Automatic dispensing and assembling equipment for transformer

Abstract

The utility model discloses a transformer automatic point gum assembly equipment, include: case, be equipped with workstation on the case, be equipped with material positioning fixture on the upper inlet material assembly line, point gum mechanism is used for to the surface point gum of magnetic core, visual detection mechanism is used for detecting the glue amount, material belt material releasing mechanism is used for releasing material belt, terminal cutting mechanism is used for cutting and forms the terminal, terminal assembly mechanism is used for assembling the terminal, robot is used for placing the terminal to the magnetic core, upper cover reflow lifting mechanism is used for conveying the upper cover of fixture, upper cover transplanting mechanism is used for clamping the upper cover of fixture and placing to material positioning fixture, PLC controller is used for controlling each mechanism cooperation work. The utility model discloses through automatic feeding, point gum, visual detection, terminal processing, assembly and upper cover mechanism, realizes the automation operation of transformer point gum assembly process, reduces manual intervention, improves work efficiency, reduces the manual cost, improves the consistency of product quality simultaneously.

Description

Technical Field

[0001] This utility model belongs to the technical field of transformer production equipment, specifically an automatic dispensing and assembly equipment for transformers. Background Technology

[0002] As a key piece of equipment in the power system, the manufacturing quality of transformers directly affects their performance, stability, and service life. In the transformer manufacturing process, gluing and assembly are crucial steps, as the quality of these processes directly impacts the transformer's insulation performance, mechanical strength, and electrical characteristics.

[0003] Currently, transformer manufacturers generally employ semi-automated production methods in the dispensing and assembly processes. Specifically, factories typically use semi-automatic dispensing machines, which require operators to manually control the dispensing position and amount, making it difficult to guarantee precision and consistency. After dispensing, transformer assembly relies on separate core assembly equipment, which can only perform basic positioning and pressing functions and cannot achieve automatic integration with the dispensing process. More importantly, the final fixture cover installation stage is entirely manual, requiring workers to manually and precisely place the cover onto the assembled transformer. This is not only time-consuming and labor-intensive but also prone to positioning deviations due to human factors.

[0004] This decentralized, semi-automated production model has many obvious drawbacks: First, it requires multiple people to operate different equipment simultaneously, resulting in high human resource consumption and low production efficiency; second, the connection between each process relies on manual transfer, increasing the production cycle and reducing the production pace; third, manual operation is highly subjective, making it difficult to ensure consistent operation standards, especially in areas such as glue dispensing control and cap positioning, which can easily cause fluctuations in product quality; fourth, prolonged repetitive operations can easily lead to worker fatigue, further increasing the rate of operational errors; and fifth, the lack of an effective quality monitoring mechanism makes it difficult to detect and intercept defective products in the first instance.

[0005] Therefore, developing an automated dispensing and assembly equipment for transformers that integrates multiple processes such as dispensing, visual inspection, assembly, and capping has significant practical value and market potential. This equipment can not only significantly improve production efficiency and reduce labor costs, but also comprehensively enhance the stability and consistency of product quality through precise control and automatic monitoring, meeting the ever-increasing quality and efficiency requirements of the modern transformer manufacturing industry. Utility Model Content

[0006] The purpose of this utility model is to provide an automatic dispensing and assembly equipment for transformers, which addresses the shortcomings of existing technologies by automating the feeding, dispensing, visual inspection, terminal processing, assembly, and cover mechanism. This automates the dispensing and assembly process of transformers, reduces manual intervention, improves work efficiency, lowers labor costs, and enhances the consistency of product quality.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] An automatic dispensing and assembly device for transformers, comprising:

[0009] A chassis, on which a workbench is mounted;

[0010] A feeding assembly line is installed on the workbench, and a material positioning fixture is provided on the feeding assembly line for placing the magnetic core;

[0011] A dispensing mechanism, installed above the worktable, is used to dispense adhesive onto the surface of the magnetic core;

[0012] A visual inspection mechanism is installed at the rear end of the dispensing mechanism to detect the amount of adhesive on the surface of the magnetic core;

[0013] A material feeding mechanism is installed on the worktable and is used to release the material belt;

[0014] A terminal cutting mechanism is installed downstream of the strip feeding mechanism and is used to cut the strip to form terminals;

[0015] A terminal assembly mechanism is installed downstream of the terminal cutting mechanism and is used to assemble the cut terminals;

[0016] A robot, mounted on the workbench, is used to place the assembled terminals onto the magnetic core that has been glued.

[0017] The top cover return lifting mechanism is installed on the workbench and is used to transport the fixture top cover;

[0018] The top cover transplanting mechanism is installed above the top cover return lifting mechanism and is used to clamp the top cover of the fixture and place it onto the material positioning fixture.

[0019] The PLC controller is used to control the actions of the feeding line, the dispensing mechanism, the vision inspection mechanism, the material feeding mechanism, the terminal cutting mechanism, the terminal assembly mechanism, the robot, the top cover return lifting mechanism, and the top cover transfer mechanism.

[0020] Preferably, the feeding assembly line includes a conveyor belt, a transmission motor that drives the conveyor belt, and guide rails installed on both sides of the conveyor belt. The transmission motor is electrically connected to the PLC controller, and the guide rails are fixedly installed on the workbench to limit the lateral movement of the material positioning fixture.

[0021] Preferably, the dispensing mechanism includes a dispensing platform, a dispensing device mounted on the dispensing platform, and a multi-axis motion system for driving the dispensing device to move. The dispensing platform is fixedly mounted on the worktable. The multi-axis motion system includes an X-axis drive assembly, a Y-axis drive assembly, and a Z-axis drive assembly. The X-axis drive assembly is mounted on the dispensing platform, the Y-axis drive assembly is mounted on the slider of the X-axis drive assembly, the Z-axis drive assembly is mounted on the slider of the Y-axis drive assembly, and the dispensing device is mounted on the slider of the Z-axis drive assembly. The X-axis drive assembly, the Y-axis drive assembly, and the Z-axis drive assembly are all electrically connected to the PLC controller.

[0022] Preferably, the dispensing equipment includes a dispensing valve, a dispensing valve driver, a glue storage tank, and a dispensing control system electrically connected to the PLC controller. The dispensing valve driver is mounted on the slider of the Z-axis drive assembly, the dispensing valve is mounted on the dispensing valve driver, the glue storage tank is connected to the dispensing valve through a glue tube, and the dispensing control system controls the opening and closing of the dispensing valve and the operation of the dispensing valve driver.

[0023] Preferably, the vision inspection mechanism includes an industrial camera, a light source system, and an image processing unit electrically connected to the PLC controller. The industrial camera and the light source system are installed above the feeding assembly line. The industrial camera is electrically connected to the image processing unit, and the image processing unit transmits the processing results to the PLC controller.

[0024] Preferably, the material feeding mechanism includes a material reel, a material reel mounting base, a tension control device, and a material guiding system. The material reel mounting base is fixedly installed on the worktable, and the material reel is rotatably installed on the material reel mounting base. The tension control device is installed on the material reel to control the tension of the material strip. The material guiding system includes multiple guide wheels, which are installed on the worktable to guide the material strip into the terminal cutting mechanism.

[0025] Preferably, the terminal cutting mechanism includes a cutting mold, a pressure cylinder that drives the cutting mold to cut, and a strip feeding device. The cutting mold is fixedly installed on the worktable, the cylinder body of the pressure cylinder is fixedly installed on the worktable, the piston rod of the pressure cylinder is connected to the upper mold of the cutting mold, and the strip feeding device includes a stepper motor and a feed wheel. The stepper motor is fixedly installed on the worktable, and the feed wheel is installed on the output shaft of the stepper motor. Both the stepper motor and the pressure cylinder are electrically connected to the PLC controller.

[0026] Preferably, the terminal assembly mechanism includes a terminal positioning device, a terminal bending mechanism, and a terminal feeding device. The terminal positioning device is fixedly installed on the workbench. The terminal bending mechanism includes multiple bending cylinders, the cylinder bodies of which are fixedly installed on the workbench, and the piston rods of which are connected to bending tools. The terminal feeding device includes a feeding cylinder and a feeding clamp. The cylinder bodies of the feeding cylinders are fixedly installed on the workbench, and the piston rods of which are connected to the feeding clamps. Both the bending cylinders and the feeding cylinders are pneumatically connected to the PLC controller.

[0027] Preferably, the robot is a six-axis articulated robot, including a robot body, an end effector installed at the end of the robot body, and a control system electrically connected to the PLC controller. The robot body is fixedly installed on the workbench, the end effector is a gripper adapted to the shape of a terminal, and the control system is used to control the movement of the robot body and the action of the end effector.

[0028] Preferably, the upper cover return lifting mechanism includes an upper cover conveyor belt, a conveyor motor that drives the upper cover conveyor belt, and an upper cover platform that can be lifted and lowered. The upper cover platform is installed on the workbench via a lifting cylinder. The upper cover conveyor belt is installed on the upper cover platform. The conveyor motor is fixedly installed on the upper cover platform and is connected to the upper cover conveyor belt for transmission. Both the lifting cylinder and the conveyor motor are electrically connected to the PLC controller.

[0029] Preferably, the top cover transplanting mechanism includes a transplanting bracket, an XY motion system mounted on the transplanting bracket, and a gripper cylinder mounted on the XY motion system. The transplanting bracket is fixedly mounted on the worktable. The XY motion system includes an X-axis linear module and a Y-axis linear module. The X-axis linear module is fixedly mounted on the transplanting bracket, the Y-axis linear module is mounted on the slider of the X-axis linear module, and the gripper cylinder is mounted on the slider of the Y-axis linear module. The X-axis linear module, the Y-axis linear module, and the gripper cylinder are all electrically or pneumatically connected to the PLC controller.

[0030] Preferably, the outer surface of the chassis is provided with a touch screen that is electrically connected to the PLC controller. The touch screen is used to display the operating status of the equipment and provide a human-machine interface. The equipment can be started, stopped and its parameters set through the touch screen.

[0031] Preferably, the material positioning fixture is provided with a positioning pin and a positioning groove. The positioning pin is used to ensure the accurate positioning of the magnetic core, and the positioning groove is used to cooperate with the upper cover of the fixture placed by the upper cover transplanting mechanism for positioning and fixing.

[0032] Preferably, the PLC controller has a built-in memory that stores dispensing parameters, visual inspection parameters, and the motion sequence of each mechanism. The PLC controller coordinates the collaborative work of each mechanism by executing the program.

[0033] Preferably, the bottom of the chassis is equipped with casters, the casters are equipped with locking devices, the casters are connected to the bottom of the chassis via brackets, and the locking devices are mounted on the brackets to fix the position of the equipment after it is positioned.

[0034] Compared with the prior art, the present invention has at least the following beneficial effects:

[0035] 1) This utility model's automatic dispensing and assembly equipment for transformers integrates dispensing, visual inspection, terminal cutting, terminal assembly, robotic handling, and cover installation into one system, achieving seamless connection between various processes in transformer assembly. The system uses a PLC controller to precisely control the timing of each mechanism, forming a complete automated production line. From core feeding to assembly and cover installation, the entire process requires no manual intervention, significantly reducing labor input, lowering labor costs, and simultaneously improving production efficiency.

[0036] 2) The dispensing mechanism of this invention employs a high-precision multi-axis motion system and precision dispensing control technology, enabling more accurate control of dispensing position and amount compared to traditional semi-braking dispensing machines. Simultaneously, the equipment is equipped with a dedicated vision inspection mechanism that monitors dispensing quality in real time. If any abnormal dispensing amount is detected, the system immediately alarms and stops the machine to prevent defective products from entering the next process. This design significantly improves the consistency of dispensing quality, effectively reducing the defect rate compared to manual operation and ensuring product quality stability.

[0037] 3) The cover transfer mechanism of this utility model adopts a precision XY motion system and pneumatic grippers, which can accurately place the fixture cover onto the material positioning fixture, ensuring the accuracy and consistency of the packaging. Compared with the traditional manual cover-loading method, this automated solution not only improves efficiency but also avoids positioning deviations that may be caused by manual operation, making the assembly quality of the products more consistent. At the same time, the design of the cover return lifting mechanism realizes the automatic transport of the cover, forming a closed cover circulation system, which greatly reduces manual intervention and improves the continuity and stability of production. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the automatic dispensing and assembly equipment for transformers according to this utility model.

[0039] Figure 2 for Figure 1 A magnified view of a portion of point A in the middle.

[0040] In the diagram: 1. Chassis; 2. Workbench; 3. Feeding line; 4. Dispensing mechanism; 5. Vision inspection mechanism; 6. Material strip feeding mechanism; 7. Terminal cutting mechanism; 8. Terminal assembly mechanism; 9. Robot; 10. Top cover return lifting mechanism; 11. Top cover transfer mechanism. Detailed Implementation

[0041] To make the technical solution and advantages of this utility model clearer, the present utility model and its beneficial effects will be described in further detail below with reference to specific embodiments and accompanying drawings. However, the embodiments of this utility model are not limited thereto.

[0042] In the description of this utility model, it should be understood that the terms "center," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, features defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0043] like Figure 1As shown, the present invention provides an automatic dispensing and assembly equipment for transformers, including a chassis 1 and a PLC controller. A workbench 2 is installed on the chassis 1. The workbench 2 is equipped with a feeding line 3, a dispensing mechanism 4, a vision inspection mechanism 5, a material strip feeding mechanism 6, a terminal cutting mechanism 7, a terminal assembly mechanism 8, a robot 9, a top cover return lifting mechanism 10, and a top cover transfer mechanism 11.

[0044] The chassis 1, serving as the supporting frame for the entire equipment, is constructed from welded steel, with a surface treated for corrosion resistance and powder coating, providing excellent strength and durability. Chassis 1 is equipped with casters at its bottom, each connected to the chassis via a bracket. The casters are fitted with locking devices mounted on the brackets, which lock the equipment in place after positioning, ensuring stable operation. Inside chassis 1 is an electrical control cabinet housing the PLC controller, frequency converter, relays, and other electrical components, along with a cooling fan to maintain the normal operating temperature of these components. A touchscreen is also mounted on the outer surface of chassis 1, electrically connected to the PLC controller. It supports multi-touch operation, featuring an intuitive and user-friendly interface, allowing operators to easily set process parameters, monitor equipment status, and view alarm information.

[0045] The worktable 2 is mounted on the upper part of the chassis 1 and is made of thick steel plate with a precision-machined surface to ensure flatness and rigidity. The worktable 2 has multiple T-slots to facilitate the installation and precise positioning of various functional components. As the basic support platform for all functional mechanisms, the flatness and rigidity of the worktable 2 directly affect the working accuracy of each mechanism.

[0046] The feeding line 3 is installed on the left side of the workbench 2 and is used to convey material positioning fixtures with magnetic cores. The feeding line 3 includes a conveyor belt, a motor that drives the conveyor belt, and guide rails installed on both sides of the conveyor belt. The conveyor belt is made of PVC material, which has good wear resistance and antistatic properties. The motor is a variable frequency speed control motor, electrically connected to the PLC controller, and the conveying speed can be adjusted according to production needs. The guide rails are fixedly installed on the workbench 2 to limit the lateral movement of the material positioning fixture, ensuring that the material positioning fixture moves accurately in a straight line and preventing deviation. The material positioning fixture is equipped with positioning pins and positioning slots. The positioning pins are used to ensure the accurate positioning of the magnetic core and ensure the processing accuracy of subsequent processes. The positioning slots are used to cooperate with the fixture cover placed by the cover transfer mechanism 11 for positioning and fixation.

[0047] The dispensing mechanism 4 is mounted above the worktable 2 for precise dispensing of adhesive onto the surface of the magnetic core. The dispensing mechanism 4 includes a dispensing platform, a dispensing device mounted on the dispensing platform, and a multi-axis motion system for driving the movement of the dispensing device. The dispensing platform is fixedly mounted on the worktable 2 and uses an aluminum alloy profile structure, providing high rigidity and stability. The multi-axis motion system includes an X-axis drive assembly, a Y-axis drive assembly, and a Z-axis drive assembly. The X-axis drive assembly is mounted on the dispensing platform, the Y-axis drive assembly is mounted on the slider of the X-axis drive assembly, and the Z-axis drive assembly is mounted on the slider of the Y-axis drive assembly. All three axes are electrically connected to a PLC controller. This three-axis orthogonal structure ensures precise positioning of the dispensing head in three-dimensional space.

[0048] The dispensing equipment is mounted on the slider of the Z-axis drive assembly and includes a dispensing valve, a valve actuator, an adhesive reservoir, and a dispensing control system electrically connected to a PLC controller. The valve actuator is mounted on the slider of the Z-axis drive assembly, and the dispensing valve is mounted on the valve actuator. The adhesive reservoir is connected to the dispensing valve via a glue tube. The dispensing control system controls the opening and closing of the dispensing valve and the movement of the valve actuator. The dispensing valve employs a precision pneumatic design, enabling accurate control of minute adhesive volumes. The dispensing control system allows setting dispensing parameters, including dot position, adhesive volume, and dispensing speed, ensuring consistency in each dispensing operation.

[0049] A vision inspection unit 5 is installed downstream of the dispensing unit 4 to detect whether the amount of adhesive on the surface of the magnetic core meets the requirements. The vision inspection unit 5 includes an industrial camera, a light source system, and an image processing unit electrically connected to a PLC controller. The industrial camera and light source system are installed above the feeding line 3. The industrial camera is electrically connected to the image processing unit, which transmits the processing results to the PLC controller. The industrial camera uses a high-resolution CMOS sensor with a precision lens to clearly capture images of the adhesive dots. The light source system uses an LED ring light source to provide uniform illumination and reduce shadows and reflection interference. The image processing unit uses professional machine vision algorithms to analyze the area, shape, and position of the adhesive dots in real time to determine whether they meet production standards. Once a non-conforming product is detected, the system immediately alarms and marks it as a defective product.

[0050] The tape feeding mechanism 6 is mounted on the worktable 2 and is used to release tape containing terminal material. The tape feeding mechanism 6 includes a tape reel, a tape reel mounting base, a tension control device, and a tape guiding system. The tape reel mounting base is fixedly mounted on the worktable 2, and the tape reel is rotatably mounted on the tape reel mounting base. The tension control device is mounted on the tape reel to control the tension of the tape. The tape reel adopts an adjustable design to accommodate tape rolls of different specifications. The tension control device ensures that the tape maintains appropriate tension during release, preventing slack or excessive tightness. The tape guiding system includes multiple guide wheels, which are mounted on the worktable 2 to guide the tape smoothly into the terminal cutting mechanism 7, avoiding twisting and deviation.

[0051] The terminal cutting mechanism 7 is installed downstream of the strip feeding mechanism 6 and is used to precisely cut the strip to form individual terminals. The terminal cutting mechanism 7 includes a cutting die, a pressure cylinder that drives the cutting die, and a strip feeding device. The cutting die is fixedly mounted on the worktable 2, and the cylinder body of the pressure cylinder is fixedly mounted on the worktable 2. The piston rod of the pressure cylinder is connected to the upper die of the cutting die. The cutting die is made of high-hardness mold steel, precision machined and heat-treated, and has high wear resistance and a long service life. The pressure cylinder provides stable cutting force, ensuring the accuracy and consistency of the cutting. The strip feeding device includes a stepper motor and a feed wheel. The stepper motor is fixedly mounted on the worktable 2, and the feed wheel is mounted on the output shaft of the stepper motor. Both the stepper motor and the pressure cylinder are electrically connected to a PLC controller. The stepper motor drives the feed wheel to rotate, which can precisely control the feed length of the strip, ensuring that the size of each terminal is consistent.

[0052] The terminal assembly mechanism 8 is installed downstream of the terminal cutting mechanism 7 and is used to assemble the cut terminals. The terminal assembly mechanism 8 includes a terminal positioning device, a terminal bending mechanism, and a terminal feeding device. The terminal positioning device is fixedly installed on the worktable 2. The terminal bending mechanism includes multiple bending cylinders, the cylinder bodies of which are fixedly installed on the worktable 2, and the piston rods of the bending cylinders are connected to bending tools. The terminal positioning device uses precision positioning pins and pressure plates to ensure that the terminals maintain the correct position during assembly. The terminal bending mechanism, composed of multiple bending cylinders, can precisely bend the terminals according to preset angles and positions. The terminal feeding device includes a feeding cylinder and a feeding clamp. The cylinder body of the feeding cylinder is fixedly installed on the worktable 2, and the piston rod of the feeding cylinder is connected to the feeding clamp. Both the bending cylinder and the feeding cylinder are pneumatically connected to the PLC controller. The terminal feeding device transports the assembled terminals to a predetermined position, awaiting gripping by the robot 9.

[0053] Robot 9 is mounted on workbench 2 and is used to place assembled terminals onto magnetic cores that have been glued. Robot 9 is a six-axis articulated robot, comprising a robot body, an end effector mounted at the end of the robot body, and a control system electrically connected to a PLC controller. The robot body is fixedly mounted on workbench 2. The end effector is a gripper adapted to the shape of the terminal. The control system controls the movement of the robot body and the actions of the end effector. The robot body features a lightweight design with high precision and high repeatability. The end effector is a specialized gripper adapted to the shape of the terminal, pneumatically driven, ensuring stable and reliable gripping. The control system connects to the PLC controller, receives control commands, and executes precise gripping and placement actions. The motion trajectory of Robot 9 is optimized, resulting in smooth and efficient movements, significantly improving the efficiency and accuracy of terminal installation.

[0054] The top cover return lifting mechanism 10 is installed on the workbench 2 for transporting the fixture top cover. The top cover return lifting mechanism 10 includes a top cover conveyor belt, a conveyor motor driving the top cover conveyor belt, and a lifting top cover platform. The top cover platform is mounted on the workbench 2 via a lifting cylinder. The top cover conveyor belt is mounted on the top cover platform, and the conveyor motor is fixedly mounted on the top cover platform and connected to the top cover conveyor belt for transmission. Both the lifting cylinder and the conveyor motor are electrically connected to a PLC controller. The top cover conveyor belt is made of polyurethane with a special surface treatment to increase friction and prevent the top cover from sliding. The conveyor motor is a variable frequency speed control motor, which can precisely control the conveying speed. The top cover platform is driven by the lifting cylinder and can be lifted vertically, facilitating the loading and unloading of the top cover.

[0055] The top cover transfer mechanism 11 is installed above the top cover return lifting mechanism 10, and is used to grip the fixture top cover and accurately place it onto the material positioning fixture. The top cover transfer mechanism 11 includes a transfer bracket, an XY motion system mounted on the transfer bracket, and a gripper cylinder mounted on the XY motion system. The transfer bracket is fixedly installed on the worktable 2. The XY motion system includes an X-axis linear module and a Y-axis linear module. The X-axis linear module is fixedly installed on the transfer bracket, the Y-axis linear module is mounted on the slider of the X-axis linear module, and the gripper cylinder is mounted on the slider of the Y-axis linear module. The X-axis linear module, Y-axis linear module, and gripper cylinder are all electrically or pneumatically connected to the PLC controller. The transfer bracket uses an aluminum alloy structure, which is lightweight and has good rigidity. The XY motion system uses linear modules and servo motors for drive, resulting in high positioning accuracy and smooth movement. The gripper cylinder is designed as a special clamp adapted to the shape of the fixture top cover, enabling it to firmly grip and accurately place the top cover.

[0056] The PLC controller is the core of the entire equipment control system, employing a Siemens S7-1500 series PLC, which boasts high reliability and powerful processing capabilities. The PLC controller has a built-in memory storing dispensing parameters, vision inspection parameters, and the program for the motion sequence of each mechanism. The PLC controller coordinates the collaborative work of each mechanism by executing the program. Through programming, the PLC controller achieves precise control and coordination of the feeding line 3, dispensing mechanism 4, vision inspection mechanism 5, material tape unloading mechanism 6, terminal cutting mechanism 7, terminal assembly mechanism 8, robot 9, top cover return lifting mechanism 10, and top cover transfer mechanism 11, ensuring that each mechanism operates according to the predetermined sequence and parameters. The PLC controller is also responsible for receiving various sensor signals, including position sensors, pressure sensors, and vision system feedback, and making corresponding control adjustments based on these signals to ensure the safe and stable operation of the equipment. Simultaneously, the PLC controller also has data acquisition and analysis functions, recording production data to provide a basis for production management and process optimization.

[0057] The working process of this utility model is as follows:

[0058] 1. Initialization and Equipment Preparation: The operator clicks the reset button on the touchscreen, and the equipment enters the reset state; all mechanisms of the equipment return to their initial positions, and the touchscreen displays the reset completion information; the operator clicks the external start button, and the equipment enters the running state.

[0059] 2. Core Feeding: The operator places the material positioning fixture carrying the magnetic core into the feeding line 3; the feeding line 3 starts, and the conveyor motor drives the conveyor belt to transport the material positioning fixture to the dispensing station. The positioning pins on the material positioning fixture ensure that the magnetic core maintains a stable position during the conveying process.

[0060] 3. Core Dispensing: After the material positioning fixture reaches below the dispensing mechanism 4, the position sensor senses the positioning signal and transmits it to the PLC controller; the PLC controller controls the feeding line 3 to stop running; the multi-axis motion system of the dispensing mechanism 4 starts working, and the X-axis drive component, Y-axis drive component and Z-axis drive component work together to move the dispensing equipment to the preset dispensing position; the dispensing control system controls the dispensing valve to open, and the dispensing valve driver drives the dispensing valve to accurately dispense glue to the surface of the magnetic core; after the dispensing is completed, the multi-axis motion system drives the dispensing equipment back to the initial position.

[0061] 4. Visual Inspection of Adhesive Dosage: The PLC controller restarts the feeding line 3, transporting the dispensed magnetic core to the visual inspection mechanism 5. The light source system provides uniform illumination, and the industrial camera captures images of the adhesive dots. The image processing unit analyzes the area, shape, and position of the adhesive dots to determine if they meet production standards. The image processing unit transmits the processing results to the PLC controller. If the inspection is qualified, the next process continues. If the inspection is unqualified, the system alarms and marks the defective product, and the material positioning fixture is guided to the defective product collection area.

[0062] 5. Terminal Processing: Simultaneously, the PLC controller controls the strip feeding mechanism 6 to release the strip; the strip maintains appropriate tension under the action of the tension control device and is guided into the terminal cutting mechanism 7 through the strip guiding system; the stepper motor of the terminal cutting mechanism 7 drives the feed wheel to rotate, sending the strip into the cutting position; the pressure cylinder drives the upper die of the cutting mold to descend, cutting the strip to form independent terminals; the cut terminals enter the terminal assembly mechanism 8; the terminal positioning device of the terminal assembly mechanism 8 fixes the terminals in the predetermined position; the piston rod of the bending cylinder drives the bending tool to bend the terminals to form the required shape; the feeding cylinder drives the feeding clamp to transport the assembled terminals to the predetermined position.

[0063] 6. Terminal Installation: After receiving the instruction from the PLC controller, the robot 9 moves to the predetermined position of the terminal assembly mechanism 8; the end effector picks up the assembled terminal; the robot moves to the magnetic core after the glue dispensing test is completed; the end effector accurately places the terminal at the glue dot position on the magnetic core; the end effector releases the terminal, and the robot returns to the initial position, waiting for the next action.

[0064] 7. Top Cover Installation: Simultaneously, the top cover return lifting mechanism 10 operates, and the top cover platform rises under the drive of the lifting cylinder. The conveyor motor drives the top cover conveyor belt to transport the fixture top cover to the predetermined position. The XY motion system of the top cover transfer mechanism 11 starts working, and the X-axis linear module and Y-axis linear module drive the gripper cylinder to move above the top cover. The gripper cylinder descends and grabs the fixture top cover. The XY motion system moves the fixture top cover above the assembled transformer material. The gripper cylinder accurately places the fixture top cover into the positioning groove on the material positioning fixture, positioning and fixing the assembled transformer material. This completes a full production cycle.

[0065] 8. Output Completion: The PLC controller restarts the feeding line 3, transporting the assembled and top-covered transformer materials to the discharge end of the equipment; the operator removes the finished product and inserts new magnetic core material to start a new production cycle.

[0066] 9. Production Monitoring: Throughout the production process, the PLC controller continuously monitors the status of each mechanism and sensor signals; the touch screen displays real-time information such as equipment operating status, production count, and defective product statistics; in case of any abnormalities, such as poor dispensing, incorrect terminal assembly, or robot malfunction, the system will immediately alarm and stop the machine, awaiting operator intervention; operators can view detailed fault information through the touch screen and take appropriate action.

[0067] 10. Production Data Management: The system automatically records production data, including production quantity, pass rate, production time, and fault information. This data can be uploaded to the factory's production management system via a network interface for easy production management and analysis. At the same time, the system also supports remote setting of production parameters and remote monitoring of equipment status, allowing managers to keep abreast of production conditions in real time.

[0068] The automatic dispensing and assembly equipment for transformers of this invention demonstrates several technical advantages in practical applications:

[0069] Firstly, the equipment adopts an automated design, integrating processes such as dispensing, visual inspection, terminal processing, assembly, and cover installation in transformer production into a single system, achieving full automation of the production process. Compared to traditional semi-automatic equipment and separate operation methods, it significantly reduces manual intervention and improves production efficiency. Testing has shown that this equipment significantly improves production efficiency compared to traditional methods, and also results in more consistent product quality.

[0070] Secondly, the equipment's dispensing mechanism employs a high-precision multi-axis motion system and precision dispensing control technology, enabling accurate control of the glue dot position and amount. Simultaneously, the equipped vision inspection mechanism monitors dispensing quality in real time, ensuring that every product meets quality standards. This design significantly improves product quality consistency, greatly reducing the defect rate compared to traditional manual operations.

[0071] Third, the equipment's terminal handling system comprises three stages: strip feeding, terminal cutting, and terminal assembly, achieving fully automated processing of terminals from strip to final form. The robotic handling system ensures precise terminal placement, significantly improving assembly accuracy. This automated terminal handling and installation method not only improves efficiency but also avoids errors that may arise from manual operation, making the product's electrical performance more reliable.

[0072] Fourth, the equipment's top cover return lifting mechanism and top cover transfer mechanism form a closed-loop top cover processing system, realizing the automatic delivery and precise installation of the fixture top cover. This design avoids the positioning deviations that may occur with traditional manual top cover installation, ensuring the dimensional accuracy and mechanical stability of the transformer after assembly.

[0073] Fifth, the equipment's control system adopts advanced PLC control technology, achieving coordinated operation of various mechanisms through precise programming. Simultaneously, the touchscreen interface is user-friendly and easy to operate, reducing the skill requirements for operators. The equipment also possesses comprehensive fault diagnosis and alarm functions; in the event of an abnormality, the system will immediately alarm and shut down, ensuring production safety and product quality.

[0074] Sixth, the modular design of the equipment gives it excellent scalability and adaptability. By changing fixtures and adjusting program parameters, it can adapt to the production needs of transformers of different specifications and models. At the same time, the modular design also facilitates equipment maintenance and upgrades, reduces maintenance costs, and extends the service life of the equipment.

[0075] In summary, this utility model's automatic dispensing and assembly equipment for transformers, through advanced automation technology and a precision control system, automates the dispensing and assembly processes in transformer production, significantly improving production efficiency and product quality while reducing labor costs and defect rates. Compared to traditional semi-automatic equipment and separate operation methods, this equipment offers significant advantages in efficiency, quality, cost, and management, providing transformer manufacturers with an ideal production equipment solution.

[0076] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0077] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An automatic dispensing and assembly equipment for transformers, characterized in that, include: A chassis, on which a workbench is mounted; A feeding assembly line is installed on the workbench, and a material positioning fixture is provided on the feeding assembly line for placing the magnetic core; A dispensing mechanism, installed above the worktable, is used to dispense adhesive onto the surface of the magnetic core; A visual inspection mechanism is installed at the rear end of the dispensing mechanism to detect the amount of adhesive on the surface of the magnetic core; A material feeding mechanism is installed on the worktable and is used to release the material belt; A terminal cutting mechanism is installed downstream of the strip feeding mechanism and is used to cut the strip to form terminals; A terminal assembly mechanism is installed downstream of the terminal cutting mechanism and is used to assemble the cut terminals; A robot, mounted on the workbench, is used to place the assembled terminals onto the magnetic core that has been glued. The top cover return lifting mechanism is installed on the workbench and is used to transport the fixture top cover; The top cover transplanting mechanism is installed above the top cover return lifting mechanism and is used to clamp the top cover of the fixture and place it onto the material positioning fixture. The PLC controller is used to control the actions of the feeding line, the dispensing mechanism, the vision inspection mechanism, the material feeding mechanism, the terminal cutting mechanism, the terminal assembly mechanism, the robot, the top cover return lifting mechanism, and the top cover transfer mechanism.

2. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The feeding production line includes a conveyor belt, a transmission motor that drives the conveyor belt, and guide rails installed on both sides of the conveyor belt. The transmission motor is electrically connected to the PLC controller, and the guide rails are fixedly installed on the workbench to limit the lateral movement of the material positioning fixture.

3. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The dispensing mechanism includes a dispensing platform, a dispensing device mounted on the dispensing platform, and a multi-axis motion system for driving the dispensing device to move. The dispensing platform is fixedly mounted on the worktable. The multi-axis motion system includes an X-axis drive assembly, a Y-axis drive assembly, and a Z-axis drive assembly. The X-axis drive assembly is mounted on the dispensing platform, the Y-axis drive assembly is mounted on the slider of the X-axis drive assembly, the Z-axis drive assembly is mounted on the slider of the Y-axis drive assembly, and the dispensing device is mounted on the slider of the Z-axis drive assembly. The X-axis drive assembly, the Y-axis drive assembly, and the Z-axis drive assembly are all electrically connected to the PLC controller. The dispensing equipment includes a dispensing valve, a dispensing valve driver, a glue storage tank, and a dispensing control system electrically connected to the PLC controller. The dispensing valve driver is mounted on the slider of the Z-axis drive assembly, the dispensing valve is mounted on the dispensing valve driver, the glue storage tank is connected to the dispensing valve through a glue tube, and the dispensing control system controls the opening and closing of the dispensing valve and the operation of the dispensing valve driver.

4. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The vision inspection mechanism includes an industrial camera, a light source system, and an image processing unit electrically connected to the PLC controller. The industrial camera and the light source system are installed above the feeding assembly line. The industrial camera is electrically connected to the image processing unit, and the image processing unit transmits the processing results to the PLC controller.

5. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The material feeding mechanism includes a material reel, a material reel mounting base, a tension control device, and a material guiding system. The material reel mounting base is fixedly installed on the worktable, and the material reel is rotatably installed on the material reel mounting base. The tension control device is installed on the material reel to control the tension of the material strip. The material guiding system includes multiple guide wheels, which are installed on the worktable to guide the material strip into the terminal cutting mechanism.

6. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The terminal cutting mechanism includes a cutting mold, a pressure cylinder that drives the cutting mold to cut, and a strip feeding device. The cutting mold is fixedly installed on the worktable, the cylinder body of the pressure cylinder is fixedly installed on the worktable, and the piston rod of the pressure cylinder is connected to the upper mold of the cutting mold. The strip feeding device includes a stepper motor and a feed wheel. The stepper motor is fixedly installed on the worktable, and the feed wheel is installed on the output shaft of the stepper motor. Both the stepper motor and the pressure cylinder are electrically connected to the PLC controller.

7. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The terminal assembly mechanism includes a terminal positioning device, a terminal bending mechanism, and a terminal feeding device. The terminal positioning device is fixedly installed on the workbench. The terminal bending mechanism includes multiple bending cylinders, the cylinder bodies of which are fixedly installed on the workbench. The piston rods of the bending cylinders are connected to bending tools. The terminal feeding device includes a feeding cylinder and a feeding clamp. The cylinder bodies of the feeding cylinders are fixedly installed on the workbench. The piston rods of the feeding cylinders are connected to the feeding clamps. Both the bending cylinders and the feeding cylinders are pneumatically connected to the PLC controller.

8. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The robot is a six-axis articulated robot, including a robot body, an end effector installed at the end of the robot body, and a control system electrically connected to the PLC controller. The robot body is fixedly installed on the worktable, the end effector is a gripper adapted to the shape of a terminal, and the control system is used to control the movement of the robot body and the action of the end effector.

9. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The upper cover return lifting mechanism includes an upper cover conveyor belt, a conveyor motor that drives the upper cover conveyor belt, and an upper cover platform that can be lifted and lowered. The upper cover platform is installed on the workbench via a lifting cylinder. The upper cover conveyor belt is installed on the upper cover platform. The conveyor motor is fixedly installed on the upper cover platform and is connected to the upper cover conveyor belt for transmission. Both the lifting cylinder and the conveyor motor are electrically connected to the PLC controller.

10. The automatic dispensing and assembly equipment for transformers according to claim 1, characterized in that: The upper cover transplanting mechanism includes a transplanting bracket, an XY motion system mounted on the transplanting bracket, and a gripper cylinder mounted on the XY motion system. The transplanting bracket is fixedly mounted on the worktable. The XY motion system includes an X-axis linear module and a Y-axis linear module. The X-axis linear module is fixedly mounted on the transplanting bracket, the Y-axis linear module is mounted on the slider of the X-axis linear module, and the gripper cylinder is mounted on the slider of the Y-axis linear module. The X-axis linear module, the Y-axis linear module, and the gripper cylinder are all electrically or pneumatically connected to the PLC controller.

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