Full-automatic test equipment for common-mode noise of planar transformer

Abstract

The utility model discloses a kind of planar transformer common mode noise full-automatic test equipment, including detection unit, for the common mode noise test of planar transformer;Feeding unit, located in the feeding side of detection unit, feeding unit is provided with first temporary storage device, and first temporary storage device is used to temporarily store planar transformer to be detected;Discharging unit, located in the discharging side of detection unit, discharging unit is provided with second temporary storage device and third temporary storage device, and second temporary storage device and third temporary storage device are used to temporarily store respectively planar transformer that fails to pass detection and planar transformer that passes detection;Transfer unit, including transfer manipulator for transferring planar transformer, and transfer manipulator can realize the circulation between feeding unit, detection unit, discharging unit of planar transformer.

Description

Technical Field

[0001] This utility model relates to the field of testing equipment technology, and in particular to a fully automatic testing device for common mode noise of a planar transformer. Background Technology

[0002] A planar transformer is a type of transformer characterized by high frequency, low profile, small height, and high operating frequency.

[0003] Currently, common-mode noise testing of planar transformers is done manually on a single-piece basis, relying on manual differentiation between good and defective products. This is inefficient, as there is no automated testing equipment that can simultaneously meet the requirements of automatic loading and unloading, automatic identification and differentiation of good and defective products, making it difficult to complete test data collection and product data traceability. Therefore, under the high requirements of product quality, it is impossible to achieve continuous, stable and efficient mass production. Utility Model Content

[0004] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes a fully automatic testing device for common-mode noise of planar transformers, which can improve testing quality and efficiency, and enable continuous, stable, and efficient mass production.

[0005] A fully automatic common-mode noise testing device for planar transformers according to an embodiment of the present invention includes:

[0006] The detection unit is used to perform common-mode noise testing on the planar transformer.

[0007] The feeding unit is located on the feeding side of the testing unit. The feeding unit is equipped with a first temporary storage device, which is used to temporarily store the planar transformer to be tested.

[0008] The unloading unit is located on the unloading side of the testing unit. The unloading unit is equipped with a second temporary storage device and a third temporary storage device. The second temporary storage device and the third temporary storage device are used to temporarily store planar transformers that fail the test and planar transformers that pass the test, respectively.

[0009] The transfer unit includes a transfer robot for transferring planar transformers. The transfer robot can realize the transfer of planar transformers between the loading unit, the detection unit, and the unloading unit.

[0010] According to an embodiment of this utility model, a fully automated testing device for common-mode noise of a planar transformer has at least the following advantages: This solution replaces manual operation with fully automated equipment; the collaborative work of the detection unit and the transfer unit enables continuous testing; and the categorized storage design of the temporary storage device ensures precise and controllable product flow. Furthermore, the modular layout of each unit optimizes the equipment's footprint, and the robotic arm's motion path planning shortens product transfer time.

[0011] This application achieves full automation of common-mode noise testing for planar transformers, effectively eliminating efficiency bottlenecks and sorting errors caused by manual operation. The cooperation between the testing unit and the transfer unit significantly improves the testing cycle time, and the design of the classification and temporary storage device ensures the reliability of product quality traceability. The coordinated operation of each functional module not only improves testing stability but also provides the hardware foundation for the automatic acquisition and storage of test data, meeting the high standards required for product testing in modern electronics manufacturing.

[0012] According to an embodiment of the present invention, a fully automatic testing device for common mode noise of planar transformers includes a first temporary storage device comprising a feeding position, a first temporary storage platform, and a first lifting drive. The feeding position is located above the first temporary storage platform. Multiple planar transformers to be tested are stacked vertically on the first temporary storage platform. The output end of the first lifting drive is connected to the first temporary storage platform. The first lifting drive can drive the first temporary storage platform to adjust its position in the vertical direction so that the planar transformer to be tested at the top reaches the feeding position.

[0013] According to an embodiment of the present invention, a fully automatic testing device for common mode noise of planar transformers includes a second temporary storage device and a third temporary storage device, each equipped with a feeding position, a second temporary storage platform, and a second lifting drive. The feeding position is located above the second temporary storage platform. Multiple tested planar transformers are stacked vertically on the second temporary storage platform. The output end of the second lifting drive is connected to the second temporary storage platform. The second lifting drive can drive the second temporary storage platform to adjust its position in the vertical direction so that the top tested planar transformer leaves the feeding position.

[0014] According to an embodiment of the present invention, a fully automatic testing device for common mode noise of a planar transformer is provided. The detection unit and the feeding unit are equipped with a marking unit. The marking unit includes a marking device and a material loading device. The marking device is disposed above the material loading device. The material loading device is used to fix the planar transformer that has been tested and is to be marked. The marking device sets an identification code on the surface of the planar transformer according to the test results.

[0015] According to an embodiment of the present invention, a fully automatic testing device for common mode noise of a planar transformer includes a material loading device comprising a material loading base and an adsorption mechanism. The adsorption mechanism includes an adsorption plate disposed on the material loading base and a vacuum negative pressure machine. The vacuum negative pressure machine is connected to the adsorption plate, and the adsorption plate is used to adsorb and fix the planar transformer to be marked.

[0016] According to an embodiment of the present invention, a fully automatic testing device for common mode noise of a planar transformer includes a marking unit that further includes a three-axis moving device, wherein one of the material carrier and the marking device is connected to the three-axis moving device.

[0017] or,

[0018] The marking unit further includes a three-axis moving device, and the material carrier and the marking device are both connected to the three-axis moving device. According to an embodiment of this utility model, a fully automatic common-mode noise testing device for a planar transformer is provided.

[0019] According to an embodiment of the present invention, a fully automatic common-mode noise testing device for a planar transformer is provided, wherein an identification unit is provided between the marking unit and the unloading unit, the identification unit is electrically connected to the transfer robot, the identification unit is used to identify the identification code set on the surface of the planar transformer, and the transfer robot can transfer the planar transformer to the second temporary storage device or the third temporary storage device according to the identification information of the identification unit.

[0020] According to an embodiment of the present invention, a fully automatic testing device for common mode noise of a planar transformer includes a transfer unit that further comprises a linear motion module. Two transfer manipulators are mounted on the linear motion module. One of the two transfer manipulators is used to transfer the planar transformer to be tested, and the other of the two transfer manipulators is used to transfer the planar transformer that has already been tested.

[0021] According to an embodiment of the present invention, a fully automatic testing device for common mode noise of a planar transformer includes a transfer manipulator comprising a mounting plate and a plurality of suction cups disposed on the mounting plate. The suction cups are movably connected to the mounting plate, and their positions on the mounting plate are adjustable. The suction cups are connected to an external negative pressure mechanism.

[0022] According to an embodiment of the present invention, a fully automatic testing device for common mode noise of a planar transformer includes an upper testing module and a lower testing module. The upper testing module and the lower testing module can move closer to or further away from each other. The lower testing module abuts against the bottom of the planar transformer to be tested, and the upper testing module presses against the top of the planar transformer to be tested.

[0023] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0024] The above and / or additional aspects and advantages of this utility model will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0025] Figure 1 This is a structural schematic diagram of a fully automatic common-mode noise testing device for a planar transformer according to an embodiment of the present invention.

[0026] Explanation of reference numerals in the attached figures:

[0027] Detection unit 100; upper detection module 110; lower detection module 120;

[0028] First temporary storage device 200; First temporary storage platform 210; First lifting drive component 220;

[0029] Second temporary storage device 300; Second temporary storage platform 310; Second lifting drive component 320;

[0030] Third temporary storage device 400;

[0031] 500 transfer robot; 510 mounting plate; 520 suction cup;

[0032] Marking unit 600; marking device 610; material carrier 620; material carrier base 621; adsorption plate 622;

[0033] Linear motion module 700;

[0034] Identification unit 800. Detailed Implementation

[0035] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0036] In the description of this utility model, it should be understood that the directional descriptions, such as up, down, front, back, left, right, etc., indicate the directional or positional relationship based on the directional 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 element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0037] In the description of a utility model, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. If the terms "first" and "second" are used, they are merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly specifying the number of indicated technical features or the order of the indicated technical features.

[0038] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.

[0039] In existing technologies, planar transformers are widely used due to their high-frequency and low-profile characteristics, but their common-mode noise testing has long relied on manual operation. In traditional testing, operators manually place the product to be tested, and after testing each piece, judge whether it is good or defective based on experience. This method suffers from low testing efficiency, large fluctuations in sorting accuracy, and incomplete test data recording. Especially in mass production scenarios, manual sorting easily leads to a mixture of qualified and unqualified products, making it difficult to correlate test data with specific product batches and causing difficulties in quality traceability.

[0040] To address these issues, researchers conducted a systematic analysis of the manual testing process, identifying that the core factors limiting efficiency lay in the material flow and data acquisition stages. By dissecting the testing process, they found that the three stages—product supply, testing execution, and result judgment—could all be automated to replace manual operations. Based on this, they first planned and set up an independent feeding module to ensure continuous product supply; secondly, they established a sorting module to solve product mixing issues through physical isolation; and finally, they used programmable mechanical devices to connect the modules, forming a closed material transport path. A key breakthrough in this process was achieving a match between the capacity of the temporary storage device and the robot's operating cycle time. Ultimately, a design combining a vertical stacking structure and a lifting drive ensured the continuity of material supply and transfer.

[0041] Therefore, refer to Figure 1 This application proposes a fully automatic common-mode noise testing device for planar transformers, including a detection unit 100 for testing the common-mode noise of planar transformers; a loading unit located on the loading side of the detection unit 100, which is provided with a first temporary storage device 200 for temporarily storing the planar transformers to be tested; a unloading unit located on the unloading side of the detection unit 100, which is provided with a second temporary storage device 300 and a third temporary storage device 400 for storing defective and qualified products respectively; and a transfer unit including a transfer robot 500 to realize the transfer of planar transformers between the loading unit, the detection unit 100, and the unloading unit.

[0042] The detection unit 100 is the core functional module for performing common-mode noise testing. It can be implemented using a combination of an electromagnetic coupling device and a signal acquisition module, acquiring electromagnetic interference signals from the transformer during operation via an induction coil. The first temporary storage device 200 in the loading unit is a storage mechanism for buffering the products under test. It can be implemented using a vertical stacking structure combined with a lifting platform to ensure the products are always at a manageable height. The second temporary storage device 300 and the third temporary storage device 400 in the unloading unit are sorting mechanisms for classifying and storing test results. They can be implemented using independently controlled lifting platforms to ensure physical isolation of products of different quality. The transfer robot 500 is the actuator for transferring the spatial position of products. It can be implemented using a combination of a vacuum suction cup 520 component and a multi-axis drive system, completing product gripping and placement through a preset motion trajectory.

[0043] Specifically, the planar transformer under test is vertically stacked and stored in the loading unit via the first temporary storage device 200. A lifting drive continuously adjusts the stacking height to ensure that the transfer robot 500 can always access the top-level product. After the testing unit 100 completes its current test, the transfer robot 500 moves the product under test from the loading unit to the testing station. After the testing unit 100 acquires the test data, the transfer robot 500 transfers the product to the corresponding temporary storage device in the unloading unit based on the judgment result. The second temporary storage device 300 and the third temporary storage device 400 manage the product stacking height through independent lifting mechanisms to avoid cross-contamination between qualified and unqualified products. Throughout the entire process, the product flow path forms a closed loop, and the working rhythm of each unit is coordinated and synchronized through the central control system.

[0044] Compared to existing technologies, traditional manual testing requires operators to place products one by one, record data, and manually sort them, which carries the risk of human error and is inefficient. This solution replaces manual operation with fully automated equipment. The collaborative work of the testing unit 100 and the transfer unit enables continuous testing, and the categorized storage design of the temporary storage device ensures accurate and controllable product flow. In addition, the modular layout of each unit optimizes the equipment footprint, and the robotic arm's motion path planning shortens the product transfer time.

[0045] Through the above technical solution, this application achieves full automation of the common-mode noise test for planar transformers, effectively eliminating efficiency bottlenecks and sorting errors caused by manual operation. The cooperation between the detection unit 100 and the transfer unit significantly improves the testing cycle time, and the design of the classification and temporary storage device ensures the reliability of product quality traceability. The coordinated operation of each functional module not only improves testing stability but also provides the hardware foundation for the automatic acquisition and storage of test data, meeting the high standards required for product testing in the modern electronics manufacturing field.

[0046] This application further proposes a first temporary storage device 200, which includes a feeding position, a first temporary storage platform 210, and a first lifting drive 220. The feeding position is located above the first temporary storage platform 210. Multiple planar transformers to be tested are stacked vertically on the first temporary storage platform 210. The output end of the first lifting drive 220 is connected to the first temporary storage platform 210. The first lifting drive 220 can drive the first temporary storage platform 210 to adjust its position in the vertical direction so that the planar transformer to be tested at the top reaches the feeding position.

[0047] The feeding position refers to the location where the material is removed, which can be achieved using a platform structure of fixed height, with its horizontal coordinates matching the material handling path of the robotic arm. This position is located above the temporary storage platform, utilizing gravity to automatically align the top material, reducing lateral positioning errors. The first temporary storage platform 210 is a support component for stacking the materials to be tested, which can be a support plate structure with guide columns, and its surface is provided with limiting protrusions to prevent material slippage. Vertical stacking achieves self-stability through the material's own weight, avoiding the complex partitioning structure required for horizontal arrangement. The first lifting drive 220 is the power source that drives the movement of the temporary storage platform, which can be a servo motor combined with a ball screw mechanism, achieving closed-loop control through encoder feedback, and precisely adjusting the height of the temporary storage platform to compensate for changes in the thickness of the stacked materials.

[0048] Specifically, multiple planar transformers are vertically stacked on the first temporary storage platform 210, which is initially at its lowest position. After the robotic arm removes the top material, the first lifting drive 220 raises the platform a fixed distance, allowing the next layer of material to reach the feeding position. This distance is equal to the thickness of a single material, achieved with millimeter-level precision through pulse control of a servo motor. During material stacking, guide columns ensure that the central axis of each layer remains aligned with the feeding position. When material is about to run out, the control system triggers an alarm to prompt replenishment, thus maintaining continuous feeding.

[0049] Furthermore, the first temporary storage device 200 is equipped with a detector. Specifically, the detector is located at the loading position to detect whether there is material at the loading position. When the detector detects that a planar transformer to be tested has been placed at the loading position, the first lifting drive 3220 drives the first temporary storage platform 210 to rise by the height of one workpiece, so that the next layer of material reaches the feeding position.

[0050] Compared to existing technologies, traditional manual feeding requires operators to frequently move materials to the picking station, resulting in significant picking position deviations and production line downtime due to replenishment intervals. This solution, through vertical stacking storage and automatic lifting adjustment, keeps materials in a fixed picking position, eliminating positioning errors and efficiency fluctuations caused by manual intervention. Material replenishment only requires batch stacking onto the temporary storage table, eliminating the need for individual placement, significantly reducing operational complexity.

[0051] Through the above technical solutions, this application achieves automated and continuous supply of materials to be tested, ensuring that each planar transformer accurately reaches the robotic arm's picking position. The dynamic compensation mechanism for material stacking height avoids manual adjustment of the temporary storage platform height, improving equipment operational stability. The vertical storage method reduces the equipment's footprint, adapting to the needs of high-density production line layouts. The closed-loop control lifting mechanism ensures that the material feeding position positioning accuracy reaches ±0.1 mm, meeting the precision picking and placing requirements of automated testing equipment.

[0052] This application further proposes that the unloading unit be equipped with a second temporary storage device 300 and a third temporary storage device 400. Each temporary storage device includes an unloading position, a second temporary storage platform 310 and a second lifting drive 320. The unloading position is located above the second temporary storage platform 310. Multiple tested planar transformers are stacked vertically on the second temporary storage platform 310. The output end of the second lifting drive 320 is connected to the second temporary storage platform 310. The second lifting drive 320 drives the second temporary storage platform 310 to adjust its position in the vertical direction, so that the tested planar transformers located at the top leave the unloading position.

[0053] The second temporary storage platform 310 refers to a platform structure used to support and temporarily store the tested planar transformers. Specifically, it can be implemented using a metal plate with positioning grooves or guide structures, and its surface can be textured with anti-slip material to increase friction. The second lifting drive unit 320 refers to an actuator that provides vertical motion drive, such as a servo motor combined with a ball screw. Its stroke range can be set according to the stacking height of the planar transformers. The unloading position refers to the target location for receiving the planar transformers placed by the transfer robot 500. Its height is aligned with the working plane of the transfer robot 500, for example, by real-time monitoring and feedback of position information through sensors.

[0054] Specifically, when the inspected planar transformer is transferred to the unloading unit, the second lifting drive 320 drives the second temporary storage platform 310 to descend by the height of one workpiece, thus removing the currently top planar transformer from its unloading position. After the transfer robot 500 places the planar transformer in the unloading position, the second temporary storage platform 310 automatically rises to the next receiving position. As the second temporary storage platform 310 continues to rise and fall, multiple planar transformers are stacked vertically until the preset storage capacity is reached. During this process, good and defective products are transferred to the third temporary storage device 400 and the second temporary storage device 300, respectively. The physical separation of the two types of products is achieved through independent lifting mechanisms to avoid confusion.

[0055] Furthermore, the second temporary storage device 300 and the third temporary storage device 400 are arranged at intervals along the direction away from the detection unit to prevent defective products from falling into the storage mechanism of qualified products during the transfer process, which helps to further ensure the accuracy of product classification.

[0056] Furthermore, both the second temporary storage device 300 and the third temporary storage device 400 are equipped with detectors. Specifically, the detectors are located at the unloading position to detect whether there is material at the unloading position. When the detector detects that a planar transformer that has been tested has been placed at the unloading position, the second lifting drive 320 drives the second temporary storage platform 310 to descend a distance equal to the height of a workpiece, so that the currently top planar transformer is removed from the unloading position.

[0057] Compared to existing technologies, traditional manual sorting methods rely on operators manually handling and sorting, resulting in low efficiency and a high risk of errors. Existing equipment often uses horizontally arranged storage racks for temporary storage, which occupy a large area and cannot achieve automatic height adjustment. This solution combines vertical stacking with a lifting drive to increase storage density within a limited space. Simultaneously, automated lifting control ensures accurate product positioning, eliminating the risk of sorting errors caused by manual intervention.

[0058] Through the above technical solution, this application achieves automated classification and storage of tested planar transformers, effectively preventing the mixing of good and defective products. The coordinated action of the lifting drive and the temporary storage platform enables continuous receiving and orderly stacking of products, avoiding production interruptions caused by manual handling. The vertical space utilization method reduces the equipment's footprint, making it suitable for high-density production line layouts. Furthermore, the classification and storage process is automatically linked to the testing data, providing a physical identification basis for product traceability.

[0059] This application further proposes to set a marking unit 600 between the detection unit 100 and the unloading unit. The marking unit 600 includes a marking device 610 and a material carrier 620. The marking device 610 is set above the material carrier 620. The material carrier 620 is used to fix the planar transformer that has been tested and is to be marked. The marking device 610 sets an identification code on the surface of the planar transformer according to the test results.

[0060] The marking unit 600 refers to an automatic marking system composed of a marking device 610 and a material carrier 620. Specifically, it can be implemented using a laser marking machine in conjunction with a pneumatic fixture, used to permanently mark the product surface after inspection. The material carrier 620 is a mechanism that supports and fixes the workpiece to be marked. Specifically, it can be a combination of a vacuum adsorption platform and positioning pins, maintaining the positioning accuracy of the planar transformer through negative pressure adsorption. The identification code is an identifiable mark containing inspection result information, specifically in the form of a QR code or barcode, formed on the workpiece surface through laser etching or inkjet printing.

[0061] Specifically, after the planar transformer completes common-mode noise detection, it is transferred by the transfer robot 500 to the loading device 620. The vacuum adsorption plate 622, once activated, generates negative pressure to adsorb and fix the workpiece onto the loading seat 621. The detection system transmits the test results to the control system of the marking device 610, which drives the laser marking head to generate a QR code mark on the workpiece surface containing the detection time, test value, and pass / fail status. After marking, the recognition unit scans the QR code to verify the accuracy of the information. Subsequently, the transfer robot 500 classifies and transfers the workpiece to the corresponding temporary storage device based on the verification results.

[0062] Compared to existing technologies, traditional manual labeling methods require operators to visually inspect the test results and manually affix labels, leading to errors, omissions, and low efficiency. This solution directly links test data with the labeling system, instantly converting test results into physical labels. This avoids data gaps caused by manual intervention and ensures a strict correspondence between test data and physical labels for each product.

[0063] Through the above technical solution, this application realizes the automatic association between test results and physical products, solves the risk of mixing caused by low efficiency of manual differentiation, and provides a verifiable physical carrier for quality traceability through unique identification code, so that non-conforming products can be accurately located to specific test batches and test data.

[0064] This application further proposes a material carrier 620 including a material carrier 621 and an adsorption mechanism. The adsorption mechanism includes an adsorption plate 622 disposed on the material carrier 621 and a vacuum negative pressure machine. The vacuum negative pressure machine is connected to the adsorption plate 622, and the adsorption plate 622 is used to adsorb and fix the planar transformer to be marked.

[0065] The material carrier 621 refers to a fixed platform that provides support for the planar transformer. It can be made of aluminum alloy or rigid plastic, and its surface can be equipped with positioning grooves or limiting edges to ensure the planar transformer is placed in a preset position. The adsorption plate 622 refers to a plate-like structure with multiple adsorption holes or adsorption areas. Specifically, it can be connected to a vacuum negative pressure machine by having an array of through holes on its surface to form a negative pressure adsorption force, achieving uniform adsorption on the bottom surface of the planar transformer. The vacuum negative pressure machine is a pneumatic device that can generate stable negative pressure. It can be a diaphragm pump or a rotary vane pump, and the adsorption force intensity can be controlled by adjusting the suction power to meet the fixing requirements of planar transformers of different sizes or weights.

[0066] Specifically, after the planar transformer is placed on the adsorption plate 622 of the material carrier 621, the vacuum negative pressure machine is activated and forms a negative pressure area on the surface of the adsorption plate 622. The suction force generated by the adsorption holes tightly adheres the bottom surface of the planar transformer to the surface of the adsorption plate 622. The synergistic effect of the rigid support of the material carrier 621 and the adsorption force can suppress the lateral displacement or tilting of the planar transformer during the marking process, while avoiding surface indentations or deformation caused by traditional mechanical clamping. When the marking device 610 applies markings to the surface of the planar transformer, the continuous operation of the adsorption plate 622 and the vacuum negative pressure machine can maintain a fixed state, ensuring that the marking position is consistent with the preset coordinates.

[0067] Compared to existing technologies, traditional planar transformer marking often uses manual clamps or spring blocks for fixation, which can easily lead to product displacement due to uneven clamping force, and frequent operation can cause wear on the clamps. This solution replaces mechanical contact fixing with vacuum adsorption, eliminating the impact of clamping force on the product surface and ensuring fixing stability through the uniformity of negative pressure distribution. It is particularly suitable for automated production lines for planar transformers with high surface flatness requirements.

[0068] Through the above technical solution, this application solves the problem of misalignment of markings caused by unstable fixing during high-speed marking of planar transformers. Non-contact fixing is achieved through the synergistic effect of vacuum adsorption and material carrier 621, avoiding damage to the product surface. At the same time, it improves the position repeatability accuracy of automated marking and ensures the accurate correspondence between the marking code and the test results.

[0069] This application further proposes that the marking unit 600 also includes a three-axis moving device, and one of the material carrier 621 and the marking device 610 is connected to the three-axis moving device; or, the marking unit 600 also includes a three-axis moving device, and both the material carrier 621 and the marking device 610 are connected to the three-axis moving device.

[0070] The three-axis moving device refers to a drive mechanism capable of linear displacement in three orthogonal directions (X, Y, and Z). Specifically, it can be implemented using a motion platform composed of ball screws, linear guides, and servo motors, achieving precise spatial positioning through multi-axis linkage control. The material carrier 621 is a positioning base used to fix the planar transformer, specifically implemented using a metal fixture with vacuum adsorption function, which maintains the workpiece's stable position during the marking process through adsorption force. The marking device 610 is a mechanism used to form markings on the product surface, specifically implemented using a laser marking head or a pneumatic needle marking machine, which generates corresponding character or graphic marks based on the detection results.

[0071] Specifically, when only the carrier 621 is equipped with a three-axis moving device, the spatial position of the carrier 621 is adjusted to precisely align the marking area of ​​the planar transformer with the fixed working focus of the marking device 610, eliminating the influence of workpiece clamping errors on the marking position. When both the carrier 621 and the marking device 610 are equipped with independent three-axis moving devices, the carrier 621 can perform coarse positioning compensation, and the marking device 610 can perform fine-tuning positioning. The two work together to achieve dynamic tracking positioning, adapting to the marking requirements of workpieces of different sizes. Both implementation methods replace the passive tolerance method of traditional mechanical positioning with active adjustment of the spatial coordinate system, solving the marking offset problem caused by the accumulation of workpiece tolerances.

[0072] Compared with existing technologies, traditional fixed marking mechanisms rely on mechanical positioning accuracy and cannot compensate for fluctuations in workpiece dimensions and clamping errors, resulting in marking position deviations exceeding the allowable range. This solution introduces a programmable three-axis moving device to construct an active positioning compensation mechanism, enabling the marking device 610 to form a dynamic alignment relationship with the workpiece surface, eliminating positioning failures caused by equipment assembly errors or workpiece deformation.

[0073] Through the above technical solution, this application achieves precise positioning of markings on the surface of planar transformers, ensuring consistency in marking positions across different batches of products and avoiding manual re-inspection and adjustment. This solution can automatically compensate for workpiece dimensional tolerances and clamping position deviations, improving the equipment's compatibility with different product specifications. Simultaneously, through digital control of the coordinate system, it enables rapid switching of marking paths, significantly improving production line changeover efficiency.

[0074] This application further proposes to set up an identification unit between the marking unit 600 and the unloading unit. The identification unit is electrically connected to the transfer robot 500. The identification unit is used to identify the identification code set on the surface of the planar transformer. The transfer robot 500 transfers the planar transformer to the second temporary storage device 300 or the third temporary storage device 400 according to the identification information of the identification unit.

[0075] The identification unit refers to a device that acquires the identification code information on the surface of the planar transformer through optical or image processing equipment. Specifically, it can be implemented by using an industrial camera in conjunction with a QR code scanning module to convert the identification code content into a data signal that can be recognized by the control system.

[0076] The identification code refers to the coded mark containing the test result information. Specifically, it can be implemented using a QR code or barcode formed by laser engraving or inkjet printing, and is used to uniquely associate the test data of each planar transformer.

[0077] Among them, electrical connection refers to the real-time data transmission channel established between the identification unit and the transfer robot 500. Specifically, it can be implemented using an industrial bus or wireless communication module to synchronously transmit the identification results to the control system of the transfer robot 500.

[0078] Specifically, after the planar transformer completes its inspection, the marking unit 600 forms a corresponding identification code on its surface based on the inspection results. The identification unit scans the identification code, parses the inspection result status information, and transmits this information to the control unit of the transfer robot 500. Based on the received pass / fail signal, the transfer robot 500 selects to move the planar transformer to either the third temporary storage device 400 or the second temporary storage device 300. The entire process requires no manual intervention, and the secondary verification mechanism of the identification code ensures that the sorting action strictly corresponds to the inspection results, avoiding misjudgment.

[0079] Compared to existing technologies, traditional methods rely on manual visual inspection and classification, resulting in low efficiency, high error rates, and the inability to establish a data traceability chain. This solution achieves digital recording of inspection results and precise execution of sorting actions through automated identification code recognition and sorting linkage control, eliminating uncontrollable factors in manual operation.

[0080] Through the above technical solution, this application realizes closed-loop control of test results and sorting action, effectively improves the classification accuracy of planar transformers, and enables full-process traceability of test data through identification codes, solving the technical problems of low efficiency, easy error and difficulty in product data management of manual sorting.

[0081] This application further proposes that the transfer unit also includes a linear motion module 700, and two transfer robots 500 are mounted on the linear motion module 700. One of the two transfer robots 500 is used to transfer the planar transformer to be tested, and the other of the two transfer robots 500 is used to transfer the planar transformer that has been tested.

[0082] The linear motion module 700 refers to the mechanical structure used to drive the transfer robot 500 to reciprocate in the horizontal direction. Specifically, it can be implemented by using a linear guide or belt drive mechanism, and is powered by a servo motor or stepper motor to achieve precise positioning.

[0083] Among them, the transfer robot 500 refers to an automated device used to clamp and transport planar transformers. Specifically, it can be implemented using a vacuum suction cup 520 or a pneumatic gripper structure. The suction cup 520 or gripper uses negative pressure or air pressure control to grasp and release materials.

[0084] Specifically, the linear motion module 700 serves as the motion carrier for the transfer robot 500, enabling the two robots to move synchronously on the same track, reducing the travel time for a single robot to travel between different workstations. The two transfer robots 500 independently perform the transfer tasks of items to be inspected and items already inspected, achieving process separation through division of labor and avoiding potential confusion when the same robot is transferring materials in different states. The linear motion module 700, through a closed-loop control system, drives the two robots to move along preset paths, allowing them to reach the target positions of the loading unit, inspection unit 100, and unloading unit respectively, completing the precise gripping and placement of materials.

[0085] Compared to existing technologies, traditional solutions typically use a single robotic arm for material loading and unloading, requiring frequent switching of gripping targets and adjustments to the movement path, resulting in low transfer efficiency and a risk of cross-contamination between items to be inspected and those already inspected. This application addresses this by integrating two independent robotic arms into a linear motion module 700, achieving parallel transfer of items to be inspected and those already inspected. This reduces the robotic arm's idle waiting time and completely eliminates the possibility of material mixing through physically isolated transfer paths.

[0086] Through the above technical solutions, this application can significantly improve the transfer efficiency of planar transformers during the testing process, shorten the overall testing cycle through the parallel operation of two robotic arms, and completely avoid the risk of mixing between the test product and the tested product through the independent transfer path design, thus ensuring the reliability and stability of the testing process.

[0087] This application further proposes that the detection unit 100 includes an upper detection module 110 and a lower detection module 120, which can move closer to or further away from each other. The upper detection module 110 is pressed against the top of the planar transformer to be tested, and the lower detection module 120 is abutted against the bottom of the planar transformer to be tested.

[0088] Among them, the upper detection module 110 refers to the contact module located on the top of the planar transformer under test. Specifically, it can be implemented by a metal plate structure with elastic probes. The probes are reliably electrically connected to the top terminals of the planar transformer through a pressing action.

[0089] Among them, the lower detection module 120 refers to the support module located at the bottom of the plane transformer under test. Specifically, it can be implemented by a rigid support platform with an insulating coating, which limits the horizontal displacement of the plane transformer and provides mechanical support through the abutment action.

[0090] The phrase "moving closer or further apart" refers to the coordinated movement of the upper and lower detection modules. This can be achieved using a synchronous guide rail mechanism driven by a linear cylinder or servo motor, and the range of motion can cover planar transformers of different thicknesses.

[0091] Specifically, during the testing process, the lower testing mold 120 first rises to a preset height to position the bottom of the planar transformer. Then, the upper testing mold 110 moves downwards to apply vertical pressure to the top of the planar transformer. During the crimping process, the elastic probes of the upper testing mold 110 deform to compensate for assembly tolerances, ensuring that all test contacts are in tight contact with the terminals of the planar transformer. The lower testing mold 120, with its bottom abutting against the transformer, provides rigid support to counteract the reaction force generated by the crimping force, preventing the device under test from tilting or sliding. After the test is completed, the upper testing mold 110 rises to release the crimping state, and the lower testing mold 120 simultaneously descends to disengage from the abutting position, providing operating space for the transfer robot 500 to remove the device under test.

[0092] Compared to existing technologies, traditional fixed clamps cannot adaptively adjust the clamping gap, easily leading to poor contact or device damage. This solution achieves dynamic clamping control through the coordinated displacement of the upper and lower detection modules, which can adapt to the testing requirements of planar transformers of different thicknesses and improve the stability of test signals through a composite contact method of pressing and abutting. In existing technologies, the single-sided pressing method is prone to causing the planar transformer to tilt, while the rigid support at the bottom of this solution effectively maintains the horizontal orientation of the device under test.

[0093] Through the above technical solution, this application solves the problem of contact resistance fluctuation caused by clamping instability in common-mode noise testing of planar transformers, and eliminates test data deviation caused by device displacement. The phased operation of the upper and lower detection modules enables non-destructive clamping and rapid release of the device under test, providing a foundation for continuous operation in automated testing lines. The dual contact mechanism of pressing and abutting ensures a low-impedance connection in the test circuit, significantly improving the accuracy of noise signal acquisition.

[0094] This application further proposes that the detection unit 100 includes an upper detection module 110 and a lower detection module 120, which can move closer to or further away from each other. The upper detection module 110 and the lower detection module 120 abut against the bottom of the planar transformer to be tested, and the upper detection module 110 is pressed against the top of the planar transformer to be tested.

[0095] The upper detection module 110 refers to the contact module located at the top of the planar transformer. It can be implemented using a pressing mechanism with elastic probes, applying a load vertically to form stable electrical contact. The lower detection module 120 refers to the support module located at the bottom of the planar transformer. It can be implemented using a rigid platform with positioning grooves, forming a reference support surface through planar limiting. The movement of the modules approaching or moving away from each other is driven by hydraulic cylinders or servo motors to accommodate the clamping requirements of test pieces of varying thicknesses. The top pressing mechanism uses a pneumatic actuator in conjunction with a pressure sensor to monitor the contact pressure in real time and prevent overload.

[0096] Specifically, when the planar transformer is transferred to the testing station, the lower testing mold 120 first aligns its bottom reference using a planar positioning mechanism. Then, the upper testing mold 110 descends vertically under the control of a drive unit, and its bottom-mounted elastic probe array makes multi-point contact with the test points on the top of the planar transformer. Simultaneously, the lower testing mold 120's built-in support platform makes a slight upward adjustment, ensuring complete contact between the bottom surface of the tested component and the support surface. The coordinated action of the upper and lower molds forms a sandwich-like clamping structure, where the lower mold provides a rigid support reference, and the upper mold applies controllable pressure to ensure a stable contact impedance between the test probes and the terminals. This structure replaces manual alignment with mechanical positioning, eliminating poor contact caused by human factors.

[0097] Compared to existing technologies, traditional manual testing relies on operators manually placing the test piece and adjusting the probe position, resulting in uneven clamping force and low positioning accuracy. This solution achieves automated positioning through the mechanical linkage of the upper and lower detection modules 120. Contact pressure is controlled by a closed-loop sensor, increasing the contact area between the test probe and the terminal by approximately three times compared to manual operation, and reducing contact resistance fluctuation from ±15% to ±2%. The planar support structure of the lower detection module 120 ensures that the bottom surface of the test piece forms an equipotential surface with the reference ground, effectively suppressing common-mode interference signals.

[0098] Through the above technical solution, this application achieves fully automated and stable clamping of the test piece during high-frequency noise testing, solving the problem of contact resistance fluctuations caused by manual operation. The synergistic effect of the upper and lower detection modules 120 enables a reliable electrical connection between the test probe and the terminal, improving test data repeatability to 99.8% and reducing single-piece testing time to 1 / 5 of manual operation. The coordinated design of the bottom support structure and the top pressing mechanism is compatible with different models of planar transformers with thicknesses ranging from 2 to 8 mm, increasing equipment utilization to over 95%.

[0099] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0100] Although embodiments of the present invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A fully automatic testing device for common-mode noise of a planar transformer, characterized in that, include: The detection unit is used to perform common-mode noise testing on the planar transformer. The feeding unit is located on the feeding side of the detection unit. The feeding unit is equipped with a first temporary storage device, which is used to temporarily store the planar transformer to be tested. The unloading unit is located on the unloading side of the detection unit. The unloading unit is equipped with a second temporary storage device and a third temporary storage device. The second temporary storage device and the third temporary storage device are respectively used to temporarily store planar transformers that fail the test and planar transformers that pass the test. The transfer unit includes a transfer robot for transferring planar transformers, which enables the planar transformers to move between the loading unit, the detection unit, and the unloading unit.

2. The fully automatic common-mode noise testing equipment for planar transformers according to claim 1, characterized in that, The first temporary storage device is provided with a feeding position, a first temporary storage platform and a first lifting drive. The feeding position is located above the first temporary storage platform. Multiple planar transformers to be tested are stacked vertically on the first temporary storage platform. The output end of the first lifting drive is connected to the first temporary storage platform. The first lifting drive can drive the first temporary storage platform to adjust its position in the vertical direction so that the planar transformer to be tested at the top reaches the feeding position.

3. The fully automatic common-mode noise testing equipment for planar transformers according to claim 1, characterized in that, Both the second and third temporary storage devices are provided with a feeding position, a second temporary storage platform, and a second lifting drive. The feeding position is located above the second temporary storage platform. Multiple tested planar transformers are stacked vertically on the second temporary storage platform. The output end of the second lifting drive is connected to the second temporary storage platform. The second lifting drive can drive the second temporary storage platform to adjust its position in the vertical direction so that the top tested planar transformer leaves the feeding position.

4. The fully automatic common-mode noise testing equipment for planar transformers according to claim 1, characterized in that, The detection unit and the feeding unit are equipped with a marking unit. The marking unit includes a marking device and a material carrier. The marking device is located above the material carrier. The material carrier is used to fix the planar transformer that has been tested and is to be marked. The marking device sets an identification code on the surface of the planar transformer according to the test results.

5. The fully automatic common-mode noise testing equipment for planar transformers according to claim 4, characterized in that, The material carrier includes a material carrier base and an adsorption mechanism. The adsorption mechanism includes an adsorption plate disposed on the material carrier base and a vacuum negative pressure machine. The vacuum negative pressure machine is connected to the adsorption plate. The adsorption plate is used to adsorb and fix the planar transformer to be marked.

6. The fully automatic common-mode noise testing equipment for planar transformers according to claim 5, characterized in that, The marking unit also includes a three-axis moving device, and one of the material carrier and the marking device is connected to the three-axis moving device; or, The marking unit also includes a three-axis moving device, and the material carrier and the marking device are both connected to the three-axis moving device.

7. The fully automatic common-mode noise testing equipment for planar transformers according to claim 4, characterized in that, An identification unit is provided between the marking unit and the unloading unit. The identification unit is electrically connected to the transfer robot. The identification unit is used to identify the identification code set on the surface of the planar transformer. The transfer robot can transfer the planar transformer to the second temporary storage device or the third temporary storage device according to the identification information of the identification unit.

8. The fully automatic common-mode noise testing equipment for planar transformers according to claim 7, characterized in that, The transfer unit also includes a linear motion module, on which two transfer manipulators are mounted. One of the two transfer manipulators is used to transfer the planar transformer to be tested, and the other of the two transfer manipulators is used to transfer the planar transformer that has already been tested.

9. The fully automatic common-mode noise testing equipment for planar transformers according to claim 1, characterized in that, The transfer robot includes a mounting plate and multiple suction cups mounted on the mounting plate. The suction cups are movably connected to the mounting plate, and their positions on the mounting plate can be adjusted. The suction cups are connected to an external negative pressure mechanism.

10. The fully automatic common-mode noise testing equipment for planar transformers according to claim 1, characterized in that, The detection unit includes an upper detection module and a lower detection module, which can move closer to or further away from each other. The lower detection module abuts against the bottom of the planar transformer to be tested, and the upper detection module presses against the top of the planar transformer to be tested.

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