Controller assembly and test flexible dual cycle production line

Abstract

The utility model discloses a controller assembly and test flexible double -cycle production line, include: the horizontal around arrangement's outer circulation conveying component, and the interval is equipped with a plurality of operation stations along the circumference, nest in the inside loop conveying component of outer circulation conveying component, constitute the fast channel of no operation station, a plurality of two -way transfer components, and the interval is distributed between outer circulation conveying component and inside loop conveying component, two -way transfer components include the stage of vertical lifting and the horizontal translation mechanism on the stage, corner link component, be located in the path turning point of outer circulation conveying component and inside loop conveying component, including rotatable jacking platform. Double -cycle layout and two -way transfer component make product according to the process demand in outer circulation line processing or transfer into inside loop line and jump, break through the process flow restriction of traditional single -cycle production line, realize multivariety collinear production.

Description

Technical Field

[0001] This utility model relates to the field of controller assembly production line technology, and in particular to a flexible dual-cycle production line for controller assembly and testing. Background Technology

[0002] In the field of industrial automation, assembly and testing production lines for controller products mainly adopt a single-loop layout. Traditional fully automated production lines use closed single-loop conveyor lines with workstations fixed along a single flow direction. While suitable for large-volume production of single products, this approach has significant limitations: when product structure or processes change, the entire conveyor path and workstation configuration must be modified, resulting in long production line downtime, high modification costs, and difficulty in accommodating multi-variety production. To improve flexibility, semi-automatic production lines have developed multi-row workstation and single-row workstation modes. The former forms multiple independent work areas through physical isolation, with products flowing through turnover carts or buffer positions, allowing for limited process adjustments. However, due to overlapping logistics paths and a lack of control over semi-finished product status, it is prone to production rhythm disruptions and quality fluctuations. The latter arranges workstations linearly according to the minimum logistics distance, allowing for repeated use of the same equipment. However, product flow relies on manual intervention, leading to problems such as missing process jump records and difficulties in material traceability, making it only suitable for small-batch sample production.

[0003] For example, the "Automated Production Line for Controller" disclosed in Chinese patent literature, publication number "CN109613893B", includes an upper mold core, which is divided into an installation part and a punching part. The installation part is installed in the upper core groove machined on the upper mold. An elastic washer is provided on the outside of the punching part. A fixing block is provided at the lower end of the elastic washer. The fixing block and the elastic washer are fixed to the upper mold by several sets of fixing bolts. It also includes a jig tray, a production line track, and an assembly and testing station. The jig tray is connected to the production line track and runs to the assembly and testing station through the production line track. The assembly and testing station includes a button assembly position for assembling buttons, a button detection position for testing various functions of the buttons, a PCBA board assembly position for assembling PCBA boards, a vibration module assembly position for assembling vibration modules, an overall detection position for testing various components inside the controller, a bottom shell assembly position for assembling the bottom shell, and a function test position for testing the functions of each phase of the controller. This invention solves the contradiction between rapidly rising labor costs and lagging labor productivity. By using automated and information-based assembly methods, it greatly reduces the number of operators on the production line, improves assembly efficiency, and can automatically detect products online and store test data.

[0004] The aforementioned existing technologies face common bottlenecks: single-cycle production lines, due to their fixed flow direction, cannot support reversed processes or multiple cycles, thus restricting the production of multiple products on the same line; for recurring process steps (such as dispensing and tightening), multiple identical machines need to be configured, resulting in increased floor space and investment costs; and there is a lack of automated connection mechanisms for semi-finished product status tracking and defective product diversion, making manual operation prone to errors and omissions.

[0005] As the manufacturing industry shifts towards multi-variety and customized production, the market demands greater compatibility from production lines. Enterprises urgently need a new production line architecture that can, with minimal modification costs, enable flexible configuration of process paths, reusable processes, and fully automated control of the entire process, while ensuring product quality and production efficiency, thus responding to rapidly changing production needs. Utility Model Content

[0006] To address the issues of fixed processes and insufficient flexibility in traditional controller production lines, which lead to poor compatibility with multiple product varieties and high transformation costs, this solution utilizes a horizontal dual-circulation layout, multiple bidirectional transfer components, and corner connection components to enable flexible transfer of products between internal and external circulation and multi-loop flow of processes. This eliminates process flow restrictions, thereby improving production line flexibility, reducing redundant equipment investment, and supporting multi-variety co-production.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A dual-circulation production line for controller assembly and testing includes: an outer circulation conveyor assembly arranged horizontally around the inner circulation conveyor assembly, with multiple workstations spaced apart along the circumference; an inner circulation conveyor assembly nested inside the outer circulation conveyor assembly, forming a fast passage without workstations; multiple bidirectional transfer assemblies spaced apart between the outer circulation conveyor assembly and the inner circulation conveyor assembly, each bidirectional transfer assembly including a vertically lifting platform and a horizontal translation mechanism mounted on the platform; and a corner connecting assembly located at the path turning point between the outer circulation conveyor assembly and the inner circulation conveyor assembly, including a rotatable lifting platform.

[0009] In this design, a horizontally encircling outer circulation conveyor assembly carries the workstations to complete process operations, while an inner circulation conveyor assembly nested within it forms a non-interference, high-speed channel. The two are connected via a vertical lifting platform and a horizontal translation mechanism of the bidirectional transfer assembly, enabling pallet transfer across lines. When a subsequent workstation is idle, the pallet is lifted off the outer circulation line by the lifting platform and slid to the adjacent inner circulation line by the horizontal translation mechanism, avoiding the fixed path limitations of traditional single-circuit lines. The rotatable lifting platform of the corner connection assembly adjusts the pallet's direction of travel at path bends, eliminating the risk of jamming caused by right-angle turns. This structure allows products to be processed in the outer circulation or transferred to the inner circulation for skipping stations, achieving flexible single- or multi-loop flow, depending on process requirements.

[0010] Preferably, in the bidirectional transfer assembly, the horizontal translation mechanism includes lifting platforms separately disposed in the inner circulation conveying assembly and the outer circulation conveying assembly, and a tray is disposed between the two lifting platforms.

[0011] Preferably, the corner connection assembly further includes a rotary drive unit, and the lifting platform is coaxially connected to the output end of the rotary drive unit via a rotary shaft.

[0012] Preferably, a vertical lifting cylinder is provided below the lifting platform, and the end of the cylinder piston rod is rigidly connected to the bottom surface of the lifting platform.

[0013] Preferably, both the external circulation conveying assembly and the internal circulation conveying assembly include a closed-loop conveyor belt, and the surface of the conveyor belt is provided with pallet blocking and anti-reverse mechanisms at intervals for limiting the position of the pallets.

[0014] Preferably, the rework channel is arranged parallel to the outside of the external circulation conveyor assembly; at least one unidirectional transfer device is connected between the external circulation conveyor assembly and the rework channel, including a conveyor line with a driving force pointing only towards the rework channel.

[0015] Preferably, the rework channel is provided with a rework return device at the end, which includes a liftable pushing mechanism and a return guide rail connected to the internal circulation conveying component.

[0016] Preferably, the lateral extension station is connected to the external circulation conveyor assembly via a rotary conveyor line, which includes a horizontally rotatable hinged section.

[0017] Preferably, each workstation is equipped with an RFID reader, and the tray positioning structure is fitted with an electronic tag corresponding to the position of the RFID reader.

[0018] Preferably, the operating speed of the inner circulation conveying component can be greater than that of the outer circulation conveying component.

[0019] Therefore, this utility model has the following beneficial effects.

[0020] The dual-circulation layout and bidirectional transfer components enable products to be processed on the outer circulation line or transferred to the inner circulation line for skipping stations according to process requirements, breaking through the process flow restrictions of traditional single-circulation production lines and realizing multi-variety co-line production.

[0021] The same process equipment can be reused through multiple cycles, avoiding the duplication of workstations with the same functions, which significantly reduces equipment investment costs and production line floor space.

[0022] The rework channel works in conjunction with the RFID positioning system to automatically divert defective products and accurately return reworked parts, reducing manual intervention and maintaining the continuity of main production.

[0023] The rotary conveyor line and modular workstation design support rapid expansion and transformation of production lines, and only partial adjustments to the workstation configuration are needed when adding new products for compatibility. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of this utility model.

[0025] Figure 2 This is a schematic diagram of the bidirectional transfer component in this utility model.

[0026] Figure 3 This is a structural schematic diagram of the corner connection component in this utility model.

[0027] Figure 4 This is a schematic diagram of the lateral expansion station in this utility model.

[0028] In the diagram: 1. External circulation conveyor assembly; 2. Internal circulation conveyor assembly; 3. Bidirectional transfer assembly; 31. Pallet; 32. Independent lifting platform; 33. Pallet stopping mechanism; 34. Bidirectional transmission section; 4. Corner connection assembly; 41. Rectangular lifting platform; 42. Reducer; 5. Rotary conveyor line; 6. Unidirectional transfer device; 7. Rework channel; 8. Rework return device; 9. Lateral expansion station; 91. Double track; 92. Conveyor table. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0030] Example 1

[0031] like Figure 1 , 2As shown in Figure 3, in this embodiment, the main frame of the controller assembly and testing dual-cycle production line is formed by a rectangular ring path consisting of an outer circulation conveyor assembly 1 arranged horizontally. Multiple workstations are equidistantly distributed along the length of the straight section, each equipped with dedicated assembly or testing equipment. Corner connecting assemblies 4 are installed at the four corners of the outer circulation. A rectangular lifting platform 41 is installed at the center of this assembly, and the bottom of the platform is connected to the output end of a reducer via a vertical rotating shaft. The reducer 42 is driven by a motor. The inner circulation conveyor assembly 2, nested inside the outer circulation, adopts the same rectangular outline but with reduced dimensions, and its height is slightly lower than the outer circulation conveyor surface. Multiple bidirectional transfer assemblies 3 are spaced apart between the inner and outer circulations. Each assembly includes two independent lifting platforms 32 located in the inner and outer circulations, with a tray 31 erected between the two platforms. A bidirectional transmission section 34 between the two platforms controls the reciprocating movement of the tray 31, and tray stopping mechanisms 33 are provided at both ends along the direction of movement of the tray 31. The external circulation side lifting platform is a rectangular steel plate, covering the pallet's projected area. Four vertical lifting cylinders are symmetrically arranged below it, with the cylinder piston rods bolted to the platform's bottom surface via flanges. The internal circulation side lifting platform has the same structure but its dimensions are adapted to the internal circulation width. The pallet consists of multiple sets of belts arranged in parallel, with the belt axes aligned with the conveying direction, and the top of the belts slightly higher than the lifting platform plane.

[0032] When a product needs to be transferred from the outer circulation to the inner circulation, the cylinders on the inner circulation side lifting platform activate synchronously, extending the piston rod to push the platform upward, causing the platform surface to lift the pallet and detach it from the outer circulation conveyor belt. Subsequently, the pallet's rollers begin to rotate, horizontally transferring the pallet to the inner circulation side lifting platform. After the pallet is fully transferred, the inner circulation side platform descends, bringing the pallet into contact with the inner circulation conveyor belt, completing the transfer process. The reverse transfer operation is performed in the same manner. When the pallet reaches the outer circulation corner area of ​​the corner connection assembly 4, the lifting cylinders below the rectangular lifting platform activate, raising the platform and detaching the pallet from the conveyor belt; the reducer drives the rotating shaft to rotate the platform 90 degrees, adjusting the pallet's orientation to the next conveyor direction; finally, the platform descends, engaging the pallet with the subsequent conveyor belt.

[0033] The rework channel 7 is fixed parallel to the outside of the outer circulation conveyor assembly 1, with the distance between them less than the length of the pallet. A one-way transfer device 6 is installed at the connection point. The main body of this device is a powered conveyor line. The inlet end of the conveyor line is connected to the outer circulation frame via a hinge, and the outlet end overlaps with the inlet of the rework channel 7. A pneumatic stopper is installed at the inlet of the conveyor line. When the piston rod of the stopper extends, it can block the pallet from moving forward. When a defective product is detected, the piston rod of the stopper retracts, and the pallet enters the rework channel 7 through the one-way transfer device. A rework return device 8 is installed at the end of the channel. Its lifting platform base is fixed to the ground, and guide rails are laid on the surface of the lifting platform. When the platform is raised to the highest position, the guide rails are flush with the inlet of the inner circulation conveyor belt. After the lifting platform is in place, an electric push rod pushes the pallet laterally into the inner circulation conveyor belt.

[0034] like Figure 4 As shown, the lateral extension station 9 can be used as a standalone station or as an extension of the entire line, or as an offline / online station. Product processes can exit the production line through this station and link with external stations or other production lines. The lateral extension station 9 also has a double track 91 and a conveyor 92 set on the double track.

[0035] The rotary conveyor line 5 can be rotated open when needed, allowing personnel and materials to enter the internal area of ​​the circulation line. The main body of rotary conveyor line 5 consists of three sections of hinged chain plates, with the middle section connected to the fixed section at both ends via slewing bearings. When an extended workstation needs to be activated, a hydraulic cylinder pushes the outer chain plate section to rotate 90 degrees around the bearing, making the chain plate conveying direction perpendicular to the external circulation, forming a material transfer channel. The workstation frame has a pre-set array of bolt mounting holes for fixing process equipment.

[0036] The RFID system hardware configuration includes a fixed reader and passive electronic tags. The reader is installed on a bracket directly above the entrance of each workstation, with the antenna facing downwards. An electronic tag is embedded in the center of a positioning slot on the bottom of the tray, with the tag plane maintaining a constant distance from the reader's antenna. When the tray stops in place via the positioning slot and the mechanical stop, the tag is precisely within the reader's effective sensing area.

[0037] In this embodiment, the spatial layout and mechanical coordination of each component form a constraint relationship. Specifically, the outer circulation workstations are evenly distributed along the circumference of the rectangle to ensure that the cycle time of each process is matched; the height difference between the inner and outer circulation is coordinated with the stroke of the lifting platform to avoid structural interference during pallet transfer; the width of the lifting platform covers the width range of the pallet to ensure the stability of the center of gravity during the transfer process; the lifting height of the lifting platform is precisely matched with the elevation of the inner circulation conveying surface; and the distance between the RFID reader and the tag is controlled within the effective range of the electromagnetic field.

[0038] Compared to traditional single-loop production lines, this device effectively decouples process flow and material flow through dual-loop path separation. The outer loop focuses on process execution, while the inner loop handles cross-station transport, allowing equipment with the same process to be reused multiple times. For example, after the dispensing station completes its first process in one outer loop, the product returns to the station via the inner loop for a second dispensing, enabling a single machine to serve multiple processes. During expansion and modification, only the hinged section of rotary conveyor line 5 needs to be opened, and the new station equipment is fixed to the expansion frame with bolts, while the main loop conveyor structure remains unchanged.

[0039] After the production line starts, the controller tray is loaded into the first workstation by the outer circulation conveyor assembly 1. The positioning structure ensures that the tray is precisely positioned within the assembly equipment's operating area. After completing the current process, the flow path is determined based on the status of the next workstation: if the subsequent workstation is idle, the tray travels along the outer circulation linear conveyor belt to the next workstation; if the subsequent workstation is detected to be busy or a process needs to be skipped, the control system triggers the bidirectional transfer assembly 3. At this time, the piston rod of the vertical lifting cylinder of the inner circulation side lifting platform extends synchronously, pushing the platform upward to lift the tray off the surface of the outer circulation conveyor belt. Subsequently, the tray's roller assembly rotates, horizontally transferring the tray to the inner circulation side platform. The platform descends, bringing the tray into contact with the inner circulation conveyor belt, and the product travels directly to the target workstation via a fast passage. When the tray reaches the outer circulation corner area, the lifting cylinder of the corner connection assembly 4 raises the circular platform, suspending the tray in the air. The rotation drive unit drives the platform to rotate 90 degrees via a reducer to adjust the tray's orientation. After the platform descends, the tray enters the next section of the linear conveyor path.

[0040] When defective products occur during production, the workstation sensor sends a signal to the main control system. The pneumatic stop piston rod of the one-way transfer device 6 retracts, and the pallet slides along the driven conveyor line into the parallel rework channel 7. After rework, the lifting platform at the end of the channel is raised to the height of the inner circulation inlet. The electric push rod pushes the pallet laterally into the return guide rail. The guide wheel at the guide rail outlet guides the pallet smoothly into the inner circulation conveyor assembly 2, realizing the automatic return of the reworked parts to the main line. When a new process needs to be added, the operator releases the mechanical lock of the hinge section of the rotary conveyor line 5. The hydraulic cylinder pushes the outer chain plate section to rotate horizontally by 90 degrees, and the extended workstation conveyor surface forms a vertical intersection with the outer circulation. The newly added testing equipment is fixed to the preset installation position of the extended frame with bolts. After the hinge section is reset, the new workstation is connected to the production flow.

[0041] The RFID system operates automatically when pallets enter each workstation: after the positioning slot and mechanical stop stabilize the pallet, the reader above the workstation entrance emits an electromagnetic field to activate the electronic tag on the bottom of the pallet. The tag then displays the pallet number and product ID. The equipment controller receives this information and communicates with the Manufacturing Execution System (MES). The MES verifies the product batch and process parameters based on the pallet number and product ID and sends the relevant data to the equipment. The control system compares the received parameters and triggers the corresponding equipment to execute the processing program. This process ensures accurate transmission of production data and precise matching of equipment actions. Throughout the process, the inner circulation conveyor component 2 operates at a higher speed than the outer circulation component, ensuring that pallets transferred between workstations quickly catch up with the production cycle. Products that have completed all processes are moved out of the production line via the end-of-line workstation, and the system automatically generates a production traceability report.

[0042] This embodiment embodies three levels of collaboration. First, there is equipment-level collaboration, where the lifting platform's raising and lowering is synchronized with the roller conveyor's start and stop sequence to prevent pallets from being suspended and stuck. Second, there is logistics-level collaboration, where the rework channel's seven-way diversion and internal circulation return are seamlessly connected, ensuring uninterrupted mainline production. Finally, there is information-level collaboration, where RFID data interacts with the MES in real time, driving equipment to operate on demand.

[0043] Example 2

[0044] This embodiment is a controller-based dual-circulation production line further constructed based on Embodiment 1 and according to product characteristics. The outer circulation conveyor assembly 1 maintains a rectangular ring path, with multiple workstations equipped with assembly equipment along the straight sections. The inner circulation conveyor assembly 2 is nested within it with a similar contour, and both are at the same horizontal level. The bidirectional transfer assembly 3 is located in the adjacent area of ​​the inner and outer circulations. Each assembly includes a vertically lifting platform and a horizontal translation mechanism fixed to the platform. The main body of this mechanism is a rectangular sliding frame, with four sets of grooved guide wheels installed at the bottom of the frame, respectively engaging with two guide rails laid on the ground: the first guide rail runs parallel to the inner circulation conveyor line, and the second guide rail runs parallel to the outer circulation conveyor line. A dense ball bearing array is embedded on the top surface of the sliding frame, allowing for low-resistance movement when a pallet is placed on it. When a pallet needs to be transferred, a cylinder at the bottom of the platform pushes the entire mechanism to rise, causing the guide wheels to disengage from the rails. Subsequently, a servo motor drives a lead screw to push the sliding frame horizontally along the guide rails. After reaching its destination, the platform descends, causing the guide wheels to re-engage with the rails.

[0045] The corner connection assembly 4 is located at the path bend, and its lifting platform is made of square steel plate. A rotating shaft is vertically welded off-center from the bottom of the platform. The rotating shaft is connected to the output end of a planetary reducer via a flexible coupling, and the reducer is fixed to the foundation by a base. Vertical lifting cylinders are symmetrically arranged at the four corners of the platform. The cylinder bodies are fixed to the foundation, and the top of the piston rod is connected to the platform via a ball joint support. This eccentric structure makes the pallet's movement trajectory a gradually curved line when the platform rotates, effectively mitigating the mechanical impact of right-angle turns. The rework channel 7 is suspended outside the outer circulation by a steel frame. The conveyor line driven by the unidirectional transfer device 6 is made of spliced ​​strip grating plates, with the grating direction strictly parallel to the sliding direction, reducing frictional resistance by minimizing the contact area. In the rework return device 8, a motor-driven rubber roller assembly is installed on the top of the lifting frame of the liftable pushing mechanism. When raised, the surface of the roller assembly forms a smooth transition interface with the inner circulation conveyor belt.

[0046] The lateral expansion station 9 adopts a linear telescopic connection. A rectangular channel is opened in the side wall of the outer circulation frame, housing a horizontally telescopic chain conveyor section. The end of the conveyor section connects to the expansion station frame via a quick-connect coupling. The RFID system embeds electronic tags into rectangular grooves at the bottom of the tray. Readers are installed on the column brackets at the station entrance, corresponding to the electronic tags, with the antenna transmitting surface facing the tag embedding position. The motor speed can be adjusted by regulating the frequency converter, thereby adjusting and optimizing the conveyor line speed of the inner circulation conveyor assembly 2.

[0047] In this embodiment, the guide rails of the sliding frame are parallel to the direction of the conveyor line to ensure that the transfer path meets the requirements of logistics continuity. The arrangement of the eccentric rotating shaft causes the center of rotation of the pallet to deviate from the geometric center, achieving natural turning by utilizing the positional difference. The telescopic chain conveyor section completely closes the outer circulation opening when retracted, avoiding impact on the main logistics line. The reader / writer located at the bottom of the pallet is vertically aligned with the label mounting surface to optimize the efficiency of radio frequency signal transmission.

[0048] Compared to Example 1, this solution improves positioning accuracy through a guide rail system. The V-groove between the guide wheel and the rail enables automatic centering, eliminating the cumulative errors that may occur with roller transmission. The eccentric rotating structure completes a 90-degree turn within a limited space, resulting in a more compact overall layout.

Claims

1. A flexible dual-cycle production line for controller assembly and testing, characterized in that, include: The horizontally arranged external circulation conveyor assembly has multiple workstations spaced circumferentially. The inner circulation conveying component, nested inside the outer circulation conveying component, forms a fast passage without work stations; Multiple bidirectional transfer components are spaced apart between the outer circulation conveying component and the inner circulation conveying component. Each bidirectional transfer component includes a vertically lifting platform and a horizontal translation mechanism disposed on the platform. The corner connecting assembly is located at the turning point of the path between the outer circulation conveying assembly and the inner circulation conveying assembly, and includes a rotatable lifting platform.

2. The dual-circulation production line according to claim 1, characterized in that: In the bidirectional transfer assembly, the horizontal translation mechanism includes lifting platforms separately disposed in the inner circulation conveying assembly and the outer circulation conveying assembly, and a bidirectional transmission section is provided between the two lifting platforms.

3. The dual-circulation production line according to claim 1, characterized in that: The corner connection assembly also includes a rotary drive unit, and the lifting platform is coaxially connected to the output end of the rotary drive unit via a rotary shaft.

4. The dual-circulation production line according to claim 1 or 2, characterized in that: A vertical lifting cylinder is installed below the lifting platform, and the end of the cylinder piston rod is rigidly connected to the bottom surface of the lifting platform.

5. The dual-circulation production line according to claim 1, characterized in that: Both the external circulation conveying assembly and the internal circulation conveying assembly include a closed-loop conveyor belt, and the surface of the conveyor belt is provided with tray positioning structures at intervals.

6. The dual-circulation production line according to claim 1, characterized in that, Also includes: The rework channel is located parallel to the outside of the external circulation conveyor assembly; At least one unidirectional transfer device is connected between the external circulation conveying assembly and the rework channel.

7. The dual-circulation production line according to claim 6, characterized in that: The rework channel is equipped with a rework return device at its end, which includes a liftable pushing mechanism and a return guide rail connected to the internal circulation conveying component.

8. The dual-circulation production line according to claim 1, characterized in that, Also includes: The lateral extension station is connected to the external circulation conveyor assembly via a rotary conveyor line, which includes a horizontally rotatable hinged section.

9. The dual-circulation production line according to claim 5, characterized in that: Each workstation is equipped with an RFID reader, and the tray positioning structure is fitted with an electronic tag corresponding to the position of the RFID reader.

10. The dual-circulation production line according to claim 1, characterized in that: The operating speed of the inner circulation conveying component is greater than that of the outer circulation conveying component.

Images