An inner door handle module assembly test line

Abstract

The utility model relates to a kind of inner door handle module assembly test line, include circulating assembly line, general fixture and multiple core function modules along line.It sequentially includes: circuit board assembly adhering welding module, responsible for PCBA and FPC pickup, positioning and hot-press welding;Lower shell feeding and hot riveting module, realize lower shell automatic feeding and with PCBA hot riveting combination;PIN needle welding and detection module, step-by-step completion welding and online visual inspection;Upper shell assembly and compression detection module, complete upper shell assembly, compression and size detection;Laser welding module, sealing welding is carried out to shell;Subsequently, air tightness test, electrical function test, information laser carving and sorting module are sequentially set;Whole line is unified by central control unit Coordination, realize production traceability and beat control.The utility model realizes the full-automatic and intelligent management of production process by integrating multiple core function modules and unified control system.

Description

Technical Field

[0001] This utility model relates to the field of automated manufacturing technology, specifically to a fully automated assembly and testing production line for digital key inner door handle modules. Background Technology

[0002] In the existing manufacturing process of digital key inner door handle modules, assembly and testing typically rely on multiple dispersed workstations or segmented semi-automated equipment. This production method has limitations in terms of material flow between modules, continuity of production data, and collaborative control of the overall process. For example, the handling of components between different devices may introduce waiting time, affecting production cycle time; quality data for each process is often recorded independently, making it difficult to form a complete product history, which inconveniences subsequent quality traceability and process analysis. In addition, since the module involves multiple complex processes such as precision welding, shell pressing, airtightness and functional testing, how to achieve high-precision and high-consistency continuous production while ensuring the traceability of data for each product is a challenge faced by the existing production model. Utility Model Content

[0003] In view of this, the present invention provides an assembly and testing line for inner door handle modules to solve the problems of low production efficiency, insufficient quality stability, and difficulty in data traceability in the prior art. This assembly and testing line achieves full automation and intelligent management of the production process by integrating multiple core functional modules with a unified control system.

[0004] The objective of this utility model is achieved through the following technical solution: An inner door handle module assembly and testing line includes a unified circulating production line, multiple universal fixtures that circulate on the production line and are equipped with traceable identification tags, and the following core functional modules arranged sequentially along the conveying direction of the production line to form a continuous automated production unit: The circuit board assembly bonding and welding module is used to pick up, clean, position, pulse hot press welding, and perform post-weld inspection of PCBA and FPC. The lower shell feeding and hot riveting module is used to realize the automatic feeding and dust removal of the lower shell, and to hot rivet and fix it to the PCBA module from the previous module and perform three-dimensional scanning. The PIN soldering and inspection module is used to complete the PIN soldering step by step through at least two sets of soldering mechanisms, and immediately perform online visual inspection of the solder joints and sort out defective products. The upper shell assembly and pressing inspection module is used to realize automatic feeding of the upper shell, precise robotic assembly with the lower shell, three-way synchronous pressing, and full-size automated inspection after pressing. The laser welding module is used for sealing welding of the upper and lower shells after pressing. The airtightness testing module is used to test the sealing performance of the welded product; The functional testing module is used to perform electrical and functional tests on products that have passed the airtightness test. The information laser engraving and sorting module is used to perform information laser engraving and laser engraving quality inspection on qualified products, and finally sort and unload the products based on all upstream inspection results. The system also includes a central control unit that communicates with each module to trace product data in real time based on the identification identifier and to coordinate and control the working rhythm and quality judgment logic of each module.

[0005] This assembly and testing line integrates multiple core functional modules into a continuous automated production unit through a unified circulating production line, achieving fully automated operation from circuit board assembly bonding and welding to final information laser engraving and sorting. The unified production line ensures smooth material flow and consistent production rhythm, reducing intermediate handling and waiting time, thereby improving overall production efficiency. Universal fixtures equipped with traceable identification tags enable real-time tracking of each product during production. Combined with the data processing capabilities of the central control unit, it achieves the collection and binding of data throughout the product's lifecycle, providing a solid foundation for quality control and problem tracing. The functional modules are arranged sequentially along the conveyor direction, forming a logically rigorous process sequence. Each module focuses on a specific process; for example, the circuit board assembly bonding and welding module is responsible for the precision welding of PCBA and FPC; the lower shell loading and hot riveting module secures the shell to the electronic components; the PIN welding and testing module ensures connection reliability; the upper shell assembly and pressing testing module ensures structural integrity; the laser welding module provides sealing; the airtightness testing module verifies leak-proof performance; the functional testing module verifies electrical characteristics; and the information laser engraving and sorting module completes final identification and classification.

[0006] Preferably, the circuit board assembly bonding and welding module includes: a first SCARA robot mechanism equipped with a first CCD camera, used to pick up the PCBA and sequentially transfer it to a cleaning station, a first imaging station, and a pulse hot press welding station; and a second SCARA robot mechanism equipped with a second CCD camera, used to pick up the FPC and sequentially transfer it to a film peeling station, the first imaging station, and the pulse hot press welding station for bonding with the PCBA.

[0007] The circuit board assembly bonding and welding module employs two independent SCARA robot mechanisms to handle the PCBA and FPC respectively, enabling parallel operation and improving the module's operational efficiency. The first SCARA robot mechanism, equipped with a first CCD camera, accurately picks up the PCBA and sequentially moves it to the cleaning station, photography station, and welding station, ensuring the cleanliness and positioning accuracy of the PCBA before welding. The second SCARA robot mechanism, also equipped with a second CCD camera, is responsible for picking up, removing the protective film from, photographing, and bonding the FPC. By sharing the photography station, relative position calibration between the PCBA and FPC is achieved, providing high-precision alignment for subsequent pulse hot-press welding. The pulse hot-press welding station uses a hot-press method, enabling reliable electrical connections while avoiding thermal damage to sensitive components.

[0008] Preferably, the lower shell loading and hot riveting module includes a four-axis industrial robot, a hot riveting mechanism, and a 3D line scan inspection mechanism. The end effector of the four-axis industrial robot is equipped with a vacuum suction plate and a third CCD camera, used to pick up the lower shell, move it to the imaging station for positioning and calibration, and finally place it in the designated position of the fixture transferred there. The hot riveting mechanism includes a hot riveting head driven by a servo electric cylinder, a temperature controller, and a pressure sensor, used to hot rivet and fix the lower shell with the placed PCBA module. The 3D line scan inspection mechanism includes two laser displacement sensors driven by a precision module, used to perform three-dimensional contour scanning and quality judgment on the hot-riveted component.

[0009] The lower shell loading and hot riveting module utilizes a four-axis industrial robot to automatically pick up and precisely place the lower shell. A vacuum suction plate at the robot's end ensures stable gripping, while a third CCD camera is used for positioning calibration at the imaging station, guaranteeing the precise position of the lower shell on the fixture and laying the foundation for subsequent assembly. The hot riveting mechanism employs a servo electric cylinder to drive the hot riveting head. Combined with a temperature controller and pressure sensor, it can precisely control the temperature, pressure, and stroke during the hot riveting process, achieving reliable fixation of the PCBA module to the lower shell. This avoids the loosening risk associated with traditional screw fixing and improves the consistency of connection strength.

[0010] Preferably, the PIN soldering and inspection module is a multi-station soldering inspection machine, which includes a soldering station, an inspection station, and a sorting station. The soldering station is equipped with three independent soldering mechanisms, each of which includes a three-axis motion module and a soldering iron tip with a rotating axis, a solder wire feeding assembly, a solder wire breaking assembly, and an automatic cleaning assembly driven by the module. The inspection station is located immediately after the soldering station and is equipped with a vision inspection device driven by a three-axis motion platform. The vision inspection device includes a zoom camera with AI recognition function and an illumination source for photographing solder joints and analyzing defects. The sorting station is equipped with an NG diversion line and a sorting execution mechanism driven by the three-axis motion platform or an independent drive mechanism for removing defective products from the main line based on the inspection results.

[0011] This PIN soldering and inspection module adopts a multi-station design, integrating soldering, inspection, and sorting functions into a compact unit, achieving an efficient and continuous workflow. The soldering station is equipped with three independent soldering mechanisms, each containing a three-axis motion module-driven soldering tip, solder wire feed assembly, solder wire breaker assembly, and automatic cleaning assembly. This allows for simultaneous soldering of multiple PINs, improving soldering efficiency. The soldering tip integrates a rotating axis, making the soldering angle adjustable to adapt to the solder joint requirements of different locations. The solder wire feed and breaker assemblies ensure a stable supply of solder wire and proper end-point handling, while the automatic cleaning assembly maintains the cleanliness of the soldering tip, guaranteeing consistent soldering quality.

[0012] Preferably, the fixture includes a base tray and a quick-change fixture tray. The fixture tray has motherboard placement holes for positioning and accommodating the motherboard, PCBA and FPC placement holes for positioning and accommodating PCBA and FPC, positioning pins, and reserved positions for wire harness plugs for online testing.

[0013] This fixture design employs a combination of a basic tray and a quick-change fixture tray, providing high flexibility and adaptability. The basic tray serves as a universal carrier, continuously circulating on the assembly line, while the fixture tray can be quickly replaced according to different product models or process requirements, reducing changeover time and improving the versatility and utilization of the production line. The motherboard placement slots, PCBA and FPC placement slots, and positioning pins on the fixture tray ensure precise positioning and fixation of components such as motherboards, PCBAs, and FPCs, preventing displacement or damage during automated handling and processing, and guaranteeing assembly accuracy.

[0014] Preferably, the upper shell assembly and pressing inspection module includes a robot handling mechanism, a three-way pressing mechanism, and a full inspection system. The robot handling mechanism is used to pick up the upper shell and, after positioning and calibration at the photography station, precisely assemble it with the lower shell in the fixture. The three-way pressing mechanism includes an upper pressing head, a left pressing head, and a right pressing head. The three pressing heads are driven by independent servo electric cylinders, which can simultaneously apply preset pressure and stroke to the assembled shell from three directions to complete the pressing. The full inspection system includes multiple laser rangefinders for scanning the four-sided contours and measuring key assembly dimensions of the pressed product.

[0015] The upper shell assembly and pressing inspection module achieves automatic picking and precise assembly of the upper shell through a robotic handling mechanism. After positioning and calibration at the photography station, the robot can accurately align the upper and lower shells, ensuring the accuracy and consistency of the assembly. The three-way pressing mechanism uses three pressure heads—upper, left, and right—each driven by an independent servo electric cylinder. It can simultaneously apply preset pressure and stroke from three directions, achieving uniform pressing of the shell and avoiding deformation or stress concentration caused by single-point pressure, thus improving pressing quality and product structural integrity.

[0016] Preferably, both the laser welding module and the airtightness testing module adopt a synchronous exchange robot collaborative loading and unloading mode; each module includes a SCARA robot set on one side of the main line and a multi-station work platform set on the other side of the main line and opposite to the SCARA robot. The SCARA robot performs synchronous exchange actions: it takes a processed / tested product out of the work platform and puts it back into the main line fixture, while taking a new product to be processed / tested out of the main line fixture and putting it into the work platform.

[0017] The laser welding module and the airtightness testing module employ a synchronous exchange robot-assisted loading and unloading mode. Through the cooperation of SCARA robots and a multi-station work platform, efficient and continuous material flow is achieved. The SCARA robot is positioned on one side of the main production line, and the multi-station work platform is on the other. This layout allows the robot to handle products on both the main line fixture and the work platform simultaneously. The synchronous exchange action allows the robot to retrieve processed or tested products from the work platform and place them back into the main line fixture within a single cycle, while simultaneously removing a new product to be processed or tested from the main line fixture and placing it into the work platform. This reduces robot idle time and travel distance, improving loading and unloading efficiency.

[0018] Preferably, the functional testing module includes a manual wiring station, a three-axis jig removal mechanism, and a parallel testing system. The three-axis jig removal mechanism is used to remove the product jig as a whole from the jig and transport it to the testing area. The parallel testing system has eight independent test boxes, which can test four products simultaneously in a "one-to-four" electrical connection manner.

[0019] This functional testing module utilizes a three-axis jig-and-place mechanism to automatically transport the product jig, removing the entire product from the jig and transferring it to the testing area. This reduces manual intervention and improves testing efficiency. The parallel testing system is equipped with eight independent test chambers, using a "one-to-four" electrical connection, enabling simultaneous testing of four products with a test cycle of 70 seconds. This brings the module's theoretical cycle time to 9.5 seconds, significantly increasing testing throughput.

[0020] Preferably, the information laser engraving and sorting module includes a laser engraving station, a laser engraving inspection station, and a robot sorting and unloading station. The laser engraving station has a lifting and positioning mechanism and a fiber laser engraving machine for laser engraving QR codes and serial numbers on the product surface. The laser engraving inspection station has a high-speed CCD camera for reading and verifying the laser engraving content. The robot sorting and unloading station has a SCARA robot for placing qualified products into qualified product shipping trays and moving unqualified products to the unqualified product collection area based on the comprehensive judgment result of the central control unit.

[0021] The laser engraving and sorting module uses a laser engraving station to laser engrave QR codes and serial numbers onto the product surface. A lifting and positioning mechanism ensures the stability and positional accuracy of the product during the laser engraving process. The fiber laser engraving machine enables high-speed, clear marking, providing a permanent mark for product traceability. The laser engraving inspection station is equipped with a high-speed CCD camera to quickly read and verify the laser engraving content, ensuring the accuracy and readability of the markings and avoiding information loss or misreading due to laser engraving errors.

[0022] Preferably, a PIN pin re-inspection station and an automatic labeling station are also provided downstream of the information laser engraving and sorting module. The PIN pin re-inspection station is used to perform final electrical contact detection and visual appearance inspection of the PIN pins on the products before unloading. The automatic labeling station is equipped with a label printer and a labeling robot, which is used to automatically affix labels to the shipping pallet or product outer packaging. The labeling robot is a SCARA robot, and its end effector integrates a vacuum label suction head and a hollow rotating platform for adjusting the label angle.

[0023] The PIN re-inspection station, located downstream of the information laser engraving and sorting module, performs final electrical contact and visual appearance inspections on the PINs before unloading, ensuring the reliability of the PIN connections and the integrity of the appearance, and preventing potential defects from reaching the customer. The automated labeling station, equipped with a label printer and labeling robot, can automatically generate and apply labels based on production data, achieving automation of the packaging process.

[0024] Preferably, the assembly and testing line further includes an intelligent logistics module, which includes a material frame loading machine. The material frame loading machine includes: a frame, a loading connection line, a loading and unloading frame roller line, a handling and picking mechanism, and an integrated control unit. The loading connection line is mounted on the frame and is used to transport blister packs containing products. The loading and unloading frame roller line is located to the side of the loading connection line and is used to transport empty material frames. The handling and picking mechanism is positioned above the loading connection line and is used to transport the blister packs on the loading connection line to the empty material frames on the loading and unloading frame roller line. The loading and unloading frame roller line is provided with a material frame guiding adjustment mechanism, a frame pushing mechanism, and a frame separating mechanism. The frame pushing mechanism includes a first linear module and a push plate driven by the first linear module. The frame separating mechanism includes a second linear module and a pair of clamping plates driven by the second linear module that can move in opposite directions or out of direction. The frame pushing mechanism and the frame separating mechanism cooperate with each other to separate stacked material frames into flat material frames.

[0025] This intelligent logistics module automates the product loading process from the production line to the crates via a crate loading machine. The frame serves as a supporting structure, ensuring equipment stability. The loading feeder line transports blister packs containing products, while the crate loading / unloading roller line transports empty crates; their parallel arrangement optimizes space utilization. A handling and picking mechanism, positioned above the loading feeder line, precisely transfers blister packs from the feeder line to the empty crates, achieving automated material transfer. An integrated control unit coordinates the actions of all components, ensuring smooth operation. The crate guiding and adjusting mechanism, crate pushing mechanism, and crate separating mechanism on the crate loading / unloading roller line work together to handle stacked crates.

[0026] Preferably, the pushing mechanism and the separating mechanism are configured to work in concert as follows: when two stacked empty frames reach a designated position, a pair of clamping plates of the separating mechanism descend to both sides of the upper empty frame and move towards each other to clamp the upper empty frame; subsequently, the pushing plate of the pushing mechanism contacts the outer wall of the lower empty frame and is driven by its first linear module to push the lower empty frame to move horizontally, separating the upper and lower frames; then, the Z-axis module of the separating mechanism drives the pair of clamping plates to descend, lowering the clamped upper empty frame to the plane where the original lower empty frame was located; finally, the pair of clamping plates move apart to release the frame, and the pushing plate and the pair of clamping plates return to their initial positions.

[0027] The coordinated operation of the push-frame mechanism and the split-frame mechanism enables the automatic separation of stacked material frames. When two stacked empty material frames reach the designated position, a pair of clamping plates from the split-frame mechanism descend to both sides of the upper empty material frame and clamp it, ensuring stable gripping of the upper frame. The push-frame mechanism's push plate then contacts the outer wall of the lower empty material frame and, driven by the first linear module, pushes the lower frame horizontally, separating the upper and lower frames and avoiding damage caused by forced separation.

[0028] Preferably, the intelligent logistics module further includes an automatic weighing unit, an automatic labeling and barcode reading unit, and an automatic palletizing unit. The automatic weighing unit is located after the robot unloading station and uses a weighing sensor to weigh the fully loaded product pallet online and bind the weight information to the product serial number. The automatic labeling and barcode reading unit is used to automatically label, affix labels, and verify double-sided barcodes on the circulating material frames. The automatic palletizing unit uses a six-axis articulated robot equipped with an adaptive vacuum suction cup clamp to automatically stack the labeled material frames on the pallet according to a preset stacking pattern.

[0029] The intelligent logistics module's automatic weighing unit, located after the robot's unloading station, uses weighing sensors to weigh fully loaded pallets online and links the weight information to the product serial number. This enables real-time monitoring and data recording of product weight, providing a basis for quality control and logistics management. The automatic labeling and barcode reading unit automatically labels, affixes labels, and verifies double-sided barcodes on the moving material frames, ensuring the accuracy and traceability of the frame markings and avoiding errors that may occur with manual labeling. The automatic palletizing unit uses a six-axis articulated robot equipped with adaptive vacuum suction cup grippers, which can automatically place labeled material frames onto pallets according to preset pallet patterns, automating the palletizing process.

[0030] Preferably, the central control unit is configured to: track the position and status of each fixture in real time via an RFID reader; record and bind key process parameters and test results for each product in pulse hot pressing welding, hot riveting, PIN pin welding, 3D line scanning, airtightness testing, and functional testing, and generate a full-process production history; based on the production history, automatically separate defective products and divert qualified products at the sorting station of the PIN pin welding and testing module and the robot sorting and unloading station of the information laser engraving and sorting module.

[0031] The central control unit tracks the location and status of each fixture in real time using RFID readers, enabling comprehensive monitoring of the production process and ensuring the visibility and controllability of material flow. It records and binds the process parameters and test results for each product in key processes, such as pulse hot-press welding, hot riveting, pin welding, 3D line scanning, airtightness testing, and functional testing, generating a complete production history and providing a comprehensive data archive for each product, facilitating quality traceability and analysis.

[0032] The advantages of this utility model compared to the prior art are: This utility model's inner door handle module assembly and testing line integrates multiple core functional modules into a continuous automated production unit through a unified circulating production line. This facilitates fully automated operation from circuit board assembly bonding and soldering to final information labeling and sorting. The unified production line provides a stable foundation for material flow, helping to reduce interruptions and waiting between processes and positively impacting overall production continuity. Universal fixtures equipped with traceable identification circulate along the line, and combined with the data coordination capabilities of the central control unit, a data chain is established for each product throughout the entire production process, providing information support for quality monitoring and problem analysis.

[0033] The various functional modules are arranged sequentially along the conveying direction, forming a logically clear and tightly connected process sequence. The circuit board assembly bonding and welding module focuses on the alignment and connection of precision electronic components; the lower shell loading and hot riveting module is responsible for structural component fixation and preliminary quality judgment; the PIN pin welding and inspection module focuses on ensuring the reliability of electrical connections and immediate inspection; the upper shell assembly and pressing inspection module focuses on structural integrity; the laser welding and airtightness testing module ensures the product's sealing performance; the functional testing module verifies the product's electrical characteristics; and the information laser engraving and sorting module completes the final product identification and classification. This modular layout enables each machine to work efficiently and collaboratively. The central control unit plays a positive role in maintaining the stability of the production process and the consistency of product output by coordinating the working rhythm and quality judgment logic of each module. At the same time, real-time data acquisition and binding based on identity identification helps to identify process abnormalities in a timely manner during production, assists in the separation of defective products, and has a beneficial effect on controlling the product defect rate. The overall design reflects an integrated and information-based manufacturing approach, suitable for the production scenario of digital key inner door handle modules with high requirements for production precision and data management. Attached Figure Description

[0034] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 This is a schematic diagram of the assembly and testing line of the inner door handle module in one embodiment of the present invention.

[0036] Figure 2 This is a structural diagram of a circuit board assembly bonding and welding module according to an embodiment of the present invention.

[0037] Figure 3 This is a structural diagram of a circuit board assembly bonding and welding module according to an embodiment of the present invention from another perspective.

[0038] Figure 4 This is a structural diagram of the lower shell feeding and hot riveting module according to an embodiment of the present invention.

[0039] Figure 5 This is a structural diagram of a PIN pin soldering and testing module according to an embodiment of the present invention.

[0040] Figure 6 This is a structural diagram of the PIN pin soldering and detection module according to another embodiment of the present invention.

[0041] Figure 7 This is a structural diagram of the welding station of the PIN pin welding and testing module according to an embodiment of the present invention.

[0042] Figure 8 This is a structural diagram of the PIN pin soldering and testing module detection station according to an embodiment of the present invention.

[0043] Figure 9 This is a structural diagram of a general-purpose fixture according to an embodiment of the present invention.

[0044] Figure 10 This is a structural diagram of the upper shell assembly and pressing detection module according to an embodiment of the present invention.

[0045] Figure 11 This is a structural diagram of the upper shell assembly and pressing detection module from another perspective, according to an embodiment of the present invention.

[0046] Figure 12 This is a structural diagram of a laser welding module according to an embodiment of the present invention.

[0047] Figure 13 This is a structural diagram of an airtightness testing module according to an embodiment of the present invention.

[0048] Figure 14 This is a structural diagram of a functional testing module according to an embodiment of the present invention.

[0049] Figure 15 This is a structural diagram of a portion of the information laser engraving and sorting module according to an embodiment of the present invention.

[0050] Figure 16 This is a structural diagram of another part of the information laser engraving and sorting module according to an embodiment of the present utility model.

[0051] Figure 17 This is a structural diagram of a material frame upper frame machine according to an embodiment of the present invention.

[0052] Figure 18 This is a structural diagram of a material frame upper frame machine according to an embodiment of the present invention from another perspective.

[0053] Figure 19 This is a partial structural diagram of a material frame mounting machine according to an embodiment of the present invention.

[0054] Figure 20 This is a structural diagram of a material frame guiding adjustment mechanism, a frame pushing mechanism, and a frame separating mechanism according to an embodiment of this utility model.

[0055] Figure 21 This is a structural diagram of an automatic weighing unit according to an embodiment of the present invention.

[0056] Figure 22 This is a structural diagram of an automatic labeling and code reading unit according to an embodiment of the present invention.

[0057] Figure 23 This is a structural diagram of an automatic palletizing unit according to an embodiment of the present invention.

[0058] Labeling Explanation: 200 General-purpose jig, 210 Identification mark, 220 Basic tray, 230 Jig tray, 231 Motherboard placement cavity, 232 PCBA and FPC placement cavity, 233 Positioning pin, 234 Wire harness plug reserved position, 300 Circuit board assembly bonding and welding module, 310 First SCARA robot mechanism, 320 Cleaning station, 330 First photography station, 340 Pulse hot press welding station, 350 Second SCARA robot mechanism, 360 Film peeling station, 400 Lower shell loading and hot riveting module, 410 Four-axis industrial robot, 420 Hot riveting mechanism, 421 Servo cylinder, 422 Hot riveting head, 423 Temperature controller, 424 Pressure sensor, 430 3D line scan detection mechanism, 431 Precision module, 432 Laser displacement sensor, 440 Photography station, 500 PIN soldering and inspection module, 510 soldering station, 511 soldering mechanism, 512 three-axis motion module, 513 rotary axis, 514 soldering tip, 515 solder wire feeding assembly, 516 solder wire breaking assembly, 517 automatic cleaning assembly, 520 inspection station, 521 three-axis motion platform, 522 vision inspection device, 523 zoom camera, 524 lighting source, 530 sorting station, 531 NG diversion line, 532 sorting actuator, 600 upper shell assembly and pressing inspection module, 610 robot handling mechanism, 611 photography station, 620 three-way pressing mechanism, 621 upper pressing head, 622 left pressing head, 623 right pressing head, 624 servo cylinder, 630 full inspection system, 631 laser rangefinder sensor, 700 laser welding module, 710 SCARA robot, 720 multi-station work platform, 800 airtightness testing module, 810 SCARA robot, 820 multi-station work platform, 900 functional testing module, 910 manual wiring station, 920 three-axis jig-and-place mechanism, 930 parallel testing system, 931 test box, 1000 information laser engraving and sorting module, 1010 laser engraving station, 1011 lifting and positioning mechanism, 1012 fiber laser engraving machine, 1020 laser engraving inspection station, 1021 high-speed CCD camera, 1030 robot sorting and unloading station, 1031 SCARA robot, 1040 PIN pin re-inspection station, 1050 automatic labeling station, 1051 label printer, 1052 labeling robot, 1053 vacuum label suction head, 1054 hollow rotary platform, 1100 material frame loading machine, 1110 frame, 1120 loading and connecting line, 1130 loading and unloading frame roller line, 1140 handling and picking mechanism, 1141 three-axis linear module, 1142 hollow rotary platform, 1143 multiple vacuum suction cups, 1160 material frame guide adjustment mechanism, 1161 bidirectional lead screw, 1162 two guide plates, 1163 third servo motor, 1170 frame pushing mechanism, 1171 first linear module, 1172 push plate, 1173 first servo motor, 1180 frame separating mechanism, 1181 second linear module, 1182 a pair of clamping plates, 1183 Z-axis module.1184 Bidirectional Screw Mechanism, 1185 Second Servo Motor, 1200 Automatic Weighing Unit, 1210 Weighing Sensor, 1300 Automatic Labeling and Code Reading Unit, 1310 Automatic Marking, 1320 Labeling, 1400 Automatic Palletizing Unit, 1410 Six-Axis Articulated Robot, 1420 Adaptive Vacuum Suction Cup Gripper. Detailed Implementation

[0059] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0060] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0061] It should be noted that similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. In the description of the embodiments of this application, it should be understood that the terms "upper," "lower," "left," "right," "vertical," "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the figures, or the orientation or positional relationship commonly used when the product of this application is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0062] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0063] The technical solutions in this application will now be described with reference to the accompanying drawings.

[0064] This embodiment provides an assembly and testing line for an inner door handle module, including: A unified, circulating production line; Multiple general-purpose fixtures 200 flow on the assembly line, and each fixture 200 is equipped with a traceable identification mark 210; The following core functional modules are sequentially arranged along the conveyor direction of the production line to form a continuous automated production unit: The circuit board assembly bonding and welding module 300 is used to pick up, clean, position, pulse hot press welding and post-weld inspection of PCBA and FPC; The lower shell feeding and hot riveting module 400 is used to realize the automatic feeding and dust removal of the lower shell, and to hot rivet and fix it to the PCBA module from the previous module and perform three-dimensional scanning. The PIN soldering and inspection module 500 is used to complete the PIN soldering step by step through at least two sets of soldering mechanisms, and immediately perform online visual inspection of the solder joints and sort out defective products. The upper shell assembly and pressing inspection module 600 is used to realize automatic feeding of the upper shell, precise robotic assembly with the lower shell, three-way synchronous pressing, and full-size automated inspection after pressing. Laser welding module 700 is used for sealing welding of the upper and lower shells after pressing; The airtightness testing module 800 is used to test the sealing performance of the welded product. Functional test module 900 is used to perform electrical and functional tests on products that have passed the airtightness test. The information laser engraving and sorting module 1000 is used to perform information laser engraving and laser engraving quality inspection on qualified products, and finally sort and unload the products based on all upstream inspection results. And a central control unit, which communicates with each module to trace product data in real time based on the identity identifier 210, and coordinates and controls the working rhythm and quality judgment logic of each module.

[0065] This assembly and testing line integrates multiple core functional modules into a continuous automated production unit through a unified, circulating production line, achieving fully automated operation from circuit board assembly bonding and soldering to final information laser engraving and sorting. The unified production line ensures smooth material flow and consistent production rhythm, reducing intermediate handling and waiting time, thereby improving overall production efficiency. The universal fixture 200 is equipped with a traceable identification tag 210, enabling real-time tracking of each product during production. Combined with the data processing capabilities of the central control unit, it achieves the collection and binding of data throughout the product's entire lifecycle, providing a solid foundation for quality control and problem traceability. The various functional modules are arranged sequentially along the conveying direction, forming a logically rigorous process sequence. Each module focuses on a specific process. For example, the circuit board assembly bonding and welding module 300 is responsible for the precision welding of PCBA and FPC; the lower shell loading and hot riveting module 400 fixes the shell and electronic components; the PIN pin welding and testing module 500 ensures connection reliability; the upper shell assembly and pressing testing module 600 ensures structural integrity; the laser welding module 700 provides sealing treatment; the airtightness testing module 800 verifies leak-proof performance; the functional testing module 900 checks electrical characteristics; and the information laser engraving and sorting module 1000 completes final identification and classification. This modular layout enables the production line to work efficiently and collaboratively. The central control unit coordinates the working rhythm and quality judgment logic of each module, ensuring the stability of the production process and the consistency of the products. At the same time, the real-time data traceability capability based on the identification tag 210 allows for the immediate identification and handling of anomalies during production, preventing defective products from flowing into subsequent processes and reducing the defect rate. The overall design embodies a highly integrated and intelligent manufacturing concept, suitable for the large-scale, high-precision production needs of digital key inner door handle modules.

[0066] The central control unit, as the core of the entire production line, adopts a distributed control system architecture based on industrial Ethernet (such as PROFINET or EtherCAT) and PLC (Programmable Logic Controller). The main control PLC exchanges data in real time with the local controllers of each functional module (such as robot controllers, vision systems, dedicated motion control cards, etc.) through industrial switches to coordinate the entire line's cycle time.

[0067] In terms of data management, the system is equipped with an industrial computer (industrial control computer) as a data server, running the Manufacturing Execution System (MES) database. The central control unit is configured as follows: Identity tracking: By deploying RFID readers at key workstations, the identity identifiers 210 (i.e. RFID tags) on the transfer fixtures 200 are read in real time, thereby tracking the location and status of each fixture and the products it carries.

[0068] Data binding and history generation: The system creates a unique product serial number for each identity identifier 210, and uses this as the core to record and bind the process parameters and test results of that product in all key processes in the MES database. This includes, but is not limited to: Temperature, pressure, and time curves for pulsed hot press welding; Temperature, pressure, and 3D line scan point cloud data and judgment results of the hot riveting mechanism; Visual inspection images and AI analysis reports of PIN soldering; Leakage rate values ​​from airtightness tests; The electrical parameters of the functional test (such as voltage, current, communication waveform) and the pass / fail status of the test.

[0069] All of this data together constitutes the product's complete digital production history.

[0070] Intelligent sorting and quality control: Based on the real-time updated production history, the central control unit issues precise sorting instructions at the sorting station 530 of the PIN welding and inspection module 500 and the robot sorting and unloading station 1030 of the information laser and sorting module 1000, so as to realize the automatic separation of non-conforming products and the directional diversion of qualified products, ensuring that only fully qualified products can flow into the next stage or be finally shipped.

[0071] The unified circulating production line adopts a double-speed chain conveyor, and its operation is uniformly scheduled by a central control unit to ensure that the cycle time of each module is matched and the material flows smoothly. Specific control strategies and connection mechanisms include: Cyclic production flow: The production line operates intermittently at a fixed production cycle (e.g., set to X seconds / piece). The operation time of each core functional module is designed to be less than or equal to this cycle time, thereby achieving synchronous production across the entire line.

[0072] Precise positioning and locking: A precise positioning mechanism (such as a cylinder-driven positioning pin) and a fixture locking mechanism are set in front of the workstation of each functional module. When the pallet carrying the fixture 200 flows to the designated workstation, the positioning mechanism is activated to ensure that the relative position of the fixture and the processing equipment is accurate. The locking mechanism then fixes the pallet, providing a stable working reference for robot loading and unloading or precision machining.

[0073] Buffer Management: Several buffers are set up before and after time-consuming critical processes (such as functional test module 900), as well as on the main line. When a downstream module is temporarily unable to receive products due to a fault or full capacity, products processed by the upstream module can be temporarily stored in the buffers and released when the downstream module is ready. This effectively decouples the strong dependencies between processes, improving the flexibility and equipment utilization (OEE) of the entire line.

[0074] Status signal interaction: Each module establishes a clear status signal interaction with the central control unit, such as "ready", "working", "complete", and "fault". The production line will only start flowing when it receives the "complete" signal of the current station and the "ready" signal of the next station, which prevents the fixture from flowing in before the module is ready and causing collisions or waiting.

[0075] In this embodiment, the circuit board assembly bonding and soldering module 300 includes: The first SCARA robot mechanism 310 is equipped with a first CCD camera, which is used to pick up PCBA and transfer it sequentially to the cleaning station 320, the first photography station 330 and the pulse hot press welding station 340. The second SCARA robot mechanism 350 is equipped with a second CCD camera, which is used to pick up the FPC and transfer it sequentially to the film peeling station 360, the first imaging station 330 and the pulse hot pressing welding station 340 for bonding with the PCBA.

[0076] The circuit board assembly bonding and welding module 300 employs two independent SCARA robot mechanisms to handle the PCBA and FPC respectively, enabling parallel operation and improving the module's operational efficiency. The first SCARA robot mechanism 310, equipped with a first CCD camera, accurately picks up the PCBA and sequentially transfers it to the cleaning station 320, the photography station, and the welding station, ensuring the cleanliness and positioning accuracy of the PCBA before welding. The second SCARA robot mechanism 350, also equipped with a second CCD camera, is responsible for picking up, removing the protective film from, photographing, and bonding the FPC. By sharing the photography station, relative position calibration between the PCBA and FPC is achieved, providing high-precision alignment for subsequent pulse hot-press welding. The pulse hot-press welding station 340 uses hot pressing to achieve reliable electrical connections while avoiding thermal damage to sensitive components. The entire module, through the combination of machine vision and robotics, automates the entire process from component picking to welding, reducing human intervention, minimizing operational errors, and improving welding quality and consistency. This design makes the circuit board assembly bonding and welding process more efficient, precise, and reliable, meeting the production requirements of high-precision electronic assembly.

[0077] In this embodiment, the lower shell feeding and hot riveting module 400 includes: The four-axis industrial robot 410 is equipped with a vacuum suction plate and a third CCD camera at its end, which is used to pick up the lower shell, move it to the imaging station 440 for positioning and calibration, and finally place it in the designated position of the fixture 200 that has been transferred there. The hot riveting mechanism 420 includes a hot riveting head 422 driven by a servo electric cylinder 421, a temperature controller 423 and a pressure sensor 424, which are used to hot rivet and fix the lower shell of the PCBA module that has been placed there. The 3D line scan inspection mechanism 430 includes two laser displacement sensors 432 driven by a precision module 431, which are used to perform three-dimensional contour scanning and quality judgment on the hot-riveted components.

[0078] The lower shell loading and hot riveting module 400 uses a four-axis industrial robot 410 to automatically pick up and precisely place the lower shell. A vacuum suction plate at the robot's end ensures stable gripping, while a third CCD camera is used for positioning calibration at the imaging station 440, guaranteeing the precise position of the lower shell on the fixture 200, laying the foundation for subsequent assembly. The hot riveting mechanism 420 uses a servo electric cylinder 421 to drive the hot riveting head 422. Combined with a temperature controller 423 and a pressure sensor 424, it can precisely control the temperature, pressure, and stroke during the hot riveting process, achieving reliable fixation of the PCBA module and the lower shell. This avoids the loosening risk associated with traditional screw fixing and improves the consistency of connection strength. The 3D line scan inspection mechanism 430 uses two laser displacement sensors 432, driven by a precision module 431, to perform a three-dimensional contour scan of the hot-riveted components. This comprehensively detects the geometric dimensions and assembly quality of the components, promptly identifies defects such as deformation and misalignment, and provides feedback through a quality judgment system, ensuring that only qualified products flow into the next process. The entire module integrates robotic loading, hot riveting, and online inspection functions, achieving full automation of the lower shell assembly. This improves production efficiency and product qualification rate, while real-time inspection reduces potential quality issues. This design makes the lower shell assembly process more precise, reliable, and efficient, meeting the assembly quality requirements of high-precision products.

[0079] In this embodiment, the PIN soldering and inspection module 500 is a multi-station soldering inspection machine, which includes: The soldering station 510 is equipped with three independent soldering mechanisms 511. Each soldering mechanism 511 includes a three-axis motion module 512, a soldering iron tip 514 with a rotating shaft 513 driven by the module, a solder wire feeding assembly 515, a solder wire breaking assembly 516, and an automatic cleaning assembly 517. Inspection station 520 is set up immediately after welding station 510 and is equipped with a vision inspection device 522 driven by a three-axis motion platform 521. The vision inspection device 522 includes a zoom camera 523 with AI recognition function and an illumination source 524, which are used to photograph the weld joints and analyze defects. The sorting station 530 is equipped with an NG diversion line 531 and a sorting execution mechanism 532 driven by a three-axis motion platform 521 or an independent drive mechanism, which is used to remove non-conforming products from the main line according to the test results.

[0080] The PIN soldering and inspection module 500 adopts a multi-station design, integrating soldering, inspection, and sorting functions into a compact unit, achieving an efficient and continuous workflow. The soldering station 510 is equipped with three independent soldering mechanisms 511. Each mechanism includes a soldering tip 514 driven by a three-axis motion module 512, a solder wire feeding assembly 515, a solder wire breaking assembly 516, and an automatic cleaning assembly 517, enabling simultaneous soldering of multiple PINs and improving soldering efficiency. The soldering tip 514 integrates a rotating axis 513, allowing for adjustable soldering angles to adapt to different solder joint requirements. The solder wire feeding and breaking assemblies ensure a stable supply of solder wire and proper end-point handling, while the automatic cleaning assembly 517 maintains the cleanliness of the soldering tip 514, ensuring consistent soldering quality. Inspection station 520 is located immediately after welding station 510. A vision inspection device 522, driven by a three-axis motion platform 521, utilizes a zoom camera 523 with AI recognition capabilities and an illumination source 524 to perform high-definition imaging and intelligent defect analysis of solder joints, quickly identifying common welding defects such as cold solder joints, short circuits, and solder balls. Based on the inspection results, sorting station 530 automatically removes defective products from the main line via NG diversion line 531 or sorting execution mechanism 532, preventing defective products from flowing into subsequent processes. This integrated design reduces intermediate handling time, achieves seamless integration of welding and inspection, and improves production cycle time and product qualification rate.

[0081] In this embodiment, the fixture 200 includes a base tray 220 and a quick-change fixture tray 230. The fixture tray 230 has a motherboard placement cavity 231 for positioning and accommodating the motherboard, a PCBA and FPC placement cavity 232 for positioning and accommodating PCBA and FPC, a positioning pin 233, and a wire harness plug reserved position 234 for online testing.

[0082] The fixture 200 is designed with a combination of a basic tray 220 and a quick-change fixture tray 230, providing high flexibility and adaptability. The basic tray 220 serves as a universal carrier, continuously circulating on the assembly line, while the fixture tray 230 can be quickly replaced according to different product models or process requirements, reducing changeover time and improving the versatility and utilization of the production line. The motherboard placement slots 231, PCBA and FPC placement slots 232, and positioning pins 233 on the fixture tray 230 ensure precise positioning and fixation of components such as motherboards, PCBAs, and FPCs, preventing displacement or damage during automated handling and processing, and guaranteeing assembly accuracy. The wire harness plug pre-reserved position 234 provides a convenient interface for online testing, allowing the functional test module 900 to directly connect to the product through the pre-reserved position on the fixture 200, simplifying the testing process and improving testing efficiency. This modular fixture design allows the production line to quickly adapt to product changes or upgrades, reducing fixture costs and maintenance burden. Simultaneously, standardized interfaces enable seamless integration with various functional modules, enhancing overall production flexibility and reliability. Furthermore, the quick-change capability of the fixture tray 230 allows the production line to switch product models without stopping the machine, further improving equipment utilization and production response speed.

[0083] In this embodiment, the upper shell assembly and pressing detection module 600 includes: The robot handling mechanism 610 is used to pick up the upper shell and, after positioning and calibration by the photo-taking station 611, precisely assemble it with the lower shell in the fixture. The three-way pressing mechanism 620 includes an upper pressing head 621, a left pressing head 622, and a right pressing head 623. The three pressing heads are driven by independent servo electric cylinders 624, which can apply preset pressure and stroke to the assembled shell synchronously from three directions to complete the pressing. The full inspection system 630 includes multiple laser rangefinders 631 for scanning the four-sided contours and measuring critical assembly dimensions of the pressed product.

[0084] The upper shell assembly and pressing inspection module 600 achieves automatic picking and precise assembly of the upper shell through a robot handling mechanism 610. After positioning and calibration by the photography station 611, the robot can accurately align the upper and lower shells, ensuring the accuracy and consistency of the assembly. The three-way pressing mechanism 620 uses three pressing heads (top, left, and right), each driven by an independent servo electric cylinder 624, which can simultaneously apply preset pressure and stroke from three directions to achieve uniform pressing of the shell, avoiding deformation or stress concentration caused by single-point pressure, and improving pressing quality and product structural integrity. The full inspection system 630 uses multiple laser rangefinders 631 to scan the four-sided contours and measure key assembly dimensions of the pressed product, which can quickly detect parameters such as assembly gaps and flatness of the shell, identify defective products in a timely manner, and guide the production process through data feedback. This integrated design of assembly, pressing, and inspection realizes full automation of upper shell assembly, improves production efficiency and product qualification rate, and reduces potential problems in subsequent processes through online inspection.

[0085] In this embodiment, both the laser welding module 700 and the airtightness testing module 800 adopt a synchronous exchange robot collaborative loading and unloading mode; specifically, each module includes: SCARA robots 710 / 810 are installed on one side of the main body; The multi-station work platform 720 / 820 is located on the other side of the main line, opposite to the SCARA robot 710 / 810; Among them, the SCARA robot 710 / 810 performs synchronous exchange action: it takes a processed / tested product out of the work platform and puts it back into the main line fixture, while taking a new product to be processed / tested out of the main line fixture and putting it into the work platform.

[0086] The laser welding module 700 and the airtightness testing module 800 employ a synchronous exchange robot-assisted loading and unloading mode. Through the cooperation of a SCARA robot and a multi-station work platform, efficient and continuous material flow is achieved. The SCARA robot is positioned on one side of the main production line, and the multi-station work platform is on the other. This layout allows the robot to handle products on both the main line fixture and the work platform simultaneously. The synchronous exchange action allows the robot to retrieve processed or tested products from the work platform and place them back into the main line fixture within a single cycle, while simultaneously removing a new product to be processed or tested from the main line fixture and placing it into the work platform. This reduces robot idle time and movement paths, improving loading and unloading efficiency. This mode ensures synchronization between welding or testing processes and the main line production rhythm, avoiding production delays caused by loading and unloading delays and improving overall equipment utilization. The multi-station work platform allows for the simultaneous processing or testing of multiple products, further enhancing the module's processing capacity. The synchronous exchange design makes material flow smoother, reduces production bottlenecks, and is suitable for the needs of high-cycle automated production lines. In addition, the precise control of the robot ensures the positioning accuracy of the product during the transfer process, avoids misalignment or damage caused by handling, and ensures the quality stability of processing and testing.

[0087] In this embodiment, the functional testing module 900 includes: Manual wiring station 910; The three-axis jig removal mechanism 920 is used to remove the product jig as a whole from the jig and transport it to the testing area; The parallel test system 930 has eight independent test boxes 931, which can test four products simultaneously in a "one-to-four" electrical connection manner.

[0088] The functional testing module 900 automatically transports product fixtures via a three-axis fixture-lifting mechanism 920, removing the entire product from the fixture and transferring it to the testing area, reducing manual intervention and improving testing efficiency. The parallel testing system 930 is equipped with eight independent test boxes 931, using a "one-to-four" electrical connection, enabling simultaneous testing of four products with a 70-second test cycle, achieving a theoretical cycle time of 9.5 seconds and significantly increasing test throughput. The manual cable connection station 910 facilitates pre-test cable connections, ensuring stable transmission of test signals. This parallel testing design fully utilizes testing resources, reduces the average testing time for a single product, and meets the demands of high-efficiency testing in large-scale production. The precise handling of the three-axis fixture-lifting mechanism 920 ensures accurate product positioning during testing, avoiding testing errors caused by poor connections. The entire module automates the testing process, reducing labor costs and improving test consistency and reliability.

[0089] In this embodiment, the information laser engraving and sorting module 1000 includes: The laser engraving station 1010 has a lifting and positioning mechanism 1011 and a fiber laser engraving machine 1012, which are used to laser engrave QR codes and serial numbers on the surface of products. Laser engraving inspection station 1020 is equipped with a high-speed CCD camera 1021, which is used to read and verify the laser engraving content; The robot sorting and unloading station 1030 is equipped with a SCARA robot 1031, which is used to place qualified products into qualified product shipping pallets and move unqualified products to unqualified product collection areas based on the comprehensive judgment results of the central control unit.

[0090] The laser engraving and sorting module 1000 uses laser engraving station 1010 to laser engrave QR codes and serial numbers on the product surface. Lifting and positioning mechanism 1011 ensures the stability and positional accuracy of the product during the laser engraving process. Fiber laser engraving machine 1012 enables high-speed, clear marking, providing permanent traceability for the product. Laser engraving inspection station 1020 is equipped with a high-speed CCD camera 1021 to quickly read and verify the laser engraving content, ensuring the accuracy and readability of the markings and avoiding information loss or misreading due to laser engraving errors. Robotic sorting and unloading station 1030 uses a SCARA robot 1031. Based on the comprehensive judgment results of the central control unit, qualified products are automatically placed into the qualified product shipping tray, while unqualified products are moved to the unqualified product collection area, achieving automatic product classification and unloading. This integrated laser engraving, inspection, and sorting function ensures the quality of product marking and the accuracy of sorting, reduces manual operation, and improves unloading efficiency. Simultaneously, based on data driven by the central control unit, sorting decisions are more intelligent and reliable, ensuring the consistency of the final product quality. The entire module achieves full automation from labeling to sorting, adapts to the needs of high-speed production lines, and provides enterprises with complete product traceability data.

[0091] In this embodiment, downstream of the information laser engraving and sorting module 1000, there is also a: PIN re-inspection station 1040 is used to perform final electrical contact testing and visual appearance inspection of the PINs on products before unloading. The automatic labeling station 1050 is equipped with a label printer 1051 and a labeling robot 1052, which are used to automatically affix labels to shipping pallets or product outer packaging. Among them, the labeling robot 1052 is a SCARA robot, whose end effector integrates a vacuum label suction head 1053 and a hollow rotating platform 1054 for adjusting the label angle.

[0092] Downstream of the information laser engraving and sorting module 1000, the PIN pin re-inspection station 1040 performs final electrical contact and visual appearance inspections on the PIN pins before unloading, ensuring the reliability of the PIN pin connection and the integrity of its appearance, preventing potential defects from reaching the customer. The automatic labeling station 1050 is equipped with a label printer 1051 and a labeling robot 1052, capable of automatically generating and affixing labels based on production data, thus automating the packaging process. The labeling robot 1052 uses a SCARA robot, with its end effector integrating a vacuum label-picking head 1053 and a hollow rotating platform 1054. The vacuum label-picking head 1053 ensures stable label pickup and affixing, while the hollow rotating platform 1054 allows for adjustment of the label angle to adapt to different affixing positions, improving labeling accuracy and flexibility. This design makes the final inspection and labeling process more efficient and accurate, reducing manual intervention and ensuring the consistency and traceability of product quality. Furthermore, the integration of the re-inspection station and the labeling station further optimizes the production process and improves overall production efficiency.

[0093] In this embodiment, the production line also includes an intelligent logistics module, which includes a material frame loading machine 1100. The material frame loading machine 1100 includes a frame 1110, a loading connection line 1120 mounted on the frame 1110 for conveying blister packs containing products, a loading and unloading frame roller line 1130 located to the side of the loading connection line 1120 for conveying empty material frames, a handling and picking mechanism 1140 located above the loading connection line 1120 for transporting blister packs on the loading connection line 1120 to empty material frames on the loading and unloading frame roller line 1130, and an integrated control unit. The loading and unloading frame roller line 1130 is provided with a material frame guiding adjustment mechanism 1160, a frame pushing mechanism 1170, and a frame separating mechanism 1180. The frame pushing mechanism 1170 and the frame separating mechanism 1180 cooperate with each other to separate stacked material frames into flat material frames.

[0094] By modularly integrating the feeding feeder line 1120, the loading / unloading frame roller line 1130, the handling and picking mechanism 1140, and the integrated control unit, a highly collaborative automated feeding system is constructed. This modular layout makes the equipment structure compact and the functional areas clearly defined, which is beneficial for production line planning and space utilization. The feeding feeder line 1120 is dedicated to transporting blister packs containing products, while the loading / unloading frame roller line 1130 is responsible for the parallel transport and preparation of empty frames. This material diversion design avoids interference between processes and lays the foundation for continuous operation. The frame guiding adjustment mechanism 1160 set on the loading / unloading frame roller line 1130 can adapt to empty frames of different sizes, improving the overall flexible production capability of the equipment. The frame pushing mechanism 1170 and the frame separating mechanism 1180 work together to separate the frames. They directly address the problem of low efficiency and error-proneness in manually handling stacked frames. Through mechanical automation, the stacked frames are reliably separated and laid flat on the roller line, preparing for subsequent automated palletizing.

[0095] In this embodiment, the frame pushing mechanism 1170 includes a first linear module 1171 and a push plate 1172 driven by the first linear module 1171; the frame separating mechanism 1180 includes a second linear module 1181 and a pair of clamping plates 1182 driven by the second linear module 1181 that can move towards or away from each other.

[0096] The specific configurations of the frame pushing mechanism 1170 and the frame separating mechanism 1180 are defined, and their core actuators are identified. The frame pushing mechanism 1170 employs a scheme where a first linear module 1171 drives a pusher plate 1172. Utilizing the high precision and stability of the linear module, accurate control of force and displacement during the frame pushing process is ensured, resulting in crisp and clean frame separation. The frame separating mechanism 1180 employs a scheme where a second linear module 1181 drives a pair of clamping plates 1182. By controlling the opposing or separating movements of the clamping plates 1182, it can stably clamp or release the upper frame. This mechanical clamping method is more adaptable to frames with irregular surfaces or holes than pneumatic or vacuum adsorption methods.

[0097] In this embodiment, the first linear module 1171 is a Y-axis module and is driven by a first servo motor 1173; the second linear module 1181 includes a Z-axis module 1183 and a bidirectional lead screw mechanism 1184 that drives a pair of clamping plates 1182 to move horizontally, and the Z-axis module 1183 is driven by a second servo motor 1185.

[0098] The configuration of the drive components has been further refined, ensuring the precise movement of the mechanism. The first linear module 1171 is designated as the Y-axis module and driven by a servo motor, allowing for precise programming control of the horizontal stroke and speed of the pushing frame action. This meets the positioning requirements for pushing the material frame at different intervals, ensuring fast and accurate movement. The separating mechanism 1180 uses a Z-axis module 1183 to achieve the vertical lifting and lowering of the clamping plate 1182, driven by another servo motor. This ensures that the clamping mechanism can accurately descend to a predetermined height to grip the material frame and smoothly lower it after separation, avoiding impact and collisions.

[0099] In this embodiment, the frame pushing mechanism 1170 and the frame splitting mechanism 1180 are configured to work together in the following manner: When the two stacked empty material frames reach the designated position, the pair of clamping plates 1182 of the frame separating mechanism 1180 descend to both sides of the upper empty material frame and move towards each other to clamp the upper empty material frame. Subsequently, the push plate 1172 of the push frame mechanism 1170 contacts the outer wall of the lower empty material frame and is driven by its first linear module 1171 to push the lower empty material frame to move horizontally, so that the upper and lower material frames are separated. Then, the Z-axis module 1183 of the frame-separating mechanism 1180 drives a pair of clamping plates 1182 to descend, lowering the clamped upper empty frame to the plane where the original lower empty frame was located. Finally, the pair of clamping plates 1182 move apart to release the material frame, and the push plate 1172 and the pair of clamping plates 1182 return to their initial positions.

[0100] The specific process of the collaborative operation of the frame pushing and separating mechanisms was clarified, and a set of efficient and reliable frame separation methods was defined. The process begins with the downward movement of the clamping plate 1182 of the separating mechanism 1180, which clamps the upper frame. This action transforms the connection between the upper and lower frames into one where the separating mechanism 1180 actively holds the upper frame, creating conditions for separation. Immediately afterwards, the frame pushing mechanism 1170 moves synchronously, horizontally pushing the lower frame, directly releasing the stacking relationship between the upper and lower frames through mechanical motion, achieving physical separation. Subsequently, the separating mechanism 1180 carries the upper frame down to the working plane. This step completes the spatial transformation from a stacked state to a side-by-side flat state, which is crucial for automated flow control. Finally, all executing components reset, ready for the next round of operation.

[0101] In this embodiment, the material frame guiding adjustment mechanism 1160 includes a bidirectional lead screw 1161, two guide plates 1162 threadedly engaged with the bidirectional lead screw 1161, and a third servo motor 1163 driving the bidirectional lead screw 1161. The two guide plates 1162 are symmetrically arranged with the center line of the upper and lower material frame roller line 1130 as a reference.

[0102] The core structure of the material frame guiding and adjusting mechanism 1160 is described in detail. A bidirectional lead screw 1161 driven by a servo motor drives two guide plates 1162 to move towards or away from each other, achieving both motorization and precision in the adjustment process. The symmetrical arrangement based on the centerline of the roller conveyor ensures that material frames of different widths remain centered on the conveyor line after adjustment. This is particularly important for the subsequent gripping and positioning by the handling and picking mechanism 1140, ensuring consistency in the gripping points.

[0103] In this embodiment, the handling and picking mechanism 1140 includes a three-axis linear module 1141, a hollow rotary platform 1142 installed at the end of the Z-axis module, and a plurality of vacuum suction cups 1143 installed on the hollow rotary platform 1142.

[0104] The specific configuration of the handling and picking mechanism 1140 is defined. The three-axis linear module 1141 enables the end effector to perform precise linear motion in three-dimensional space, covering the entire working area from the blister tray pickup point of the loading and unloading conveyor line 1120 to the material frame placement point of the loading and unloading roller line 1130, with efficient and controllable motion path. The hollow rotary platform 1142 installed at the end of the Z-axis is a key feature, enabling the vacuum suction cup 1143 assembly to not only perform linear motion but also achieve rotational motion around the axis.

[0105] In this embodiment, the vacuum chuck 1143 is an anti-static vacuum chuck.

[0106] The vacuum chuck 1143 is required to have anti-static properties. In the electronics manufacturing industry, many product components are highly sensitive to electrostatic discharge. Using the anti-static vacuum chuck 1143 can effectively prevent the generation and accumulation of static electricity due to friction during the picking up and transferring of blister packs (which typically contain precision electronic components), thereby preventing electrostatic discharge from breaking down or damaging sensitive electronic components.

[0107] In this embodiment, the feeding connection line 1120 also includes a weighing sensor 1210 located below its line frame.

[0108] Weighing and precise positioning functions have been added to the feeding and connecting line 1120. The weighing sensor 1210, integrated under the line frame, can perform online weight detection on the blister packs and the products inside during transmission. This function can be used in various quality control stages, such as checking the completeness of product assembly (e.g., missing parts, incomplete parts), or performing weight sorting, thus realizing an important quality checkpoint in the production process.

[0109] In this embodiment, the integrated control unit is an integrated device combining a touch screen and a button control box.

[0110] The specific form of the integrated control unit was clarified. The touchscreen and button control box were integrated into one unit, forming a centralized human-machine interface. The touchscreen can intuitively display equipment status, operating parameters, alarm information, and production data in a graphical manner, allowing operators to quickly understand and grasp the equipment's operating status.

[0111] In this embodiment, the frame 1110 is provided with safety guardrails around the loading connection line 1120 and the handling and picking mechanism 1140.

[0112] A safety protection structure was added to the entire system. The installation of safety guardrails creates a physical barrier between the high-speed moving transport and picking mechanism 1140, the automatically running roller conveyor, and other moving parts and external operators. This effectively prevents mechanical collisions, pinching injuries, and other safety accidents that may occur due to personnel accidentally entering the equipment's working area, providing basic personal safety protection for on-site operators.

[0113] In this embodiment, the intelligent logistics module further includes: An automatic weighing unit 1200 is installed after the robot unloading station. It uses a weighing sensor 1210 to weigh the full-loaded product pallet online and bind the weight information to the product serial number. The automatic labeling and barcode reading unit 1300 is used to automatically mark 1310, apply 1320, and perform double-sided barcode reading verification on the circulating material frames; The automatic palletizing unit 1400 uses a six-axis articulated robot 1410 and is equipped with an adaptive vacuum suction cup gripper 1420 to automatically stack labeled material frames onto a pallet according to a preset stacking pattern.

[0114] The automatic weighing unit 1200 of this intelligent logistics module is located after the robot unloading station. It uses a weighing sensor 1210 to weigh the fully loaded product pallets online and binds the weight information to the product serial number, enabling real-time monitoring and data recording of product weight, providing a basis for quality control and logistics management. The automatic labeling and barcode reading unit 1300 automatically marks (1310), affixes labels (1320), and performs double-sided barcode verification on the circulating material frames, ensuring the accuracy and traceability of the frame markings and avoiding errors that may occur with manual labeling. The automatic palletizing unit 1400 uses a six-axis articulated robot 1410 equipped with an adaptive vacuum suction cup gripper 1420, which can automatically place the labeled material frames on the pallet according to a preset pallet type, realizing the automation of the palletizing process. The flexibility of the six-axis articulated robot 1410 allows it to handle material frames of different sizes and weights, while the adaptive vacuum suction cup gripper 1420 ensures the stability and adaptability of the gripping process. This integrated system of weighing, labeling, barcode reading, and palletizing automates the entire logistics process, improving shipping efficiency, reducing labor costs, and ensuring the accuracy and integrity of logistics information through data binding and verification. The overall logistics module is tightly integrated with the production line, forming a closed-loop management system from production to shipment, thus enhancing overall operational efficiency.

[0115] In this embodiment, the central control unit is configured as follows: The location and status of each fixture 200 are tracked in real time using RFID readers; Record and bind the key process parameters and test results of each product in pulse hot pressing welding, hot riveting, PIN pin welding, 3D line scanning, air tightness test, and functional test to generate a full-process production history. Based on production history, the automatic separation of defective products and the directional diversion of qualified products are achieved at the sorting station 530 of the PIN welding and testing module 500 and the robot sorting and unloading station 1030 of the information laser engraving and sorting module 1000.

[0116] The central control unit tracks the location and status of each fixture 200 in real time using RFID readers, achieving comprehensive monitoring of the production process and ensuring the visualization and controllability of material flow. It records and binds the process parameters and test results of each product in key processes, such as pulse hot pressing welding, hot riveting, PIN pin welding, 3D line scanning, airtightness testing, and functional testing, generating a complete production history and providing a complete data archive for each product, facilitating quality traceability and analysis. Based on the production history, the central control unit automatically separates defective products and directs qualified products at the sorting station 530 of the PIN pin welding and testing module 500 and the robotic sorting and unloading station 1030 of the information laser engraving and sorting module 1000, ensuring timely removal of defective products and accurate classification of qualified products. This data-driven quality control method improves the accuracy and efficiency of sorting, reduces human error, and ensures the consistency of final product quality. Simultaneously, the full-process data recording provides data support for enterprises to optimize processes and improve management.

[0117] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An assembly and testing line for an inner door handle module, characterized in that, include: A unified, circulating production line; Multiple general-purpose fixtures (200) that flow on the assembly line body, each fixture (200) being provided with a traceable identification mark (210); The following core functional modules are arranged sequentially along the conveying direction of the assembly line to form a continuous automated production unit: The circuit board assembly bonding and welding module (300) is used to realize the picking, cleaning, positioning, pulse hot pressing welding and post-welding inspection of PCBA and FPC; The lower shell feeding and hot riveting module (400) is used to realize the automatic feeding and dust removal of the lower shell, and to hot rivet and fix it to the PCBA module from the previous module and perform three-dimensional scanning. The PIN soldering and inspection module (500) is used to complete the PIN soldering step by step through at least two sets of soldering mechanisms, and immediately perform online visual inspection and defective product sorting on the solder joints; The upper shell assembly and pressing inspection module (600) is used to realize automatic feeding of the upper shell, precise robot assembly with the lower shell, three-way synchronous pressing, and full-size automated inspection after pressing. Laser welding module (700) is used for sealing welding of the upper and lower shells after pressing; The airtightness test module (800) is used to test the sealing performance of the welded product; The functional test module (900) is used to perform electrical and functional tests on products that have passed the airtightness test. The information laser engraving and sorting module (1000) is used to perform information laser engraving and laser engraving quality inspection on qualified products, and finally sort and unload the products based on all upstream inspection results. And a central control unit, which is connected to each module in communication, for tracing product data in real time based on the identity identifier (210), and coordinating and controlling the working rhythm and quality judgment logic of each module; It also includes an intelligent logistics module, which includes a material frame loading machine (1100), the material frame loading machine (1100) comprising: Rack (1110); The feeding connection line (1120) is installed on the frame (1110) and is used to transport blister trays containing products; The loading and unloading frame roller line (1130) is located on the side of the loading connection line (1120) and is used to transport empty frames; The transport and pick-up mechanism (1140) is positioned above the loading connection line (1120) and is used to transport the blister pack on the loading connection line (1120) to the empty material frame on the loading and unloading frame roller line (1130). And integrated control unit; The upper and lower material frame roller line (1130) is provided with a material frame guiding adjustment mechanism (1150), a frame pushing mechanism (1160), and a frame separating mechanism (1170). The frame pushing mechanism (1160) includes a first linear module and a push plate driven by the first linear module. The frame separating mechanism (1170) includes a second linear module and a pair of clamping plates driven by the second linear module that can move towards or away from each other. The frame pushing mechanism (1160) and the frame separating mechanism (1170) cooperate with each other to separate the stacked material frames into flat material frames.

2. The inner door handle module assembly and testing line according to claim 1, characterized in that, The circuit board assembly bonding and welding module (300) includes: The first SCARA robot mechanism (310) is equipped with a first CCD camera for picking up PCBA and transferring it sequentially to the cleaning station (320), the first photography station (330), and the pulse hot press welding station (340). The second SCARA robot mechanism (350) is equipped with a second CCD camera, which is used to pick up the FPC and transfer it sequentially to the film-peeling station (360), the first imaging station (330) and the pulse hot-press welding station (340) for bonding with the PCBA.

3. The inner door handle module assembly and testing line according to claim 1, characterized in that, The lower shell feeding and hot riveting module (400) includes: A four-axis industrial robot (410) is equipped with a vacuum suction plate and a third CCD camera at its end, which is used to pick up the lower shell, move it to the photography station (440) for positioning and calibration, and finally place it in the designated position of the fixture (200) that has been transferred there. The hot riveting mechanism (420) includes a hot riveting head (422) driven by a servo electric cylinder (421), a temperature controller (423) and a pressure sensor (424), used to hot rivet and fix the lower shell of the PCBA module that has been placed there; The 3D line scan inspection mechanism (430) includes two laser displacement sensors (432) driven by a precision module (431) for performing three-dimensional contour scanning and quality judgment on the hot-riveted components.

4. The inner door handle module assembly and testing line according to claim 1, characterized in that, The PIN soldering and inspection module (500) is a multi-station soldering inspection machine, which includes: The soldering station (510) is equipped with three independent soldering mechanisms (511). Each soldering mechanism (511) includes a three-axis motion module (512) and a soldering iron tip (514) with a rotating axis (513) driven by the module, a solder wire feeding assembly (515), a solder wire breaking assembly (516), and an automatic cleaning assembly (517). The inspection station (520) is set up immediately after the welding station (510) and is equipped with a vision inspection device (522) driven by a three-axis motion platform (521). The vision inspection device (522) includes a zoom camera (523) with AI recognition function and an illumination source (524) for photographing the weld joints and analyzing defects. The sorting station (530) is equipped with an NG diversion line (531) and a sorting execution mechanism (532) driven by the three-axis motion platform (521) or an independent drive mechanism, for removing non-conforming products from the main line according to the detection results.

5. The inner door handle module assembly and testing line according to claim 1, characterized in that, The upper shell assembly and pressing detection module (600) includes: The robot handling mechanism (610) is used to pick up the upper shell and, after positioning and calibration by the photo-taking station (611), precisely assemble it with the lower shell in the fixture; The three-way pressing mechanism (620) includes an upper pressing head (621), a left pressing head (622) and a right pressing head (623). The three pressing heads are driven by independent servo electric cylinders (624), which can apply preset pressure and stroke to the assembled housing synchronously from three directions to complete the pressing. The full inspection system (630) includes multiple laser rangefinders (631) for scanning the four-sided contours and measuring critical assembly dimensions of the pressed product.

6. The inner door handle module assembly and testing line according to claim 1, characterized in that, Both the laser welding module (700) and the airtightness testing module (800) adopt a synchronous exchange robot collaborative loading and unloading mode; specifically, each module includes: SCARA robots (710, 810) are located on one side of the main body; A multi-station work platform (720, 820) is located on the other side of the main line body, opposite to the SCARA robot (710, 810); The SCARA robots (710, 810) perform synchronous exchange actions: they take a processed / tested product out of the work platform and put it back into the main line fixture, while simultaneously taking a new product to be processed / tested out of the main line fixture and putting it into the work platform.

7. The inner door handle module assembly and testing line according to claim 1, characterized in that, The functional test module (900) includes: The three-axis jig removal mechanism (920) is used to remove the product jig from the jig as a whole and transport it to the testing area; The parallel test system (930) has eight independent test boxes (931) that can test four products simultaneously in a "one-to-four" electrical connection manner.

8. The inner door handle module assembly and testing line according to claim 1, characterized in that, The information laser engraving and sorting module (1000) includes: The laser engraving station (1010) has a lifting and positioning mechanism (1011) and a fiber laser engraving machine (1012) for laser engraving QR codes and serial numbers on the product surface; The laser engraving inspection station (1020) is equipped with a high-speed CCD camera (1021) for reading and verifying the laser engraving content; The robot sorting and unloading station (1030) is equipped with a SCARA robot (1031) which, based on the comprehensive judgment result of the central control unit, places qualified products into the qualified product shipping pallet and moves unqualified products to the unqualified product collection area.

9. The inner door handle module assembly and testing line according to claim 1, characterized in that, The intelligent logistics module also includes: An automatic weighing unit (1200) is installed after the robot unloading station. It uses a weighing sensor (1210) to weigh the full-loaded product pallet online and bind the weight information to the product serial number. The automatic labeling and barcode reading unit (1300) is used to automatically mark (1310), label (1320) and double-sided barcode reading verification of the circulating material frames; The automatic palletizing unit (1400) employs a six-axis articulated robot (1410) equipped with an adaptive vacuum suction cup gripper (1420) to automatically stack labeled material frames onto a pallet according to a preset pallet pattern.

10. The inner door handle module assembly and testing line according to claim 1, characterized in that, The central control unit is configured as follows: The location and status of each fixture (200) are tracked in real time using an RFID reader; Record and bind key process parameters and test results for each product in pulse hot press welding, hot riveting, PIN pin welding, 3D line scanning, airtightness testing, and functional testing to generate a full-process production history. Based on the production history, the automatic separation of defective products and the directional diversion of qualified products are realized at the sorting station (530) of the PIN welding and inspection module (500) and the robot sorting and unloading station (1030) of the information laser and sorting module (1000).

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