异形电子元件自动插件机设计及其关键技术研究

发布时间：2018-02-26 14:55

本文关键词： 异形电子元件自动插件机结构设计校形模态分析　出处：《山东大学》2015年硕士论文　论文类型：学位论文

【摘要】：电子产品印制电路板(PCB板)上电子元件的自动插件装配技术是电子产品生产的关键。当前,中国电子制造业特别是家电制造业广泛使用的异形电子元件仍为手工插件装配方式,存在着工作效率低、劳动力成本高、错插和漏插现象严重、管理任务繁重的问题。本课题异形电子元件自动插件机,主要用于电子电器行业异形电子元件的自动插件装配,针对异形电子元件手工插件方式所产生的诸多问题,设计能够替代手工插件各工序的自动化设备,能以单台或数台插件机替代手工插件流水线上异形电子元件的大部分手工插件过程。介绍电子制造业常用电阻、电容、变压器等电子元件的种类及其来料方式,分析国外Panasonic品牌RG131、AV132型号及国产新泽谷品牌4000系列的常规电子元件插件机(AI)实现物料自动上料、自动插件的工作方式和技术特点。通过对某典型产品异形元件手工插件流水线的分析,阐述异形电子元件手工插件的技术特点和存在的问题。通过分析当前工业自动化技术的发展现状和电子制造业高速轻载机械手精密自动化装配的应用需求,并结合本课题异形电子元件自动插件机的国内外研究开发现状、发展趋势和当前存在的问题,引出本文异形电子元件自动插件机的主要研究内容和论文的结构框架。基于对异形电子元件自动插件机的设计流程分析,确定插件机设计参数要求,进行了各功能模块的划分,分析插件机设计的主要内容和设计理论。分析标准PCB板和异形电子元件的制造工艺,确定PCB板及电子元件的尺寸精度,为后续PCB板上电子元件的插装提供理论依据。分析实现自动插件所需自由度要求,阐述插件机机体结构形式、PCB板自动上下料形式、多种类型异形电子元件自动供料的方式；提出基于运动控制卡的插件机控制系统的搭建方案。分析并提出了自动插件所需关键技术的解决方法。结合异形元件的可机插性,选定MKP-X2型安规电容异形电子元件作为研究对象,设计插件机的重复定位精度-0.04mm、插件效率2000-2500pcs/h、插件不良率小于800ppm。分析所满足的插件动作要求,插件机为6自由度直角坐标结构形式。设计单个插件周期为1.6s,按照自动插件技术要求分析插件机的工作流程,进行各工步时间的分配。基于异形电子元件自动插件技术可行性方案,进行插件机轴系、PCB板自动上下料、异形电子元件自动上料结构、快速精密电动夹爪的设计和选型。通过分析插件机振动影响因素,进行插件机机械结构减振改进设计。建立了振动器供料的振动方向角、振动强度和振动频率的计算公式。从提高自动插件的可靠性、降低插件废品率的角度出发,设计MKP-X2元件针脚校形机构。进行插件机的仿真分析与实验研究。基于有限元分析的基本理论并借助于ANSYS仿真分析软件进行插件机的模态仿真分析,找出机体的薄弱环节,进行优化后的插件机结构的模态分析和谐响应分析,发现了在第1阶模态固有频率值34.596Hz附近存在共振的危险,X轴方向为敏感方向,在设计时应予以避免。分别进行3批次MKP-X2安规电容异形元件针脚的卧式校形和立式校形实验,得到卧式校形和立式校形的校形力峰值分别为65.3N、36.5N,校形后的中心距公差范围分别为(-0.16,+0.04)m.m、(-0.05,+0.07)mm,卧式校形和立式校形的回弹量分别为0-0.2mm、0-O.1mm,确定针脚立式校形结构对于提高元件的可机插率的可行性。通过测试插件机样机不同位置点重复定位精度,确定插件机样机X轴、Y轴的重复定位精度分别约为+0.025mm和±0.0265mm,满足设计要求。
[Abstract]:Electronic products, printed circuit board (PCB board) electronic component assembly automatic plug-in technology is the key to the production of electronic products. At present, Chinese electronic manufacturing industry especially special electronic components widely used for household appliances manufacturing industry is still manual plug-in assembly method, there exists low efficiency, high labor costs, the plug and plug leakage phenomenon serious and arduous management tasks to solve this problem. Special electronic components automatic plug-in machine, mainly used for electronic industry special electronic components automatic plug-in assembly, many problems due to special electronic components manual plug-in mode, design automation equipment can replace the process manual plug-in, can replace the special electronic components of the most manual plug-in process manual on plug-in lines with single or multiple plug machine. Introduced the electronic manufacturing industry commonly used resistors, capacitors, transformers and other types of electronic components and The incoming Panasonic, analysis of foreign brands RG131, AV132 models and domestic brand new sawatani plug-in conventional electronic components 4000 series machine (AI) to realize automatic material feeding, working methods and technical features of automatic plug-in. Through the analysis of a typical product shaped components manual plug-in lines, describes the technical characteristics of special electronic components manual the plug-in and the existing problems. Through the development status and application requirements of electronic manufacturing industry analysis of the current industrial automation technology, high speed and light load precision automatic assembly manipulator, and combined with the development status of this research special electronic components automatic plug-in machine at home and abroad, the development trend and the existing problems, the main research content and the frame structure this leads to the special electronic components automatic plug-in machine. Analysis of the design process of special electronic components automatic plug-in machine based on the determined plug-in Requirements of machine design parameters, the division of each functional module, main content analysis and design theory of plug-in machine design. Manufacturing process analysis of standard PCB plate and shaped electronic components, determine the size of precision PCB board and electronic components, electronic components for the subsequent PCB board is inserted to provide a theoretical basis for analysis of freedom. Is required to achieve the automatic plug-in, this plug-in machine structure, automatic loading and unloading form PCB board, various types of special electronic components for automatic feeding; puts forward to build the plug-in machine control system motion control card scheme based on analysis and put forward methods to resolve the key technology of automatic plug-in. Combined with plug shaped components the machine can be selected, MKP-X2 type capacitor special electronic components as the research object, -0.04mm repeated positioning precision machine design plug-in, plug-in plug-in efficiency 2000-2500pcs/h, the defect rate of less than 80 Meet the 0ppm. analysis plug-in movement requirements, plug-in machine structure form 6 degree of freedom Cartesian coordinate. The design of a single plug-in cycle is 1.6s, in accordance with the requirements of the automatic plug-in technology analysis plug-in machine working process, the allocation of each step time. Special electronic components automatic plug-in technology feasibility scheme based on plug-in shafting, PCB board automatic feeding, automatic feeding structure of special-shaped electronic components, precision design and selection of electric fast clamp claw. Through the analysis of influence factors of the vibration of the mechanical structure design of card machine, card machine vibration improved. Established the vibration direction of the vibrator feeding angle, calculation formula of vibration intensity and vibration frequency. In order to improve the reliability of automatic the plug-in, plug-in to reduce scrap rate perspective, design MKP-X2 element pin shape correction mechanism. Simulation analysis and experimental research of plug-in machine. Based on finite element analysis This theory and with the help of modal analysis in ANSYS simulation analysis software plug-in machine, find out the weak link of the body, modal analysis and structure optimization of the plug-in machine after the harmonic response analysis, found the risk of resonance near 34.596Hz value in first modal frequency, X direction sensitive direction, at design time should be avoided. The horizontal and vertical respectively sizing sizing experiments of 3 batches of MKP-X2 capacitor element shaped pin, get the shape correction force peak horizontal and vertical sizing sizing were 65.3N, 36.5N, shape correction after center distance tolerance range respectively (-0.16, M.M, -0.05 (+0.04). +0.07) mm, horizontal and vertical springback correction correction for 0-0.2mm 0-O.1mm, respectively, to determine the vertical pin shape correction structure for the feasibility of improving the machine inserted rate components. By testing the prototype plug-in machine from different positions of repeat positioning accuracy, indeed The repeat positioning accuracy of the Y axis is about +0.025mm and + 0.0265mm, which meets the design requirements for the X axis of the prototype.

【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TN405

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