Foaming injection device of water heater

Abstract

The utility model discloses a water heater foaming material injection device which comprises a fixing rack and a material injection gun, a positioning adjusting mechanism is installed on the fixing rack, a connecting assembly is connected to the positioning adjusting mechanism in a transmission mode, and the material injection gun is installed on the connecting assembly. According to the utility model, a water heater injection hole needing to be injected is captured and positioned through the hole site identification mechanism, and the positioning and adjusting mechanism synchronously adjusts the X-axis position, the Y-axis position and the Z-axis position, so that the injection gun is preliminarily aligned with a target hole site of the water heater, X-direction and Y-direction position deviation is identified and calculated, and the positioning and adjusting mechanism is driven to complete X-direction and Y-direction position positioning; a first Z-direction driving servo motor drives a Z-direction ball screw to drive a material injection gun, a gun hole of the material injection gun penetrates into a water heater material injection hole, accurate positioning and posture adjustment of the foaming material injection gun among the material injection holes are achieved, a foaming material with a preset volume is injected into the water heater hole, the foaming material injection procedure of the water heater is completed, automatic accurate material injection and filling operation is achieved, and the production efficiency is improved. The structure is simple, reliable and convenient to use.

Description

Technical Field

[0001] This utility model relates to the field of automatic foaming material injection, and in particular to a foaming material injection device for water heaters. Background Technology

[0002] The cavity between the inner tank and outer shell of a water heater is typically insulated with polyurethane foam. Because this cavity contains pipe connections and related electronic components, the flow of the foam material is somewhat hindered. When the water heater is held in place by a fixture, multiple injection holes exist. The injection gun is used to distribute the foam injection volume appropriately, ensuring uniform filling of the cavity. However, when the injection gun moves between the multiple injection holes, misalignment between the gun head and the holes often occurs, causing foam material to overflow, resulting in material waste and equipment contamination.

[0003] Therefore, it is necessary to develop a foaming and injection device for water heaters to solve the above problems. Utility Model Content

[0004] The technical problem to be solved by this utility model is to provide a water heater foaming and injection device that addresses the shortcomings of the prior art, enabling the injection gun to automatically and accurately position the injection hole and adjust its orientation, effectively avoiding overflow, and with a simple and reliable structure, thus overcoming the technical defects of the prior art mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0006] A water heater foaming and injection device includes a fixed frame and an injection gun. A positioning and adjustment mechanism is installed on the fixed frame, and a connecting component is driven to it. The injection gun is installed on the connecting component, and the injection gun moves with the connecting component in the X-axis, Y-axis and Z-axis directions of the fixed frame, wherein the X-axis, Y-axis and Z-axis directions correspond to the length direction, width direction and height direction of the fixed frame, respectively.

[0007] The injection gun has an anti-collision sealing structure on the outside of the gun body output port to protect the gun body structure and seal the gap between the injection gun output port and the injection hole.

[0008] The device also includes a hole position recognition mechanism, which is used to identify the position of the injection hole and drive the injection gun to move so that its gun hole is coaxially aligned with the injection hole to be positioned.

[0009] Preferably, the connecting assembly includes a second Y-direction transition connecting plate, a third linear guide rail, and a connecting plate. The second Y-direction transition connecting plate has an L-shaped cross-section and is equipped with two guide posts for guiding the connecting plate to slide vertically along the Y direction on the third linear guide rail. Anti-collision springs are sleeved on the outer side of the guide posts.

[0010] The linear guide rail is fixed to one side of the Y-direction transition connecting plate, and the connecting plate is vertically fixed to one side of the injection gun, so that the output port of the injection gun is set vertically downward.

[0011] Preferably, the positioning adjustment mechanism includes an X-axis adjustment component, a Y-axis adjustment component, a Z-axis adjustment component, and a mounting plate, wherein the mounting plate is movably attached to the top of the fixed frame, and a suspension bracket is fixedly connected at the center of the bottom of the mounting plate. The mounting plate moves in the X-axis direction of the fixed frame through the X-axis adjustment component, and the Y-axis adjustment component and the Z-axis adjustment component move with the mounting plate.

[0012] The Y-axis adjustment component is used to adjust the position of the injection gun in the Y-axis direction;

[0013] The Z-axis adjustment component is used to adjust the position of the injection gun in the Z-axis direction.

[0014] Preferably, the X-axis adjustment assembly includes an X-axis drive servo motor II fixedly connected to the mounting plate, the output shaft of which extends to the bottom of the mounting plate and is connected to an X-axis drive gear. An X-axis linear guide rail IV is installed on one side of the top of the fixed frame, and an X-axis rack that meshes with the X-axis drive gear is installed on the X-axis linear guide rail IV.

[0015] Preferably, the Z-axis adjustment assembly includes a Z-axis transition connecting plate and a Z-axis linear guide rail, wherein the number of Z-axis linear guide rails is set to two, the two Z-axis linear guide rails are distributed in parallel and fixed on the outer wall of the suspension frame, and the Z-axis transition connecting plate slides on the Z-axis linear guide rails.

[0016] The Z-axis adjustment assembly also includes a Z-axis drive unit for driving the Z-axis transition connecting plate to move in the Z-axis direction.

[0017] Preferably, the Z-axis drive unit adopts a pneumatic drive structure, which includes a Z-axis drive cylinder fixed on the mounting plate. The drive cylinder connection end is provided with an air supply device as a power source, and the Z-axis drive cylinder output end is connected to the Z-axis transition connection plate through a hinge transmission.

[0018] Preferably, the Z-axis drive unit adopts a screw drive structure, which includes a Z-axis drive servo motor fixedly connected to the suspension frame. The output shaft of the Z-axis drive servo motor is driven by a Z-axis ball screw. A Z-axis limiting groove is provided on the side of the suspension frame. A traction plate that slides with the Z-axis limiting groove is fixedly connected to a Z-axis transition connecting plate, and the traction plate is connected to a movable nut on the Z-axis ball screw.

[0019] Preferably, the Y-axis adjustment component includes a Y-axis linear module fixed on a Z-axis transition connecting plate, and parallel Y-axis linear guide rails are also provided on both sides of the Y-axis linear module on the Z-axis transition connecting plate. The Y-axis transition connecting plate is slidably connected to the two Y-axis linear guide rails, and the drive slider of the Y-axis linear module is connected to the Y-axis transition connecting plate.

[0020] Preferably, the anti-collision sealing structure adopts a rubber kit, which is interference-fitted on the outside of the injection gun body, and the outer diameter of the rubber kit is larger than the inner diameter of the injection hole.

[0021] Preferably, the hole position recognition mechanism includes a 2D vision sensor and a microcontroller, wherein the 2D vision sensor is mounted on the bottom of the connecting plate via an L-shaped bracket, and the 2D vision sensor is vertically attached to one side of the injection gun.

[0022] The microcontroller's input and output terminals are electrically connected to an A / D converter and a D / A converter, respectively. The 2D vision sensor is communicatively connected to the A / D converter. The X-axis drive servo motor, the Z-axis drive unit, and the Y-axis linear module are all communicatively connected to the D / A converter.

[0023] This utility model has the following beneficial effects:

[0024] The hole position recognition mechanism captures and positions the water heater injection hole that needs to be filled. The positioning adjustment mechanism simultaneously adjusts the X, Y, and Z axis positions, so that the injection gun is initially aligned with the target hole position of the water heater. The X and Y position deviations are identified and calculated, and the positioning adjustment mechanism is driven to complete the X and Y position positioning. The Z-axis drive servo motor drives the Z-axis ball screw to drive the injection gun, so that its gun hole is inserted into the water heater injection hole. This achieves precise positioning and attitude adjustment of the foaming injection gun among multiple injection holes, injecting a predetermined volume of foaming material into the water heater hole, completing the water heater foaming injection process, and realizing automated and precise injection and filling operation. The structure is simple, reliable, and easy to use. Attached Figure Description

[0025] Figure 1 A schematic diagram of the overall structure of the water heater foaming and injection device provided by this utility model;

[0026] Figure 2 This is a perspective view of the positioning adjustment mechanism (Z-axis drive unit adopts Embodiment 1) in this utility model;

[0027] Figure 3 This is a perspective view of the Z-axis adjustment component (the Z-axis drive unit adopts Embodiment 2) in this utility model;

[0028] Figure 4 This is a schematic diagram showing the distribution structure of the connecting components, the injection gun, and the 2D vision sensor in this utility model.

[0029] Figure 5 This is a system control flowchart of the hole position recognition control system in this utility model.

[0030] Among them are:

[0031] 1-Fixed frame; 2-Positioning adjustment mechanism; 3-Injection gun;

[0032] 21-Mounting plate; 22-Z-direction linear guide rail one; 23-Z-direction transition connecting plate one; 24-Z-direction drive cylinder; 25-Z-direction ball screw; 26-Z-direction drive servo motor one; 27-Y-direction linear guide rail two; 28-Y-direction linear module; 29-Y-direction transition connecting plate two; 210-Linear guide rail three; 211-Connecting plate; 212-X-direction drive servo motor two; 213-X-direction drive gear; 215-X-direction linear guide rail four; 214-X-direction rack; 216-2D vision sensor; 217-Guide post; 218-Anti-collision spring; 219-Suspension bracket; 220-Z-direction limiting groove; 221-Traction plate; 222-Microcontroller; 223-L-shaped bracket. Detailed Implementation

[0033] The present invention will now be described in further detail with reference to the accompanying drawings and specific preferred embodiments.

[0034] In the description of this utility model, it should be understood that the terms "left side," "right side," "upper part," "lower part," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. "First," "second," etc., do not indicate the importance of the components, and therefore should not be construed as a limitation of this utility model. The specific dimensions used in this embodiment are only for illustrating the technical solution and do not limit the protection scope of this utility model.

[0035] like Figure 1-4 As shown, a water heater foaming and injection device includes a fixed frame 1 and an injection gun 3. A positioning and adjustment mechanism 2 is installed on the fixed frame 1, and a connecting component is driven to it. The injection gun 3 is installed on the connecting component, and the injection gun 3 moves with the connecting component in the X-axis, Y-axis and Z-axis directions of the fixed frame 1, wherein the X-axis, Y-axis and Z-axis directions correspond to the length direction, width direction and height direction of the fixed frame 1, respectively.

[0036] The injection gun 3 has an anti-collision sealing structure on the outside of the gun body output port, which is used to protect the gun body structure of the injection gun 3 and seal the joint gap between the injection gun 3 output port and the injection hole.

[0037] The device also includes a hole position recognition mechanism, which is used to identify the position of the injection hole and drive the injection gun 3 to move so that its gun hole is coaxially aligned with the injection hole to be positioned.

[0038] Specifically, in the above technical solution, the connecting assembly includes a Y-direction transition connecting plate 29, a linear guide rail 210, and a connecting plate 211. The Y-direction transition connecting plate 29 has an L-shaped cross section and is equipped with two guide posts 217 to guide the connecting plate 211 to slide vertically along the Y direction on the linear guide rail 210. Anti-collision springs 218 are sleeved on the outside of the guide posts 217.

[0039] Linear guide rail 210 is fixed to one side of Y-direction transition connecting plate 29, and connecting plate 211 is vertically fixed to one side of injection gun 3, so that the output port of injection gun 3 is vertically downward. When the device is working, injection gun 3 moves to the lower limit position of linear guide rail 210 by gravity. Anti-collision spring 218 is used to absorb the impact and vibration on injection gun 3 during device positioning and adjustment, further improving the stability and working accuracy of injection gun 3.

[0040] Specifically, in the above technical solution, the positioning adjustment mechanism 2 includes an X-axis adjustment component, a Y-axis adjustment component, a Z-axis adjustment component, and a mounting plate 21. The mounting plate 21 is movably attached to the top of the fixed frame 1, and a suspension bracket 219 is fixedly connected to the center of the bottom of the mounting plate 21. The mounting plate 21 moves in the X-axis direction of the fixed frame 1 through the X-axis adjustment component, and the Y-axis adjustment component and the Z-axis adjustment component move with the mounting plate 21.

[0041] The Y-axis adjustment component is used to adjust the position of the injection gun 3 in the Y-axis direction;

[0042] The Z-axis adjustment component is used to adjust the position of the injection gun 3 in the Z-axis direction.

[0043] Specifically, in the above technical solution, the X-axis adjustment component includes an X-axis drive servo motor 212 fixedly connected to the mounting plate 21. Its output shaft extends to the bottom of the mounting plate 21 and is connected to an X-axis drive gear 213. An X-axis linear guide rail 215 is mounted on one side of the top of the fixed frame 1, and an X-axis rack 214 meshes with the X-axis drive gear 213 on the X-axis linear guide rail 215. When the X-axis drive servo motor 212 is working, its output shaft drives the X-axis drive gear 213 to rotate. The X-axis drive gear 213 meshes with the X-axis rack 214, thereby causing the mounting plate 21 to move along the direction of the linear guide rail 215 (i.e., the X-axis). The entire positioning adjustment mechanism 2 achieves X-axis movement. The use of gear and rack transmission enables high-precision linear motion, is suitable for applications requiring high precision, and features a simple transmission structure, high reliability, and convenient maintenance.

[0044] Specifically, in the above technical solution, the Z-axis adjustment component includes a Z-axis transition connecting plate 23 and a Z-axis linear guide rail 22. The number of Z-axis linear guide rails 22 is set to two. The two Z-axis linear guide rails 22 are distributed in parallel and fixed on the outer wall of the suspension frame 219, and the Z-axis transition connecting plate 23 slides on the Z-axis linear guide rail 22.

[0045] The Z-axis adjustment assembly also includes a Z-axis drive unit for driving the Z-axis transition connecting plate 23 to move in the Z-axis direction.

[0046] Example 1:

[0047] As one embodiment of the Z-axis drive unit in this utility model, it adopts a pneumatic drive structure, specifically including a Z-axis drive cylinder 24 fixed on the mounting plate 21. The connecting end of the drive cylinder 24 is equipped with an air supply device as a power source. The output end of the Z-axis drive cylinder 24 is connected to the Z-axis transition connecting plate 23 via a hinge transmission. Rapid Z-axis movement is achieved by the Z-axis drive cylinder 24 driving the Z-axis transition connecting plate 23 and its connecting structure.

[0048] Example 2:

[0049] As another embodiment of the Z-axis drive unit in this utility model, it adopts a screw drive structure, specifically including a Z-axis drive servo motor 26 fixedly connected to the suspension frame 219, a Z-axis ball screw 25 driven by the output shaft of the Z-axis drive servo motor 26, a Z-axis limiting groove 220 opened on the side of the suspension frame 219, a traction plate 221 fixedly connected to the Z-axis transition connecting plate 23 and slidingly engaged with the Z-axis limiting groove 220, and the traction plate 221 connected to the movable nut on the Z-axis ball screw 25. The Z-axis ball screw 25 is driven by the output shaft of the Z-axis drive servo motor 26, causing the traction plate 221 to move precisely in the Z-axis direction along with the Z-axis transition connecting plate 23 and its connecting parts. The ball screw transmits motion by the rolling of balls between the nut and the screw, reducing friction and wear, making the movement smoother and more precise, enabling the injection gun 3 and its connecting parts to achieve high-precision and repeatable Z-axis positioning.

[0050] Specifically, in the above technical solution, the Y-axis adjustment component includes a Y-axis linear module 28 fixed on a Z-axis transition connecting plate 23. Parallel Y-axis linear guide rails 27 are also provided on both sides of the Y-axis linear module 28 on the Z-axis transition connecting plate 23. A Y-axis transition connecting plate 29 is slidably connected to the two Y-axis linear guide rails 27, and the drive slider of the Y-axis linear module 28 is connected to the Y-axis transition connecting plate 29 via a transmission connection. Driving this structure enables the injection gun 3 and its accessories to move in the Y-axis direction. The internal transmission of the Y-axis linear module 28 uses a ball screw drive, meeting the requirements for high precision and repeatability in the Y-axis direction.

[0051] Specifically, in the above technical solution, the anti-collision sealing structure adopts a rubber kit, which is interference-fitted on the outside of the injection gun 3, and the outer diameter of the rubber kit is larger than the inner diameter of the injection hole.

[0052] like Figure 1-5 As shown, the hole position recognition mechanism includes a 2D vision sensor 216 and a microcontroller 222. The 2D vision sensor 216 is mounted on the bottom of the connecting plate 211 via an L-shaped bracket 223, and the 2D vision sensor 216 is vertically attached to one side of the injection gun 3.

[0053] The microcontroller 222 has its input and output terminals electrically connected to an A / D converter and a D / A converter, respectively. The 2D vision sensor 216 is communicatively connected to the A / D converter. The X-axis drive servo motor 212, the Z-axis drive unit, and the Y-axis linear module 28 are all communicatively connected to the D / A converter. This ensures precise alignment between the injection gun's three nozzles and the water heater's injection hole.

[0054] In this invention, during the foaming and injection of water heater, the water heater is placed on a tooling plate and clamped. After it stabilizes, it is moved to the bottom of the fixed frame 1, i.e., transferred to the predetermined position on the production line. The hole position recognition mechanism captures and positions the water heater injection hole that needs to be injected. Specifically, the positioning adjustment mechanism 2 synchronously adjusts the X, Y, and Z axis positions so that the injection gun 3 is initially aligned with the water heater injection hole A (i.e., the target hole position). Then, the 2D vision sensor 216 begins to capture images of the water heater workpiece, obtains the area of ​​the injection hole A, and performs image preprocessing, edge detection, contour extraction, shape fitting, center calculation, and other operations to obtain the geometric center coordinates of the hole. The calculated center coordinates of the hole are compared with the hole of the injection gun 3 to obtain the X and Y positional deviations, and the results are fed back to the microcontroller 222, which serves as the control system. The microcontroller 222 analyzes and calculates the deviations and drives the positioning adjustment mechanism 2 to complete the X and Y positional positioning. The Z-axis drive servo motor 26 drives the Z-axis ball screw 25 to move the injection gun 3, so that its hole is inserted into the water heater's injection hole, realizing the working positioning process of the injection gun 3. A predetermined volume of foaming material is injected into the water heater hole, completing the water heater foaming injection process. Following these steps, this device can complete the positioning of multiple holes on the workpiece surface and the foaming injection process, realizing automated and precise injection filling operations.

[0055] The embodiments of this utility model have been described in detail above with reference to the accompanying drawings, but this utility model is not limited to the described embodiments. For those skilled in the art, various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of this utility model, and these variations still fall within the protection scope of this utility model.

Claims

1. A water heater foam injection device comprising a fixed gantry (1) and an injection lance (3), characterised in that: The fixed rack (1) is provided with a positioning adjusting mechanism (2), a connecting assembly is drivenly connected to the positioning adjusting mechanism (2), and the injection gun (3) is mounted on the connecting assembly and moves with the connecting assembly in the X-axis direction, the Y-axis direction and the Z-axis direction of the fixed rack (1), wherein the X-axis direction, the Y-axis direction and the Z-axis direction correspond to the length direction, the width direction and the height direction of the fixed rack (1) respectively; An anti-collision sealing structure is arranged outside the output port of the gun body of the injection gun (3), so as to protect the gun body structure of the injection gun (3) and seal the joint gap between the output port of the injection gun (3) and the injection hole; The device further comprises a hole position identifying mechanism, which is used for identifying the position of the injection hole, driving the injection gun (3) to move so that the gun hole is coaxially connected with the injection hole to be positioned.

2. A water heater foam-in-place unit according to claim 1 wherein: The connecting assembly comprises a Y-direction transition connecting plate two (29), a linear guide rail three (210) and a connecting plate (211), wherein the Y-direction transition connecting plate two (29) is L-shaped in cross section, two guide columns (217) are mounted on the Y-direction transition connecting plate two (29), and the connecting plate (211) is guided to vertically slide on the linear guide rail three (210) in the Y-direction, and an anti-collision spring (218) is sleeved outside the guide column (217); The linear guide rail three (210) is fixed on one side of the Y-direction transition connecting plate two (29), and the connecting plate (211) is vertically fixed on one side of the injection gun (3), so that the output port of the gun body of the injection gun (3) is vertically arranged downward.

3. A water heater foam-in-place unit according to claim 2 wherein: The positioning adjusting mechanism (2) comprises an X-direction adjusting assembly, a Y-direction adjusting assembly, a Z-direction adjusting assembly and a mounting plate (21), wherein the mounting plate (21) is movably connected to the top end of the fixed rack (1), a suspension frame (219) is fixedly connected to the center position of the bottom of the mounting plate (21), the mounting plate (21) moves in the X-axis direction of the fixed rack (1) through the X-direction adjusting assembly, and the Y-direction adjusting assembly and the Z-direction adjusting assembly move with the mounting plate (21); The Y-direction adjusting assembly is used for adjusting the position of the injection gun (3) in the Y-axis direction; The Z-direction adjusting assembly is used for adjusting the position of the injection gun (3) in the Z-axis direction.

4. A water heater foam-in-place unit as claimed in claim 3 wherein: The X-direction adjusting assembly comprises an X-direction drive servo motor two (212) fixedly connected to the mounting plate (21), an output shaft of the X-direction drive servo motor two (212) extends to the bottom of the mounting plate (21) and is drivingly connected with an X-direction drive gear (213), an X-direction linear guide rail four (215) is mounted on one side of the top end of the fixed rack (1), and an X-direction rack (214) drivingly engaged with the X-direction drive gear (213) is mounted on the X-direction linear guide rail four (215).

5. A water heater foam-in-place unit as claimed in claim 4 wherein: The Z-direction adjusting assembly comprises a Z-direction transition connecting plate one (23) and a Z-direction linear guide rail one (22), wherein the number of the Z-direction linear guide rail one (22) is two, the two Z-direction linear guide rail one (22) are parallelly distributed and fixed to the outer wall of the suspension frame (219), and the Z-direction transition connecting plate one (23) slides on the Z-direction linear guide rail one (22); The Z-direction adjusting assembly further comprises a Z-direction drive part, which is used for driving the Z-direction transition connecting plate one (23) to move in the Z-direction.

6. A water heater foam injection unit as claimed in claim 5 wherein: The Z-direction driving part adopts a pneumatic driving structure, which comprises a Z-direction driving cylinder (24) fixed on a mounting plate (21), the driving cylinder (24) is provided with a gas supply device as a power source at a connecting end, and an output end of the Z-direction driving cylinder (24) is connected with a Z-direction transition connecting plate I (23) through a hinge transmission.

7. A water heater foam-in-place unit as defined in claim 5, wherein: The Z-direction driving part adopts a screw rod driving structure, which comprises a Z-direction driving servo motor I (26) fixedly connected with a suspension frame (219), an output shaft of the Z-direction driving servo motor I (26) is drivingly connected with a Z-direction ball screw (25), a Z-direction limiting groove (220) is formed in a side surface of the suspension frame (219), a traction plate (221) is fixedly connected on the Z-direction transition connecting plate I (23) and is in sliding fit with the Z-direction limiting groove (220), and the traction plate (221) is connected with a movable nut on the Z-direction ball screw (25).

8. A water heater foam-in-place unit as defined in claim 5, wherein: The Y-direction adjusting assembly comprises a Y-direction linear module (28) fixed on the Z-direction transition connecting plate I (23), and parallelly distributed Y-direction linear guide rails II (27) are arranged on both sides of the Y-direction linear module (28) on the Z-direction transition connecting plate I (23), a Y-direction transition connecting plate II (29) is slidingly connected on the two Y-direction linear guide rails II (27), and a driving block of the Y-direction linear module (28) is drivingly connected with the Y-direction transition connecting plate II (29).

9. A water heater foam-in-place unit according to claim 1 wherein: The anti-collision sealing structure adopts a rubber sleeve, which is in interference fit on the outside of a gun body of the injection gun (3), and the outer diameter of the rubber sleeve is greater than the inner diameter of the injection hole.

10. A water heater foam-in-place unit as defined in claim 5, wherein: The hole position recognition mechanism comprises a 2D vision sensor (216) and a single-chip microcomputer (222), the 2D vision sensor (216) is installed on the bottom of a connecting plate (211) through an L-shaped support (223), and the 2D vision sensor (216) is vertically attached to one side of the injection gun (3); The input end and the output end of the single-chip microcomputer (222) are electrically connected with an A / D converter and a D / A converter respectively, the 2D vision sensor (216) is in communication connection with the A / D converter, and the X-direction driving servo motor II (212), the Z-direction driving part and the Y-direction linear module (28) are in communication connection with the D / A converter.

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