stopping or releasing the sheath as needed, ensuring that the sheath enters the sheath receiving mechanism 312 at a predetermined rhythm. The discharge port of the vibratory feeding assembly 3111 directly connects to the feeding guide rail 3112, ensuring that the sheath can be smoothly conveyed from the tray to the guide rail. The discharge end of the feeding guide rail 3112 is located close to the sheath receiving mechanism 312 so that the sheath can directly enter the receiving mechanism. The material stopping module 3113 is installed at the discharge end of the feeding guide rail 3112 and works in conjunction with the sheath receiving mechanism 312 to control the feeding time and quantity of the sheath.

[0064] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A planar transformer production and testing line, characterized in that, include: An assembly fixture, wherein the assembly fixture is provided with an installation station; The front-end assembly line includes a magnetic core assembly device for loading magnetic cores and assembling them onto the assembly fixture to form a workpiece, a PCB mounting device for loading PCB boards and assembling them onto the workpiece, a dispensing device for applying adhesive to the workpiece, and a magnetic core scraping assembly device for scraping adhesive from the magnetic cores after dispensing. The assembly fixture passes sequentially through the magnetic core assembly device, the PCB mounting device, the dispensing device, and the magnetic core scraping assembly device. The intermediate assembly line includes an automatic sheath assembly station for feeding and assembling sheaths onto workpieces, a body assembly station for feeding the main body and assembling it onto workpieces, and a cover assembly station for feeding the top cover and assembling it onto workpieces to form the product; the automatic sheath assembly station, the main body assembly station, and the cover assembly station are arranged in sequence. The final testing line includes a test fixture for placing products, a horizontal return conveyor for moving the test fixture, a laser marking and scanning device for marking and scanning the products on the test fixture to generate corresponding product identification codes, a testing station for testing products, and a unloading device for sorting and unloading the tested products. An adjustable-width conveyor is provided on both the front assembly line and the middle assembly line; the adjustable-width conveyor is used to convey assembly fixtures. A baking device is provided between the front assembly line and the middle assembly line, and between the middle assembly line and the final test line, for drying the workpieces on the assembly fixture; The baking feeding station is provided in both the front assembly line and the middle assembly line. The baking feeding station receives the assembly fixture conveyed by the width-adjustable conveyor and conveys the assembly fixture to the baking device.

2. The planar transformer production and testing line according to claim 1, characterized in that: The width-adjustable conveying device includes a first conveying mechanism and a second conveying mechanism with opposite conveying directions. The first conveying mechanism is located above the second conveying mechanism. The length of the first conveying mechanism is less than the length of the second conveying mechanism.

3. The planar transformer production and testing line according to claim 2, characterized in that: The first conveying mechanism includes a fixed bracket, a first conveying component, a second conveying component, a driving element, and a width adjustment module. The first conveying component and the second conveying component are arranged parallel to each other and spaced apart on the width adjustment module, and a conveying position for conveying an assembly fixture is formed between the first conveying component and the second conveying component. The width adjustment module is disposed on the fixed bracket and is used to adjust the distance between the first conveying component and the second conveying component. The driving element is used to drive the first conveying component and the second conveying component to operate and realize conveying.

4. The planar transformer production and testing line according to claim 2, characterized in that: Both the front assembly line and the middle assembly line are equipped with fixture lifts. The fixture lifts are used to receive the assembly fixtures conveyed by the second conveying mechanism and convey them to the first conveying mechanism.

5. The planar transformer production and testing line according to claim 1, characterized in that: The baking feeding station includes a docking bracket, and a leveling mechanism and a roller conveying mechanism, both mounted on the docking bracket. One end of the roller conveying mechanism is connected to the width-adjustable conveying device, and the other end is connected to the baking device. The conveying surface of the roller conveying mechanism is inclined downward in the conveying direction. The leveling mechanism is located above the roller conveying mechanism and is used to level the assembly fixture located on the roller conveying mechanism.

6. The planar transformer production and testing line according to claim 5, characterized in that: The alignment mechanism includes a horizontal drive module, a vertical drive module, and an alignment plate; the horizontal drive module is mounted on the docking bracket; the vertical drive module is installed on the moving end of the horizontal drive module and can move horizontally by drive; the alignment plate is installed on the lifting end of the vertical drive module and can move vertically by drive, and the bottom of the alignment plate is parallel to the conveying surface of the roller conveying mechanism.

7. The planar transformer production and testing line according to claim 1, characterized in that: The horizontal return conveying device includes two sets of parallel and spaced-apart horizontal conveying mechanisms. The conveying surfaces of the two sets of horizontal conveying mechanisms are located on the same horizontal plane, and the conveying directions are opposite.

8. The planar transformer production and testing line according to claim 1, characterized in that: The testing station includes a high-voltage testing station, a comprehensive testing station, and a common-mode testing station arranged in sequence. The product is tested in sequence through the high-voltage testing station, the comprehensive testing station, and the common-mode testing station, and the data is transmitted to the unloading device.

9. The planar transformer production and testing line according to claim 1, characterized in that: The magnetic core assembly device includes a mounting frame, and a magnetic core loading platform, a magnetic core waiting mechanism, a loading robot, and a transfer robot, all mounted on the mounting frame. The magnetic core loading platform has stacked trays containing magnetic cores. The magnetic core waiting mechanism is located beside the magnetic core loading platform. The loading robot picks up the magnetic cores from the magnetic core loading platform and places them onto the magnetic core waiting mechanism. The transfer robot picks up the magnetic cores from the magnetic core waiting mechanism using magnetic attraction and transfers them to the assembly position for assembly.

10. The planar transformer production and testing line according to claim 1, characterized in that: The automatic assembly sheathing station includes a sheathing feeding mechanism, a sheathing receiving mechanism, a sheathing positioning mechanism, and a sheathing picking robot. The sheathing feeding mechanism is provided with a feeding position located next to the sheathing receiving mechanism. The sheathing receiving mechanism is used to receive the sheaths conveyed by the feeding position and rotates the received sheaths to achieve reversal. The sheathing positioning mechanism is located on the sheathing receiving mechanism and is used to position the reversed sheaths. The sheathing picking robot is located above the sheathing receiving mechanism and is used to pick up the positioned sheaths and move them to the assembly position for assembly.

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