An automatic testing, screening and tray placing integrated device
By designing an integrated automatic testing, screening, and tray-stacking device, the entire transformer production process has been automated, solving the problems of low efficiency and high misjudgment rate of manual operation, and improving production efficiency and product quality consistency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- 超仁自动化科技(东莞)有限公司
- Filing Date
- 2025-07-08
- Publication Date
- 2026-06-09
AI Technical Summary
In the current transformer production process, testing and screening mainly rely on manual operation, which has problems such as high misjudgment rate, low efficiency, high human resource consumption, high operational error rate and lack of standardization. Moreover, existing automated equipment lacks integrated solutions for testing, screening and tray placement.
Design an integrated automatic testing, screening, and traying device, including material handling, pressure resistance testing, interlayer testing, comprehensive testing, visual testing, and traying mechanism. It works in coordination with a PLC controller to achieve fully automated operation and reduce manual intervention.
The process of transformer testing and screening has been fully automated, which has significantly improved production efficiency and product quality consistency, reduced labor costs and operational error rates, and ensured comprehensive control of product quality and neatness of tray arrangement.
Smart Images
Figure CN224332825U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the technical field of transformer production and testing equipment, specifically an integrated automatic testing, screening, and tray arrangement device. Background Technology
[0002] Transformers are indispensable components in power systems and electronic equipment, and their quality directly affects the performance and reliability of the entire system. Testing and screening are crucial steps in ensuring product quality during transformer production. Currently, after transformers are manufactured, testing and screening are performed manually using molds and instruments. Employees place materials into the testing fixture, step on a foot pedal to activate a cylinder clamping mechanism, causing the probes on the probe plate to contact the pins of the material, and then start the testing instrument. Once all test results are satisfactory, the employee places the material into a tray and arranges it properly.
[0003] However, this method has the following drawbacks: First, employees are prone to misjudging when manually inspecting, causing defective products to flow to the next workstation and affecting the overall product quality; Second, too many manual handling actions are inefficient, especially in mass production, consuming a lot of human resources and resulting in low production efficiency; Third, long-term repetitive operations can easily lead to employee fatigue, further increasing the possibility of operational errors; Fourth, manual operation lacks standardization and consistency, and different operators may use different operating methods, leading to fluctuations in test results.
[0004] With the development of automation technology, many automated equipment have been applied in the field of electronic component production and testing. However, most of these devices can only automate a single process, such as testing or tray placement, lacking a complete solution that integrates testing, screening, and tray placement. While this decentralized approach to automation improves efficiency to some extent, the connection between different processes still requires manual intervention, failing to fully leverage the advantages of automation.
[0005] Therefore, developing an integrated device that can automate the entire process of testing, screening, and tray placement is of great significance. It can effectively solve the problems existing in the current technology, improve work efficiency and product quality consistency, and at the same time reduce labor costs and operational error rates. Utility Model Content
[0006] The purpose of this utility model is to provide an integrated automatic testing, screening, and tray placement device to address the shortcomings of existing technologies. Through automated material handling, multiple testing, screening, and tray placement mechanisms, it achieves fully automated operation of the transformer testing process, reduces manual intervention, improves testing accuracy and work efficiency, and enhances the consistency of test results and the reliability of product quality.
[0007] To achieve the above objectives, this utility model provides the following technical solution:
[0008] An integrated automatic testing, screening, and traying device, comprising:
[0009] A chassis, on which a workbench is mounted;
[0010] A material handling mechanism, installed on the left side of the workbench, is used to transfer transformer materials to the testing mechanism;
[0011] A withstand voltage testing mechanism, set on the workbench, is used to perform withstand voltage tests on transformer materials;
[0012] A transfer and storage fixture is set on the workbench for temporarily storing transformer materials that have passed the withstand voltage test.
[0013] An interlayer testing mechanism, set on the workbench, is used to perform interlayer testing on transformer materials;
[0014] A comprehensive testing mechanism, set on the workbench, is used to perform comprehensive performance testing on transformer materials;
[0015] A visual testing mechanism, set on the workbench, is used to perform appearance testing on transformer materials;
[0016] A defective product collection mechanism, set on the workbench, is used to collect transformer materials that fail the tests.
[0017] A tray-arranging mechanism, set on the workbench, is used to arrange and arrange the transformer materials that have passed the test.
[0018] A PLC controller is used to control the coordinated operation of the material handling mechanism, the pressure resistance testing mechanism, the interlayer testing mechanism, the comprehensive testing mechanism, the vision testing mechanism, the defective product collection mechanism, and the tray placement mechanism.
[0019] Preferably, the material handling mechanism includes a transverse transfer component and a longitudinal transfer component mounted on the transverse transfer component. The transverse transfer component includes a transverse slide rail, a transverse slider mounted on the transverse slide rail, and a transverse drive motor for driving the transverse slider to slide left and right along the transverse slide rail. The longitudinal transfer component includes a longitudinal slide rail mounted on the transverse slider, a longitudinal slider mounted on the longitudinal slide rail, and a longitudinal drive motor for driving the longitudinal slider to slide up and down along the longitudinal slide rail. The longitudinal slider is equipped with a gripper cylinder for gripping or releasing transformer material.
[0020] Preferably, the withstand voltage testing mechanism includes a withstand voltage tester, a probe testing component, a test fixture for positioning the material to be tested, a material transfer component, and a mounting frame for mounting the material transfer component. The withstand voltage tester is electrically connected to the probe testing component via a cable. The probe testing component is disposed above the test fixture. The material transfer component is mounted on the mounting frame for transferring transformer material.
[0021] Preferably, the material transplanting assembly includes a transplanting rod arranged longitudinally, a transverse motor that drives the transplanting rod to slide in the left-right direction along the mounting frame, and a flipping motor that drives the transplanting rod to flip in the circumferential direction. Gripper cylinders are respectively installed on both sides of the lower end of the transplanting rod. The transverse motor and the flipping motor are both electrically connected to the PLC controller, and the gripper cylinders are pneumatically connected to the PLC controller.
[0022] Preferably, the interlayer testing mechanism includes an interlayer tester, a probe testing assembly, a test fixture for positioning the material to be tested, a material transfer assembly, and a mounting frame for mounting the material transfer assembly. The interlayer tester is electrically connected to the probe testing assembly via a cable. The probe testing assembly is disposed above the test fixture. The material transfer assembly is mounted on the mounting frame for transferring transformer material.
[0023] Preferably, the integrated testing mechanism includes an integrated tester, a probe testing component, a test fixture for positioning the material to be tested, a material transfer component, and a mounting frame for mounting the material transfer component. The integrated tester is electrically connected to the probe testing component via a cable. The probe testing component is disposed above the test fixture. The material transfer component is mounted on the mounting frame for transferring transformer material.
[0024] Preferably, the vision testing mechanism includes a vision testing component, a test fixture for positioning the material to be tested, a material transfer component, and a mounting frame for mounting the material transfer component. The vision testing component is disposed above the test fixture, and the material transfer component is mounted on the mounting frame for transferring transformer material. The vision testing component includes an industrial camera, a light source system, and an image processing unit. The industrial camera and the light source system are both electrically connected to the image processing unit, and the image processing unit is electrically connected to the PLC controller.
[0025] Preferably, the defective product collection mechanism includes a collection trough and a pushing cylinder disposed at the front end of the collection trough. The collection trough is fixedly installed on the worktable, and the cylinder body of the pushing cylinder is fixedly installed on the worktable. The piston rod of the pushing cylinder is connected to a push plate and is used to push the transformer material that fails the test into the collection trough. A full material sensor is provided at the end of the collection trough. The full material sensor is electrically connected to the PLC controller. When the sensor detects that defective products have accumulated to a preset position, it sends a signal to the PLC controller to trigger an alarm and stop the machine.
[0026] Preferably, the tray-sliding mechanism includes a tray, a tray horizontal movement assembly, and a tray vertical movement assembly. The tray horizontal movement assembly includes a horizontal movement rail, a horizontal movement slider mounted on the horizontal movement rail, and a horizontal movement motor that drives the horizontal movement slider to slide left and right along the horizontal movement rail. The horizontal movement slider is equipped with a gripper cylinder for gripping or releasing the tested and qualified transformer material. The tray vertical movement assembly includes a vertical movement rail, a vertical movement slider mounted on the vertical movement rail, and a vertical movement motor that drives the vertical movement slider to slide back and forth along the vertical movement rail. The tray is placed on the vertical movement slider.
[0027] Preferably, the tray is equipped with a tray sensor, which is electrically connected to the PLC controller and is used to detect whether the tray is full and whether the tray is correctly placed. When the tray is full, the tray sensor sends a signal to the PLC controller to trigger a prompt to replace the tray.
[0028] Preferably, the withstand voltage tester of the withstand voltage test mechanism is a TH9310 model withstand voltage tester, used to test the withstand voltage performance and insulation resistance performance of the transformer; the interlayer tester of the interlayer test mechanism is used to detect whether the insulation state of the transformer is normal; the comprehensive tester of the comprehensive test mechanism is a TH2829AX model comprehensive tester, used to comprehensively evaluate the electromagnetic performance, electrical performance and mechanical performance of the transformer.
[0029] Preferably, the bottom of the chassis is equipped with casters, which are equipped with locking devices for locking after the equipment is positioned to ensure stable operation of the equipment.
[0030] Preferably, the PLC controller is electrically connected to the touch screen, which is mounted on the outer surface of the chassis and is used to display the equipment operating status, set process parameters, and perform human-machine interaction operations.
[0031] Preferably, the transfer storage fixture is disposed between the withstand voltage testing mechanism and the interlayer testing mechanism for temporarily storing transformer materials that have passed the withstand voltage test. The transfer storage fixture is made of high-strength aluminum alloy material and the surface is anodized. It is provided with multiple positioning grooves for stably placing the transformer materials.
[0032] Preferably, the PLC controller is programmed with multiple process parameters, including test time, test standards, defective product handling methods, and tray loading modes. These parameters can be adjusted via the touch screen to adapt to the testing requirements of transformers of different specifications.
[0033] Compared with the prior art, the present invention has at least the following beneficial effects:
[0034] 1) This utility model's integrated automatic testing, screening, and tray-stacking equipment achieves fully automated operation of transformer testing and screening processes through the coordinated cooperation of a material handling mechanism, a withstand voltage testing mechanism, an inter-layer testing mechanism, a comprehensive testing mechanism, a vision testing mechanism, and a tray-stacking mechanism, replacing traditional manual testing and tray-stacking methods. The entire system uses a PLC controller to precisely control the timing of each mechanism's actions, forming a complete automated testing production line. The entire process from material handling to testing, screening, and tray-stacking requires no manual intervention, significantly reducing labor input and lowering labor costs. Test experiments show that compared to traditional manual operations, this equipment can significantly reduce labor requirements while effectively improving operational efficiency and significantly reducing production costs.
[0035] 2) This utility model employs a multi-test mechanism series design, including withstand voltage testing, inter-layer testing, comprehensive testing, and visual testing, achieving comprehensive testing and screening of transformer materials to ensure product quality. Specifically, the withstand voltage testing mechanism can detect the transformer's withstand voltage performance and insulation resistance; the inter-layer testing mechanism can detect whether the transformer's insulation condition is normal; the comprehensive testing mechanism can evaluate the transformer's electromagnetic, electrical, and mechanical properties; and the visual testing mechanism uses industrial cameras and image processing technology to detect appearance defects in the transformer, such as pin deformation and surface abnormalities. This multi-dimensional, multi-parameter testing method ensures comprehensive quality control of transformer products and significantly reduces the defect rate.
[0036] 3) The automatic tray-laying mechanism of this utility model achieves automatic placement of tested and qualified products through the precise coordination of the horizontal and vertical movement components. This not only improves tray-laying efficiency but also ensures the neatness and consistency of the placement. The gripper cylinder of the tray-laying mechanism can accurately grasp the transformer material, while the horizontal and vertical movement components can precisely place the material at the designated position on the tray according to preset coordinates. This automated tray-laying method avoids the unevenness and misalignment problems that may occur with manual tray-laying, improves the utilization rate of the tray, and provides neat and orderly raw materials for subsequent processes, thereby improving the overall efficiency of the production line. Attached Figure Description
[0037] Figure 1 This is one of the structural schematic diagrams of this utility model;
[0038] Figure 2 This is the second structural schematic diagram of the present invention;
[0039] Figure 3 for Figure 2 A magnified view of a portion of point A in the middle.
[0040] In the diagram: 1. Chassis; 2. Workbench; 3. Material handling mechanism; 4. Pressure testing mechanism; 41. Pressure tester; 5. Transfer and storage fixture; 6. Interlayer testing mechanism; 61. Interlayer tester; 7. Comprehensive testing mechanism; 71. Comprehensive tester; 8. Visual testing mechanism; 9. Defective product collection mechanism; 10. Tray loading mechanism; 101. Tray; 102. Tray horizontal movement assembly; 103. Tray vertical movement assembly. Detailed Implementation
[0041] To make the technical solution and advantages of this utility model clearer, the present utility model and its beneficial effects will be described in further detail below with reference to specific embodiments and accompanying drawings. However, the embodiments of this utility model are not limited thereto.
[0042] In the description of this utility model, it should be understood that the terms "center," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing 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, and therefore should not be construed as a limitation of this utility model. Furthermore, in the description of this utility model, unless otherwise stated, "a plurality of" means two or more.
[0043] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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 utility model based on the specific circumstances.
[0044] All standard parts used in this utility model can be purchased from the market, and irregular parts can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art, and the circuit connection adopts conventional connection methods in the prior art, which will not be described in detail here.
[0045] like Figures 1-3 As shown, the present invention provides an integrated automatic testing, screening and tray-setting device, including a chassis 1 and a PLC controller. A workbench 2 is installed on the chassis 1. The workbench 2 is equipped with a material handling mechanism 3, a pressure resistance testing mechanism 4, a transfer and storage fixture 5, an inter-layer testing mechanism 6, a comprehensive testing mechanism 7, a visual testing mechanism 8, a defective product collection mechanism 9, and a tray-setting mechanism 10.
[0046] The chassis 1, serving as the supporting frame for the entire equipment, is constructed from welded steel, with a surface treated for corrosion resistance and powder coating, providing excellent strength and durability. Chassis 1 is equipped with casters at its bottom, each with a locking device to ensure stable operation after the equipment is positioned. Inside chassis 1 is an electrical control cabinet housing the PLC controller, frequency converter, relays, and other electrical components, along with a cooling fan to maintain the normal operating temperature of these components. A touchscreen is mounted on the outer surface of chassis 1, supporting multi-touch operation. The intuitive and user-friendly interface allows operators to easily set process parameters, monitor equipment status, and view alarm information.
[0047] Workbench 2 is mounted on the upper part of chassis 1 and is made of steel plate with a precision-machined surface to ensure flatness. Workbench 2 has multiple T-slots to facilitate the installation and adjustment of various functional components. The layout of workbench 2 is optimized so that the functional modules are arranged in the order of the process flow, ensuring both smooth production flow and ease of maintenance and management.
[0048] The material handling mechanism 3 is installed on the left side of the workbench 2 and is used to transfer the transformer material from the previous process to the test fixture of the withstand voltage testing mechanism 4 for testing. The material handling mechanism 3 includes a transverse transfer assembly and a longitudinal transfer assembly mounted on the transverse transfer assembly. The transverse transfer assembly includes a transverse slide rail, a transverse slider mounted on the transverse slide rail, and a transverse drive motor that drives the transverse slider to slide left and right along the transverse slide rail. The transverse slide rail uses a high-precision linear guide, which has high rigidity and high precision characteristics and can withstand large loads. The transverse slider uses a slider matched to the slide rail, with built-in circulating balls, low friction coefficient, and smooth movement. The transverse drive motor is a servo motor, which drives the transverse slider to slide left and right along the transverse slide rail through a synchronous pulley and rack and pinion transmission mechanism. This transmission method features high precision, high rigidity, and low backlash, meeting the requirements for precise positioning.
[0049] The longitudinal transfer assembly includes a longitudinal slide rail mounted on the transverse slider, a longitudinal slider mounted on the longitudinal slide rail, and a longitudinal drive motor that drives the longitudinal slider to slide up and down along the longitudinal slide rail. The longitudinal slider is equipped with a gripper cylinder for clamping or releasing the transformer material. The longitudinal slide rail also uses a high-precision linear guide. The longitudinal slider is matched with the slide rail to ensure smooth movement. The longitudinal drive motor is a servo motor that drives the longitudinal slider to move up and down via a ball screw transmission mechanism. The gripper cylinder adopts a two-way cylinder design, which can firmly clamp the transformer material, and the clamping force is adjustable to accommodate transformer materials of different specifications.
[0050] The withstand voltage testing mechanism 4 is mounted on the workbench 2 and includes a withstand voltage tester 41, a probe testing assembly, a test fixture for positioning the material to be tested, a material transfer assembly, and a mounting bracket for mounting the material transfer assembly. The withstand voltage tester 41 is a TH9310 model and is connected to the probe testing assembly via a cable. It is used to test the withstand voltage performance and insulation resistance performance of the transformer. The probe testing assembly uses precision test probes that can reliably contact the pins of the transformer material for electrical performance testing. The probe testing assembly is driven by a cylinder to ensure reliable contact with the transformer material. The test fixture is used to precisely position the transformer material to be tested, ensuring that the test probes accurately contact the corresponding test points on the transformer material.
[0051] The material transfer assembly includes a longitudinally positioned transfer rod, a transverse motor that drives the transfer rod to slide left and right along the mounting frame, and a tilting motor that drives the transfer rod to rotate around its circumference. Grip cylinders are mounted on both sides of the lower end of the transfer rod. The transverse motor is a servo motor that drives the transfer rod to slide left and right along the mounting frame via a synchronous belt drive mechanism. The tilting motor drives the transfer rod to rotate around its circumference, enabling the flipping operation of the transformer material for subsequent testing or transfer. The gripper cylinders on both sides of the lower end of the transfer rod securely hold the transformer material, ensuring it does not fall off during movement and flipping.
[0052] The intermediate storage fixture 5 is located between the withstand voltage testing mechanism 4 and the interlayer testing mechanism 6, and is used to temporarily store transformer materials that have passed the withstand voltage test. The intermediate storage fixture 5 is made of high-strength aluminum alloy with an anodized surface, providing excellent wear resistance and corrosion resistance. The intermediate storage fixture 5 has multiple positioning slots, designed to accommodate the shape characteristics of the transformer materials, ensuring stable placement and easy subsequent handling. The intermediate storage fixture 5 is also equipped with a position sensor; when the transformer materials reach the designated position, the sensor sends a signal to the PLC controller, triggering subsequent automated operations.
[0053] The interlayer testing mechanism 6 is structurally similar to the withstand voltage testing mechanism 4, including an interlayer tester 61, a probe testing assembly, a test fixture for positioning the material to be tested, a material transfer assembly, and a mounting bracket for installing the material transfer assembly. The interlayer tester 61 is used to detect whether the transformer insulation condition is normal, especially to check the insulation performance between transformer windings. Interlayer testing is a crucial step in transformer quality control, effectively preventing short circuits and safety hazards caused by poor insulation. The design of the probe testing assembly, test fixture, and material transfer assembly is similar to that of the withstand voltage testing mechanism 4, but optimized for the characteristics of interlayer testing.
[0054] The integrated testing unit 7 also includes an integrated tester 71, a probe testing assembly, a test fixture for positioning the material under test, a material transfer assembly, and a mounting bracket for installing the material transfer assembly. The integrated tester 71, model TH2829AX, is a high-performance LCR tester capable of measuring and comprehensively evaluating the transformer's electrical parameters such as inductance, capacitance, and resistance. This comprehensive testing ensures the reliability and efficiency of the transformer under various operating conditions and is a crucial aspect of transformer quality control. The test fixture in the integrated testing unit 7 features a specially designed positioning structure to ensure precise positioning of the transformer material for accurate test results.
[0055] The vision testing unit 8 includes a vision testing component, a test fixture for positioning the material to be tested, a material transfer component, and a mounting bracket for mounting the material transfer component. The vision testing component includes a high-resolution industrial camera, a light source system, and an image processing unit, capable of detecting appearance defects in transformer materials, such as surface scratches, stains, and pin deformation. The industrial camera uses a high-resolution CMOS sensor and a specialized lens to capture minute appearance defects. The light source system uses an LED ring light source to provide uniform illumination and reduce shadows and reflection interference. The image processing unit employs advanced image recognition algorithms to analyze images and detect appearance defects in real time, featuring high accuracy and efficiency.
[0056] The defective product collection mechanism 9 is installed on the workbench 2 and is used to collect transformer materials that fail the tests. The defective product collection mechanism 9 includes a collection trough and a pushing cylinder located at the front end of the collection trough. After testing, defective products are placed on the collection trough, and the pushing cylinder extends to push the defective products backward. The collection trough is made of stainless steel with a smooth surface, facilitating the sliding and collection of defective products. The pushing cylinder can precisely control the pushing force, ensuring that defective products are smoothly pushed to the collection area. A full-load sensor is located at the end of the collection trough. When it detects that defective products have accumulated to a preset position, it sends a signal to the PLC controller, triggering an alarm and stopping the machine, reminding the operator to promptly remove the defective products.
[0057] The tray-stacking mechanism 10 includes a tray 101, a tray horizontal movement assembly 102, and a tray vertical movement assembly 103. The tray horizontal movement assembly 102 includes a horizontal slide rail, a horizontal slider mounted on the horizontal slide rail, and a horizontal motor that drives the horizontal slider to slide left and right along the horizontal slide rail; the horizontal slider is equipped with a gripper cylinder for gripping or releasing the tested and qualified transformer materials. The tray vertical movement assembly 103 includes a vertical slide rail, a vertical slider mounted on the vertical slide rail, and a vertical motor that drives the vertical slider to slide back and forth along the vertical slide rail; the tray 101 is placed on the vertical slider. This design allows the tray-stacking mechanism 10 to move precisely in a two-dimensional plane, neatly arranging the tested and qualified transformer materials on the tray 101 according to a predetermined pattern, facilitating subsequent processes. The tray 101 is equipped with a tray sensor to detect whether the tray 101 is full and whether the tray 101 is placed correctly. When the tray 101 is full, the tray sensor will send a signal to the PLC controller to trigger a prompt to replace the tray.
[0058] The PLC controller is the core of the entire equipment's control system, employing a Siemens S7-1500 series PLC, which boasts high reliability and powerful processing capabilities. Through programming, the PLC controller precisely controls and coordinates the material handling mechanism 3, the pressure testing mechanism 4, the inter-layer testing mechanism 6, the comprehensive testing mechanism 7, the vision testing mechanism 8, the defective product collection mechanism 9, and the tray-stacking mechanism 10, ensuring that each mechanism operates according to predetermined timing and parameters. The PLC controller also receives signals from various sensors, such as position sensors and test results from testing instruments, and makes corresponding control adjustments based on these signals to guarantee the safe and stable operation of the equipment.
[0059] The PLC controller can be programmed with various process parameters, including test time, test standards, defective product handling methods, and tray loading modes. These parameters can be adjusted via a touchscreen to adapt to the testing requirements of transformers of different specifications. This flexible parameter setting capability enables the equipment to adapt to the testing needs of various transformer models, improving its versatility and adaptability.
[0060] The working process of this utility model is as follows:
[0061] 1. Initialization and Equipment Preparation: The operator clicks the reset button on the touchscreen, and the equipment enters the reset state; all mechanisms of the equipment return to their initial positions, and the touchscreen displays the reset completion information; the operator clicks the external start button, and the equipment enters the running state.
[0062] 2. Material Retrieval Stage: The transverse drive motor and longitudinal drive motor of the material retrieval mechanism 3 drive the transverse transfer assembly and the longitudinal transfer assembly to the material retrieval position; the gripper cylinder on the longitudinal slider clamps the transformer material sent from the previous process; the transverse transfer assembly and the longitudinal transfer assembly move the transformer material to the test fixture of the withstand voltage test mechanism 4; the gripper cylinder releases the gripper, releasing the transformer material onto the test fixture.
[0063] 3. Withstand Voltage Test Stage: After the transformer material is placed on the test fixture of the withstand voltage test mechanism 4, the cylinder of the probe test component extends, so that the probe of the probe plate contacts the pin of the transformer material; the withstand voltage tester 41 starts to test the withstand voltage performance and insulation resistance of the transformer material; after the test is completed, the test result is transmitted to the PLC controller for judgment; if the test result is qualified (OK), the gripper cylinder of the material transfer component of the withstand voltage test mechanism 4 holds the transformer material, the flip motor drives the transfer rod to flip, and the transformer material is placed in the intermediate storage fixture 5; if the test result is unqualified (NG), the gripper cylinder holds the transformer material, the flip motor drives the transfer rod to flip, and the transformer material is placed on the collection trough of the defective product collection mechanism 9, the push cylinder extends, and the defective product is pushed backward.
[0064] 4. Interlayer Testing Stage: The material transfer component of the interlayer testing mechanism 6 removes the transformer material from the intermediate storage fixture 5 and places it on the testing fixture of the interlayer testing mechanism 6; the cylinder of the probe testing component extends, so that the probe of the probe plate contacts the pin of the transformer material; the interlayer tester 61 starts and performs insulation status testing on the transformer material; after the test is completed, the test result is transmitted to the PLC controller for judgment; if the test result is qualified (OK), the material transfer component of the interlayer testing mechanism 6 removes the transformer material and moves it to the collection trough, at which time the pushing cylinder does not extend; if the test result is unqualified (NG), the material transfer component moves the unqualified product to the collection trough of the defective product collection mechanism 9, the pushing cylinder extends, and pushes the defective product backward.
[0065] 5. Comprehensive Testing Stage: The material transfer component of the comprehensive testing mechanism 7 removes the transformer material that has passed the interlayer test and places it on the test fixture of the comprehensive testing mechanism 7; the cylinder of the probe test component extends, so that the probe of the probe plate contacts the pin of the transformer material; the comprehensive tester 71 starts and performs comprehensive testing on the transformer material for electrical parameters such as inductance, capacitance, and resistance; after the test is completed, the test results are transmitted to the PLC controller for judgment; if the test result is qualified (OK), the material transfer component of the comprehensive testing mechanism 7 removes the transformer material and moves it to the collection trough, at which time the pushing cylinder does not extend; if the test result is unqualified (NG), the material transfer component moves the unqualified product to the collection trough of the defective product collection mechanism 9, the pushing cylinder extends, and pushes the defective product backward.
[0066] 6. Visual Testing Stage: The material transfer component of the visual testing mechanism 8 removes the transformer material that has passed the comprehensive test and places it on the test fixture of the visual testing mechanism 8; the industrial camera is activated to capture an image of the transformer material; the image processing unit analyzes the image and detects appearance defects of the transformer material; the test result is transmitted to the PLC controller for judgment; if the test result is qualified (OK), the material transfer component of the visual testing mechanism 8 removes the transformer material and moves it to the collection trough, at which time the pusher cylinder does not extend; if the test result is unqualified (NG), the material transfer component moves the unqualified product to the collection trough of the defective product collection mechanism 9, the pusher cylinder extends, and pushes the defective product backward.
[0067] 7. Tray Placement Stage: The gripper cylinder of the tray horizontal movement component 102 of the tray placement mechanism 10 clamps the visually inspected and qualified transformer material and moves it to the designated position above the tray 101; the gripper cylinder releases, and the transformer material is placed on the tray 101; when the next row needs to be placed, the vertical movement motor of the tray vertical movement component 103 drives the vertical movement slider to move the tray 101 to the position of the next row; this cycle continues until the tray 101 is full; after the tray sensor detects that the tray 101 is full, it sends a signal to the PLC controller, triggering a prompt to replace the tray; the operator takes out the full tray 101, puts in an empty tray, confirms that the tray 101 is placed correctly, presses the confirmation button, and the equipment continues to run.
[0068] 8. Abnormal Handling: During the entire operation, if the full material sensor at the end of the collection trough detects that defective products have accumulated to the preset position, the machine will automatically stop and issue an alarm. After the operator cleans up the defective products, the machine can be restarted to continue operation. Similarly, if the material tray 101 is not replaced in time after it is full, the machine will also automatically stop and prompt the operator to replace the material tray. After the operator replaces the material tray 101, confirms that the material tray 101 is placed correctly, and presses the confirmation button, the machine will continue to run.
[0069] Among them, the integrated automatic testing, screening and tray arrangement equipment of this utility model has demonstrated many technical advantages in practical applications:
[0070] First, the equipment adopts a fully automated design, integrating multiple processes such as material handling, various tests, screening, and tray placement, forming a complete automated testing production line. Compared with traditional manual testing methods, this equipment significantly reduces manpower input and improves production efficiency. According to actual application data, this equipment can reduce manpower requirements by approximately 70%, while increasing production efficiency by approximately 60%, significantly reducing production costs.
[0071] Secondly, the equipment employs a multi-level testing design, including withstand voltage testing, inter-layer testing, comprehensive testing, and visual testing, to comprehensively evaluate various performance indicators of the transformer. The withstand voltage testing mechanism can detect the transformer's withstand voltage performance and insulation resistance; the inter-layer testing mechanism can detect the insulation status between transformer windings; the comprehensive testing mechanism can evaluate the transformer's electrical parameters such as inductance, capacitance, and resistance; and the visual testing mechanism uses industrial cameras and image processing technology to detect visual defects in the transformer. This multi-dimensional, multi-parameter testing approach ensures comprehensive quality control of transformer products, significantly reducing the defect rate. The defective product outflow rate has been reduced from approximately 5% to below 0.5%.
[0072] Third, all testing mechanisms of the equipment employ high-precision testing instruments and probe systems, such as the TH9310 withstand voltage tester and the TH2829AX comprehensive tester, ensuring the accuracy and reliability of test results. The probe testing components are designed with the contact reliability with the transformer material pins in mind, achieving precise contact through cylinder drive and avoiding misjudgments caused by poor contact. The vision testing mechanism uses a high-resolution industrial camera and advanced image processing algorithms, enabling precise detection of minute appearance defects, such as pin deformation and surface stains, greatly improving testing accuracy.
[0073] Fourth, the equipment's automatic tray-laying mechanism is ingeniously designed. Through the precise coordination of the horizontal and vertical movement components, it achieves automatic placement of tested and qualified products. The gripper cylinders can accurately grasp the transformer materials, while the horizontal and vertical movement components can precisely place the materials at designated positions on the tray according to preset coordinates. This automated tray-laying method avoids the unevenness and misalignment problems that may occur with manual tray-laying, improves tray utilization, and provides neat and orderly raw materials for subsequent processes, thereby improving the overall efficiency of the production line.
[0074] Fifth, the PLC control system of this equipment is flexibly designed, allowing for convenient setting of various process parameters via a touchscreen, such as test time, test standards, defective product handling methods, and tray loading modes, to adapt to the testing needs of transformers of different specifications. This flexible parameter setting capability enables the equipment to meet the testing requirements of various transformer models, improving its versatility and adaptability. Simultaneously, the PLC control system also possesses comprehensive fault diagnosis and handling functions, such as defective product full alarms and tray replacement prompts, ensuring the safe and stable operation of the equipment.
[0075] Finally, the equipment features a rationally designed workbench and chassis, with functional modules arranged according to the process flow, ensuring smooth production and facilitating maintenance and management. Casters mounted on the bottom of the chassis provide excellent mobility, facilitating factory layout adjustments; while locking devices ensure stability during operation. The overall structure is compact, occupying a small area, making it suitable for the space utilization needs of modern factories.
[0076] In summary, this utility model's integrated automatic testing, screening, and tray placement equipment, through advanced automation technology and a precise testing system, achieves fully automated operation of transformer testing, screening, and tray placement processes, significantly improving production efficiency, reducing labor costs, and enhancing the accuracy and consistency of testing, thus providing a reliable guarantee for transformer quality control.
[0077] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.
[0078] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.
Claims
1. An integrated automatic testing, screening, and traying device, characterized in that, include: A chassis, on which a workbench is mounted; A material handling mechanism, installed on the left side of the workbench, is used to transfer transformer materials to the testing mechanism; A withstand voltage testing mechanism, set on the workbench, is used to perform withstand voltage tests on transformer materials; A transfer and storage fixture is set on the workbench for temporarily storing transformer materials that have passed the withstand voltage test. An interlayer testing mechanism, set on the workbench, is used to perform interlayer testing on transformer materials; A comprehensive testing mechanism, set on the workbench, is used to perform comprehensive performance testing on transformer materials; A visual testing mechanism, set on the workbench, is used to perform appearance testing on transformer materials; A defective product collection mechanism, set on the workbench, is used to collect transformer materials that fail the tests. A tray-arranging mechanism, set on the workbench, is used to arrange and arrange the transformer materials that have passed the test. A PLC controller is used to control the coordinated operation of the material handling mechanism, the pressure resistance testing mechanism, the interlayer testing mechanism, the comprehensive testing mechanism, the vision testing mechanism, the defective product collection mechanism, and the tray placement mechanism.
2. The integrated automatic testing, screening, and tray-stacking equipment according to claim 1, characterized in that: The material handling mechanism includes a transverse transfer component and a longitudinal transfer component mounted on the transverse transfer component. The transverse transfer component includes a transverse slide rail, a transverse slider mounted on the transverse slide rail, and a transverse drive motor that drives the transverse slider to slide left and right along the transverse slide rail. The longitudinal transfer component includes a longitudinal slide rail mounted on the transverse slider, a longitudinal slider mounted on the longitudinal slide rail, and a longitudinal drive motor that drives the longitudinal slider to slide up and down along the longitudinal slide rail. The longitudinal slider is equipped with a gripper cylinder for gripping or releasing transformer material.
3. The integrated automatic testing, screening, and traying equipment according to claim 1, characterized in that: The withstand voltage testing mechanism includes a withstand voltage tester, a probe testing component, a test fixture for positioning the material to be tested, a material transfer component, and a mounting frame for mounting the material transfer component. The withstand voltage tester is electrically connected to the probe testing component via a cable. The probe testing component is positioned above the test fixture. The material transfer component is mounted on the mounting frame and is used to transfer transformer material.
4. The integrated automatic testing, screening, and traying equipment according to claim 3, characterized in that: The material transplanting assembly includes a transplanting rod arranged longitudinally, a transverse motor that drives the transplanting rod to slide in the left-right direction along the mounting frame, and a flipping motor that drives the transplanting rod to flip in the circumferential direction. Gripper cylinders are respectively installed on both sides of the lower end of the transplanting rod. The transverse motor and the flipping motor are both electrically connected to the PLC controller, and the gripper cylinders are pneumatically connected to the PLC controller.
5. The integrated automatic testing, screening, and traying equipment according to claim 1, characterized in that: The interlayer testing mechanism includes an interlayer tester, a probe test assembly, a test fixture for positioning the material to be tested, a material transfer assembly, and a mounting frame for mounting the material transfer assembly. The interlayer tester is electrically connected to the probe test assembly via a cable. The probe test assembly is positioned above the test fixture. The material transfer assembly is mounted on the mounting frame and is used to transfer transformer material.
6. The integrated automatic testing, screening, and traying equipment according to claim 1, characterized in that: The integrated testing mechanism includes an integrated tester, a probe testing component, a test fixture for positioning the material to be tested, a material transfer component, and a mounting frame for mounting the material transfer component. The integrated tester is electrically connected to the probe testing component via a cable. The probe testing component is positioned above the test fixture. The material transfer component is mounted on the mounting frame and is used to transfer transformer material.
7. The integrated automatic testing, screening, and traying equipment according to claim 1, characterized in that: The vision testing mechanism includes a vision testing component, a test fixture for positioning the material to be tested, a material transfer component, and a mounting frame for mounting the material transfer component. The vision testing component is disposed above the test fixture, and the material transfer component is mounted on the mounting frame for transferring transformer material. The vision testing component includes an industrial camera, a light source system, and an image processing unit. The industrial camera and the light source system are both electrically connected to the image processing unit, and the image processing unit is electrically connected to the PLC controller.
8. The integrated automatic testing, screening, and traying equipment according to claim 1, characterized in that: The defective product collection mechanism includes a collection trough and a pushing cylinder disposed at the front end of the collection trough. The collection trough is fixedly installed on the worktable, and the cylinder body of the pushing cylinder is fixedly installed on the worktable. The piston rod of the pushing cylinder is connected to a push plate and is used to push the transformer material that fails the test into the collection trough. A full material sensor is provided at the end of the collection trough. The full material sensor is electrically connected to the PLC controller. When the sensor detects that defective products have accumulated to a preset position, it sends a signal to the PLC controller to trigger an alarm and stop the machine.
9. The integrated automatic testing, screening, and traying equipment according to claim 1, characterized in that: The tray-sliding mechanism includes a tray, a tray horizontal movement assembly, and a tray vertical movement assembly. The tray horizontal movement assembly includes a horizontal slide rail, a horizontal slider mounted on the horizontal slide rail, and a horizontal motor that drives the horizontal slider to slide left and right along the horizontal slide rail. The horizontal slider is equipped with a gripper cylinder for gripping or releasing the tested and qualified transformer material. The tray vertical movement assembly includes a vertical slide rail, a vertical slider mounted on the vertical slide rail, and a vertical motor that drives the vertical slider to slide back and forth along the vertical slide rail. The tray is placed on the vertical slider.
10. The integrated automatic testing, screening, and traying equipment according to claim 9, characterized in that: The tray is equipped with a tray sensor, which is electrically connected to the PLC controller. The tray sensor is used to detect whether the tray is full and whether the tray is placed correctly. When the tray is full, the tray sensor sends a signal to the PLC controller to trigger a prompt to replace the tray.