CN109865910B - Configurable flexible production line for assembling light modulator - Google Patents
Configurable flexible production line for assembling light modulator Download PDFInfo
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- CN109865910B CN109865910B CN201910238668.2A CN201910238668A CN109865910B CN 109865910 B CN109865910 B CN 109865910B CN 201910238668 A CN201910238668 A CN 201910238668A CN 109865910 B CN109865910 B CN 109865910B
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Abstract
The invention discloses a configurable flexible production line for assembling a light modulator, which comprises a manual module and an automatic module, wherein a front-end lifter is arranged at the starting end of the production line, and the manual module and/or the automatic module are/is arranged between the front-end lifter and a backflow lifter to perform light modulator assembling operation; each module on the production line is connected with an independent PLC controller, and SMEMA communication is adopted among the PLC controllers. The beneficial effects are as follows: the automatic module is arranged, so that the automatic module can be selected and applied according to needs, the dependence of the product quality on personnel is reduced, the stability of the automatic module is high, and the product quality is guaranteed; the combination of the automatic module and the manual module effectively improves the production efficiency and reduces the cost; the configurable flexible production mode is created, so that the demand of multiple varieties and small quantity in the future can be effectively met.
Description
Technical Field
The invention relates to a dimmer assembling production line, in particular to a flexible configuration production line capable of combining manual assembling and automatic assembling for dimmer assembling.
Background
A dimmer is an electrical device that varies the luminous flux of a light source in a lighting device, adjusting the level of illumination. A so-called dimming device having a large capacity and constituting a system; the basic principle is to change the effective value of the current of the input light source to achieve the aim of dimming. As the application of the dimmer becomes more widespread, the assembly of the dimmer, which includes assembling a PCB (printed circuit board) and a rear cover, welding terminals and spring pieces, mounting and welding a triode, assembling and welding an antenna board, driving screws and rivets, and mounting a gasket and a panel, becomes an inevitable research subject. Traditionally, the assembly in the aspect is mainly completed by manual operation, the dimmer is tested after the manual assembly is completed, and the dimmer package meeting the test requirement is sold. The manual assembly has many problems in the operation process, such as:
(1) the assembly of the dimmer has extremely high dependence on personnel, the quality of the assembly is directly determined by the technical level and the operation stability of operators, and the quality is uneven;
(2) the manual operation efficiency is low, the operation speed is slow, and the quality cannot be ensured;
(3) the labor cost is high, and the operation burden of enterprises is increased;
(4) the multiple varieties and small amount are the main production modes of the later-stage light modulator, and the mode cannot be realized by manual operation.
Accordingly, there is a need for improvements in the art that address the above-mentioned deficiencies.
Disclosure of Invention
In view of the above-mentioned drawbacks of the prior art, an object of the present invention is to provide a configurable flexible production line for assembling a dimmer, so as to solve the problems in the prior art.
In order to achieve the purpose, the invention provides a configurable flexible production line for assembling a dimmer, which comprises a manual module and an automatic module, wherein a front-end lifter is arranged at the starting end of the production line, all components of the dimmer are sent to the production line by the front-end lifter for assembly, and a backflow lifter is arranged at the tail end of the production line, so that after all components of the dimmer are assembled, object placing pieces on the production line flow back to the front-end lifter in a no-load manner, and the next group of dimmers are assembled; the manual module and/or the automatic module are/is arranged between the front-end lifter and the backflow lifter to carry out assembly operation of the dimmer; and each module on the production line is connected with an independent PLC (programmable logic controller), and the PLC controllers are communicated with each other by adopting an SMEMA (simple message engine architecture).
The automatic module mainly comprises an automatic welding machine module, a PLC (programmable logic controller) and an automatic screw driving module; the automatic welding machine module comprises an automatic welding soldering iron head, an automatic tin feeding mechanism, a temperature controller and a temperature probe, wherein the automatic welding soldering iron head is used for welding each component of a light modulator, the temperature probe is used for detecting and feeding back the temperature of the automatic welding soldering iron head, the temperature probe is connected with the temperature controller, and the temperature controller acquires the temperature detected and fed back by the temperature probe so as to control the welding temperature of the automatic welding soldering iron head; and the automatic tin feeding mechanism and the PLC are used for finishing automatic tin feeding operation according to the setting of the PLC connected with the automatic tin feeding mechanism.
In addition, based on the same dimmer assembly production line, the automatic module can also be configured with locking mechanisms, coating and glue dispensing mechanisms, auxiliary assembly mechanisms and the like, wherein the locking mechanisms, the coating and glue dispensing mechanisms, the auxiliary assembly mechanisms and the like are used for realizing the assembly of the components of the dimmer, the mechanisms are the same as the mechanisms in the prior art, the mechanisms are controlled to operate through the PLC on the production line, and the mechanisms can be configured in the production line in any sequence, so that the flexible configuration of the dimmer assembly production line is realized.
Preferably, the automatic module and the manual module are independent modules so as to facilitate the automatic operation of the light modulator assembly line and the free allocation of manual operation equipment.
Preferably, the operation area of the automatic module and/or the manual module is arranged in a C-shaped structure, and a conveying track is arranged on the C-shaped structure to realize conveying and mounting of the dimmer component.
Preferably, the conveying track is a short track, the short track is matched with the single automatic module and/or the single manual module, and when the dimmer assembly production line works, the short tracks installed on the automatic modules and/or the manual modules are in butt joint; the short track is in signal connection with the PLC.
Preferably, the conveying track is a long track, and at least one automatic module and/or manual module is arranged on the long track; the long track is in signal connection with the PLC.
Preferably, when the conveying track is used, the long track and the short track can be freely matched and arranged, so that the flexible configuration of a production line is realized.
Preferably, each module is provided with a manipulator to realize automatic operation.
Preferably, the manipulator adopts a SCARA four-shaft manipulator, the length of the manipulator arm is 350mm, and the load is 6 KG.
Preferably, in the production line, the manual module is suitable for a pure assembly station with high freedom degree, and the automatic module is suitable for an assembly station with high assembly standard requirements, such as welding and screwing of each component.
Preferably, each module of the production line can increase or decrease the number or the process sequence according to the needs, and the modules can be coordinately operated only by front-back communication when being increased or decreased.
Based on above-mentioned structure, implement above-mentioned dimmer equipment with configurable flexible production line, have following beneficial effect: the automatic module is arranged, so that the automatic module can be selected and applied according to needs, the dependence of the product quality on personnel is reduced, the stability of the automatic module is high, and the product quality is guaranteed; the combination of the automatic module and the manual module effectively improves the production efficiency and reduces the cost; a configurable flexible production mode is created, so that the requirements of multiple varieties and small quantity in the future can be effectively met; the conveying track is arranged on the C-shaped structure, can be configured at will through the conveying track, and modules are added into the line body at any time and at any time according to process requirements, so that flexible configuration operation of the production line is realized.
Drawings
The conception, the specific structure and the technical effects of the present invention will be further described with reference to the accompanying drawings to fully understand the objects, the features and the effects of the present invention.
FIG. 1 is a schematic diagram of modules of a configurable flexible production line according to an embodiment of the invention;
FIG. 2 is a schematic diagram of a combination of automatic configuration and manual configuration according to embodiment 1 of the present invention;
FIG. 3 is a schematic diagram of a fully automatically configured module assembly according to embodiment 2 of the present invention;
FIG. 4 is a schematic diagram of a fully manually configured module assembly according to embodiment 3 of the present invention;
FIG. 5 is a schematic diagram of an increase/decrease module configuration according to embodiment 4 of the present invention;
FIGS. 6-8 are schematic structural views of a "C" type automatic module according to an embodiment of the present invention;
FIGS. 9-10 are schematic structural views of a "C" type manual module according to an embodiment of the present invention;
fig. 11 is a flow chart of dimmer assembly in the embodiment.
Reference numerals:
1. a front-end elevator; 2. an automatic module; 3. a manual module; 4. a reflux elevator; 5. a "C" type structure; 51. an operating window; 6. a long track.
The arrows in the figure indicate the dimmer assembly orientation.
It is to be noted, however, that the appended drawings illustrate rather than limit the invention. It is noted that the drawings representing structures may not be drawn to scale. Also, in the drawings, the same or similar elements are denoted by the same or similar reference numerals.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The configurable flexible production line for assembling the light modulator shown in fig. 1 comprises a manual module 3 and an automatic module 2, wherein a front-end lifter 1 is arranged at the initial end of the production line, each component of the light modulator is sent to the production line by the front-end lifter 1 for assembly, and a backflow lifter 4 is arranged at the tail end of the production line, so that after each component of the light modulator is assembled, a material placing part on the production line returns to the front-end lifter 1 in a no-load manner, and the next group of light modulators are assembled; the manual module 3 and/or the automatic module 2 are/is arranged between the front-end lifter 1 and the backflow lifter 4 to carry out the assembly operation of the dimmer; each module on the production line is connected with an independent PLC controller, and SMEMA communication is adopted among the PLC controllers.
As shown in fig. 6-11, the operation areas of the automatic module 2 and/or the manual module 3 are arranged in a "C" type structure, the "C" type structure is arranged in an upper layer and a lower layer, and a conveying rail is arranged on each layer of the "C" type structure operation area to realize the conveying and installation of the dimmer pack; an operation window 51 is arranged outside the operation area of each layer of the C-shaped structure, and the conveying track enters the C-shaped structure to be installed after the operation window 51 is opened, so that conveying is completed.
As shown in fig. 6-11, the conveying track is configured as a long track 6, on which at least one automatic module and/or manual module is arranged; the long track is in signal connection with the PLC.
It should be noted that the conveying track may also be a short track, the structure of a single short track is basically the same as that of the long track 6, the short track is matched with the single automatic module 2 and/or the manual module 3, and when the dimmer assembly line operates, the short tracks installed on the respective movable modules 2 and/or the manual module 3 are butted; the short track is in signal connection with the PLC.
Based on the structure, when the conveying track is installed and used, the long track and the short track can be freely matched, and the short tracks can be completely selected to be connected and matched with the automatic modules 2 and/or the manual modules 3 to realize the conveying and installation of the light modulator assembly; or the long track is selected to be combined with the respective movable module 2 and/or the manual module 3, so that the transmission and installation of the dimmer component are realized; or the long track and the short track are connected and matched with the automatic modules 2 and/or the manual modules 3 to realize the transmission and installation of the light modulator assembly, and the light modulator assembly can be freely combined according to the requirements in practical use only in a plurality of combination forms of the transmission tracks.
In addition, based on the same dimmer assembly production line, the automatic module 2 can be also configured with locking mechanisms, coating and glue dispensing mechanisms, auxiliary assembly mechanisms and the like for realizing the assembly of all components of the dimmer, the mechanisms are the same as the mechanisms in the prior art, and the mechanisms are controlled to operate by a PLC (programmable logic controller) on the production line so as to realize the automatic flow operation of a group of dimmer production lines; and all mechanisms can be arranged in the production line in any sequence, so that the flexible configuration of the dimmer assembly production line is realized.
The embodiments of the present invention will be described in detail below with reference to several embodiments.
Example 1
As shown in fig. 2, a front-end lifter 1, five manual modules 3, two automatic welding modules, an automatic screw driving module and a reflow lifter 4 are configured on a production line, wherein the automatic welding machine modules comprise an automatic welding soldering iron head, a temperature controller, a temperature probe, an automatic tin feeding mechanism and a PLC controller, the automatic welding soldering iron head is used for welding each component of a dimmer, the temperature probe is used for detecting and feeding back the temperature of the automatic welding soldering iron head, the temperature probe is connected with the temperature controller, and the temperature controller acquires the temperature detected and fed back by the temperature probe and further controls the welding temperature of the automatic welding soldering iron head.
Preferably, the temperature controller controls the temperature of the automatic welding soldering iron head, and ensures that the temperature of the welding process is controlled within 350-400 ℃; more preferably, the temperature of the welding process is ensured to be controlled at 375 ℃.
The automatic tin feeding mechanism finishes automatic tin feeding operation according to the setting of a PLC (programmable logic controller) connected with the automatic tin feeding mechanism; the automatic tin feeding mechanism is also provided with a tin breaking structure, the tin breaking structure can punch holes on a tin wire and directly reach the soldering flux at the center, so that the soldering flux is melted when an automatic welding soldering bit is welded and heated and overflows from the holes, the solderability and the flowability of solder are enhanced, the phenomenon that the soldering flux is heated unevenly to cause explosion is avoided, and the phenomenon that tin balls are splashed onto pins of other components on a PCB (printed circuit board) to cause short circuit and other defects is avoided.
The automatic screw driving module adopts an automatic screw machine, the automatic screw machine comprises an automatic feeder, a guide rail module, an electric screw driver and a PLC (programmable logic controller), and the automatic feeder, the guide rail module and the electric screw driver are all connected with the PLC and are controlled by the PLC to automatically operate; the automatic feeder comprises a feeding belt and a material shortage monitoring system, wherein the material shortage monitoring system monitors whether a dimmer component on the feeding belt is in shortage or not and feeds back the dimmer component to the PLC, and the PLC communicates with other modules to feed and supply materials; the guide rail module is provided with a buffer cylinder, so that the error of screwing caused by oscillation is avoided; the electric screw driver is provided with a torque monitoring device, the torque of the electric screw driver is monitored in real time and recorded, and the torque information acquired and recorded by the torque monitoring device is transmitted to the PLC controller and is monitored by the PLC controller.
Preferably, each module is provided with a manipulator to realize automatic operation.
Preferably, the manipulator adopts a SCARA four-shaft manipulator, the length of the manipulator arm is 350mm, and the load is 6 KG.
The automatic module 2 is also provided with a locking mechanism for realizing the assembly of each component of the light modulator, a coating and glue dispensing mechanism, each auxiliary assembly mechanism and the like, the mechanisms are the same as the mechanisms in the prior art, and the mechanisms are controlled to operate by a PLC (programmable logic controller) on the production line to realize the automatic flow operation of a group of light modulator production lines; and all mechanisms can be arranged in the production line in any sequence, so that the flexible configuration of the dimmer assembly production line is realized.
Based on the above-mentioned production line structure, in combination with the assembly process of the dimmer in fig. 11, the operation flow is as follows: carrying out board splitting and program burning on the PCB assembly; placing each component of the dimmer on an object placing part (such as a tray), conveying the components to a manual module 3 through a front-end lifter 1 to install terminals and spring pieces, and installing a PCB on a rear cover; conveying the assembly assembled in the previous step to an automatic welding module to weld a terminal and a spring leaf, and conveying the assembly with the welded terminal and the spring leaf to a manual module 3 to install a rear cover gasket, a triode and an antenna plate on a modulation aluminum sheet; conveying the assembly adjusted in the previous step to an automatic welding module for triode welding and heat dissipation glue dispensing; the assembly with the welded triode is conveyed into a manual module 3 to be mounted with an antenna, welded with an antenna plate and mounted with an aluminum sheet; conveying the components welded with the antenna board to an automatic screwing module for screwing; conveying the screwed components to a manual module 3 for riveting, installing soft gaskets and installing panels, and taking out the assembled dimmer after the assembly is finished for testing and packaging; the empty object after the dimmer is taken out is returned to the initial position of the production line through the return lifter 4, and the procedure is repeated to assemble the next batch of assembly parts.
Example 2
As shown in fig. 3, the basic structure of the present embodiment is the same as that of embodiment 1, except that the modules of the production line in the present embodiment are combined by a front-end elevator 1, a fully automatic module 2 and a reflow elevator 4, and the operation flow is as follows in conjunction with the assembly process in fig. 11: carrying out board splitting and program burning on the PCB assembly; placing each component of the dimmer on an object placing part (such as a tray), conveying the components to each automatic module 2 through a front-end lifter 1 to install terminals and spring pieces, and installing a PCB on a rear cover; welding a terminal and a spring piece, and mounting the assembly welded with the terminal and the spring piece on a rear cover gasket, a triode and an antenna plate on a modulation aluminum sheet; performing triode welding and heat dissipation glue dispensing operation on the adjusted assembly; mounting an antenna, welding an antenna plate and mounting an aluminum sheet on the component after the triode is welded; conveying the components welded with the antenna board to an automatic screwing module for screwing; riveting the screwed assembly, installing a soft gasket and installing a panel, and taking out the assembled dimmer after the assembly is finished to carry out testing and packaging operations; the empty object after the dimmer is taken out is returned to the initial position of the production line through the return lifter 4, and the procedure is repeated to assemble the next batch of assembly parts.
Example 3
As shown in fig. 4, the basic structure of the present embodiment is the same as that of embodiment 1, except that the modules of the production line in the present embodiment are combined by a front-end elevator 1, a full-manual module 3 and a reflow elevator 4, and the operation flow is as follows in conjunction with the assembly process in fig. 11: carrying out board splitting and program burning on the PCB assembly; placing each component of the dimmer on an object placing part (such as a tray), conveying the components to each manual module 3 through a front-end lifter 1 to install terminals and spring pieces, and installing a PCB on a rear cover; welding a terminal and a spring piece, and mounting the assembly welded with the terminal and the spring piece on a rear cover gasket, a triode and an antenna plate on a modulation aluminum sheet; performing triode welding and heat dissipation glue dispensing operation on the adjusted assembly; mounting an antenna, welding an antenna plate and mounting an aluminum sheet on the component after the triode is welded; screwing the components welded with the antenna plates; riveting the screwed assembly, installing a soft gasket and installing a panel, and taking out the assembled dimmer after the assembly is finished to carry out testing and packaging operations; the empty object after the dimmer is taken out is returned to the initial position of the production line through the return lifter 4, and the procedure is repeated to assemble the next batch of assembly parts.
Example 4
As shown in fig. 5, the basic structure of the present embodiment is the same as that of embodiment 1, except that the number of the automatic die sets 2 and the manual die sets 3 in the production line is arbitrarily increased or decreased in the present embodiment.
It should be noted that, in the technical solution of the present application, the assembly of the dimmer may configure a flexible production line, different modules may be set according to different processes, for example, several manual modules 3 and several automatic modules 2 may be added, and the process sequence may be increased or decreased arbitrarily, the above configuration is only one or several of them, and is not limited to the present invention in any form, each module of the production line may increase or decrease the number or the process sequence as required, and the modules may be increased or decreased in coordination only by front-back communication. Any simple modification or equivalent changes made to the technical essence of the present invention shall be protected by the present invention unless departing from the content of the technical solution.
It should be added that, unless otherwise defined, technical or scientific terms used herein shall have the ordinary meaning as understood by those of ordinary skill in the art to which this invention belongs. The terms "connected" or "coupled" and the like as used in the description and claims of the present patent application are not restricted to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "upper", "lower", "end", "side", and the like are used merely to indicate relative positional relationships, and when the absolute position of the object to be described is changed, the relative positional relationships are changed accordingly.
Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any uses or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
It will be understood that the present invention is not limited to the structures that have been described above and shown in the drawings, and that various modifications and changes can be made without departing from the scope thereof. The scope of the invention is limited only by the appended claims.
Claims (9)
1. A configurable flexible production line for assembling a light modulator is characterized by comprising a manual module and an automatic module, wherein a front-end lifter is arranged at the starting end of the production line, all components of the light modulator are conveyed to the production line by the front-end lifter to be assembled, and a backflow lifter is arranged at the tail end of the production line, so that after all components of the light modulator are assembled, object placing pieces on the production line flow back to the front-end lifter in a no-load manner to assemble the next group of light modulators; the manual module and/or the automatic module are/is arranged between the front-end lifter and the backflow lifter to carry out assembly operation of the dimmer; each module on the production line is connected with an independent PLC (programmable logic controller), and the PLC controllers are communicated with one another by adopting an SMEMA (simple message engine architecture);
the automatic module mainly comprises an automatic welding machine module, an automatic screw driving module and a PLC (programmable logic controller); the automatic welding machine module comprises an automatic welding soldering iron head, an automatic tin feeding mechanism, a temperature controller and a temperature probe, wherein the automatic welding soldering iron head is used for welding each component of a light modulator, the temperature probe is used for detecting and feeding back the temperature of the automatic welding soldering iron head, the temperature probe is connected with the temperature controller, and the temperature controller acquires the temperature detected and fed back by the temperature probe so as to control the welding temperature of the automatic welding soldering iron head; the automatic tin feeding mechanism is connected with the PLC, and finishes automatic tin feeding operation according to the setting of the PLC connected with the automatic tin feeding mechanism;
the operation area of the automatic module and/or the manual module is provided with a conveying track, and the conveying track is a short track or a long track.
2. The flexible production line according to claim 1, wherein in the production line, the manual module is adapted to a pure assembly station having a high degree of freedom, and the automatic module is adapted to an assembly station having a high requirement for assembly standards.
3. The flexible production line of claim 1, wherein the number or process sequence of modules in the production line can be increased or decreased as desired, and the modules can be increased or decreased in a coordinated manner by only communicating back and forth.
4. The flexible production line as claimed in claim 1, wherein the operation area of the automatic module and/or the manual module is arranged in a "C" type structure, and a conveying rail is arranged on the "C" type structure to realize conveying installation of the dimmer component.
5. The flexible production line according to claim 1, wherein the conveying track is a short track, the short track is matched with the single automatic module and/or manual module, and when the dimmer assembly production line operates, the short tracks mounted on the automatic modules and/or manual modules are in butt joint; the short track is in signal connection with the PLC.
6. The flexible production line according to claim 1, wherein the conveying track is a long track on which at least one of the automatic module and/or the manual module is disposed; the long track is in signal connection with the PLC.
7. The flexible production line according to claim 1, wherein the long track and the short track are freely arranged in a matched manner when the conveying track is used.
8. The flexible production line of claim 1, wherein each module is provided with a robot for automated operation.
9. The flexible production line of claim 8, wherein the robot is a SCARA 2 four-axis robot having a robot arm length of 350mm and a load of 6 KG.
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