A kind of disordered feeding and installation device of junction box

Abstract

The utility model belongs to terminal box installation equipment technical field, especially relate to a terminal box disorderly feeding and installation device. Include: rack, conveying mechanism: including the lower conveying machine of installing in the lower position of one end of rack, and the lifting device of installing on the output end rack of lower conveying machine, and the upper conveying machine of installing on the upper rack of lower conveying machine, and the side belt conveyor of installing on the upper rack of lifting device, disorderly grabbing mechanism: including the robot of installing on the rack of upper conveying machine input end, and the horizontal straight line module of installing on the upper rack of robot, and the 3D camera of installing in horizontal straight line module mobile end, and the material taking gripper of installing in the robot output end. The utility model carries out visual identification through 3D camera in the feeding station, utilizes its disorderly grabbing function to realize the complete automation process of disorderly feeding to accurate positioning, and the efficiency is improved 300% compared with manual operation.

Description

Technical Field

[0001] This utility model belongs to the technical field of junction box installation equipment, and in particular relates to a junction box unordered feeding and installation device. Background Technology

[0002] With the rapid growth of the photovoltaic industry, the demands for production scale and output are also increasing. To meet these demands, photovoltaic module manufacturers need to improve production efficiency and consistency, reduce labor costs, and ensure product quality stability. The introduction of automation technology, especially in junction box installation technology, has become a key way to improve production efficiency and quality. While visual recognition devices such as 3D and 2D cameras are increasingly used in photovoltaic production, current junction box installation production systems are not fully utilizing their advantages. Some workstations still require manual intervention, such as junction box loading. Currently, junction boxes still need to be neatly hung on a loading trolley and then picked up sequentially; additional loading is required based on the production rhythm, consuming manpower. Summary of the Invention

[0003] The purpose of this utility model is to provide a junction box unordered feeding and installation device to solve the problems existing in the prior art.

[0004] The technical solution adopted by this utility model to solve its technical problem is:

[0005] A junction box unordered feeding and installation device, comprising:

[0006] frame;

[0007] Conveying mechanism: including a lower conveyor installed at one lower end of the frame, a lifting device installed on the frame at the output end of the lower conveyor, an upper conveyor installed on the frame above the lower conveyor, and a side belt conveyor installed on the frame above the lifting device;

[0008] Disorderly gripping mechanism: includes a robot mounted on a frame at the input end of the upper conveyor, a horizontal linear module mounted on a frame above the robot, a 3D camera mounted on the moving end of the horizontal linear module, and a gripper mounted on the output end of the robot.

[0009] The junction box mounting mechanism includes a robotic arm mounted on the frame at the output end of the side conveyor belt, and a smoothing gripper and a 2D camera mounted on the output end of the robotic arm.

[0010] Intermediate box feeding mechanism: includes a hopper and a vibratory feeder installed at the output end of the hopper.

[0011] Furthermore, there are two conveying mechanisms and two junction box installation mechanisms. The two conveying mechanisms are located on both sides inside the frame, and the two junction box installation mechanisms and the non-gripping mechanism are located between the two conveying mechanisms. The intermediate box feeding mechanism is located between the two junction box installation mechanisms.

[0012] Furthermore, the lifting device includes a vertical linear module, a mounting frame, rollers, a pulley mechanism, and a drive motor. The moving end of the vertical linear module is fixed with a gate-shaped mounting frame. Several horizontally distributed rollers are rotatably connected inside the mounting frame. One end of two adjacent rollers is connected through a pulley mechanism, and one end of each roller is connected to a drive motor fixed on the mounting frame.

[0013] Furthermore, the material gripper includes a mounting rod, a feeding connecting seat, a spring, a gripping cylinder, a gripping connecting seat, two linear guides, two sliders, two connecting blocks, and two material gripping rods. The mounting rod is fixed to the bottom end of the feeding connecting seat. The two linear guides are respectively fixed to both sides of the mounting rod. The two sliders are respectively slidably connected to the two linear guides. The two connecting blocks are respectively fixed to the two sliders. The gripping connecting seat is fixed to the bottom end of the two connecting blocks. The gripping cylinder is fixed to the bottom end of the gripping connecting seat. The two material gripping rods are respectively fixed to the two output ends of the gripping cylinder. A limit post is provided at the top of the gripping connecting seat. The spring is sleeved on the limit post, and the two ends of the spring abut against the mounting rod and the gripping connecting seat respectively. The robot is connected to the smoothing gripper through the feeding connecting seat.

[0014] Furthermore, the material-grabbing clamp has two bends, and the bottom end of the material-grabbing clamp has a clamping groove. The clamping grooves of the two material-grabbing clamps cooperate to form an elongated hole.

[0015] Furthermore, the smoothing gripper includes a smoothing cylinder, a connecting rod, two smoothing rods, a connecting plate, a long-side cylinder, two long-side clamping plates, a short-side cylinder, and a short-side positioning rod. The smoothing cylinder is fixed to the bottom of the connecting rod, and the two smoothing rods are respectively fixed to the two output ends of the smoothing cylinder through the connecting plate. The long-side cylinder is fixed to the bottom of the smoothing cylinder, and the two long-side clamping plates are fixed to the two output ends of the long-side cylinder. The short-side cylinder is fixed to the end of the long-side cylinder, and the short-side positioning rod is fixed to the output end of the short-side cylinder. The robotic arm is connected to the smoothing gripper through the connecting rod.

[0016] Furthermore, a smoothing claw perpendicular to the smoothing rod is fixed on the smoothing rod, and the 2D camera is fixed on the connecting rod.

[0017] This utility model has the following beneficial effects:

[0018] 1. This utility model uses a 3D camera for visual recognition at the loading station and utilizes its disordered grasping function to realize a complete automated process from disordered loading to precise positioning, which improves efficiency by 300% compared to manual operation.

[0019] 2. The junction box installation mechanism uses two robotic arms to work together, with a single piece processing time of ≤13 seconds.

[0020] 3. By temporarily storing junction boxes through the intermediate box feeding mechanism, manual intervention can be eliminated for extended periods.

[0021] 4. The conveying mechanism automatically exits the empty material box after feeding, thus achieving the purpose of feeding without stopping the machine. Attached Figure Description

[0022] Figure 1 This is a top view of the structure of this utility model.

[0023] Figure 2 This is a three-dimensional structural diagram of the present invention.

[0024] Figure 3 This is a schematic diagram of the lifting device structure of this utility model.

[0025] Figure 4 This is a schematic diagram of the 3D camera mounting structure of this utility model.

[0026] Figure 5 This is a schematic diagram of the intermediate box feeding mechanism of this utility model.

[0027] Figure 6 This is a schematic diagram of the material handling gripper structure of this utility model.

[0028] Figure 7 This is a side view of the material handling gripper structure of this utility model.

[0029] Figure 8 This is a utility model Figure 7 Enlarged structural diagram at point A in the middle.

[0030] Figure 9 This is a schematic diagram of the smoothing gripper structure of this utility model.

[0031] Figure 10 This is a schematic diagram of the bottom structure of the smoothing gripper of this utility model.

[0032] The components include: 1. Frame; 2. Conveying mechanism; 21. Lower conveyor; 22. Upper conveyor; 23. Side belt conveyor; 24. Lifting device; 241. Vertical linear module; 242. Mounting frame; 243. Idler roller; 244. Pulley mechanism; 245. Drive motor; 3. Disorderly gripping mechanism; 31. Robot; 32. Horizontal linear module; 33. 3D camera; 34. Gripping gripper; 341. Mounting rod; 342. Loading connector; 343. Spring; 344. Gripping cylinder; 345. Gripping connector; 34 6. Linear guide rail; 347. Slider; 348. Connecting block; 349. Material handling clamp; 350. Clamping groove; 351. Limiting rod; 4. Wire box mounting mechanism; 41. Robotic arm; 42. 2D camera; 43. Smoothing gripper; 431. Smoothing cylinder; 432. Connecting rod; 433. Smoothing rod; 434. Connecting plate; 435. Long side cylinder; 436. Long side clamping plate; 437. Short side cylinder; 438. Short side positioning rod; 439. Smoothing claw; 5. Intermediate box feeding mechanism; 51. Hopper; 52. Vibratory feeder. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description is provided in conjunction with specific embodiments and accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the utility model and are not intended to limit the scope of the utility model.

[0034] like Figures 1-10 As shown, a junction box unordered feeding and installation device includes: a frame 1;

[0035] Conveying mechanism 2: includes a lower conveyor 21 installed at one lower end of the frame 1, a lifting device 24 installed on the frame 1 at the output end of the lower conveyor 21, an upper conveyor 22 installed on the frame 1 above the lower conveyor 21, and a side belt conveyor 23 installed on the frame 1 above the lifting device 24.

[0036] The disordered gripping mechanism 3 includes a robot 31 installed on the frame 1 at the input end of the upper conveyor 22, a horizontal linear module 32 installed on the frame 1 above the robot 31, a 3D camera 33 installed on the moving end of the horizontal linear module 32, and a gripper 34 installed on the output end of the robot 31.

[0037] The junction box mounting mechanism 4 includes a robotic arm 41 mounted on the frame 1 at the output end of the side belt conveyor 23, and a smoothing gripper 43 and a 2D camera 42 mounted at the output end of the robotic arm 41.

[0038] The intermediate box feeding mechanism 5 includes a hopper 51 and a vibratory feeder 52 installed at the output end of the hopper 51.

[0039] There are two conveying mechanisms 2 and two wire box mounting mechanisms 4. The two conveying mechanisms 2 are located on both sides inside the frame 1. The two wire box mounting mechanisms 4 and the non-gripping mechanism are located between the two conveying mechanisms 2. The intermediate box feeding mechanism 5 is located between the two wire box mounting mechanisms 4.

[0040] The lifting device 24 includes a vertical linear module 241, a mounting frame 242, rollers 243, a pulley mechanism 244, and a drive motor 245. The moving end of the vertical linear module 241 is fixed with a door-shaped mounting frame 242. Several horizontally distributed rollers 243 are rotatably connected inside the mounting frame 242. One end of two adjacent rollers 243 is connected through the pulley mechanism 244. One end of a roller 243 is connected to a drive motor 245 fixed on the mounting frame 242.

[0041] The material gripper 34 includes a mounting rod 341, a feeding connecting seat 342, a spring 343, a gripping cylinder 344, a gripping connecting seat 345, two linear guide rails 346, two sliders 347, two connecting blocks 348, and two material gripping rods 349. The mounting rod 341 is fixed to the bottom end of the feeding connecting seat 342. The two linear guide rails 346 are respectively fixed to both sides of the mounting rod 341. The two sliders 347 are slidably connected to the two linear guide rails 346 respectively. The two connecting blocks 348 are respectively fixed to the two linear guide rails 346. On the two sliders 347, the gripping connecting seat 345 is fixed to the bottom of the two connecting blocks 348, the gripping cylinder 344 is fixed to the bottom of the gripping connecting seat 345, the two material picking clamps 349 are respectively fixed to the two output ends of the gripping cylinder 344, the top of the gripping connecting seat 345 is provided with a limiting post, the spring 343 is sleeved on the limiting post and the two ends of the spring 343 respectively abut against the mounting rod 341 and the gripping connecting seat 345, and the robot 31 is connected to the smoothing gripper 43 through the feeding connecting seat 342.

[0042] The material-grabbing clamp 349 has two bends and a clamping groove 350 at the bottom end. The clamping grooves 350 of the two material-grabbing clamps 349 cooperate to form an elongated hole.

[0043] The smoothing gripper 43 includes a smoothing cylinder 431, a connecting rod 432, two smoothing rods 433, a connecting plate 434, a long-side cylinder 435, two long-side clamping plates 436, a short-side cylinder 437, and a short-side positioning rod 438. The smoothing cylinder 431 is fixed to the bottom end of the connecting rod 432. The two smoothing rods 433 are respectively fixed to the two output ends of the smoothing cylinder 431 through the connecting plate 434. The long-side cylinder 435 is fixed to the bottom of the smoothing cylinder 431. The two long-side clamping plates 436 are fixed to the two output ends of the long-side cylinder 435. The short-side cylinder 437 is fixed to the end of the long-side cylinder 435. The short-side positioning rod 438 is fixed to the output end of the short-side cylinder 437. The robotic arm 41 is connected to the smoothing gripper 43 through the connecting rod 432.

[0044] A smoothing claw 439 perpendicular to the smoothing rod 433 is fixed on the smoothing rod 433, and the 2D camera 42 is fixed on the connecting rod 432.

[0045] The working principle of this utility model is as follows:

[0046] Workers place the bin containing the junction boxes onto the lower conveyor 21. The lower conveyor 21 transports the bin to the rollers 243 of the lifting device 24. The lifting device 24 raises the mounting frame 242 via the vertical linear module 241. The drive motor 245 rotates the rollers 243, moving the bin to the upper conveyor 22. Subsequently, the mounting frame 242 descends and resets. The 3D camera 33 moves via the horizontal linear module 32 to scan and identify the junction boxes inside the bin. The robot 31 uses the gripper 34 to pick up the junction boxes and place them on the side conveyor 23. The side conveyor 23 transports the junction boxes to the junction box mounting mechanism 4. When the bin is empty, the upper conveyor 22 transports the empty bin to the outside of the frame 1.

[0047] The junction box installation mechanism 4 handles the junction boxes on the side conveyor belt 23 in two ways: first, it directly grabs the junction boxes and moves them to the installation station for smoothing and installation; second, it places the junction boxes into the hopper 51 (existing technology, equipped with a vibrator) for temporary storage. This allows for the temporary storage of a larger number of junction boxes at once, eliminating the need for frequent manual feeding. The junction boxes in the hopper 51 slide from the outlet of the hopper 51 into the vibrating plate 52 (existing technology, which can adjust the front of the junction box to face upwards through vibration) through the vibration of its vibrator. Subsequently, the robotic arm 41 grabs the junction boxes and moves them to the installation station for smoothing and installation.

[0048] The gripper 34 drives the two gripping rods 349 to open and close via the gripping cylinder 344, using the gripping groove 350 at its bottom to grip the junction box. The spring 343 acts as a buffer. When the gripper 34 grips or places the junction box, the gripping rods 349 are subjected to external force. The component connected to the gripping rods 349 drives the slider 347 to slide upward on the linear guide rail 346 and compress the spring 343. After the external force is eliminated, the gripping rods 349 are reset by the elastic force of the spring 343.

[0049] When the smoothing gripper 43 is in operation, it is positioned by taking pictures with a 2D camera 42. The robotic arm 41 controls the movement path and posture of the smoothing gripper 43. The long-side cylinder 435 controls the long-side clamping plate 436 to hold the two long sides of the junction box. The short-side cylinder 437 controls the short-side positioning rod 438 to move the junction box to position it, thereby gripping the junction box. It should be noted that the short-side cylinder 437 can have one or two output ends. This utility model uses a short-side cylinder 437 with one output end. Therefore, a fixed positioning rod with a similar shape to the short-side positioning rod 438 needs to be fixed to the smoothing gripper 43 (such as by fixing it to the side of the long-side cylinder 435 with a plate). In this way, as long as the junction box is located between the short-side positioning rod 438 and the fixed positioning rod, the junction box can be positioned by moving the junction box with the short-side positioning rod 438. After the smoothing gripper 43 is moved to the installation position by the robotic arm 41, the 2D camera 42 takes pictures before installation to confirm the status of the leads and improve the success rate. After taking photos, the smoothing gripper 43 moves to the lead wire position for installation. The smoothing cylinder 431 drives the smoothing claw 439 to smooth and press the lead wire through the connecting plate 434 and the smoothing rod 433 in sequence. The welding machine at the installation station performs welding. Then, the long side cylinder 435, the short side cylinder 437, and the smoothing cylinder 431 reset and release the junction box, thus completing the installation of the junction box.

[0050] The above embodiments are merely descriptions of preferred embodiments of the present invention and are not intended to limit the concept and scope of the present invention. Various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the design concept of the present invention should fall within the protection scope of the present invention.

[0051] The technologies, shapes, and structures not described in detail in this utility model are all known technologies.

Claims

1. A junction box unordered feeding and installation device, characterized in that, include: frame; Conveying mechanism: including a lower conveyor installed at a lower position at one end of the frame, a lifting device installed on the frame at the output end of the lower conveyor, an upper conveyor installed on the frame above the lower conveyor, and a side belt conveyor installed on the frame above the lifting device. Disorderly gripping mechanism: includes a robot mounted on a frame at the input end of the upper conveyor, a horizontal linear module mounted on a frame above the robot, a 3D camera mounted on the moving end of the horizontal linear module, and a gripper mounted on the output end of the robot. The junction box mounting mechanism includes a robotic arm mounted on the frame at the output end of the side conveyor belt, and a smoothing gripper and a 2D camera mounted on the output end of the robotic arm. Intermediate box feeding mechanism: includes a hopper and a vibratory feeder installed at the output end of the hopper.

2. The junction box unordered feeding and installation device according to claim 1, characterized in that, There are two conveying mechanisms and two wire box installation mechanisms. The two conveying mechanisms are located on both sides inside the frame, and the two wire box installation mechanisms and the non-gripping mechanism are located between the two conveying mechanisms. The intermediate box feeding mechanism is located between the two wire box installation mechanisms.

3. The junction box unordered feeding and installation device according to claim 1, characterized in that, The lifting device includes a vertical linear module, a mounting frame, rollers, a pulley mechanism, and a drive motor. The moving end of the vertical linear module is fixed with a gate-shaped mounting frame. Several horizontally distributed rollers are rotatably connected inside the mounting frame. One end of two adjacent rollers is connected through a pulley mechanism, and one end of each roller is connected to a drive motor fixed on the mounting frame.

4. The junction box unordered feeding and installation device according to claim 1, characterized in that, The material gripper includes a mounting rod, a feeding connecting seat, a spring, a gripping cylinder, a gripping connecting seat, two linear guides, two sliders, two connecting blocks, and two material gripping rods. The mounting rod is fixed to the bottom end of the feeding connecting seat. The two linear guides are respectively fixed to both sides of the mounting rod. The two sliders are respectively slidably connected to the two linear guides. The two connecting blocks are respectively fixed to the two sliders. The gripping connecting seat is fixed to the bottom end of the two connecting blocks. The gripping cylinder is fixed to the bottom end of the gripping connecting seat. The two material gripping rods are respectively fixed to the two output ends of the gripping cylinder. A limit post is provided at the top of the gripping connecting seat. The spring is sleeved on the limit post, and the two ends of the spring abut against the mounting rod and the gripping connecting seat respectively. The robot is connected to the smoothing gripper through the feeding connecting seat.

5. The junction box unordered feeding and installation device according to claim 4, characterized in that, The material-grabbing clamp has two bends and a clamping groove at the bottom end. The clamping grooves of the two material-grabbing clamps cooperate to form an elongated hole.

6. The junction box unordered feeding and installation device according to claim 1, characterized in that, The smoothing gripper includes a smoothing cylinder, a connecting rod, two smoothing rods, a connecting plate, a long-side cylinder, two long-side clamping plates, a short-side cylinder, and a short-side positioning rod. The smoothing cylinder is fixed to the bottom of the connecting rod. The two smoothing rods are respectively fixed to the two output ends of the smoothing cylinder through the connecting plate. The long-side cylinder is fixed to the bottom of the smoothing cylinder. The two long-side clamping plates are fixed to the two output ends of the long-side cylinder. The short-side cylinder is fixed to the end of the long-side cylinder. The short-side positioning rod is fixed to the output end of the short-side cylinder. The robotic arm is connected to the smoothing gripper through the connecting rod.

7. The junction box unordered feeding and installation device according to claim 6, characterized in that, The smoothing rod is fixed with a smoothing claw perpendicular to the smoothing rod, and the 2D camera is fixed on the connecting rod.

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