Flexible fully automated optical module assembly production line

Abstract

This utility model discloses a flexible, fully automated optical module assembly production line, comprising: a lower shell loading device, including a first frame and a first conveyor belt and a first material handling module mounted on the first frame; a lower shell heat-conducting pad pasting device, including a second frame and a second conveyor belt, a second material handling module, a first working platform, and a first heat-conducting pad pasting module mounted on the second frame; an optical engine loading device, including a fifth frame and a fifth conveyor belt mounted on the fifth frame, an optical engine feeding mechanism, a working platform that can move left and right, a lower shell transfer robot, and an optical engine transfer robot; an upper cover pasting loading device, including a sixth frame and a sixth conveyor belt mounted on the sixth frame, a transfer platform that can move left and right, a sixth material handling module, an upper cover feeding module, a second heat-conducting pad pasting module, a flipping module, an assembly tooling platform, and an assembly robot; and a screw-driving device and an optical module pull ring detection device.

Description

Technical Field

[0001] This utility model relates to the technology in the field of optical module production, and in particular to a flexible, fully automated optical module assembly production line. Background Technology

[0002] Optical communication modules (also known as optical modules) typically include a main optical engine body, a lower housing body, a pull ring, an unlocking elastic element (usually a spring), a top cover, screws, and other main accessories. The main optical engine body includes the main body of the optical module PCBA, a head, and flexible optical fiber cables. The flexible optical fiber cables connect the head and the main body of the optical module PCBA.

[0003] Previously, manual assembly was commonly used in the industry. Later, in order to improve assembly efficiency, some automated assembly lines emerged. For example, CN109702473A discloses a disc-type automatic assembly machine for optical modules, which includes a main frame, a worktable, a turntable mechanism, a fixing fixture, an upper base mechanism, a rocker arm mechanism, a spring assembly mechanism, a pull ring assembly mechanism, a left and right pressure block assembly mechanism, a screw assembly mechanism, an optical fiber detection mechanism, and a defective product unloading mechanism. The worktable is installed above the main frame, the turntable mechanism is installed above the worktable, and the fixing fixture is installed above the turntable mechanism. The turntable mechanism drives the fixing fixture to rotate and pass through the upper base mechanism, rocker arm mechanism, spring assembly mechanism, pull ring assembly mechanism, left and right pressure block assembly mechanism, screw assembly mechanism, optical fiber detection mechanism, and defective product unloading mechanism in sequence. It automatically realizes the assembly of the optical module housing (assembled from the base, rocker arm, spring, pull ring, left pressure block, right pressure block, screws, etc.). For example, CN108080952A proposes an automatic assembly process for SFP optical modules, which realizes the automatic assembly of SFP optical modules through several robotic arms and several CCD positioning modules. It also provides an automatic assembly mechanism for SFP optical modules, including an automatic conveyor line, and a semi-finished product feeding mechanism, a pressing block feeding mechanism, a sheet metal feeding mechanism, a pull ring feeding mechanism, and a slider feeding mechanism that are fixed sequentially on the same side of the automatic conveyor line. It also includes a finished product recycling mechanism.

[0004] It is evident that while industry technology has already replaced manual assembly for the bottom shell components, the subsequent installation of the optical engine into the lower shell still relies on manual assembly. This is especially true because the flexible fiber optic cable connecting the optical engine's main body to the optical module's PCBA main body is prone to uncontrollable deformation during handling, causing a misalignment between the head and the main body. If an automated assembly method were used, with a suction cup robot lifting the optical engine and installing it into the lower shell cavity, the difficulty in aligning it properly due to the optical engine's unique structure (composed of the main body, head, and flexible fiber optic cable) would inevitably lead to low assembly yield and high production costs, rendering the automated assembly option impractical. Therefore, currently, it is common practice to manually install the optical engine into the lower shell to form a semi-finished product, which is then assembled with other components of the optical module.

[0005] With the development of communication technology, the application demand for optical communication modules is increasing, and the development of 400G / 800G optical modules has put forward higher requirements for the quality and precision of optical modules. The quality and precision of optical modules are related to the entire assembly process. Therefore, how to study a highly automated, high-precision, highly flexible and intelligent optical module assembly equipment and method based on the overall structure of optical modules has become a key technical problem that the industry urgently needs to solve. Utility Model Content

[0006] In view of this, the present invention addresses the deficiencies of the existing technology, and its main purpose is to provide a flexible and fully automated optical module assembly production line, which realizes automated, highly flexible and intelligent assembly of optical modules, improves assembly accuracy, assembly efficiency and yield, and increases production capacity, utilization rate and overall manufacturing efficiency of optical modules.

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

[0008] A flexible, fully automated optical module assembly production line includes:

[0009] The lower shell loading device includes a first frame and a first conveyor belt and a first material picking module disposed on the first frame. The first material picking module automatically places the lower shell on the material tray onto the first conveyor belt.

[0010] A device for attaching thermally conductive pads to the lower shell; it includes a second frame and a second conveyor belt, a second material handling module, a first working platform, and a first thermally conductive pad material handling and pasting module mounted on the second frame; the second material handling module is connected between the second conveyor belt and the first working platform, and the first thermally conductive pad material handling and pasting module is used to pick up thermally conductive pads and paste them onto the lower shell on the first working platform;

[0011] A light engine loading device includes a fifth frame and a fifth conveyor line mounted on the fifth frame, a light engine feeding mechanism, a work platform that can move left and right, a lower shell transfer robot, and a light engine transfer robot. The lower shell transfer robot is connected between the fifth conveyor line and the work platform that can move left and right, and the light engine transfer robot is connected between the light engine feeding mechanism and the work platform that can move left and right.

[0012] The cover pasting and loading equipment includes a sixth frame and a sixth conveyor line set on the sixth frame, a transfer platform that can move left and right, a sixth material picking module, a cover feeding module, a second heat-conducting pad picking and pasting module, a flipping module, an assembly tooling platform, and an assembly robot.

[0013] A screw-driving device; comprising a seventh frame and a seventh conveyor belt, a seventh material handling module, and a screw-driving module mounted on the seventh frame; the seventh material handling module is connected between the seventh conveyor belt and the screw-driving module;

[0014] Optical module pull ring testing equipment; it is used to test pull rings.

[0015] Compared with existing technologies, this utility model has significant advantages and beneficial effects. Specifically, as can be seen from the above technical solution, it mainly divides the entire optical module into three parts: the lower shell assembly, the optical engine, and the upper cover. The lower shell assembly, the optical engine, and the upper cover are prefabricated, eliminating the need for assembly of internal parts of the lower shell on the production line and for the production of the optical engine on the production line. This facilitates parallel production. On the production line, the process of attaching thermal pads to the lower shell assembly, installing the optical engine into the lower shell assembly, attaching thermal pads to the upper cover, assembling the upper cover and the lower shell, screwing, labeling, and pull ring inspection are all performed. This solution not only realizes the automatic production and assembly of the optical module, achieving highly flexible and intelligent assembly, but also improves assembly accuracy, assembly efficiency, and yield. The production capacity can reach at least 250 PCS / hour, with an utilization rate of over 90%, while also improving the overall manufacturing efficiency of the optical module.

[0016] To more clearly illustrate the structural features and effects of this utility model, the following detailed description of this utility model is provided in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0017] Figure 1 This is a perspective view of a flexible, fully automated optical module assembly production line according to an embodiment of the present invention;

[0018] Figure 2 This is a perspective view of the lower shell insertion device according to an embodiment of the present utility model;

[0019] Figure 3 This is a top view of the lower shell insertion device according to an embodiment of the present utility model;

[0020] Figure 4 This is a perspective view of a device for attaching a heat-conducting pad to the lower shell according to an embodiment of this utility model;

[0021] Figure 5 This is a perspective view of a light engine mounting device according to an embodiment of the present invention;

[0022] Figure 6 This is a perspective view of the device into which the top cover is pasted and installed according to an embodiment of this utility model;

[0023] Figure 7 This is a perspective view of a screw-driving device according to an embodiment of the present utility model;

[0024] Figure 8 This is a perspective view of an automatic labeling device according to an embodiment of the present invention;

[0025] Figure 9 This is a perspective view of an optical module pull ring testing device according to an embodiment of the present invention;

[0026] Figure 10 This is a perspective view of the detection device according to an embodiment of the present utility model;

[0027] Figure 11 This is a structural diagram of the product pressing module according to an embodiment of the present utility model;

[0028] Figure 12 This is a structural diagram of a transfer testing platform according to an embodiment of the present invention;

[0029] Figure 13 This is a structural diagram of a plug gauge detection and positioning module and a plug gauge detection module according to an embodiment of this utility model;

[0030] Figure 14 This is a structural diagram of the pull ring detection module according to an embodiment of the present invention;

[0031] Figure 15 This is a structural diagram of the left height testing module and the right height testing module according to an embodiment of this utility model;

[0032] Figure 16 The following diagram illustrates the steps of the detection method for the optical module pull ring detection device according to an embodiment of this utility model. Detailed Implementation

[0033] Please refer to Figures 1 to 16 As shown, it illustrates the specific structure of an embodiment of the present invention.

[0034] An optical communication module is an important component in fiber optic communication systems. It converts electrical signals into optical signals and enables high-speed data transmission between optical fibers. Its applications are wide-ranging, covering a variety of products, such as network switching equipment, servers and storage devices, base stations, transmission equipment, fiber optic modems, security monitoring systems, broadcast television systems, medical equipment, industrial automation equipment, and home network equipment.

[0035] A flexible, fully automated optical module assembly production line is used to automatically assemble the lower shell (including the lower shell body, pull rings and unlocking elastic components installed on the lower shell body), optical engine, and upper cover together, and to automatically perform screwing and labeling, pull ring unlocking dimension inspection, and automatic unloading and tray placement. It includes several devices arranged in series, each equipped with an independent control system to control its respective functional units. Simultaneously, the control systems of each device can communicate with each other, enabling timely information feedback between related devices, which is beneficial for online monitoring, real-time dynamic control, and adjustment of the equipment. These devices are, in order:

[0036] The lower shell loading device 100 includes a first frame 110 and a first conveyor belt 120 extending laterally on the first frame 110, and a first material handling module 130. The first material handling module 130 automatically places the lower shell (here, the lower shell is a lower shell assembly, including the lower shell body, a pull ring installed on the lower shell body, and an unlocking elastic element, which is automatically assembled separately by other equipment using existing mature assembly technology; the lower shell is placed on a material tray) onto the first conveyor belt 120. Specifically, the device automatically lifts the material handling tray module to place the lower shell onto the first conveyor belt 120. After a full material tray in the manual material cage is placed on the lower shell loading platform, the first material handling module places the lower shell onto the first conveyor belt. Once the tray is empty, the lifting material tray module loads the empty tray into the manual material cage. The lower shell loading equipment 100 also includes a first material cage 140, a first lifting material handling module 150, a pushing and correcting module 160, and a secondary correction platform 170 (optional), all mounted on the first frame 110. The first material cage 140 includes multiple sets of shelves spaced vertically, each set including two shelves spaced horizontally, with each shelf used to supply one material tray. The placement and positioning are such that the space reserved between the two layered plates allows the first lifting and material-retrieving module 150 to enter and exit the first material cage 140 for filling and emptying the material tray. The first lifting and material-retrieving module 150 includes a first material-retrieving plate 151 driven to move back and forth by a linear module, and a first lifting drive unit 152 (e.g., a lifting cylinder) for driving the first material-retrieving plate 151 to move up and down. Thus, when the first material-retrieving plate 151 moves into the first material cage 140, it starts retrieving material from the bottommost full tray, i.e., the first material-retrieving plate 151 is located at the bottommost... Below the full material tray, the first lifting drive unit 152 drives the first picking plate 151 to lift the full material tray upwards and separate it from the layer plate, and then it moves horizontally to extend out of the first material cage 140, and then descends after it is in place; the pushing correction module 160 includes a pushing cylinder and a pushing component driven by the pushing cylinder to move horizontally left and right, and also includes a limiting component set on the opposite side of the pushing component, which is set corresponding to the first picking plate 151 after it is in place, and pushes the full material tray on the first picking plate 151 toward the limiting component, so that the position of the full material tray on the first picking plate 151 is corrected. The first material handling module 130 includes a first X-axis drive unit 131 for left-right translation, a first Y-axis drive unit 132 for front-back translation, a first Z-axis drive unit for up-down lifting, a first mounting base 134, a first material handling robot 135, and a first CCD guide module 136. The first material handling robot 135 is equipped with a rotary motor to drive the first material handling robot 135 to rotate horizontally around the Z-axis to adjust the angle. The first CCD guide module 136 is equipped with a lifting fine-tuning drive unit. The first CCD guide module 136 and the first material handling robot 135 are arranged around the first mounting base 134, and the first mounting base 134 is driven to move up and down as a whole by the first Z-axis drive unit.The first X-axis drive unit 131 drives the first Z-axis drive unit and the first mounting base 134 to move horizontally, and the first Y-axis drive unit 132 drives the first X-axis drive unit 131, the first Z-axis drive unit, and the first mounting base 134 to move backward. To ensure smooth operation, guide rails in the X, Y, and Z axes can be provided for displacement along these rails during the aforementioned forward / backward, left / right, and up / down movements. During operation, the first material handling robot 135, guided by the vision of the first CCD guide module 136, removes the shell from the full material tray on the first material handling plate 151 and places it above the secondary calibration platform 170. The robot then rotates the shell as needed to ensure accurate positioning on the secondary calibration platform 170. The first material handling robot 135 then moves the calibrated shell onto the first conveyor belt 120, where it is conveyed to the right to enter the second conveyor belt of the next device. In terms of layout: the first production line 120 is located at the front, and the first material cage 140 is located at the rear. The full material trays are loaded layer by layer from the rear, and the empty material trays can also be removed from the rear. The first lifting and picking module 150 is located in the area between the first production line 120 and the first material cage 140. The pushing and correcting module 160 and the secondary correction platform 170 are also located in the area between the first production line 120 and the first material cage 140. The second picking module 230 adopts a gantry design, and its moving coverage area can connect at least the first lifting and picking module 150, the secondary correction platform 170, and the first production line 120.

[0037] A device 200 for attaching thermally conductive pads to a lower casing includes a second frame 210 and a second conveyor belt 220, a second material handling module 230, a first working platform 240, and a first thermally conductive pad material handling and attaching module 250, all mounted on the second frame 210. The input end of the second conveyor belt 220 is connected to the output end of the first conveyor belt 120. The first working platform 240 is equipped with a tooling platform 241 that can move left and right between the first and second workstations, driven by a linear module 242. The second material handling module 230 is connected between the second conveyor belt 220 and the first workstation to remove the lower casing from the second conveyor belt 220 and place it onto the tooling platform 250 at the first workstation. On the 41, the lower shell with the thermal pad pasted on can be placed back from the tooling platform 241 of the first station onto the second conveyor belt 220. The first thermal pad picking and pasting module 250 is connected between the first thermal pad feeding module 280 and the tooling platform 241 of the second station. The first thermal pad picking and pasting module 250 is used to pick up the thermal pad and paste the thermal pad onto the lower shell on the tooling platform 241 of the second station. The lower shell thermal pad pasting equipment 200 also includes a first thermal pad calibration and detection module 260 and a defective product collection area 270 (e.g., a collection box) set on the second frame 210. The first thermal pad calibration and detection module 260 includes The system includes a horizontal transparent carrier plate and a CCD for detecting thermally conductive pads located below the carrier plate. The first thermally conductive pad picking and pasting module 250 uses an XYZ three-axis drive structure to drive a second picking robot, whose drive structure is the same as that of the first picking module 130. The second picking robot of the first thermally conductive pad picking and pasting module 250 can be equipped with one or more picking nozzles to pick up one or more thermally conductive pads. Simultaneously, a second CCD guiding module is configured on the second picking robot to guide the picking and placing of materials and to photograph and inspect the picked-up thermally conductive pads. If a defect is detected, the second picking robot places the thermally conductive pad into the defective product collection area 27. 0. Only qualified thermal pads are placed one by one on a horizontal transparent carrier plate for calibration testing. If a thermal pad is skewed, the rotating mechanism on each of the pick-up nozzles drives the nozzle to rotate, thus correcting the thermal pad by rotating it. Under the guidance of CCD vision positioning, the calibrated thermal pad is then fed into the lower shell waiting on the tooling platform 241 at the second station and pasted downwards, so that the thermal pad is pasted in the designated position on the lower shell, automatically completing the thermal pad pasting. Subsequently, the tooling platform 241 is moved to the first station, and the second picking module 230 sends the lower shell with the pasted thermal pad on the tooling platform 241 to the second production line 220. The structure of the second picking module 230 is the same as that of the first picking module 130.The second production line 220 includes an infeed conveyor belt 221 and an outfeed conveyor belt 222 connected side-by-side. The second picking module 230 removes the shell from the infeed conveyor belt 221 and places the shell with the heat-conducting pad attached onto the outfeed conveyor belt 222. Furthermore, it also includes an NG conveyor belt 223 located in front of the outfeed conveyor belt 222. The CCD guiding module of the second picking module 230 can also perform CCD image inspection on the shell after the heat-conducting pad is attached, mainly to check whether the attachment position of the heat-conducting pad is accurate, determining OK or NG. If it is a good product, it is placed on the outfeed conveyor belt 222; if it is a defective product, it is placed on the NG conveyor belt 223. To further improve efficiency, two first working platforms 240 arranged parallel to each other can be set up.

[0038] Bottom shell mounting and unloading equipment 300; Bottom shell mounting and unloading equipment 300 is used to load bottom shells with attached thermal pads onto trays, and bottom shell mounting and unloading equipment 300 is equipped with a third conveyor belt extending to the left and right;

[0039] The lower shell mounting and feeding device 400 is equipped with a fourth conveyor belt extending to the left and right. The lower shell mounting and feeding device 400 is used to place the lower shells with attached thermal pads from the material tray one by one onto the fourth conveyor belt. The structure of the lower shell mounting and feeding device 400 is the same as or basically the same as that of the finished product unloading and traying device 1000.

[0040] The light engine loading device 500 includes a fifth frame and a fifth conveyor line mounted on the fifth frame, a light engine feeding mechanism 5300, a horizontally movable work platform 5400, a lower shell transfer robot 5500, a light engine transfer robot 5600, a second CCD module 5700, and a QC inspection module. The lower shell transfer robot 5500 is connected between the fifth conveyor line and the horizontally movable work platform 5400 to place the lower shell with a heat-conducting pad attached onto the horizontally movable work platform. On the work platform 5400, the optical engine transfer robot 5600 is connected between the optical engine feeding mechanism 5300 and the work platform 5400, which can move left and right. The optical engine feeding mechanism 5300 is used to pick up the optical engine (the optical engine includes an optical module PCBA body, a head, and flexible optical fiber cables, with the flexible optical fiber cables connecting the head and the optical module PCBA body. The optical engine is manufactured using existing mature equipment and is placed on a material tray) and load it onto the work platform 5400, which can move left and right. The lower housing is fitted with a thermally conductive pad. A light engine transfer robot arm, comprising a YZ two-axis motion mechanism, a floating pressing mechanism, a first picking mechanism, a second picking mechanism, an XYθ axis adjustment mechanism, and a first CCD module, is included. The XYθ axis adjustment mechanism is configured for the first and / or second picking mechanisms to adjust the position and orientation of the first picking mechanism relative to the second picking mechanism. The floating pressing mechanism jointly controls the first and second picking mechanisms to press the light engine downwards. The YZ two-axis motion mechanism jointly controls the positions of the first, second, and first CCD modules, enabling the second robot arm to transfer between the light engine feeding mechanism and the second workstation. The first CCD module is configured to detect the pose of the upper tray and the light engine of the light engine feeding mechanism, as well as the pose of the lower housing of the work platform. The light engine loading device 500 also includes a second CCD module, located between the light engine feeding mechanism and the work platform, and positioned on the movement path of the second robot arm, configured to take upward-facing images to sample pose information. Specifically, on the light engine mounting device 500, the fifth conveyor line extends to the left and right and is located in the front area of ​​the fifth frame to convey the product from left to right; a picking area 52011 is defined on the fifth conveyor line; the fifth conveyor line can be designed as a synchronous belt type, which is divided into a left section 5201 and a right section 5202, each controlled independently. The left section 5201 receives the lower shell with heat-conducting pads attached from the upstream equipment and sends it to the picking area 52011.The light engine feeding mechanism 5300 is located on the fifth frame, corresponding to the rear area of ​​the fifth conveyor line. It extends to the left and right and is located in the rear area of ​​the fifth frame. The light engine feeding mechanism 5300 conveys multi-layer stacked trays from right to left. Each tray is equipped with several light engines arranged in a matrix. The light engine feeding mechanism 5300 includes a stacking lifting mechanism 5301 located at the right end, which is used to place several stacked trays. It also includes a linear motor module 5302 that conveys the bottom tray of the stacked trays one by one from right to left to the light engine loading station. The empty trays after material removal are sent to the left to the empty tray stacking mechanism 5304. The light engine feeding mechanism 5300 can realize the separation of stacked trays and the output of empty trays. These technologies are existing technologies and are not the first invention of this utility model. Here, it is mainly emphasized that the light engine feeding mechanism 5300 conveys from right to left, and its layout application on the fifth frame is quite ingenious.

[0041] The work platform 5400, which can move left and right, has a first station corresponding to the material handling area 52011 and a second station corresponding to the light engine assembly; the first station is located to the left of the second station. Position sensors can be configured at both the first and second stations.

[0042] The first robotic arm 5500 (also known as the shell transfer robotic arm) has an XYZ three-axis motion mechanism and is configured to transfer the shell between the picking area 52011 and the first workstation after removing the shell, so as to send the shell to the working platform 5400. The first robotic arm 5500 includes an automatic gripper. The XYZ three-axis motion mechanism includes an X-axis motion mechanism, a Y-axis motion mechanism, and a Z-axis motion mechanism. The automatic gripper is mounted on the Z-axis motion mechanism and is driven by the Z-axis motion mechanism to move up and down. The Z-axis motion mechanism is mounted on the X-axis motion mechanism and is driven by the X-axis motion mechanism to move left and right. The X-axis motion mechanism is mounted on the Y-axis motion mechanism and is driven by the Y-axis motion mechanism to move back and forth.

[0043] The second robotic arm 5600 (also known as the light engine transfer robotic arm) has a YZ two-axis motion mechanism, a floating pressing mechanism, a first picking mechanism, a second picking mechanism, an XYθ axis adjustment mechanism, and a first CCD module. The first picking mechanism is used to pick up the head of the light engine, and its bottom is designed with a head-shaped cavity that conforms to the shape of the light engine head. The second picking mechanism is used to pick up the body of the light engine. Since the body is relatively long, two picking heads can be set as needed. Both the first and second picking mechanisms pick up materials downwards, so that the head and bottom of the body of the light engine are exposed downwards. The XYθ axis adjustment mechanism is configured for the first picking mechanism and / or the second picking mechanism to adjust the position and direction of the first picking mechanism relative to the second picking mechanism (therefore, the distance and direction angle of the head of the light engine relative to the body can be adjusted). In this embodiment, the first picking mechanism is installed on the side of the second picking mechanism and is equipped with a lifting drive to control the vertical displacement of the first picking mechanism relative to the second picking mechanism, which can better adjust the position (vertical relative position) of the head of the light engine relative to the body. The XYθ axis adjustment mechanism includes an θ-axis adjustment drive, an X-axis translation drive, and a Y-axis translation drive. These drives can be cylinders or motors, etc. The θ-axis adjustment drive is connected to the first material-picking mechanism to control the rotation angle of the first material-picking mechanism, which is equivalent to controlling the head angle of the light engine. The X-axis translation drive and Y-axis translation drive are connected to the second material-picking mechanism to control the distance between the second material-picking mechanism and the first material-picking mechanism, which is equivalent to adjusting the distance between the head of the light engine and the main body. The floating pressing mechanism together controls the first and second material-picking mechanisms to press the light engine downward. The floating pressing mechanism is a mature technology in automatic equipment in the mechanical field. It can be a spring-loaded up-and-down drive mechanism, where the spring part can also be replaced by a pneumatic buffer component. At the same time, a pressure sensor can be added to monitor the contact pressure in real time during the pressing process and automatically compensate for the Z-axis displacement. Multi-stage control can be used in the floating pressing process. For example, the first stage is to press down at a slightly faster speed to the contact detection threshold, the second stage switches to a slightly slower constant force control to continuously press down a small distance, and the third stage maintains constant force to complete stress release. Of course, the implementation method is not limited to this.The YZ two-axis motion mechanism jointly controls the positions of the first material handling mechanism, the second material handling mechanism, and the first CCD module, enabling the second robot arm 5600, configured as a light engine, to move between the light engine feeding mechanism 5300 and the second workstation. The first CCD module is configured to detect the position and orientation of the tray on the light engine feeding mechanism 5300 and the light engine, feeding the information back to the main control system to better guide the movement of the second robot arm 5600 (specifically, to guide the movement of the YZ two-axis motion mechanism), and to detect the position and orientation of the lower shell of the work platform 5400 (also referring to 3D positioning), feeding the information back to the main control system to better guide the movement of the second robot arm 5600 (specifically, to guide the movement of the YZ two-axis motion mechanism, the movement of the floating pressing mechanism, and especially to guide the movement of the XYθ axis adjustment mechanism as needed so that the relative position and orientation of the light engine head and the main body match the lower shell).

[0044] The second CCD module 5700 is located between the light engine feeding mechanism 5300 and the work platform 5400 (usually closer to the work platform 5400 of the second workstation), and is set on the forward and backward movement path of the second robot arm 5600, usually facing the rear of the second workstation; it is configured to take pictures and sample pose information facing upward to know the position and direction of the head of the light engine relative to the main body.

[0045] The control system of the light engine installation device 500 is at least configured to control the XYθ axis adjustment mechanism to adjust the position and direction of the first material handling mechanism relative to the second material handling mechanism based on the lower shell pose information and light engine pose information fed back by the first CCD module and the second CCD module 5700. That is, it dynamically adjusts the distance between the two suction cups and the deflection angle of the light engine head based on the data from the two CCDs. Preferably, the control system is connected to various functional modules, such as: the fifth conveyor line, the light engine feeding mechanism 5300, the work platform 5400, the first robot arm 5500, the second robot arm 5600, the second CCD module 5700, and the third CCD module 5900. A human-machine interface is provided on the front side of the fifth frame's housing to facilitate the display of the equipment's real-time operating status / parameters, and for operators to input settings on the human-machine interface. The equipment frame is typically equipped with alarm mechanisms, such as light alarms and sound alarms.

[0046] Furthermore, the light engine installation device 500 also includes a QC inspection module, which is used to inspect the assembled semi-finished products;

[0047] The defective product sorting area 5200' (in this embodiment, it is an NG product guide track with a sensing area at its left end. When an NG product is placed in the sensing area, the track will start and the NG product will flow out. The sensing area, the picking area 52011, and the first station are arranged facing each other from front to back) is located on the side of the fifth conveyor line, for example, on the front side. According to the inspection results, the first robot arm 500 picks up the defective products on the work platform 5400 and sends them to the defective product sorting area 5200', and picks up the qualified products on the work platform 5400 and sends them to the fifth conveyor line, which is generally located on the right side of the picking area 52011.

[0048] The QC inspection module includes a third CCD module 5900, which is positioned above the left-right translation path of the work platform 5400 and configured to take downward-facing photos to inspect the assembled semi-finished products. The third CCD module 5900 performs multi-point measurements on the height difference between the top of the light engine and the top of the lower shell (acquiring assembly depth distribution data) to check whether the light engine is pressed into the inner cavity of the lower shell to the required depth. Measuring the relative height value by taking points from the top plane of the lower shell and the corresponding top surface of the light engine is relatively simple.

[0049] The fifth conveyor line is designed with two parts: a left section 5201 and a right section 5202, each controlled independently. The material handling area 52011 is located at the upper right end of the left section 5201. The first robot arm 5500 picks up qualified products from the work platform 5400 and transfers them to the right section 5202 (e.g., near the left end). The QC inspection module is located to the right of the second station. Considering the layout, it is generally also located to the right of the area where the second robot arm 5600 is located, which is equivalent to the third station of the work platform 5400.

[0050] Next, we will introduce an assembly method based on the automated assembly equipment for installing the light engine into the lower shell, which includes the following steps:

[0051] Step S100: Receive the upstream lower shell through the segmented fifth conveyor line and position it to the material collection area 52011;

[0052] Step S200: The first robotic arm 5500 transfers the lower shell to the work platform 5400 of the first workstation;

[0053] Step S300: The work platform 5400 moves to the right and switches to the second workstation to perform the light engine assembly operation, including:

[0054] Step S310: The tray is scanned and positioned by the first CCD module to obtain the initial pose data of the light engine head and the main body, so as to guide the subsequent movement of the second robot arm 5600.

[0055] Step S320: Based on the initial pose data, dynamically adjust the distance between the first material handling mechanism and the second material handling mechanism, as well as the deflection angle of the first material handling mechanism;

[0056] Step S330: Simultaneously capture the main body and head of the light engine, transfer them above the second CCD module 5700, and take pictures of the pose information from the second CCD module 5700 facing upwards. The pose information includes the position and direction of the head of the light engine relative to the main body.

[0057] Step S340: Continue to transfer to the upper part of the second workstation. At this time, the first CCD module is located directly above the lower shell, while the light engine is slightly offset from the front of the lower shell. The first CCD module obtains the pose information of the lower shell on the work platform 5400 (e.g., the three-dimensional spatial coordinates of the lower shell cavity).

[0058] Step S350: Calculate the deviation between the current pose of the light engine and the target assembly pose. Based on the deviation, the XYθ axis adjustment mechanism adjusts the distance and deflection angle of the first material picking mechanism and the second material picking mechanism in real time, which is equivalent to adjusting the distance between the head of the light engine and the main body and the direction / angle of the head relative to the main body.

[0059] Step S360: Rotate to the top of the second station so that the light engine is facing the cavity of the lower shell. Then, perform floating press fitting with constant contact pressure. The Z-axis displacement can be dynamically controlled by the pressure value feedback.

[0060] In step S400, the second robot arm 600 moves away from the work platform 5400 towards the light engine feeding mechanism 5300 to provide the light engine for the next cycle. The work platform 5400 moves to the left (for example, to the first work station), and the first robot arm 500 takes out the assembled semi-finished product from the work platform 5400 and sends it to the fifth conveyor line.

[0061] Furthermore, after step S360 and before step S400, a QC quality inspection step (which belongs to the quality verification stage) is also included:

[0062] Step S370: The second robotic arm 5600 moves forward a short distance and uses the first CCD module to inspect the appearance defects of the assembled semi-finished product.

[0063] If the product is found to be of acceptable appearance, proceed to step S380. The work platform 5400 moves to the right to the third workstation, where the third CCD module 5900 takes a downward-facing photo to inspect the assembled semi-finished product. The inspection checks whether the depth of the light engine installed in the lower housing meets the standard. If it does, in step S400, the first robot arm 5500 removes the assembled semi-finished product from the work platform 5400 and sends it to the fifth conveyor line. If it does not meet the standard, in step S400, the first robot arm 5500 removes the assembled semi-finished product from the work platform 5400 and sends it to the defective product sorting area 5200'.

[0064] If the product is found to be defective in appearance, proceed directly to step S400, where the first robotic arm 5500 removes the assembled semi-finished product from the work platform 5400 and sends it to the defective product sorting area 5200'.

[0065] In the aforementioned assembly method, from the perspective of its overall process control flow, step S100 is designed as the lower shell positioning stage. The lower shell, conveyed by the upstream equipment, is received by the left section 5201 of the segmented assembly line. Position sensors 5A1, such as proximity sensors or photoelectric sensors, are respectively installed at the left and right ends of the picking area 52011. Furthermore, the posture correction of the lower shell can be completed within the picking area 52011, for example, by installing correction mechanisms at the front and / or rear of the left section 5201 assembly line to move the lower shell to the side. A qualified product receiving area is also provided at the left end of the right section 202, with position sensors 5A2 installed at its left and right ends. Similarly, an NG product receiving area is also provided at the left end of the defective product sorting area 5200', with position sensors 5A3 installed at its left and right ends. Step S200 is designed as the lower shell transfer stage: the XYZ three-axis driven first robot arm 5500 grasps the lower shell and transfers it to the work platform 5400 located at the first workstation. The work platform 5400 is driven by a linear motor module 5401 (also called a linear module, linear motor, or linear motor) to move left and right. The linear motor module extends left and right, and the work platform 5400 can move left and right on top of the linear motor module. Compared with traditional lead screw and belt modules, this type of drive design for the work platform 5400 has advantages such as high single-unit movement speed, high repeatability, light weight, small equipment space occupation, and long service life, making light-load automation more flexible and positioning more accurate. Typically, the first robot arm 5500 and the first and second picking mechanisms of the second robot arm 5600 support adaptation to various lower shell and light engine specifications.

[0066] The top cover pasting and loading device 600 includes a sixth frame and a sixth conveyor line 601, an NG conveyor line 602, a transfer platform 603 that can move left and right (driven by a linear module 6031), a sixth material picking module 604, a top cover feeding module (including a top cover feeding cage 605, a second lifting material picking module 606, the top cover feeding cage 605 and the first material cage 140 having the same structure, used to provide a full tray containing several top covers, the second lifting material picking module 606 having the same structure as the first lifting material picking module 150, and also equipped with a pushing and correction module), a second heat-conducting pad picking and pasting module 607, a flipping module 608, an assembly tooling platform 609, an assembly robot 610, and a top cover correction and detection module 611; the sixth conveyor line 601 is located on the sixth frame. At the upper front position, the upper cover feeding module is located at the rear of the sixth frame. The left-right movable transfer platform 603 is located between the upper cover feeding module and the sixth conveyor line 601. The right side of the upper cover feeding cage 605 is arranged with the second heat-conducting pad feeding module, which is located behind the left-right movable transfer platform 603. The flipping module 608 is located above the left-right movable transfer platform 603. The assembly tooling platform 609 is located between the left-right movable transfer platform 603 and the sixth conveyor line 601. The sixth picking module 604 has XYZ three-axis translation function. Its robot arm is equipped with a CCD guidance module and a rotary motor. When picking up the upper cover, the CCD guidance module is used for visual guidance and positioning. At the same time, the upper cover is photographed and inspected to rotate and adjust its angle as needed.The sixth material handling module 604 is connected between the left section of the sixth conveyor line 601 and the upper cover feeding module, and also between the left section of the sixth conveyor line 601 and the laterally movable transfer platform 603. This allows the lower shell with the heat-conducting pad attached to it to be fed from the sixth conveyor line 601 onto the laterally movable transfer platform 603, and the upper cover to be fed from the upper cover feeding module onto the laterally movable transfer platform 603. The second heat-conducting pad material handling and attaching module 607 is connected between the second heat-conducting pad feeding module and the laterally movable transfer platform 603. The second heat-conducting pad material handling and attaching module 607 has the same or essentially the same structure as the sixth material handling module 604, and also has… Equipped with XYZ three-axis translation function, a CCD guidance module for visual guidance positioning and photographic inspection of thermal pads, and rotational angle adjustment; the assembly robot 610 connects between the flipping module 608 and the assembly tooling platform 609, and between the assembly tooling platform 609 and the right section of the sixth conveyor line 601; during operation, the sixth material handling module 604 removes the shell assembly (including the light engine) from the sixth conveyor line 601 and places it on the left-right movable transfer platform 603. At this time, the left-right movable transfer platform 603 is located at the left end waiting for material, and then the left-right movable transfer platform 603 moves to the right end, where the assembly robot 610 moves the shell assembly from the left-right movable transfer platform 603 to the right end. The transfer platform 603 is removed and sent to the assembly tooling platform 609. Then, the transfer platform 603, which can move left and right, moves to the left end. The sixth material picking module 604 takes the top cover from the second lifting material picking module 606 and places it on the transfer platform 603. Then, the transfer platform 603 moves to the right to the area below the second thermal pad picking and pasting module 607. The second thermal pad picking and pasting module 607 takes the second thermal pad from the second thermal pad feeding module and pastes it on the inner top surface of the top cover (at this time, the inner top surface of the top cover is facing upwards). Then, it continues to move to the right to the area below the flipping module 608, where the flipping module 608 holds the inner top surface of the top cover. The cover is then flipped 180 degrees so that the outer top surface of the cover faces upward (the second thermal pad faces downward). Then, the assembly robot 610 takes the cover from the flipping module 608 and assembles it onto the lower shell assembly. Furthermore, due to the addition of the cover calibration and detection module 611, the assembly robot 610 takes the cover from the flipping module 608 and places it above the cover calibration and detection module 611 for CCD imaging and detection. The assembly robot 610 then rotates and adjusts the angle accordingly to correct the position of the cover before assembling it onto the lower shell assembly of the assembly tooling platform 609. The assembled product is then transported by the assembly robot 610 to the right section of the sixth conveyor line 601.

[0067] Screw-driving equipment 700; it includes a seventh frame and a seventh conveyor belt 701 extending laterally on the seventh frame (with an NG conveyor belt 702 at its front), a seventh material handling module 703, and a screw-driving module 706; the seventh material handling module 703 connects the seventh conveyor belt 701 and the screw-driving module 706, feeding the product to the screw-driving module 706, completing the screw installation, and then feeding the product back to the seventh conveyor belt 701. Specifically, on the seventh frame... The seventh frame also includes a screw-driving work platform 704, which has the same structure as the first work platform 240 and is driven by a linear module 705 to move left and right. A screw height measuring module 707 is also installed on the seventh frame. The screw-driving work platform 704 defines at least three workstations on its left-right translation trajectory: left, middle, and right. The seventh material handling module 703 has the same structure as the first material handling module 130, featuring XYZ three-axis drive, a material handling robot, and a configured CCD guide module. The seventh material handling module 703 picks up the product from the seventh conveyor belt and transfers it to the screw-driving work platform 704 at the left workstation. The screw-driving work platform 704 then moves to the right workstation, where the screw-driving module 706 performs the screw-driving operation. After completing the screw-driving operation, the screw-driving work platform 704 moves to the left workstation, below the screw height measuring module 707, where the screw height is measured. Then, the screw-driving operation... The platform 704 moves to the left to the left workstation. If it is a good product, the seventh material handling module 703 sends the screwed product to the seventh conveyor belt 701. If it is an NG product, the seventh material handling module 703 sends the screwed product to the NG conveyor belt 702. Further, the CCD guide module configured in the seventh material handling module 703 performs appearance inspection on the screwed product, mainly inspecting the appearance of the screw. If it is qualified, it is considered a good product; if it is NG, it is considered an NG product.

[0068] An automatic labeling device 800 includes an eighth frame and an eighth conveyor belt 801 extending horizontally on the eighth frame (with an NG conveyor belt 802 at its front), an eighth material handling module 803 (similar in structure to the first material handling module 130, featuring XYZ three-axis drive and a material handling robot), a labeling worktable 804 (similar in structure to the first work platform 240, also driven by a linear module 805 for horizontal translation), and a labeling module 806. The eighth material handling module 803 picks up products from the eighth conveyor belt 801 and transfers them to the labeling worktable 804, where the labeling module 806 labels the products, and then the eighth material handling module 803 transfers the products back to the eighth conveyor belt 801. 01. Further, the labeling workbench 804 defines at least two stations on its left and right translational trajectory: a loading station and a labeling station. Further, a calibration fixture 807 is set directly in front of the loading station. The eighth picking module 803 picks up the product from the eighth conveyor belt 801 and sends it to the transfer fixture 807. After rotating it 180 degrees, it is placed in the transfer fixture 807 for positioning. Then, it is moved to the labeling workbench 804 at the loading station. The labeling workbench 804 moves to the right to the labeling station, where the labeling module 806 labels the product. After labeling, the labeling workbench 804 moves to the left to the loading station, where the eighth picking module 803 sends the product to the eighth conveyor belt 801. During the labeling process, as the labeling workbench 804 moves to the labeling station, the eighth picking module 803 can remove a product from the eighth conveyor belt 801, flip it over, and place it in the transfer fixture 807. Thus, after the eighth picking module 803 delivers the previously labeled product to the eighth conveyor belt 801, it can quickly deliver the flipped product from the transfer fixture 807 to the labeling workbench 804 at the loading station, effectively improving operational efficiency. Of course, the eighth picking module 803 can also be equipped with a CCD guide module, which inspects the labeled product, primarily checking the accuracy of the labeling position. If it is a good product, it is sent to the eighth conveyor belt 801; if it is an NG (not good), it is sent to the NG conveyor belt 802. As for the labeling module 806, it includes a labeling robot, whose structure is the same or basically the same as that of the second thermal pad picking and pasting module 607. It also has XYZ three-axis translation function and a CCD guide module for visual guidance positioning and photographic inspection of the label. The robot can rotate to adjust the angle and also detect missing characters or blurry images when inspecting the label. If the label is defective, it is discarded as an NG product and another label is taken to ensure that the label used for labeling is a qualified label.

[0069] Optical module pull ring testing equipment 900; it includes a ninth frame and a ninth conveyor belt set on the ninth frame, an optical module transport three-axis 910, and a pull ring testing device 920; the optical module transport three-axis 910 is connected between the ninth conveyor belt and the pull ring testing device 920. The pull ring detection device 920 includes a transfer test platform 921, a product clamping module 922, a plug gauge detection and positioning module 923, a plug gauge detection module 924, a pull ring detection module 925, a left height testing module 926, and a right height testing module 927. A three-axis optical module transporter 910 is connected to the ninth conveyor belt and the transfer test platform 921. The product clamping module 922 is used to clamp the products on the transfer test platform 921. The plug gauge detection and positioning module 923 is used to position the products on the transfer test platform 921. The plug gauge detection module 924 is used to perform shape inspection on the products on the transfer test platform 921. The pull ring detection module 925 is used to test the pull force and reset capability of the pull rings on the products on the transfer test platform 921. The left height testing module 926 and the right height testing module 927 are used to detect the dimensions of the latches on both sides of the pull rings on the products on the transfer test platform 921.

[0070] Specifically, in this embodiment, the optical module pull ring testing equipment is mainly used for: 1. detecting the product's external dimensions; 2. detecting the pull ring's tensile force and whether it can be reset; 3. detecting the dimensions of the latches on both sides when the pull ring is pulled out. The external dimensions include the left-right width L1 and the top-bottom thickness L2 of the optical module's head. The product (i.e., the optical module) flows from the previous workstation into this workstation, is transported by the optical module transport triaxial 910, and then placed into the pull ring testing device 920 for testing. After testing, it is removed and placed into the conveyor belt to flow into the next workstation. Specifically, the ninth conveyor belt includes a product infeed conveyor belt 931, a product outfeed conveyor belt 932, and an NG discharge conveyor belt 933. Products flow into the product infeed conveyor belt 931 and are positioned accordingly. The optical module transport three-axis 910 picks up the product from the product infeed conveyor belt 931. Then, the optical module transport three-axis 910 places the product into the pull ring detection device 920 for detection. After detection, the optical module transport three-axis 910 places the product onto the product outfeed conveyor belt 932. If it is an NG product, it is placed onto the NG discharge conveyor belt 933.

[0071] The pull ring detection device 920 includes a transfer testing platform 921, a product clamping module 922, a plug gauge detection and positioning module 923, a plug gauge detection module 924, a pull ring detection module 925, a left height testing module 926, a right height testing module 927, and a product information scanning module 928. When the product is placed in the transfer station (i.e., the transfer testing platform 921), the product clamping module 922 extends to clamp the product; then, the plug gauge detection and positioning module 923 extends to position the product; then, the plug gauge detection module 924 performs product shape inspection and uses a pressure sensor to determine whether the product shape is compliant; then, the pull ring detection module 925 tests the pull ring and uses a pressure sensor to determine the pull ring tension; then, the left height testing module 926 and the right height testing module 927 extend to detect whether the pull ring notch is compliant; after the product testing is completed, the optical module transport three-axis 910 clamps the product and moves it to the barcode scanning station where the product information barcode scanning module 928 performs barcode scanning and matching, achieving high-precision, high-efficiency, and highly integrated fully automatic detection.

[0072] The relay test platform 921 is provided with a positioning groove 2101. A stop block 9211 is provided on the left side of the relay test platform 921 corresponding to the positioning groove 2101. A limiting block 9212 is provided on the rear side of the relay test platform 921 corresponding to the positioning groove 2101. The (optical module) product 9300 is placed on the relay test platform 921 and is located in the positioning groove 2101. The ring hole of its pull ring is sleeved on the limiting block 9212. The product clamping module 922 includes an upper and lower clamping mechanism and a left and right clamping mechanism. The upper and lower clamping mechanism includes a translation cylinder 9221, a pressing cylinder 9222, and a pressing block 9223. The pressing block 9223 is connected to the pressing cylinder 9222 and the pressing cylinder 9222 controls the pressing block 9223 to press down. The translation cylinder 9221 is connected to the pressing cylinder 9222 to move the pressing cylinder 9222 and the pressing block 9223 left and right towards the transfer test platform 921 to extend or move away from it (to the right to the top of the transfer test platform 921, and then the pressing cylinder 9222 controls the pressing block 9223 to press down; when moving away, it is reset upward and then translated to the left). The left and right pressing mechanism includes a side pressing cylinder 9224 and a side pressing block 9225. The side pressing cylinder 9224 drives the side pressing block 9225 to move left and right to press against one side of the (optical module) product 9300 (when the product is placed on the relay test platform 921, the other side of the product is restricted by the stop block 9211 pre-set on the relay test platform 921). When product 9300 is placed in the transfer position (i.e., transfer test platform 921), the ring hole of the pull ring is fitted onto the limit block 9212. The side pressure cylinder 9224 drives the side pressure block 9225 to move to the left to press against the right side of product 9300. At this time, the left side of product 9300 is positioned by the stop block 9211. Then, the translation cylinder 9221 controls the pressing cylinder 9222 and the pressing block 9223 to extend to the right, and the pressing cylinder 9222 controls the pressing block 9223 to press down on the top of product 9300. Therefore, the left, right, top and bottom surfaces of product 9300 are all positioned. Furthermore, a product lifting cylinder 9226 and a support platform 9227 are installed on the front side of the transfer testing platform 921. The product lifting cylinder 9226 drives the support platform 9227 to move up and down. When the product 9300 is placed in the transfer position, the product lifting cylinder 9226 drives the support platform 9227 to rise to support the bottom of the optical module's head (at this time, it is in a supported state), preventing the optical module's head from being unstable. Then, the upper and lower clamping mechanisms and the left and right clamping mechanisms complete the clamping and positioning of the optical module. After that, the product lifting cylinder 9226 drives the support platform 9227 to descend and reset (at this time, it is in an avoidance state). The dynamic support and positioning of the support platform 9227 ensures that the product is not suspended or deformed, which is beneficial to the accuracy of product size detection.

[0073] The plug gauge detection and positioning module 923 includes a lifting and positioning mechanism 9231, which includes a lifting cylinder 2311 and a lifting and positioning component 2312. The lifting cylinder 2311 drives the lifting and positioning component 2312 to move up and down. The plug gauge detection module 924 includes a plug gauge 9241, a plug gauge floating mechanism 9242, a first pressure sensor 9243, and a first test transfer mechanism 9244. The plug gauge 9241 is connected to the plug gauge floating mechanism 9242. The plug gauge floating mechanism 9242 can tilt in all directions to allow the plug gauge 9241 to float and improve the detection matching accuracy. The first pressure sensor 9243 is connected to the plug gauge floating mechanism 9242 in the front-to-back direction, so that the pressure value is continuously read by the first pressure sensor 9243 when the plug gauge 9241 moves back and forth during the test. The first test transfer mechanism 9244 is connected to the first transfer seat 2441. The first test transfer mechanism 9244 drives the first transfer seat 2441 to move back and forth. The plug gauge detection and positioning module 923, the plug gauge 9241, the plug gauge floating mechanism 9242, and the first pressure sensor 9243 are all set on the transfer seat 2411. After the product is placed in the transfer position (and positioned), the first test transfer mechanism 9244 extends the lifting and positioning mechanism 9231 toward the side where the product is located. The lifting and positioning component 2312 lowers to position the top of the product. After the product is positioned, the lifting and positioning component 2312 is raised, and the first test transfer mechanism 9244 retracts to avoid emptying. Then, the first test transfer mechanism 9244 extends toward the side where the product is located again, so that the plug gauge 9241 is nested in the head of the optical module in the front-to-back direction to detect the product. At the same time as the test, the first pressure sensor 9243 continuously reads the pressure value. When the pressure value exceeds the set upper limit and the first test transfer mechanism 9244 controls the first transfer seat 2441 to not reach the designated position, it is judged as NG. Conversely, if the pressure value does not exceed the set upper limit during the entire process of the first test transfer mechanism 9244 controlling the first transfer seat 2441 to move to the designated position, it is OK. Thus, the setting of the plug gauge floating mechanism 9242 facilitates multi-directional adaptive runout compensation for assembly tolerances. Combined with the pressure-displacement dual signal criterion, it effectively reduces the false detection rate and helps to ensure enhanced product accuracy and reliability.

[0074] The pull ring detection module 925 includes a pull ring test hook 9251, a lifting platform 9252, a second test transfer mechanism 9253, and a second pressure sensor 9254. The second test transfer mechanism 9253 is connected to a second transfer seat 2531 and drives the second transfer seat 2531 to move back and forth. The lifting platform 9252 is set on the second transfer seat 2531. The pull ring test hook 9251 is set on the lifting platform 9252 and the lifting platform 9252 controls the lifting and lowering of the pull ring test hook 9251. The first pressure sensor 9243 is connected to the pull ring test hook 9251 in the front-back direction. During testing, the product is placed in the transfer position. After the product is positioned, the second test transfer mechanism 9253 moves towards the side where the pull ring is located (forward). When the pull ring test hook 9251 is positioned below the ring hole of the pull ring, the lifting platform 9252 controls the pull ring test hook 9251 to rise, so that the pull ring test hook 9251 extends into the ring hole of the pull ring. Subsequently, the second test transfer mechanism 9253 moves backward. When the pull ring test hook 9251 contacts the pull ring, the pull ring tension value is read by the second pressure sensor 9254. By repeatedly pulling back and forth to reset (pulling the pull ring backward and resetting it forward), the values ​​of the pull ring force from small to large and from large to small are read to determine whether the product is OK or NG. Specifically, when pulling backward, the pull ring force is read from small to large. If the value exceeds the set upper limit and the second test transfer mechanism 9253 has not reached the designated position, it means that too much tension needs to be applied, and the product is judged as NG; otherwise, it is OK. OK; During forward displacement, the system checks whether the pull ring can reset. Specifically: During reset, the pull ring resets using its own spring force. The pull ring test hook 9251 only acts as a blockage (not actively pushed back). At this time, the mechanical performance of the second pressure sensor 9254 can reflect the reset state. Combining dynamic mechanical characteristics analysis, when the pull ring resets using its own spring force, the role of the pull ring test hook 9251 becomes a passive blockage. At this time: If the reset is normal, the pull ring impacts the pull ring test hook 9251 at high speed, generating an instantaneous peak impact force. Subsequently, the spring force continuously compresses the pull ring test hook 9251 (steady-state force change). If the reset fails, it means that the pull ring has not reset and popped out. The pull ring test hook 9251 needs to be actively pushed back. At this time, the pull ring test hook 9251 will push against the other end (front end) inside the ring hole of the pull ring, generating a thrust. This difference will be directly reflected in the pressure data of the second pressure sensor 9254 as the shape characteristics of the "force-time curve". The specific test performance and judgment method are as follows:

[0075] (1) Curve characteristics of successful normal repositioning

[0076] At the moment of impact in stage ①: the pull ring impacts the pull ring test hook 9251 at high speed, and the second pressure sensor 9254 displays the impact force peak for a very short time (e.g., milliseconds) (the peak value may be far greater than the steady-state force).

[0077] In stage ② steady-state compression: after the impact, the pull ring (spring force) continues to compress the pull ring test hook 9251, and the pressure stabilizes at the pre-pressure value of the reset spring. The second pressure sensor 9254 reads that the force of the pull ring decreases from large to small in a short time (more quickly).

[0078] (2) Curve characteristics of reset failure (pull ring test, pull hook 9251 actively pushes back)

[0079] Impact-free phase: Because the pull ring does not pop out, the pull ring test hook 9251 directly contacts the stationary pull ring when it moves in the reverse direction. Then, the pull ring test hook 9251 needs to push the pull ring to overcome friction / jamming force. During the process of pushing back (forward), the second pressure sensor 9254 reads that the force on the pull ring decreases from large to small over a longer period of time (more slowly).

[0080] like Figure 9 As shown, both the left height testing module 926 and the right height testing module 927 include a height measuring and transferring mechanism G1 and a contact sensor G2. The height measuring and transferring mechanism G1 drives the contact sensor G2 to move left and right. When the product is placed in the transfer position and the product positioning is completed, the left height testing module 926 and the right height testing module 927 move towards each other simultaneously. When the head probe of the contact sensor G2 contacts the product, the height value is obtained (to check whether the size of the latch is compliant when the pull ring is pulled out). Then, the left height testing module 926 and the right height testing module 927 move back in opposite directions and compare the obtained value with the reference value to determine whether the product is OK or NG.

[0081] Because the left height testing module 926 and the right height testing module 927 are located on the left and right sides of the transfer testing platform 921, the plug gauge detection and positioning module 923 and the plug gauge detection module 924 are located on the front side of the transfer testing platform 921, and the pull ring detection module 925 is located on the rear side of the transfer testing platform 921, its structure is compact and reasonable. This surrounding layout optimizes space utilization, makes the entire testing device structure more compact, reduces the equipment's footprint, facilitates the execution of testing steps, minimizes the displacement distance of each testing function, and reduces the device's operating energy. The time consumption is reduced, which helps improve testing efficiency. The product is placed on the transit testing platform 921. First, the head shape dimensions (left and right width L1, top and bottom thickness L2) of the optical module are tested using plug gauge 9241. If the plug gauge 9241 fails the test, subsequent tests are not required. Then, the pull ring pull force and whether it can be reset are tested. If the test fails, subsequent tests are not required. If the test is passed, the pull ring is fully pulled out by the pull ring test hook 9251 to test whether the pull ring notch (also known as the notch) size is compliant.

[0082] Furthermore, a method for detecting optical module pull rings is provided, which utilizes the aforementioned optical module pull ring detection equipment for detection. The detection method includes the following steps:

[0083] Step 1: Position the product on the transfer testing platform: The three-axis transporter places the product onto the transfer testing platform, which then initiates the positioning. Subsequently, the product clamping module extends to clamp the product for calibration and positioning.

[0084] Step 2: Inspect the product's external dimensions: First, the plug gauge inspection and positioning module extends towards the transfer test platform to position the product. Then, the plug gauge inspection module inspects the product's external dimensions towards the transfer test platform. If the product fails to meet the requirements, the three-axis transporter removes the product from the transfer test platform and treats it as an NG product. If the product meets the requirements, proceed to Step 3.

[0085] Step 3: Test the pull ring tension and whether it can be reset: The pull ring detection module is directed toward the transfer test platform for testing. Specifically, the pull ring detection module repeatedly pulls and resets the pull ring to test the pull ring tension and determine whether it can be reset. If it fails, the three-axis handling unit removes the product from the transfer test platform and treats it as an NG product. If it passes, continue to step 4.

[0086] Step 4: Check the size of the pull ring when the product pulls out: The left and right height test modules extend towards the transfer test platform to check whether the size of the pull ring is compliant. If it is not compliant, the three-axis transporter will remove the product from the transfer test platform and treat it as an NG product. If it is compliant, the three-axis transporter will remove the product from the transfer test platform and treat it as an OK product and let it flow out along the conveyor belt.

[0087] Finished product unloading and tray loading equipment 1000; it is connected to the output end of optical module pull ring detection equipment 900, and includes a tenth frame and a tenth conveyor belt 1001, a tenth material picking module 1002, a product loading platform 1003, a product lifting and picking module 1004, and a product cage 1005 set on the tenth frame; the tenth material picking module 1002 is connected between the tenth conveyor belt 100 and the product loading platform 1003, the product lifting and picking module 1004 drives the product loading platform 1003 to move up and down, and the product loading platform 1003 can move back and forth to extend into and exit the product cage 1005, so as to take out empty trays from the product cage 1005 and send full trays into the product cage 1005.

[0088] An assembly method based on the aforementioned flexible, fully automated optical module assembly production line includes the following steps:

[0089] Step 1: The lower shell in the material tray is loaded into the first conveyor belt of the production line through the lower shell loading equipment 100; the lower shell in the material tray refers to the lower shell assembly, which includes the lower shell body, the pull ring installed on the lower shell body and the unlocking elastic element. It is automatically assembled by another lower shell assembly equipment. The assembly technology is a mature existing technology. The assembled lower shell is placed on the material tray.

[0090] Step 2: The lower shell enters the second production line of the lower shell thermal pad pasting equipment 200 from the first production line. After the thermal pad pasting operation is completed in the lower shell thermal pad pasting equipment 200, it is sent back to the second production line.

[0091] Step 3: The lower shell with the thermal pad attached enters the fifth production line of the light engine loading equipment 500 from the second production line. Inside the light engine loading equipment 500, the light engine is guided and loaded into the lower shell with the thermal pad attached to form a semi-finished component. The semi-finished component is then sent back to the fifth production line. The light engine is made using existing mature equipment - the light engine production equipment - and is placed on a material tray.

[0092] Step 4: The semi-finished components enter the sixth production line of the cover pasting and loading equipment 600 via the third production line. The heat-conducting pads of the cover are pasted in the cover pasting and loading equipment 600. The cover with the pasted heat-conducting pads is then assembled with the semi-finished components to form a preliminary finished product. The first-stage finished product is then sent back to the sixth production line.

[0093] Step 5: The first-stage finished product enters the seventh production line of the screw-driving machine 700 via the sixth production line. The screw-driving machine 700 completes the screw fastening and positioning of the upper cover and lower shell, forming the second-stage finished product, and then sends the second-stage finished product back to the seventh production line.

[0094] Step 6: The second-stage finished product enters the eighth production line of the automatic labeling equipment 800 via the seventh production line. The automatic labeling operation is completed in the automatic labeling equipment 800 to form the third-stage finished product, and the third-stage finished product is sent back to the eighth production line.

[0095] Step 7: The finished products of the third stage enter the ninth production line of the optical module pull ring testing equipment 900 via the eighth production line. After the optical module pull ring testing equipment 900 completes the testing, the qualified products are sent back to the ninth production line for output.

[0096] Therefore, the lower shell and optical engine are manufactured separately using their respective mature equipment outside the production line. This eliminates the need for assembling internal parts of the lower shell on the production line, and also eliminates the need for optical engine manufacturing on the production line. This facilitates parallel production, essentially dividing the entire optical module into three main parts: the lower shell assembly, the optical engine, and the top cover. The lower shell assembly, optical engine, and top cover are manufactured in advance. Then, on the production line, the process of attaching thermal pads to the lower shell assembly, installing the optical engine into the lower shell assembly, attaching thermal pads to the top cover, assembling the top cover and lower shell, screwing, labeling, and checking the pull ring can be completed. Finished products can also be automatically unloaded and trayed as needed. This solution not only achieves automated production and assembly of the optical module, realizing highly flexible and intelligent assembly, but also improves assembly accuracy, efficiency, and yield. The production capacity can reach at least 250 pieces per hour, with an utilization rate of over 90%, while simultaneously improving the overall manufacturing efficiency of the optical module.

[0097] The equipment in the production line is arranged in series, with each piece of equipment operating independently, making it easy to assemble into a production line. The first to tenth conveyor belts are connected sequentially.

[0098] Alternatively, in other embodiments, the light engine mounting device 500 can be connected to the output end of the lower shell heat-conducting pad pasting device 200, which means that the lower shell pad feeding device 300 and the lower shell pad loading device 400 are eliminated.

[0099] The above description is merely a preferred embodiment of the present utility model and does not constitute any limitation on the technical scope of the present utility model. Therefore, any minor modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model shall still fall within the scope of the technical solution of the present utility model.

Claims

1. A flexible, fully automated optical module assembly production line, characterized in that, include: The lower casing is installed into the equipment; It includes a first frame and a first conveyor belt and a first material handling module disposed on the first frame. The first material handling module automatically places the lower shell on the material tray onto the first conveyor belt. Equipment for attaching thermally conductive pads to the lower casing; It includes a second frame and a second conveyor belt, a second material handling module, a first working platform, and a first heat-conducting pad material handling and pasting module mounted on the second frame; The second material handling module is connected between the second conveyor belt and the first working platform. The first heat-conducting pad material handling and pasting module is used to pick up the heat-conducting pad and paste the heat-conducting pad onto the lower shell of the first working platform. Light engine installed in device; It includes a fifth frame and a fifth conveyor line set on the fifth frame, a light engine feeding mechanism, a work platform that can move left and right, a lower shell transfer robot, and a light engine transfer robot; the lower shell transfer robot is connected between the fifth conveyor line and the work platform that can move left and right, and the light engine transfer robot is connected between the light engine feeding mechanism and the work platform that can move left and right. The top cover is then pasted and installed into the equipment. It includes a sixth frame and a sixth conveyor line set on the sixth frame, a transfer platform that can move left and right, a sixth material picking module, a top cover feeding module, a second heat-conducting pad picking and pasting module, a flipping module, an assembly tooling platform, and an assembly robot. Screw-driving equipment; It includes a seventh frame and a seventh conveyor belt, a seventh material handling module, and a screw-driving module mounted on the seventh frame; The seventh material handling module connects the seventh conveyor belt and the screw-driving module. Optical module pull ring testing equipment; it is used to test pull rings.

2. The flexible full-automatic optical module assembly production line according to claim 1, characterized in that, The optical module pull ring testing equipment includes a ninth frame and a ninth conveyor belt, an optical module transport three-axis, and a pull ring testing device mounted on the ninth frame; the optical module transport three-axis is connected between the ninth conveyor belt and the pull ring testing device; the input end of the ninth conveyor belt is connected to the output end of the eighth conveyor belt.

3. The flexible full-automatic optical module assembly production line according to claim 1, wherein, Also includes: Finished product unloading and traying equipment; It is connected to the output end of the optical module pull ring testing equipment. It includes a tenth frame and a tenth conveyor belt, a tenth material handling module, a product loading platform, a product lifting and material handling module, and a product cage set on the tenth frame. The tenth material handling module is connected between the tenth conveyor belt and the product loading platform. The product lifting and material handling module drives the product loading platform to move up and down. The product loading platform can move back and forth to extend into and out of the product cage.

4. The flexible full-automatic optical module assembly production line according to claim 1, wherein, Also includes: Automatic labeling equipment; It includes an eighth frame and an eighth conveyor belt, an eighth material handling module, a labeling workbench, and a labeling module, all mounted on the eighth frame.

5. The flexible full-automatic optical module assembly production line according to claim 1, wherein, The light engine installation device is connected to the output end of the device with the heat-conducting pad attached to the lower shell. or: Between the light engine installation equipment and the lower shell heat-conducting pad pasting equipment, there are also lower shell patch feeding equipment and lower shell patch loading equipment.

6. The flexible fully-automatic optical module assembly production line according to claim 1, wherein, The lower shell loading device also includes a first material cage, a first lifting and picking module, a pushing and correcting module, and a secondary correction platform, all mounted on the first frame. The first material cage includes multiple sets of shelves with vertical spacing. Each set of shelves includes two shelves with horizontal spacing. The two shelves are used to position a material tray. The space between the two shelves is reserved for the first lifting and picking module to enter and exit the first material cage to pick up and empty the material tray. The first lifting and picking module includes a first picking plate that is driven to move back and forth by a linear module and a first lifting drive unit that drives the first picking plate to move up and down. The pushing and correcting module includes a pushing cylinder and a pushing component that is driven to move left and right by the pushing cylinder. It also includes a limiting component located on the opposite side of the pushing component, which corresponds to the first picking plate after it is in position. The limiting component pushes the full material tray on the first picking plate toward the limiting component, thereby correcting the position of the full material tray on the first picking plate.

7. The flexible fully-automatic optical module assembly production line according to claim 1, wherein, The device for attaching thermally conductive pads to the lower shell also includes a first thermally conductive pad calibration and detection module mounted on a second frame. The first thermally conductive pad calibration and detection module includes a horizontal transparent carrier plate and a thermally conductive pad detection CCD mounted below the horizontal transparent carrier plate. The first thermally conductive pad picking and pasting module uses an XYZ three-axis drive structure to drive a second picking robot, whose drive structure is the same as that of the first picking module. The second picking robot of the first thermally conductive pad picking and pasting module can be equipped with one or more picking nozzles for adsorbing one or more thermally conductive pads. At the same time, a second CCD guide module is mounted on the second picking robot. The rotating mechanism mounted on each picking nozzle drives the picking nozzle to rotate, thereby rotating the thermally conductive pad to correct its rotation angle.

8. The flexible fully-automatic optical module assembly production line according to claim 1, wherein, A light engine transfer robot includes a YZ two-axis motion mechanism, a floating pressing mechanism, a first picking mechanism, a second picking mechanism, an XYθ axis adjustment mechanism, and a first CCD module. The XYθ axis adjustment mechanism is configured for the first picking mechanism and / or the second picking mechanism to adjust the position and orientation of the first picking mechanism relative to the second picking mechanism. The floating pressing mechanism jointly controls the first and second picking mechanisms to press the light engine downward. The YZ two-axis motion mechanism jointly controls the positions of the first picking mechanism, the second picking mechanism, and the first CCD module, so that the second robot is configured to transfer between the light engine feeding mechanism and the second workstation. The first CCD module is configured to detect the pose of the upper tray and the light engine of the light engine feeding mechanism, as well as the pose of the lower shell of the work platform. The light engine loading device also includes a second CCD module, which is located between the light engine feeding mechanism and the working platform, and is set on the movement path of the second robot arm. It is configured to take pictures and sample pose information facing upwards.

9. The flexible fully-automatic optical module assembly production line according to claim 2, wherein, The pull ring testing device includes a transfer testing platform, a product clamping module, a plug gauge testing and positioning module, a plug gauge testing module, a pull ring testing module, a left height testing module, and a right height testing module; The three-axis transport system connects to the conveyor belt and the transfer test platform. The product clamping module is used to clamp products on the transit test platform; The plug gauge inspection and positioning module is used to locate products on the transit testing platform; The plug gauge inspection module is used to perform shape inspection on products on the transit testing platform; The pull ring testing module is used to test the pull force and whether the pull rings of products on the transit testing platform can be reset. The left height test module and the right height test module are used to test the dimensions of the latches on both sides of the pull ring of the product on the transfer test platform.

10. The flexible full-automatic optical module assembly production line according to claim 1, wherein, The sixth material handling module is connected between the left section of the sixth conveyor line and the upper cover feeding module, and also between the left section of the sixth conveyor line and the transfer platform that can move left and right; the second thermal pad material handling and pasting module is connected between the second thermal pad feeding module and the transfer platform that can move left and right; the assembly robot is connected between the flipping module and the assembly tooling platform, and between the assembly tooling platform and the right section of the sixth conveyor line.

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