An ESC sensor assembly and welding equipment

Abstract

This utility model relates to the field of automated assembly, conditioning, testing, and production of ESC sensors. It discloses an ESC sensor assembly and welding equipment, including a turntable mechanism and multiple assembly loading devices mounted on the turntable mechanism and driven for transfer and positioning by the turntable mechanism. Each assembly loading device is provided with at least one cavity for placing a housing and at least one cavity for placing a sensor semi-finished product. The outside of the turntable mechanism is equipped with a welding mechanism that automatically welds the pre-pressed and flipped sensor semi-finished product and the spring-loaded housing into a sensor product, and a resistance testing mechanism that automatically performs resistance detection on the welded sensor product. The equipment achieves fully automated welding and testing of the sensor product, with high speed, high efficiency, and stable quality.

Description

Technical Field

[0001] This utility model relates to the field of automatic assembly, conditioning, testing and production of ESC sensors, and in particular to an ESC sensor assembly and welding equipment. Background Technology

[0002] ESC sensors are increasingly widely used in the automotive industry. While the demand for ESC sensors is increasing, the quality requirements are also rising, leading to increasingly fierce competition among ESC sensor manufacturers. The ESC sensor manufacturing process involves assembling components such as the main body, PFC, housing, and springs, followed by post-assembly adjustments. This process involves numerous assembly steps and welding processes. Current production processes rely heavily on manual labor in assembly and welding, resulting in high production costs, difficulty in improving production efficiency, and inconsistent product quality due to staff turnover and individual differences. Utility Model Content

[0003] This invention provides an ESC sensor assembly and welding equipment, which solves the technical problems of excessive manual operation, low efficiency, and poor quality stability in the existing automatic assembly, conditioning, testing and production process of ESC sensors.

[0004] The technical solution adopted by this utility model to solve its technical problem is: an ESC sensor assembly and welding equipment, including a turntable mechanism and multiple assembly loading devices mounted on the turntable mechanism and driven by the turntable mechanism for transfer and positioning. Each assembly loading device is provided with at least one cavity for placing the housing and at least one cavity for placing the sensor semi-finished product. The outside of the turntable mechanism is provided with a welding mechanism that automatically welds the pre-pressed and flipped sensor semi-finished product and the spring-loaded housing into a sensor product, and a resistance testing mechanism that automatically performs resistance detection on the welded sensor product. The welding and testing of the sensor product are completed fully automatically, with high speed, high efficiency, and stable quality.

[0005] Furthermore, the welding mechanism includes a welding assembly for welding the pre-pressed assembled product, a welding rotation module for transferring and positioning the product and driving its rotation to cooperate with the welding assembly in completing the welding, and an auxiliary rotation module that, during the transfer of the product by the welding rotation module, lifts the pre-pressed assembled product from the corresponding loading container and supports the lower end of the product as it rotates with the welding rotation module. This bottom lifting and rotation prevents the pre-pressed assembled product from falling off, dispersing, or shifting during welding, resulting in better welding quality.

[0006] Furthermore, the welding assembly includes a seventh horizontal drive mechanism located on one side of the turntable mechanism; an eighth horizontal drive mechanism driven by the seventh horizontal drive mechanism to move horizontally relative to the corresponding loading fixtures on the turntable mechanism; a fourth vertical drive mechanism driven by the eighth horizontal drive mechanism to move horizontally along a direction perpendicular to the eighth horizontal drive mechanism; a first rotary drive mechanism driven by the fourth vertical drive mechanism to move vertically; and a laser welding machine whose angle is adjusted by the first rotary drive mechanism in the vertical direction. The laser welding machine can be adjusted in position and angle according to actual conditions, allowing for welding at a wide range of selected positions, thus offering greater applicability.

[0007] Furthermore, the welding rotary module includes a rotary module support, at least one fifth vertical drive mechanism fixedly mounted on the rotary module support and located on the corresponding loading unit, a second rotary drive mechanism driven by the fifth vertical drive mechanism to move vertically relative to the corresponding loading unit, and a product clamping mechanism driven by the second rotary drive mechanism to rotate. The product clamping mechanism is equipped with three-finger grippers for clamping the non-welding end of the product. With three-directional clamping and rotation, the clamping is stable, and displacement or mis-welding is less likely to occur during the welding process.

[0008] Furthermore, the product clamping mechanism is equipped with a shielding plate that allows the three-finger gripper to move and shields the main body of the product clamping mechanism. The product clamping mechanism also has a shielding fixing frame plate with multiple vertically penetrating third limiting holes. Each third limiting hole contains a limiting rod that restricts vertical movement. The lower end of the limiting rod is fixed to the shielding fixing frame plate, and the upper end of the limiting rod passes through the third limiting hole and has a limiting boss with a diameter larger than the third limiting hole. A support spring, located between the shielding plate and the shielding fixing frame plate and in a compressed state, is fitted onto the limiting rod. This effectively protects the welding rotating module.

[0009] Furthermore, the rotating module support is equipped with a nitrogen protection device that blows nitrogen gas to the welding position during the welding process. This prevents oxidation during welding, increases weldability, and improves welding quality.

[0010] Furthermore, the rotating module support is equipped with a fume extraction duct for fume extraction during the welding process. This helps maintain a safe welding environment and protects the health of welding personnel.

[0011] Furthermore, the auxiliary rotation module includes a sixth vertical drive mechanism located below the turntable mechanism and the corresponding loading unit; a second vertical moving plate driven by the sixth vertical drive mechanism to move vertically relative to the corresponding loading unit; a first pressure sensor mounted on the second vertical moving plate; a bearing fixing plate assembly fixedly mounted on the first pressure sensor; a bearing assembly mounted on the bearing fixing plate assembly; and a welding lifting rod mounted on the bearing assembly that can rotate freely. The turntable mechanism and the corresponding loading unit have welding lifting holes at positions corresponding to the welding lifting rod, allowing the welding lifting rod to move up and down. Real-time detection and control of the pressure on the bottom of the product prevents damage, and precise control of the lifting force ensures the accuracy of product assembly and pressing, improving the welding precision and quality of the product.

[0012] Furthermore, the resistance testing mechanism includes a resistance detection component fixedly mounted on one side of the corresponding loading unit on the turntable mechanism, and a resistance detection transfer mechanism mounted on one side of the turntable mechanism for transferring products from the corresponding loading unit to a preset position for resistance detection to perform resistance testing, and transferring the products back to the corresponding loading unit after testing. This automates the resistance testing of products, resulting in high efficiency and stable test quality. Attached Figure Description

[0013] Figure 1 This is a front view schematic diagram of the present invention;

[0014] Figure 2 This is a front view schematic diagram of the welding mechanism;

[0015] Figure 3 This is a front view schematic diagram of the welding assembly;

[0016] Figure 4 A front view schematic diagram of the welding rotating module and the auxiliary rotating module;

[0017] Figure 5 This is a front view schematic diagram of the resistance testing mechanism.

[0018] The components in the diagram are labeled as follows: turntable mechanism 1001, assembly loading device 1002, welding mechanism 1500, welding assembly 1510, seventh horizontal drive mechanism 1511, eighth horizontal drive mechanism 1512, fourth vertical drive mechanism 1513, first rotary drive mechanism 1514, laser welding machine 1515, welding rotary module 1520, rotary module support 1521, fifth vertical drive mechanism 1522, second rotary drive mechanism 1523, product clamping mechanism 1524, and three-finger gripper 1525. 1526, shielding plate 1527, shielding fixing frame plate 1528, limiting rod 1529, support spring 1520, auxiliary rotation module 1530, sixth vertical drive mechanism 1531, second vertical moving plate 1532, first pressure sensor 1533, bearing fixing plate assembly 1534, bearing assembly 1535, welding lifting rod 1536, nitrogen protection device 1540, smoke extraction pipe 1550, resistance testing mechanism 1700, resistance detection assembly 1710, resistance detection transfer mechanism 1720. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0020] like Figure 1 The ESC sensor assembly and welding equipment shown includes a turntable mechanism 1001 and multiple assembly loading units 1002 disposed on the turntable mechanism 1001 and driven and positioned by the turntable mechanism 1001. Each assembly loading unit 1002 is provided with at least one cavity for placing a housing and at least one cavity for placing a sensor semi-finished product. The turntable mechanism 1001 is provided with a welding mechanism 1500 that automatically welds the pre-pressed and flipped sensor semi-finished product and the housing with springs into a sensor product, and a resistance testing mechanism 1700 that automatically performs resistance detection on the welded sensor product. In this specific embodiment, the turntable mechanism 1001 is a commercially available double-layer turntable comprising a fixed upper plate and a rotating lower plate. In practice, the turntable mechanism 1001, using a carrier 1002, transfers the pre-compressed, flipped sensor semi-finished product and the spring-loaded housing to the corresponding position of the welding mechanism 1500. The welding mechanism 1500 automatically welds the pre-compressed, flipped sensor semi-finished product and the spring-loaded housing into a sensor product. The turntable mechanism 1001, using a carrier 1002, then transfers the welded sensor product to the corresponding position of the resistance testing mechanism 1700. The resistance testing mechanism 1700 automatically performs resistance testing on the welded sensor product. The welding and testing of the sensor product are completed in a fully automated manner, with high speed, high efficiency, and stable quality.

[0021] Based on the above, such as Figure 1 and Figure 2As shown, the welding mechanism 1500 includes a welding assembly 1510 for welding pre-pressed assembled products, a welding rotation module 1520 for transferring and positioning the product and driving its rotation to cooperate with the welding assembly 1510 in completing the welding, and an auxiliary rotation module 1530 that, during the transfer of products by the welding rotation module 1520, lifts the pre-pressed assembled products from the corresponding assembly loading fixture 1002 and supports the lower end of the product as it rotates with the welding rotation module 1520. In specific implementations, the welding rotation module 1520 and the auxiliary rotation module 1530 work together to automatically complete a 360-degree weld on the product's circumference and then move it back into the corresponding assembly loading fixture 1002 for subsequent processing. The bottom lifting and rotation prevents the pre-pressed assembled products from falling off, dispersing, or shifting during the welding process, resulting in better welding quality.

[0022] Based on the above, such as Figures 1 to 3 As shown, the welding assembly 1510 includes a seventh horizontal drive mechanism 1511 disposed on one side of the turntable mechanism 1001, an eighth horizontal drive mechanism 1512 driven by the seventh horizontal drive mechanism 1511 to move horizontally relative to the corresponding loading device 1002 on the turntable mechanism 1001, a fourth vertical drive mechanism 1513 driven by the eighth horizontal drive mechanism 1512 to move horizontally along the direction perpendicular to the eighth horizontal drive mechanism 1512, a first rotary drive mechanism 1514 driven by the fourth vertical drive mechanism 1513 to move vertically, and a laser welding machine 1515 whose angle is adjusted by rotating vertically by the first rotary drive mechanism 1514. In this specific embodiment, the seventh horizontal drive mechanism 1511, the eighth horizontal drive mechanism 1512, and the fourth vertical drive mechanism 1513 are all linear drive mechanisms composed of servo motors and ball screw slide modules. The first rotary drive mechanism 1514 is a rotary drive mechanism composed of servo motors and rotary platform components. In specific implementations, the seventh horizontal drive mechanism 1511, the eighth horizontal drive mechanism 1512, and the fourth vertical drive mechanism 1513 can also be linear motor components or stroke-controllable cylinder components. The laser welding machine 1515 is a commercially available laser welding machine. The laser welding machine 1515 can be adjusted in position and angle according to actual conditions, and can perform welding at a wide range of selected positions, making it more versatile.

[0023] Based on the above, such as Figures 1 to 4As shown, the welding rotating module 1520 includes a rotating module support 1521, at least one fifth vertical drive mechanism 1522 fixedly mounted on the rotating module support 1521 and located on the corresponding loading unit 1002, a second rotating drive mechanism 1523 driven by the fifth vertical drive mechanism 1522 to move vertically relative to the corresponding loading unit 1002, and a product clamping mechanism 1524 driven by the second rotating drive mechanism 1523 to rotate. The product clamping mechanism 1524 is provided with a three-finger gripper 1525 for clamping the non-welded end of the product. In this specific embodiment, the fifth vertical drive mechanism 1522 has two linear drive mechanisms consisting of a servo motor and a ball screw slide module, and the second rotary drive mechanism 1523 is a rotary cylinder. In specific implementations, the fifth vertical drive mechanism 1522 can also be a linear motor assembly or a cylinder assembly with controllable stroke, and the second rotary drive mechanism 1523 can also be a combination of a motor assembly and a rotary assembly. It can clamp and rotate in three directions, providing stable clamping and preventing displacement or mis-welding during the welding process.

[0024] Based on the above, such as Figures 1 to 4 As shown, the product clamping mechanism 1524 is provided with a shielding plate 1526 for the three-finger gripper 1525 to move through and to cover the main body of the product clamping mechanism 1524. The product clamping mechanism 1524 is also provided with a shielding fixing frame plate 1527. The shielding fixing frame plate 1527 has multiple vertically penetrating third limiting holes. A limiting rod 1528 is provided within each third limiting hole, limiting its vertical movement. The lower end of the limiting rod 1528 is fixed to the shielding fixing frame plate 1527, and the upper end of the limiting rod 1528 passes through the third limiting hole and has a limiting boss with a diameter larger than the third limiting hole. A support spring 1529, located between the shielding plate 1526 and the shielding fixing frame plate 1527 and in a compressed state, is sleeved on the limiting rod 1528. This effectively protects the welding rotating module 1520.

[0025] Based on the above, such as Figure 1 , Figure 3 and Figure 4 As shown, the rotating module support 1521 is equipped with a nitrogen protection device 1540 that blows nitrogen gas to the welding position during the welding process. This prevents oxidation during welding, increases weldability, and improves welding quality.

[0026] Based on the above, such as Figure 1 , Figure 3 and Figure 4 As shown, the rotating module support 1521 is equipped with a fume extraction pipe 1550 for fume extraction during welding. This maintains the welding environment and protects the health of welding personnel.

[0027] Based on the above, such as Figures 1 to 4 As shown, the auxiliary rotating module 1530 includes a sixth vertical drive mechanism 1531 located below the turntable mechanism 1001 and the corresponding loading unit 1002, a second vertical moving plate 1532 driven by the sixth vertical drive mechanism 1531 to move vertically relative to the corresponding loading unit 1002, a first pressure sensor 1533 disposed on the second vertical moving plate 1532, a bearing fixing plate assembly 1534 fixedly disposed on the first pressure sensor 1533, a bearing assembly 1535 disposed on the bearing fixing plate assembly 1534, and a welding lifting rod 1536 disposed on the bearing assembly 1535 and freely rotatable. The product placement cavity in the turntable mechanism 1001 and the corresponding loading unit 1002 is provided with a welding lifting hole corresponding to the position of the welding lifting rod 1536 for the welding lifting rod 1536 to move up and down. In this specific embodiment, the sixth vertical drive mechanism 1531 is a linear drive mechanism consisting of a servo motor and a ball screw slide module. In specific implementations, the sixth vertical drive mechanism 1531 can also be a linear motor assembly or a cylinder assembly with controllable stroke. During the process of lifting and rotating the bottom of the product for welding, the pressure on the bottom of the product is detected and controlled in real time to avoid damage to the product. The lifting force is precisely controlled, ensuring the accuracy of the product assembly and pressing together, and improving the welding accuracy and quality of the product.

[0028] Based on the above, such as Figure 1 and Figure 5As shown, the resistance testing mechanism 1700 includes a resistance detection component 1710 fixedly mounted on one side of the corresponding loading container 1002 on the turntable mechanism 1001, and a resistance detection transfer mechanism 1720 mounted on one side of the turntable mechanism 1001 for transferring the product in the corresponding loading container 1002 to a preset position of the resistance detection component 1710 for resistance detection, and transferring the product back to the corresponding loading container 1002 after the detection is completed. In this specific embodiment, the loading fixture 1002 is provided with two placement slots for loading products after welding; the resistance detection assembly 1710 includes a resistance detection plate frame and two resistance detection heads fixed on the resistance detection plate frame near the corresponding loading fixture 1002. The lower ends of the two resistance detection heads are respectively provided with resistance detection probes located above the two products in the corresponding loading fixture 1002; the resistance detection transfer mechanism 1720 includes a slide cylinder vertically arranged on one side of the corresponding loading fixture 1002. The upper end of the slide cylinder is provided with two gripper cylinders that drive vertical movement. Both gripper cylinders are provided with contoured claws for gripping the products. Each gripper cylinder has its contoured claws positioned above two products within its corresponding loading fixture 1002. During operation, the slide cylinder drives the two gripper cylinders to move up and down, clamping the products and completing the docking, detection, and reset of the products with the resistance detection probes above. Simultaneously, the resistance detection transfer mechanism 1720 automatically transfers the two products from the corresponding loading fixture 1002 to the preset detection position of the resistance detection component 1710. The resistance detection component 1710 automatically performs resistance detection on both products simultaneously. After detection, the resistance detection transfer mechanism 1720 resets and transfers the two tested products back into the corresponding loading fixture 1002, where they are automatically transferred to the next process under the drive of the turntable mechanism 1001. This automated resistance detection process is highly efficient and provides stable detection quality.

[0029] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this utility model. It should be understood that the above descriptions are merely specific embodiments of this utility model and are not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An ESC sensor assembly welding apparatus characterized by: The device includes a turntable mechanism (1001) and multiple loading units (1002) mounted on the turntable mechanism (1001) and driven by the turntable mechanism (1001) for transfer and positioning. Each loading unit (1002) is provided with at least one acupoint for placing the housing and at least one acupoint for placing the sensor semi-finished product. The turntable mechanism (1001) is provided with a welding mechanism (1500) that automatically welds the sensor semi-finished product and the housing with springs after pre-pressure flipping into a sensor product and a resistance testing mechanism (1700) that automatically performs resistance detection on the welded sensor product.

2. The ESC sensor assembly and welding equipment according to claim 1, characterized in that: The welding mechanism (1500) includes a welding assembly (1510) for welding the pre-pressed assembled product, a welding rotation module (1520) for transferring and positioning the product and driving the product to rotate in coordination with the welding assembly (1510) to complete the welding, and an auxiliary rotation module (1530) for lifting the pre-pressed assembled product from the corresponding loading container (1002) in coordination with the welding rotation module (1520) during the product transfer process and for supporting the lower end of the product as it rotates in coordination with the product during the product rotation driven by the welding rotation module (1520).

3. The ESC sensor assembly and welding equipment according to claim 2, characterized in that: The welding assembly (1510) includes a seventh horizontal drive mechanism (1511) disposed on one side of the turntable mechanism (1001), an eighth horizontal drive mechanism (1512) driven by the seventh horizontal drive mechanism (1511) to move horizontally relative to the corresponding loading device (1002) on the turntable mechanism (1001), a fourth vertical drive mechanism (1513) driven by the eighth horizontal drive mechanism (1512) to move horizontally along the direction perpendicular to the movement of the eighth horizontal drive mechanism (1512), a first rotary drive mechanism (1514) driven by the fourth vertical drive mechanism (1513) to move vertically, and a laser welding machine (1515) that is rotated vertically by the first rotary drive mechanism (1514) to adjust its angle.

4. The ESC sensor assembly and welding equipment according to claim 3, characterized in that: The welding rotary module (1520) includes a rotary module support (1521), at least one fifth vertical drive mechanism (1522) fixedly mounted on the rotary module support (1521) and located on the corresponding loading unit (1002), a second rotary drive mechanism (1523) driven by the fifth vertical drive mechanism (1522) to move vertically relative to the corresponding loading unit (1002), and a product clamping mechanism (1524) driven by the second rotary drive mechanism (1523) to rotate. The product clamping mechanism (1524) is provided with a three-finger gripper (1525) for clamping the non-welded end of the product.

5. The ESC sensor assembly and welding equipment according to claim 4, characterized in that: The product clamping mechanism (1524) is provided with a shielding plate (1526) for the three-finger gripper (1525) to pass through and to shield the main body of the product clamping mechanism (1524). The product clamping mechanism (1524) is provided with a shielding fixing frame plate (1527). The shielding fixing frame plate (1527) is provided with a plurality of vertically penetrating third limiting holes. A limiting rod (1528) is provided in the third limiting hole to limit vertical movement. The lower end of the limiting rod (1528) is fixed to the shielding fixing frame plate (1527). The upper end of the limiting rod (1528) passes through the third limiting hole and is provided with a limiting boss with a diameter larger than the third limiting hole. A support spring (1529) is sleeved on the limiting rod (1528) and is located between the shielding plate (1526) and the shielding fixing frame plate (1527) and is in a compressed state.

6. The ESC sensor assembly and welding equipment according to claim 5, characterized in that: The rotating module support (1521) is equipped with a nitrogen protection device (1540) that blows nitrogen gas to the welding position during the welding process.

7. The ESC sensor assembly and welding equipment according to claim 5, characterized in that: The rotating module support (1521) is equipped with a fume extraction pipe (1550) for fume extraction during the welding process.

8. The ESC sensor assembly and welding equipment according to claim 5, characterized in that: The auxiliary rotating module (1530) includes a sixth vertical drive mechanism (1531) located below the turntable mechanism (1001) and the corresponding loading unit (1002), a second vertical moving plate (1532) driven by the sixth vertical drive mechanism (1531) to move vertically relative to the corresponding loading unit (1002), a first pressure sensor (1533) set on the second vertical moving plate (1532), a bearing fixing plate assembly (1534) fixedly set on the first pressure sensor (1533), a bearing assembly (1535) set on the bearing fixing plate assembly (1534), and a welding lifting rod (1536) set on the bearing assembly (1535) that can rotate freely. The product placement cavity in the turntable mechanism (1001) and the corresponding loading unit (1002) is provided with a welding lifting hole at a position corresponding to the welding lifting rod (1536) for the welding lifting rod (1536) to move up and down.

9. The ESC sensor assembly and welding equipment according to claim 5, characterized in that: The resistance testing mechanism (1700) includes a resistance detection component (1710) fixedly installed on one side of the corresponding loading unit (1002) on the turntable mechanism (1001) and a resistance detection transfer mechanism (1720) installed on one side of the turntable mechanism (1001) for transferring the product in the corresponding loading unit (1002) to a preset position for resistance detection and transferring the product back to the corresponding loading unit (1002) after the detection is completed.

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