WO2021109736A1 - 全自动收料机及其收料方法 - Google Patents

全自动收料机及其收料方法 Download PDF

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Publication number
WO2021109736A1
WO2021109736A1 PCT/CN2020/122143 CN2020122143W WO2021109736A1 WO 2021109736 A1 WO2021109736 A1 WO 2021109736A1 CN 2020122143 W CN2020122143 W CN 2020122143W WO 2021109736 A1 WO2021109736 A1 WO 2021109736A1
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WO
WIPO (PCT)
Prior art keywords
metal terminal
terminal strip
joint
cut
metal
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Application number
PCT/CN2020/122143
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English (en)
French (fr)
Inventor
周爱和
门松明珠
Original Assignee
昆山一鼎工业科技有限公司
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Application filed by 昆山一鼎工业科技有限公司 filed Critical 昆山一鼎工业科技有限公司
Priority to JP2021572100A priority Critical patent/JP7207794B2/ja
Publication of WO2021109736A1 publication Critical patent/WO2021109736A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C47/00—Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
    • B21C47/02—Winding-up or coiling
    • B21C47/04—Winding-up or coiling on or in reels or drums, without using a moving guide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D43/00—Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
    • B21D43/28—Associations of cutting devices therewith
    • B21D43/287—Devices for handling sheet or strip material

Definitions

  • the invention belongs to the technical field of automatic material collection for surface treatment products, and specifically relates to a fully automatic material receiving machine and a fully automatic material receiving method.
  • Continuous metal terminals are made of thin copper, thin copper alloy and thin stainless steel strips as raw materials through precision punching. Under normal circumstances, the collection of test samples of the obtained continuous metal terminal products and the reel replacement operation of the receiver are performed manually. In the process of operation, it is inevitable to encounter abnormal phenomena such as deforming the continuous metal terminal. For example, after the continuous metal terminal product is filled with the tray, if you use scissors to cut the continuous metal terminal product, if the operation is not careful, the continuous metal terminal product will be deformed; subsequently, when the sample for testing is about 20mm to 30mm, the same will happen. The continuous metal terminal product is deformed due to improper operation; when the continuous metal terminal product is placed in the new receiving tray, a slight improper operation will also cause the continuous metal terminal product to deform.
  • the continuous metal terminal obtained in the stamping section is subjected to surface treatment.
  • nickel metal is deposited on the surface of the continuous metal terminal, and then part of the surface is treated on the surface to deposit gold, or palladium, or palladium.
  • Connectors and other electronic components assembled from these surface-treated metal terminals and plastic cases are widely used in precision electronics industries such as smart phones, computers, cameras, aerospace, automobiles, and general civilian electronics industries such as TVs and refrigerators.
  • the continuous metal terminals are processed through the continuous production line surface treatment, when collecting and inspecting the surface treatment samples and replacing the new receiving tray, the manual operation will touch the electroplated products, which will leave touch marks on the surface of the surface treatment terminals.
  • the metal precipitated by various surface treatments is highly active, and the surface of the touched part will change color and even corrode with the prolonged storage time, resulting in poor electrical conductivity of electronic components, which seriously affects the quality of its products; thus, the above-mentioned precision electronic products It can’t be used, especially when the smartphones, computers, cameras, cars and other commodities that use the above electronic components have problems during use, it will cause immeasurable serious consequences and huge economic losses.
  • the metal terminals that make up the electronic components of the connector are becoming more and more miniaturized and miniaturized.
  • the connector terminals for insertion of flexible printed circuit boards referred to as FPC terminals
  • FPC terminals have an effective length of only 2mm to 3mm; the total width of the product plus the positioning hole connection belt is only 5mm to 6mm.
  • the design of board-to-board metal terminals is also in order to meet the requirements of this change, from flat metal terminals to curved metal terminals with complex shapes.
  • Patent Document 1 (CN 207792202U), an automatic coil rewinding machine used for stamping is described.
  • the equipment receives the signal of the punch motor through the controller.
  • the controller controls the drag motor to rotate in the positive direction, and the drag motor drags the support roller shaft to move upward, and the support roller shaft The distance between it and the reel shaft will increase, thereby slowing down the speed of rewinding and making the tightness of the coil consistent.
  • the invention patent does not involve automatic cutting of continuous metal terminals, automatic collection of test samples, and automatic rolling of continuous metal terminals in continuous production into a new receiving tray.
  • Patent Document 2 CN 206645615U
  • the photoelectric sensor of this invention senses the distance between it and the metal product.
  • the control system uses the distance to judge the winding speed of the metal product.
  • the upper limit position is used to sense whether the material is winding too fast, and the offline position is used to sense the metal product. Whether the winding speed is too slow, the structure is simple, and the degree of automation is high, which avoids the problem of manual winding speed.
  • Patent Document 3 CN 108555175B
  • the equipment realizes the pushing and reclaiming of the workpiece after the stamping die is completed, avoiding the dangerous operation of the operator reaching out to the die to take out the workpiece, reducing the probability of accidents of the stamping equipment, and improving the production efficiency.
  • Patent Document 4 Japanese Patent No. 30844757
  • a guide roller that can prevent the continuous metal segment from swaying laterally is arranged at the exit of the punching machine, thereby solving the problem that the continuous metal segment is prone to deformation at the exit of the stamping equipment.
  • Patent Document 5 Japanese Patent No. 4979510
  • This patent addresses the problem that the winding machine with multi-layer take-up reels needs to move up and down to automatically change reels and the equipment is relatively cumbersome. It adopts a reel change method that rotates and moves horizontally on the central axis to provide a simple and convenient reel change method; at the same time, the The reel-changing method runs stably, and the spacing between each layer of the rewinding reel does not require too much space, and it has the characteristics of safe and reliable operation; therefore, the rewinding machine provided by this patent not only saves space, but also has more volume than the usual rewinding machine. It is small and light in weight, thereby reducing the production cost of the equipment.
  • Patent Documents 1 to 5 various receivers are provided.
  • the design principles of all the equipment and their actual operation cannot solve the automatic joint shearing of continuous metal terminal products after surface treatment and test products.
  • Various practical problems such as automatic sampling, continuous metal terminals automatically placed in the new receiving tray.
  • the present invention aims to solve at least one of the technical problems existing in the prior art.
  • the present invention proposes an automatic material receiving machine, which can effectively reduce the production cost of the terminal and realize continuous production.
  • the invention also proposes a fully automatic material receiving method, which can improve the production efficiency of the terminal, increase the degree of automation and product quality.
  • the fully automatic rewinding machine can be used to continuously rewind the metal terminal strip to form a tray, the metal terminal strip having at least one joint extending along its conveying direction
  • the The automatic rewinding machine includes: a body; a rewinding pan, the rewinding pan is arranged on the body, the rewinding pan is capable of rewinding the metal terminal strip; a detection mechanism, the detection mechanism is arranged on the The machine body can obtain the number of joints within a preset distance; a shearing piece, the shearing piece is provided on the machine body and can cut the metal terminal strip, and the shearing piece is located between the receiving tray and Between the detection mechanism; the controller, the controller is respectively connected with the detection mechanism and the shearing member to control the shearing member to the metal terminal material according to the number of joints detected by the detection mechanism The strip is cut, wherein, when the number of joints within the preset distance is one, the controller controls the shearing element to cut the
  • the detection mechanism is matched with the shearing member, the detection mechanism can obtain the number of joints within a preset distance, and the controller can perform different operations according to the detection results of the detection mechanism.
  • the controller can control the shearing piece to cut the metal terminal strips on both sides of the joint.
  • the controller can control the shearing piece. Cut the metal terminal strip in the front area of the first connector and the metal terminal strip in the rear area of the last connector among all the connectors within the preset range. The cut metal terminal strip can be discarded.
  • the fully automatic material receiving machine according to the embodiment of the present invention can realize automatic joint cutting in the production process of continuous metal terminal products, and improve terminal production and processing efficiency.
  • the fully automatic rewinding machine further includes: a CCD detector, which is provided in the body and can detect the deformation of the metal terminal in the metal terminal strip, so The controller is connected with the CCD detector to control the shearing member to cut the metal terminal strip on both sides of the deformed metal terminal according to the detected deformation.
  • the machine body is provided with a receiving position and a discharging position
  • the number of the receiving tray is more than two
  • the two receiving trays are spaced apart in the vertical direction
  • each receiving tray is spaced apart from each other in the vertical direction.
  • the receiving tray can be movable between the receiving position and the unloading position.
  • the shearing element is configured to perform at least three cuts on the upstream and downstream areas of the joints on the metal terminal strip when the number of joints within the preset distance is one, wherein the first The cutting position and the second cutting position are respectively located upstream and downstream of the joint, and the third cutting position is located upstream of the first cutting position.
  • the shearing element is configured to perform a contact with the two end joints on the metal terminal strip located at both ends in the transport direction when the number of joints within the preset distance is multiple.
  • the upstream and downstream areas are cut at least twice, and the two cut positions are respectively located upstream and downstream of the two end joints.
  • the fully automatic receiving method of the fully automatic receiving machine can be used to continuously receive the metal terminal strip to form a tray, and the metal terminal strip has an extending direction along its conveying direction. At least one joint, the method includes the following steps: S1, judging whether the fully automatic rewinding machine meets the formal production conditions; S2, when the formal production conditions are met, production is performed, and when the formal production conditions are not met, the production conditions are adjusted, Production is carried out when the production conditions are qualified; S3, detecting whether there are deformed metal terminals on the metal terminal strip, cutting out the deformed metal terminals when there are deformed metal terminals, and receiving materials when there are no deformed metal terminals; S4, Detect whether there is a joint within a preset distance on the metal terminal strip, and execute step S5 when the metal terminal strip has one joint, and execute step S6 when the metal terminal strip has multiple joints.
  • the step S1 includes: S11, connecting the front end of the metal terminal strip to be adjusted for surface treatment conditions with the metal traction material of equal height to form a front joint, and adjusting the rear end of the metal terminal strip and Metal traction materials of equal height are connected into one body to form a rear joint; S12, surface treatment of the metal terminal strip; S13, at least a part of the front joint of the front joint and at least a part of the rear joint along the conveying direction The metal terminal strip between the backs is cut, and a part of the cut metal terminal strip is used as a test sample to check the surface treatment performance of the test sample, and repeat step S11 if it does not meet the requirements.
  • step S13 when the metal traction material needs to be reused, the connection position between the front end and the corresponding metal traction material and the corresponding rear end are aligned along the conveying direction.
  • the metal terminal strip between the connection positions between the metal traction materials is cut off, and the metal traction material corresponding to the front joint is rolled into the tray, and the metal traction material corresponding to the rear joint is Wrapped into the traction material tray, and when the metal traction material needs to be discarded, the metal terminal strip between the front of the front joint and the rear of the rear joint is cut along the conveying direction.
  • step S4 the preset distance is 5m, and in step S5, the distance between the first cutting position and the second cutting position and the joint is 10cm, so The distance between the third cutting position and the first cutting position is 20 cm-100 cm.
  • step S5 the metal terminal strip between the first cutting position and the third cutting position is cut with an interval of 20 cm as the cutting length.
  • Figure 1 is a schematic diagram of the structure of a fully automatic rewinding machine according to an embodiment of the present invention
  • Figure 2 is a schematic structural diagram of a detection mechanism of a fully automatic rewinding machine according to an embodiment of the present invention
  • Fig. 3 is a schematic flowchart of a fully automatic material receiving method according to an embodiment of the present invention.
  • Body 10 Receiving tray 20; Paper tray 30;
  • Detection mechanism 40 micro-motion sensor 41; optical fiber probe 42; distance sensor 43;
  • Shearing member 50 Controller 60; Feeding driving member 70; Receiving speed sensor 80.
  • the fully automatic rewinding machine 100 can be used to continuously rewind metal terminal strips to form trays, and the metal terminal strips have at least one extending along its conveying direction.
  • the fully automatic rewinding machine 100 includes: a body 10, a rewinding tray 20, a detection mechanism 40, a shearing member 50 and a controller 60.
  • the receiving tray 20 is provided in the machine body 10, the receiving tray 20 can wind metal terminal strips, the detection mechanism 40 is provided in the machine body 10 and can obtain the number of joints within a preset distance, and the shearing piece 50 is provided in The machine body 10 can cut metal terminal strips.
  • the cutting member 50 is located between the receiving tray 20 and the detection mechanism 40.
  • the controller 60 is respectively connected with the detection mechanism 40 and the cutting member 50 to detect the joints according to the detection mechanism 40
  • the quantity control shear 50 cuts the metal terminal strip. When the number of joints within the preset distance is one, the controller 60 controls the shear 50 to cut the metal terminal strip on both sides of a joint.
  • the controller 60 controls the shearing member 50 to cut the metal terminal strip on the side adjacent to the position of the receiving tray 20 of the first joint within the preset distance and within the preset distance The last joint of the metal terminal strip on the side facing away from the receiving tray 20 is located.
  • the machine body 10 is respectively provided with a receiving tray 20, a receiving tray 20, a detection mechanism 40, a shearing member 50 and a controller 60, and the metal terminal strip can be reeled through the receiving tray 20, and when the rewinding is full A material tray is formed on the receiving tray 20.
  • the detection mechanism 40 may include a micro-motion sensor 41, which can determine whether there is a joint or not.
  • the detection mechanism 40 may further include an optical fiber probe 42 through which the length of the material can be calculated, so that the distance between two adjacent joints can be obtained.
  • the controller 60 controls the cutting member 50 to move the cutting piece 50 between the area in front of the first joint and the area behind the last joint within the preset distance in the conveying direction.
  • the metal terminal strip between the two can be cut, and the cut metal terminal strip can be discarded.
  • the controller 60 controls the shearing member 50 to cut the metal terminal strips on the front and rear sides of the joint, and can discard the cut metal terminal strips.
  • the metal terminal strip can move along the conveying direction, and the shearing member 50 cuts the metal terminal strip passing through its location. When the current tray is full, the next tray can be moved.
  • the rewinding has a joint at the connection between the previous tray and the next tray. After the area near the joint is processed, the next roll of metal terminal tape starts to be automatically wound into the updated receiving tray 20, and the above process is continuously and continuously repeated to achieve fully automatic receiving of surface-treated terminal products.
  • the fully automatic rewinding machine 100 is mainly composed of a body 10, a rewinding tray 20, a detection mechanism 40, a shearing member 50 and a controller 60, and the detection mechanism 40 cooperates with the shearing member 50. , Can realize the rapid and accurate processing of the joints with different numbers within the preset distance, and can process the joints in the process of continuous material collection, so as to realize the automatic material collection.
  • the fully automatic material receiving machine 100 has a simple structure. , Easy to implement, improve work efficiency and other advantages.
  • the fully automatic receiving machine 100 further includes a paper tray 30, which is arranged opposite to the receiving tray 20 and corresponds to each other.
  • the paper tray 30 corresponding to the receiving tray 20 can be used in the receiving tray.
  • the metal terminal strip is packaged.
  • the receiving tray 20 and the paper tray 30 cooperate with each other to perform finishing work on the previous tray.
  • the fully automatic rewinding machine 100 further includes a feeding driving member 70.
  • the feeding driving member 70 may be provided on the body 10 and located between the detection mechanism 40 and the shearing member 50. It can guide the conveying of the metal terminal strip and improve the conveying continuity of the metal terminal strip.
  • the fully automatic material receiving machine 100 further includes a material receiving speed sensor 80.
  • the material receiving speed sensor 80 can be arranged on the body 10 and located on the side of the detection mechanism 40 facing away from the receiving tray 20.
  • the receiving speed sensor 80 can acquire the conveying speed of the metal terminal strip.
  • the automatic rewinding machine 100 further includes a CCD detector.
  • the CCD detector is provided in the body 10 and connected to the controller 60.
  • the CCD detector can detect the deformation of the metal terminal in the metal terminal strip.
  • the controller 60 is connected with the CCD detector to control the shear 50 to cut the metal terminal strips on both sides of the deformed metal terminal according to the detected deformation, that is to say, the deformed terminal can be detected by the CCD detector.
  • the deformed terminal can be cut off by the shearing piece 50, so that even when sudden terminal deformation occurs during electroplating production, the purpose of fully automatic continuous production of products can be achieved.
  • the CCD can be used to detect and alarm, and the electroplating product will be cut 50cm before the deformed product through the shearing piece 50, with an interval of 20cm as the cutting length, and discarded after cutting.
  • the waste bucket When the cut continuous metal terminal surface treatment product is rolled into the material tray, the protective tape (such as paper tape) is rolled into 3 more turns, and the rotation is automatically stopped.
  • the machine body 10 is provided with a receiving position and an unloading position, the number of receiving trays 20 is more than two, and the two receiving trays 20 are spaced apart in the vertical direction, each receiving The tray 20 can move between the receiving position and the unloading position.
  • the current receiving tray 20 is full, the area near the joint between the previous tray and the following tray is cut off, corresponding to the full receiving The tray 20 moves from the receiving position to the unloading position, and another empty receiving tray 20 moves from the unloading position to the receiving position, which can automatically replace the receiving tray and automatically collect the surface treatment products.
  • the shearing member 50 is configured to perform at least three cuts on the upstream and downstream areas of the joints on the metal terminal strip when the number of joints within the preset distance is one, wherein the first cutting position and the second cutting position The two cutting positions are respectively located upstream and downstream of the joint, and the third cutting position is located upstream of the first cutting position.
  • the metal terminal strip between the third cutting position and the first cutting position can be discarded or at least a part of it can be used as an inspection sample, and the metal terminal strip between the first cutting position and the second cutting position can be discarded.
  • the shearing member 50 is configured to treat the upstream and downstream ends of the two end joints on the metal terminal strip located at both ends in the transport direction when the number of joints within the preset distance is multiple.
  • the area is cut at least twice, and the two cut positions are located upstream and downstream of the two end joints.
  • the metal terminal strips are all rolled into the reel 20.
  • the reel 20 can be circular, and the surface treatment product protection paper on the paper tray 30
  • the belt or soft plastic belt
  • M is preferably 3.
  • M is preferably 3.
  • the metal terminal strip of the next tray runs along with it.
  • the cut section can be cut off.
  • the metal terminal strip between the first cutting position and the third cutting position is used as an inspection sample.
  • the front of the metal terminal strip refers to the side adjacent to the direction where the receiving tray 20 is located
  • the rear refers to the side facing away from the direction where the receiving tray 20 is located
  • the conveying direction of the metal terminal strip refers to the side where the receiving tray 20 is located. The direction in which the tray 20 is conveyed.
  • the automatic receiving machine 100 can not only realize automatic receiving of surface treatment terminal products, but also realize automatic cutting of joints through the cooperation of the cutting member 50 and the joint sensor 40, and adopts CCD detection.
  • the machine can automatically detect deformed surface-treated terminal products, and cooperate with the shearing piece 50 to remove the deformed terminals.
  • the automatic rewinding machine 100 has the advantages of being able to achieve continuous and uninterrupted production, improving production efficiency, and reducing production costs.
  • the fully automatic receiving method of the fully automatic receiving machine can be used to continuously receive the metal terminal strip to form a tray, and the metal terminal strip has an extension along its conveying direction.
  • the method includes the following steps:
  • step S1 includes:
  • Step S13 Cut the metal terminal strip between at least a part of the front joint and at least a part of the rear joint along the conveying direction, and use the cut part of the metal terminal strip as a test sample to check the surface treatment performance of the test sample. Step S11 is repeated when the requirements are not met.
  • step S13 when the metal traction material needs to be reused, the connection position between the front end and the corresponding metal traction material and the connection position between the rear end and the corresponding metal traction material are separated along the conveying direction. Cut off the metal terminal strip, and roll the metal traction material corresponding to the front joint into the material tray, and roll the metal traction material corresponding to the rear joint into the traction material tray. When the metal traction material needs to be discarded, move the front side along the conveying direction. The metal terminal strip between the front of the connector and the back of the rear connector is cut.
  • the front end of the continuous metal terminal material 5m-10m to be adjusted for the surface treatment condition is connected with a metal traction material of approximately the same height to form a front joint, and the rear end of the debugging material is also connected with
  • the highly similar metal traction materials are connected into one body and become the rear joint.
  • the metal traction material corresponding to the front joint is automatically rolled into the take-up tray 20, and the metal traction material corresponding to the rear joint can continue to be rolled into the traction material tray, and the machine stops to check the performance of the surface treatment sample. If the inspection of the surface treatment sample is not qualified, the same adjustment work is started from the beginning until the surface treatment performance inspection meets the requirements.
  • the traction materials before and after the joint are no longer used and need to be discarded, they are cut and discarded according to 20cm.
  • 10 20cm debugging electroplated terminals are cut off and automatically discarded into the waste bucket; 4 inspection samples are cut according to the set requirements, and Arrange and store in order; continue to cut and debug the electroplated terminal by 20cm each and discard it until the last joint is cut and the machine stops.
  • the deformation of the metal terminal can be detected by a CCD detector.
  • the CCD detector can have an alarm function and can send out an alarm message when a deformed metal terminal is detected.
  • the detection mechanism 40 may further include a distance sensor 43, through which the speed of the motor of the feeding driving member 70 can be adjusted.
  • the preset distance is 5m, that is, the number of joints within the range of 5m is detected.
  • the shortest length of the electroplated product (metal terminal strip) is preferably more than 5 meters, because the automatic assembly machine in the assembly workshop can only operate normally and continuously when the length of the surface treatment product is greater than 5 meters. Therefore, the preset distance is preferably 5m.
  • S5. Perform at least three cuts on the upstream and downstream areas of the joint on the metal terminal strip, where the first cutting position and the second cutting position are respectively located upstream and downstream of the joint, and the third cutting position is located at the first cutting position. Upstream of the location
  • the metal terminal strip between the first cutting position and the second cutting position can be automatically discarded into the waste bucket, and the metal terminal strip between the first cutting position and the third cutting position can be discarded or used for detection
  • the sample when used as a test sample, can be used for product quality inspection, and it is cut and placed in a fixed location for storage. It should be noted that when the samples are stored, the samples can be marked, so as to facilitate the identification of the previous test sample and the next test sample without confusion.
  • the distance between the first cutting position and the joint and the distance between the second cutting position and the joint are both 10 cm, and the distance between the third cutting position and the first cutting position is 20 cm-100 cm.
  • the shearing member 50 can start at every interval along the conveying direction with the third cutting position as the starting point. Cut the metal terminal strip at a distance of s.
  • s is set to 20cm, that is, in step S5, the metal terminal strip between the first cutting position and the third cutting position is cut with an interval of 20cm as the cutting length.
  • the cutting and cutting quantity range can be set within 2 to 4, and the cut samples are arranged and stored in an orderly manner, which is convenient for testing the performance of the samples.
  • the metal terminal strip between the first cutting position and the third cutting position needs to be discarded, the metal terminal strip can be cut at an interval of 20 cm as the cutting length, and then discarded into a waste bucket after being cut.
  • the subsequent surface treatment product is automatically wound into the tray and the protective tape also automatically starts to run, so that when there are one or more joints in the surface treatment production , It can also be fully automatic and continuous for the purpose of surface treatment production.
  • the fully automatic material receiving machine 100 and the automatic material receiving method according to the embodiments of the present invention have at least the following advantages:
  • the automatic rewinding machine 100 and the automatic rewinding method can make continuous metal terminals accurately and accurately detected by CCD inspection equipment even if sudden product deformation occurs. Deformation range, automatic shearing and discarding of deformed products, automatic continuous surface treatment production will not be affected.
  • the automatic winding method and equipment can be used to accurately and automatically complete the shearing and collecting surface treatment test samples; greatly reduce the debugging time and greatly improve the production efficiency; Thus, the production cost of surface treatment is greatly reduced.
  • the continuous metal terminal in the embodiment of the present invention may be formed by depositing nickel metal on the surface of the terminal, and then performing partial analysis to extract gold, or palladium, or palladium nickel, or rhodium ruthenium, or silver, or tin. Treat the product; it can also be after the copper metal is precipitated on the surface of the metal terminal, and then the metal tin is precipitated.
  • the traction material used for debugging the production conditions of the surface treatment can be a copper alloy strip or a stainless steel strip, or can be a thin plastic strip dedicated to surface treatment.
  • the automatic multi-layer winding machine in the embodiment of the present invention is a multifunctional winding machine designed and manufactured by our company to adapt to the automatic winding method of surface treatment products.
  • the traction material can be made of thin plastic strips that are similar in width to the metal terminals and do not need to be resistant to high temperatures.
  • the thin plastic strip is rolled into the disk after the joint is cut and the rotating motor automatically stops, and the metal terminal is electroplated to adjust the material. Cut 10 sections of 20cm and discard them in the waste bucket, and then collect 4 inspection samples for each 20cm length according to the set requirements, and arrange them in order; continue to cut and debug the surface treatment terminals by 20cm each and discard them until the subsequent cuts After the metal terminal and the thin plastic strip are connected, press the stop button to complete the operation of collecting surface treatment terminal inspection samples.
  • the surface treatment inspection samples are checked by the inspector according to whether the appearance of the surface treatment is normal, whether the terminal is deformed, whether the bonding force between the surface treatment metal and the metal material meets the requirements, whether the surface treatment metal film thickness is within the product specifications, etc. an examination. If all inspection items meet the specifications, the surface treatment production can be started. If any of the inspection contents do not meet the specifications, the entire process should be repeated from the initial preparation [raw materials] to the final [surface treatment product inspection]. This repeat process until all the inspection contents meet the product specifications.
  • the thin plastic strips in the reel at the reel and the thin plastic strips in the surface treatment equipment are used to fix the continuous metal with a staple at 3 points.
  • the terminal and the thin plastic strip are firmly nailed together and the staples are wrapped tightly with tape; in addition, a receiving tray is prepared, and the protective tape that protects the electroplating product is tightly pasted in the receiving tray with tape.
  • the continuous metal terminal is 1 meter and the continuous metal terminal and the thin plastic strip are firmly nailed together by the method of staples at 3 points and fixed with tape.
  • the staples are wound tightly; the other end of the 1-meter continuous metal terminal debugging material and the continuous metal terminal in the production material tray are firmly welded together with the continuous metal terminal and the thin plastic strip with an electric welding machine.
  • the front and back must be welded together.
  • the positioning holes of the metal terminals are completely overlapped to ensure that the positioning pin positions of the gold-plating process and the gold-plated jig are completely consistent.
  • the continuous metal terminal turn on the pumps of each treatment process and each surface treatment process, and open the washing water and air knife with pressurized air to confirm whether the temperature of each process reaches the specified set value. If the result is checked It is accurate and ready to boot.
  • start the surface treatment equipment manually open the corresponding rectifier when the continuous metal terminal enters the electrolytic cell, and close the corresponding rectifier when all the surface treatment materials run out of the electrolytic cell; the same rectifier operation is similar to the nickel-plated metal
  • the positioning holes of the continuous metal terminals must match the positioning pins of the gold-plated fixture to ensure the surface treatment position and the quality of the plating film thickness.
  • the joint is cut 20cm centered on the joint, and then 4 sections of the electroplated product 20cm terminal are cut and discarded.
  • cut the 20cm joint between the debugging material terminal and the production material terminal to discard; immediately cut the inspection sample of the 100cm surface treatment production terminal and store it.
  • the continuous metal terminal surface treatment product is automatically sent to the prepared reel and In the gap between the protective tape, the receiving tray is automatically opened and the protective tape also runs, and the surface treatment products of the continuous metal terminal are rolled into the tray.
  • the current continuous metal terminal is pulled out of the tray and is clamped by the stop jig at the joint connection position, and the next continuous metal terminal product is quickly welded to the continuous metal terminal at the fixture with a spot welder.
  • the stop jig switch. In this way, the electroplating production of continuous metal terminal products can be carried out continuously.
  • the cut end is 10cm before the joint between the two plates of the continuous metal terminal product. It is necessary to cut the quality inspection sample of the electroplating product, and the sample should be cut off one by one.
  • the length is 100cm.
  • the length of the joint is The 100cm terminal product is cut off and stored in a fixed location for storage; the sample can be selected for disposal or used as an inspection sample to confirm the quality of the product. The sample storage location must be clearly marked to clearly identify the previous 100cm and the next 100cm and cannot be confused.
  • the next roll of continuous metal terminal surface treatment product is automatically fed into the gap between the prepared reel and the protective tape, the take-up tray is automatically opened, and the continuous metal terminal surface treatment product starts to be rolled into the tray.
  • the deformed terminal product When abnormal terminal deformation occurs in the continuous metal terminal electroplating production, the deformed terminal product will be alarmed by CCD detection, and the surface treatment product will be automatically cut 50cm before the deformed product. The cut length is 20cm, and the cut will be discarded in the waste bucket. ,
  • the protective tape will be rolled in 3 more times, and the transmission will automatically stop and wait for the non-deformed electroplated product to be involved after the deformation of the product is cut; the deformed product will be cut again after 50cm, and then When the surface treatment products are automatically rolled into the tray, the protective tape also automatically starts to run.
  • a plate of surface treatment product When a plate of surface treatment product has one or more joints, it is automatically detected that the length between the two joints is less than 5 meters, and it can be automatically cut at an interval of 20cm and discarded in the waste bucket; at the same time, the cut surface treatment product After being wound into the reel, the protective tape automatically stops rotating after being wound in 3 more turns; when the second joint is cut off, the extra 50cm is cut again, and the subsequent surface treatment products are automatically wound into the reel and the protective tape also starts to run automatically .
  • the traction material must be copper alloy or stainless steel strip that can withstand high temperatures.
  • Example 1 After the end of Example 1, replace the product tray at the receiving place with a tray wrapped with thin plastic strips, and fix them with the thin plastic strips in the surface treatment equipment by using staples to fix them at 3 points. Staple the ground together and wrap the staples tightly with tape.
  • Example 1 Except that the traction belt is replaced by a thin stainless steel strip instead of a thin plastic strip, and the electroplating conditions are changed from Example 1 to Example 2, all other contents are the same as in (Example 1).
  • Example 1 Except that the traction belt is replaced by a thin stainless steel strip instead of a thin plastic strip, and the electroplating conditions are changed from Example 1 to Example 2, all other contents are the same as in (Example 1).
  • Example 1 Except that the traction belt is replaced by a thin stainless steel strip instead of a thin plastic strip, and the electroplating conditions are changed from Example 1 to Example 2, all other contents are the same as in (Example 1).
  • Example 1 Except that the traction belt is replaced by a thin stainless steel strip instead of a thin plastic strip, and the electroplating conditions are changed from Example 1 to Example 2, all other contents are the same as in (Example 1).
  • the traction material must be copper alloy or stainless steel strip that can withstand high temperatures.
  • the fully automatic material receiving machine 100 and the fully automatic material receiving method according to the embodiments of the present invention aim to solve at least one of the following problems as the research and development goal.
  • the requirements include:
  • the metal traction material used should be able to automatically cut the joints and automatically roll the metal traction material into the tray when the metal traction material needs to be reused after the test sample is automatically cut and collected;
  • metal traction materials need to be discarded, it can automatically cut all the metal traction materials and discard them in the waste bucket.
  • the automatic material receiving machine 100 and the automatic material receiving method according to the embodiments of the present invention can reduce the percentage of errors in manual operation, reduce the number of shutdowns of continuous metal terminal product production equipment, improve efficiency and quality, and reduce the production of continuous metal terminals cost.

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Abstract

一种全自动收料机（100）及其收料方法，能够用于对金属端子料带进行连续收料形成料盘，金属端子料带具有沿其输送方向延伸的至少一个接头，全自动收料机（100）包括：机体（10）；收料盘（20）；检测机构（40），能够获取在预设距离内的接头数量；剪切件（50），能够剪切金属端子料带；控制器（60），分别与检测机构（40）和剪切件（50）相连以根据检测机构（40）检测到的接头数量控制剪切件（50）对金属端子料带进行剪切。全自动收料机（100）能够实现连续收料，并且能够在连续收料的过程中自动切断接头，可以有效降低连续金属端子的生产成本。

Description

全自动收料机及其收料方法 技术领域
本发明属于表面处理产品自动收料技术领域，具体涉及一种全自动收料机和全自动收料方法。
背景技术
在电子工业中，用于各种电器设备的连接器电子元件是由各种各样的金属端子与塑壳组装而成。因此各种各样的金属端子也就自然成为电子工业的最重要的基础原材料。在连续金属端子表面处理生产中的测试样品的采集，接头的剪切以及收集连续金属端子产品卷盘的换盘等操作通常都是用手工来完成。
连续金属端子是以薄铜、薄铜合金以及薄不锈钢带材为原材料通过精密冲床加工而成。在通常情况下，得到的连续金属端子产品的测试样品的采集以及收料机的换盘操作是用手工操作来进行。在操作过程中难免会遇到使连续金属端子变形等异常现象的发生。例如，连续金属端子产品收满料盘后，使用剪刀切断连续金属端子产品时如果操作稍有不慎就会使连续金属端子产品变形；随后，在采集测试用样品约20mm～30mm时同样会有操作不当而使连续金属端子产品变形；在将连续金属端子产品放入新收料盘时，操作稍有不当也会使连续金属端子产品变形。特别是，由于精密冲床加工是以一定速度连续运行，连续金属端子产品的剪断，测试样品的采集以及将连续金属端子产品放入新收料盘的系列操作受到上述连续金属端子产品变形的影响而不能在规定时间内完成操作时，就必须紧急停机进行处理。从而造成连续金属端子产品的浪费和冲床运行效率的降低。
在表面处理工艺过程，对冲压工段得到的连续金属端子进行表面处理，首先在连续金属端子表面上析出镍金属后，然后在其表面上再进行部分表面处理析出金，或析出钯，或析出钯镍，或析出铑钌，或析出银，或析出锡等形成表面处理产品；也可以是在金属端子的表面上析出铜金属后，再表面处理析出金属锡。由这些表面处理金属端子和塑壳一起组装而成的连接器等电子元器件广泛应用于智能手机、计算机、照相机、航天航空、汽车等精密电子产业以及电视和电冰箱等一般民用电子行业。连续金属端子通过连续生产线表面处理加工后，在采集检查表面处理样品和换新的收料盘时，手工操作会接触电镀产品，因而会在表面处理端子表面留下触摸痕迹，由于连续端子表面的各种表面处理析出的金属活性高，触摸部分的表面会随着放置时间的延长而发生颜色变化甚至会发生腐蚀现象，导致电子元件导电不良等现象严重影响其产品质量；从而使上述精密电子产品不能使用，尤其是采用上述电子元件的智能手机、计算机、照相机、汽车等商品在使用过程中发生问题时，会造成不可估量的严重后果和巨大的经济损失。
近年来，随着智能手机、照相机、计算机和电视机等电子产品向着小型化、薄型化和高机能化发展，组成连接器电子元件的原材料金属端子越来越向小型化和微型化发展。例如，软式印刷电路板插入用连接器端子，简称FPC端子，有效长度只有2mm～3mm；加上定位孔连接带产品总宽度也只有5mm～6mm。此外，为了使电子设备向小型化和薄型化转化，板对板用金属端子的设计也为了满足这种变化的要求，从平面金属端子向形状复杂的弯曲形金 属端子转变，通过这种方式的改变既符合多种多样高精密电子产品向小型化微型化发展的需求，也满足了各种精密电子产品对高机能化的要求。然而，金属端子的小型化和复杂化给金属端子产品的加工提出了十分高的要求；特别是，各种金属带材经过精密冲压模具加工成为连续金属端子后，人工用剪刀切断连续金属端子的操作，采集测试样品和将连续金属端子放入新收料盘时，由于连续金属端子产品小形状复杂，对人工操作的要求很高，导致人工操作失误的异常百分率很高，经常造成大量连续金属端子产品变形，常常迫使精密冲压模具设备的突发性停机，使生产效率降低很多。同样，该类连续金属端子的电镀生产中，在采集连续金属端子电镀的测试样品，切断接头，将连续金属端子电镀产品放入新收料盘的一系列手工操作中，发生操作失误的百分率也很高，由于在连续金属端子的表面进行了表面处理而使产品成本变得很高，随着连续金属端子表面处理产品异常的增加导致产品报废率的提高，因而异常产品的损失费用是非常巨大的；特别是，当采集连续金属端子电镀的测试样品，剪切接头，将连续金属端子表面处理产品放入新的收料盘的一系列手工操作中由于操作不当而使连续表面处理生产线停机时，由于被迫停留在连续表面处理生产线中的连续金属端子产品全部需要报废，其经济损失很庞大；同时由于停机也造成连续表面处理设备的生产加工效率的降低。
针对以上所述问题，降低在连续金属端子产品生产中的采集连续金属端子的测试样品、剪切接头、将连续金属端子表面处理产品放入新的收料盘的一系列手工操作中的失误百分率，降低连续金属端子产品生产设备的停机次数，从而达到大幅度降低连续金属端子的生产成本是亟待解决的课题。
针对以上要解决的课题，用薄铜、薄铜合金以及薄不锈钢带材为原材料经过精密冲压加工所得倒的连续金属端子，用卷盘式自动收料机代替人工的操作方式得到不断的研究和发展，目前该项技术已得到长足的进步，使冲压后得到的连续金属端子的合格率得到大幅度提高，因而问题得到比较圆满的解决。但是，连续金属端子经过表面处理设备加工后的连续金属端子的自动收料还存在许多问题没有得到解决，有关解决这些问题的专利文献也很少见。
在专利文献1(CN 207792202U)中，描述了一种用于冲压后的自动卷料收料机。该设备在冲床生产过程中，通过控制器接受冲床电机的信号，冲床电机速度较快的时候，控制器控制拖动电机正向转动，拖动电机拖动支撑辊轴向上移动，支撑辊轴与卷料轴之间的距离就会增大，进而减慢收料速度，使卷料的松紧度一致。但是，在该发明专利中没有涉及自动剪切连续金属端子，自动采集测试样品，自动将连续生产中的连续金属端子卷入新的收料盘中的内容。
在专利文献2(CN 206645615U)中，描述了一种收料机的收卷装置。该发明的光电感应器感应其与金属产品之间的距离，控制系统通过距离来判断金属产品的收卷速度，上限位置用于感知材料是否收卷速度过快，下线位置用于感知金属产品是否收卷速度过慢，结构简单，自动化程度高，避免了人工收卷速度的问题。
在专利文献3(CN 108555175B)中，公开了一种用于冲压设备的收料机器人。该设备实现了冲压模具冲压完成之后对工件的推动取料，避免了操作者伸手到模具中取出工件的危险操作，降低了冲压设备事故发生的概率，提高了生产效率。
在专利文献4(日本专利第3084477号)中，提供了连续金属端子冲压后的收料机和 控制装置。该专利在冲床出口处设置可以防止连续金属段子横向摇摆的导向滚轮，从而解决了连续金属段子在冲压设备出口处容易发生变形的问题。
在专利文献5(日本专利第4979510号)中，提供了多层收料盘的收料机。该专利针对具有多层收料盘的收卷机需要上下移动自动换盘并且设备比较笨重的问题，采用以中心轴水平旋转移动的换盘方式从而提供了简洁方便的换盘方法；同时，该换盘方式运行稳定，每层收料盘之间的间距不需要太大的空间，具有操作安全可靠的特点；因而该专利所提供的收料机不仅能节省空间，比通常的收料机体积小，重量轻，从而降低了设备的制作成本。
在专利文献1至5中分别提供了各种各样的收料机，然而所有设备的设计原理和它们的实际操作都不能解决表面处理生产后的连续金属端子产品的自动接头剪切，测试产品的自动取样，连续金属端子自动放入新收料盘中等的各种各样实际问题。
我司在专利文献6(CN 205934071U)的前期报道中，提供了一种全自动收料机计数接头报警剪切取样一体机构装置。由于该装置只能在小范围内满足连续金属端子表面处理生产中的表面处理产品的自动剪切测试样品的取样和保存，自动剪切接头并废弃到废料桶中，自动更换收料用圆形收料盘，自动卷式收取连续金属端子表面处理产品。
但是对连续金属端子表面处理生产中突发性产品变形的自动处理以及连续金属端子产品在不足5米有两个接头的表面处理产品处理并没有涉及，因而极大地限制了该自动设备在实际连续金属端子的表面处理生产中的应用。此外，也没有提供在调试产品表面处理条件时，自动剪切接头、自动采集测试样品、根据金属牵引用材料是否再利用与否而剪切金属牵引材料或者保留金属牵引材料等功能。
发明内容
本发明旨在至少解决现有技术中存在的技术问题之一。
为此，本发明提出一种全自动收料机，该全自动收料机能够有效降低端子生产成本，实现连续生产。
本发明还提出一种全自动收料方法，能够提高端子生产效率，提高自动化程度以及产品质量。
根据本发明第一方面实施例的全自动收料机，能够用于对金属端子料带进行连续收料形成料盘，所述金属端子料带具有沿其输送方向延伸的至少一个接头，所述全自动收料机包括：机体；收料盘，所述收料盘设于所述机体，所述收料盘能够收卷所述金属端子料带；检测机构，所述检测机构设于所述机体且能够获取在预设距离内的接头数量；剪切件，所述剪切件设于所述机体且能够剪切所述金属端子料带，所述剪切件位于所述收料盘与所述检测机构之间；控制器，所述控制器分别与所述检测机构和所述剪切件相连以根据所述检测机构检测到的接头数量控制所述剪切件对所述金属端子料带进行剪切，其中，在所述预设距离内的接头数量为一个时，所述控制器控制所述剪切件切断所述一个接头两侧的所述金属端子料带，在所述预设距离内的接头数量为两个以上时，所述控制器控制所述剪切件切断所述预设距离内的第一个接头邻近所述收料盘所在位置的一侧的所述金属端子料带以及所述预设距离内的最后一个接头背向所述收料盘所在位置的一侧的所述金属端子料带。
根据本发明实施例的全自动收料机，采用检测机构与剪切件相配合，检测机构能 够获取在预设距离内的接头的数量，控制器能够根据检测机构的检测结果执行不同的操作，当预设范围内的接头数量为一个时，控制器能够控制剪切件切断接头两侧的金属端子料带，当预设范围内的接头数量为两个以上时，控制器能够控制剪切件切断在预设范围内所有接头中的第一个接头的前方区域的金属端子料带以及最后一个接头的后方区域的金属端子料带，切断的金属端子料带可以废弃处理。根据本发明实施例的全自动收料机能够实现连续金属端子产品生产过程中的自动接头剪切，提高端子生产加工效率。
根据本发明一个实施例，所述的全自动收料机还包括：CCD检测器，所述CCD检测器设于所述机体且能够检测所述金属端子料带中的金属端子的变形情况，所述控制器与所述CCD检测器相连以根据检测到的变形情况控制所述剪切件切断变形的所述金属端子两侧的所述金属端子料带。
根据本发明一个实施例，所述机体上设有收料位置与下料位置，所述收料盘的数量为两个以上，两个所述收料盘沿上下方向间隔开分布，每个所述收料盘能够在所述收料位置与所述下料位置之间可活动。
根据本发明一个实施例，所述剪切件被构造成在所述预设距离内的接头数量为一个时对所述金属端子料带上接头的上下游区域进行至少三次切割，其中，第一切割位置和第二切割位置分别位于接头的上游和下游，第三切割位置在位于所述第一切割位置的上游。
根据本发明一个实施例，所述剪切件被构造成在所述预设距离内的接头数量为多个时对所述金属端子料带上位于运输方向上的两端的两个端部接头的上下游区域进行至少两次切割，两次切割位置分别位于两个所述端部接头的上游和下游。
根据本发明第二方面实施例的全自动收料机的全自动收料方法，能够用于对金属端子料带进行连续收料形成料盘，所述金属端子料带具有沿其输送方向延伸的至少一个接头，所述方法包括以下步骤：S1、判断全自动收料机是否满足正式生产条件；S2、在满足正式生产条件时，进行生产，在不满足正式生产条件时，调试生产条件，在生产条件合格时进行生产；S3、检测所述金属端子料带上是否有变形的金属端子，在有变形的金属端子时切除变形的金属端子，在无变形的金属端子时进行收料；S4、检测所述金属端子料带上的预设距离内是否有接头，并在所述金属端子料带上具有一个接头时执行步骤S5，在所述金属端子料带上具有多个接头时执行步骤S6；S5、对所述金属端子料带上接头的上下游区域进行至少三次切割，其中，第一切割位置和第二切割位置分别位于接头的上游和下游，第三切割位置在位于所述第一切割位置的上游；S6、对所述金属端子料带上位于运输方向上的两端的两个端部接头的上下游区域进行至少两次切割，两次切割位置分别位于两个所述端部接头的上游和下游；S7、继续对所述金属端子料带进行收料，直至收料完成。
根据本发明一个实施例，所述步骤S1包括：S11、将要调试表面处理条件的金属端子料带的前端与高度相等的金属牵引材料连接成一体成为前接头，调试金属端子料带的后端与高度相等的金属牵引材料连接成一体成为后接头；S12、将所述金属端子料带进行表面处理；S13、沿输送方向将所述前接头的至少一部分的前方与所述后接头的至少一部分的后方之间的所述金属端子料带切断，切断的一部分所述金属端子料带作为检测样品，检查检测样品的表面处理性能，在不符合要求时重复步骤S11。
根据本发明一个实施例，在步骤S13中，在所述金属牵引材料需要再利用时，沿输 送方向将所述前端与对应的所述金属牵引材料之间的连接位置与所述后端与对应的所述金属牵引材料之间的连接位置之间的所述金属端子料带切断，并将所述前接头对应的金属牵引材料卷入所述料盘，将所述后接头对应的金属牵引材料卷入至属牵引材料盘，在所述金属牵引材料需要废弃时，沿输送方向将所述前接头的前方与所述后接头的后方之间的所述金属端子料带切断。
根据本发明一个实施例，在步骤S4中，所述预设距离为5m，在步骤S5中，所述第一切割位置和所述第二切割位置与所述接头之间的距离为10cm，所述第三切割位置与所述第一切割位置之间的距离为20cm-100cm。
根据本发明一个实施例，在步骤S5中，以间隔20cm为切断长度对所述第一切割位置与所述第三切割位置之间的所述金属端子料带进行切割。
本发明的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本发明的实践了解到。
附图说明
本发明的上述和/或附加的方面和优点从结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1是根据本发明实施例的全自动收料机的结构示意图；
图2是根据本发明实施例的全自动收料机的检测机构的结构示意图；
图3是根据本发明实施例的全自动收料方法的流程示意图。
附图标记：
全自动收料机100；
机体10；收料盘20；纸盘30；
检测机构40；微动传感器41；光纤探头42；距离传感器43；
剪切件50；控制器60；送料驱动件70；收料速度传感器80。
具体实施方式
下面详细描述本发明的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本发明，而不能理解为对本发明的限制。
在本发明的描述中，需要理解的是，术语“中心”、“纵向”、“横向”、“长度”、“宽度”、“厚度”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”“内”、“外”、“顺时针”、“逆时针”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。此外，限定有“第一”、“第二”的特征可以明示或者隐含地包括一个或者更多个该特征。在本发明的描述中，除非另有说明，“多个”的含义是两个或两个以上。
在本发明的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是 两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本发明中的具体含义。
下面参考附图具体描述根据本发明实施例的全自动收料机100以及全自动收料方法。
如图1和图2所示，根据本发明实施例的全自动收料机100，能够用于对金属端子料带进行连续收料形成料盘，金属端子料带具有沿其输送方向延伸的至少一个接头，全自动收料机100包括：机体10、收料盘20、检测机构40、剪切件50和控制器60。
具体而言，收料盘20设于机体10，收料盘20能够收卷金属端子料带，检测机构40设于机体10且能够获取在预设距离内的接头数量，剪切件50设于机体10且能够剪切金属端子料带，剪切件50位于收料盘20与检测机构40之间，控制器60分别与检测机构40和剪切件50相连以根据检测机构40检测到的接头数量控制剪切件50对金属端子料带进行剪切，其中，在预设距离内的接头数量为一个时，控制器60控制剪切件50切断一个接头两侧的金属端子料带，在预设距离内的接头数量为两个以上时，控制器60控制剪切件50切断预设距离内的第一个接头邻近收料盘20所在位置的一侧的金属端子料带以及预设距离内的最后一个接头背向收料盘20所在位置的一侧的金属端子料带。
换言之，在机体10上分别设有收料盘20、收料盘20、检测机构40、剪切件50和控制器60，通过收料盘20能够收卷金属端子料带，在收卷满时收料盘20上形成有一料盘。为了满足连续生产的需求，可以通过检测机构40获取在预设距离内的接头的数量，接头可以为相邻两个料盘之间的接头，也可以为在一个料盘对应的金属端子料带中具有的接头，检测机构40可以包括微动传感器41，通过微动传感器41能够判断有无接头。检测机构40还可包括光纤探头42，通过光纤探头42能够计算过料长度，从而能够获取相邻两个接头之间的距离。在检测机构40检测到在预设距离内具有两个以上接头，控制器60控制剪切件50沿输送方向将在预设距离内的第一个接头的前方区域与最后一个接头的后方区域之间的金属端子料带切断，可以将切断的金属端子料带废弃。在检测机构40检测到在预设距离内具有一个接头时，控制器60控制剪切件50将该接头前后两侧的金属端子料带切断，并可将切断的金属端子料带废弃。在收料的过程中，金属端子料带可沿着输送方向活动，剪切件50对经过其所在位置的金属端子料带进行剪切，当前一个料盘装满时，可以进行下一个料盘的收卷，在前一个料盘与后一个料盘之间的接续处具有一接头。在对接头附近的区域进行处理后，下一卷金属端子料带开始自动卷入更新后的收料盘20中，连续并且持续不断重复以上过程即能达到表面处理端子产品的全自动收料。
由此，根据本发明实施例的全自动收料机100主要由机体10、收料盘20、检测机构40、剪切件50和控制器60组成，通过检测机构40与剪切件50相互配合，能够实现对于在预设距离内具有不同数量的接头的快速、准确处理，能够在连续收料的过程中对接头进行处理，从而能够实现自动化收料，该全自动收料机100具有结构简单，便于实施，提高工作效率等优点。
根据本发明实施例的全自动收料机100还包括纸盘30，纸盘30与收料盘20相对设置且一一对应，通过与收料盘20相对应的纸盘30能够在收料的同时对金属端子料带进行包装。与此同时，收料盘20与纸盘30相互配合，对前一个料盘进行收尾工作。
在本发明的一些具体实施方式中，全自动收料机100还包括送料驱动件70，送料驱 动件70可设于机体10且位于检测机构40与剪切件50之间，通过送料驱动件70能够引导金属端子料带输送，提高金属端子料带的输送连续性。
根据本发明的一个实施例，全自动收料机100还包括收料速度传感器80，收料速度传感器80可设于机体10且位于检测机构40背向收料盘20所在位置的一侧，通过收料速度传感器80能够获取金属端子料带的输送速度。
根据本发明的一个实施例，全自动收料机100还包括CCD检测器，CCD检测器设于机体10且与控制器60相连，CCD检测器能够检测金属端子料带中的金属端子的变形情况，控制器60与CCD检测器相连以根据检测到的变形情况控制剪切件50切断变形的金属端子两侧的金属端子料带，也就是说，通过CCD检测器能够检测出变形的端子，在检测到有变形的端子时，通过剪切件50能够将变形的端子切除，从而即使在电镀生产中有突发性的端子变形发生时，也能达到全自动连续不间断生产产品的目的。可选地，在连续金属端子表面处理生产中发生端子变形时，可以通过CCD检测报警，通过剪切件50在变形产品前50cm处开始切断电镀产品，以间隔20cm为切断长度，切断后废弃到废料桶中。当剪断的连续金属端子表面处理产品卷入料盘后，保护带(例如纸带)多卷入3圈，自动停止转动。当变形产品检测报警结束，在变形产品后方再多余切断50cm，随后的连续金属端子表面处理产品自动卷入料盘的同时保护带也自动开始运行，这样就能即使在电镀生产中有突发性的表面处理端子产品变形发生时，也能达到全自动连续不间断生产表面处理产品的目的。
在本发明的一些具体实施方式中，机体10上设有收料位置与下料位置，收料盘20的数量为两个以上，两个收料盘20沿上下方向间隔开分布，每个收料盘20能够在收料位置与下料位置之间可活动，当前一个收料盘20满料时，前一盘与后一盘之间的接头的附近区域被切断，对应的满料的收料盘20从收料位置移动至下料位置，又一个空的收料盘20从下料位置移动至收料位置，能够实现自动更换收料盘，自动收取表面处理产品。
根据本发明的一个实施例，剪切件50被构造成在预设距离内的接头数量为一个时对金属端子料带上接头的上下游区域进行至少三次切割，其中，第一切割位置和第二切割位置分别位于接头的上游和下游，第三切割位置在位于所述第一切割位置的上游。其中，第三切割位置与第一切割位置之间的金属端子料带可废弃或者其至少一部分作为检查样品，第一切割位置与第二切割位置之间的金属端子料带可废弃。
在本发明的一些具体实施方式中，剪切件50被构造成在预设距离内的接头数量为多个时对金属端子料带上位于运输方向上的两端的两个端部接头的上下游区域进行至少两次切割，两次切割位置分别位于两个端部接头的上游和下游。
需要说明的是，在对前一个料盘进行收料收尾工作时，金属端子料带全部卷入收料盘20中，收料盘20可为圆形，纸盘30上的表面处理产品保护纸带(或软塑料带)再卷入M圈后自动切断，M优选为3。并能够在保护带末端自动封上胶带，防止收料盘20中的料盘产品松卷，导致产品脱落造成损失。在两个料盘之间的接头被切除后，随之运行而来的是下一盘的金属端子料带，为了保证金属端子料带上的金属端子表面处理产品的质量，可将切断的第一切割位置与第三切割位置之间的金属端子料带作为检查样品。
其中，金属端子料带的前方指的是邻近收料盘20所在方向的一侧，后方指的是背向收料盘20所在方向的一侧，金属端子料带的输送方向指的是向收料盘20进行输送的方向。
由此，根据本发明实施例的全自动收料机100不仅能够实现表面处理端子产品的自动化收料，还能够通过剪切件50与接头感应器40相配合实现自动剪切接头，采用CCD检测器能够自动检测变形的表面处理端子产品，并配合剪切件50将变形的端子切除，该全自动收料机100具有能够实现连续不间断生产，提高生产效率，降低生产成本等优点。
如图3所示，根据本发明实施例的全自动收料机的全自动收料方法，能够用于对金属端子料带进行连续收料形成料盘，金属端子料带具有沿其输送方向延伸的至少一个接头，方法包括以下步骤：
S1、判断全自动收料机是否满足正式生产条件。
根据本发明的一个实施例，步骤S1包括：
S11、将要调试表面处理条件的金属端子料带的前端与高度大致相等的金属牵引材料连接成一体成为前接头，调试金属端子料带的后端与高度大致相等的金属牵引材料连接成一体成为后接头。
S12、将金属端子料带进行表面处理。
S13、沿输送方向将前接头的至少一部分的前方与后接头的至少一部分的后方之间的金属端子料带切断，切断的一部分金属端子料带作为检测样品，检查检测样品的表面处理性能，在不符合要求时重复步骤S11。
可选地，在步骤S13中，在金属牵引材料需要再利用时，沿输送方向将前端与对应的金属牵引材料之间的连接位置与后端与对应的金属牵引材料之间的连接位置之间的金属端子料带切断，并将前接头对应的金属牵引材料卷入料盘，将后接头对应的金属牵引材料卷入至属牵引材料盘，在金属牵引材料需要废弃时，沿输送方向将前接头的前方与后接头的后方之间的金属端子料带切断。
例如，在连续金属端子的调试表面处理条件时，将要调试表面处理条件的连续金属端子材料5m～10m的前端与高度大致相等的金属牵引材料连接成一体，成为前接头，调试材料后端也与高度相似的金属牵引材料连接成一体，成为后接头。按该产品的性能要求进行表面处理后，当金属牵引材料需要重复使用时，以前接头中的前端与金属牵引材料的连接处为起点，以后接头的后端与金属牵引材料的连接处为终点，向后端所在方向剪断20cm，随后连续剪断10个20cm调试表面处理端子，将剪断的金属端子料带自动废弃到废料桶中，随后，按设定要求剪断4条检查样品，并按顺序排列保管，然后继续按20cm每条剪断调试表面处理端子并废弃，直至终点。前接头对应的金属牵引材料自动卷入收料盘20中，后接头对应的金属牵引材料可继续卷入到属牵引材料盘中，停机检查表面处理样品的性能。如果表面处理样品的检查没有合格，同样的调节工作从头开始，直到表面处理性能检查符合要求为止。
此外，接头前后的牵引材料不再利用需要废弃时，按20cm剪断废弃，前接头剪断后，剪断10个20cm调试电镀端子，自动废弃到废料桶中；按设定要求剪断4条检查样品，并按顺序排列保管；继续按20cm每条剪断调试电镀端子并废弃，直到剪断最后的接头后停机。
S2、在满足正式生产条件时，进行生产，在不满足正式生产条件时，调试生产条件，在生产条件合格时进行生产。
S3、检测金属端子料带上是否有变形的金属端子，在有变形的金属端子时切除变形的金属端子，在无变形的金属端子时进行收料。
在本发明的一些具体实施方式中，步骤S3中，可以通过CCD检测器检测金属端子的变形情况，CCD检测器可具有报警功能，在检测到变形的金属端子时能够发出报警信息。
S4、检测所述金属端子料带上的预设距离内是否有接头，并在所述金属端子料带上具有一个接头时执行步骤S5，在所述金属端子料带上具有多个接头时执行步骤S6。检测机构40还可包括距离传感器43，通过距离传感器43能够调节的送料驱动件70的马达的快慢。根据本发明的一个实施例，在步骤S4中，所述预设距离为5m，也就是说，检测在5m的范围内的接头的数量。其中，电镀产品(金属端子料带)的最短长度优选为5米以上，是由于在组装车间的自动组装机在表面处理产品的长度大于5米时，自动组装机才能正常连续运行。由此，预设距离优选为5m。
S5、对所述金属端子料带上接头的上下游区域进行至少三次切割，其中，第一切割位置和第二切割位置分别位于接头的上游和下游，第三切割位置在位于所述第一切割位置的上游；
可选地，第一切割位置与第二切割位置之间的金属端子料带可以自动废弃至废料桶内，第一切割位置与第三切割位置之间的金属端子料带可以废弃或者用作检测样品，在用作检测样品时能够供产品质量检查用，切断后放到固定位置进行保管。需要说明的是，在进行样品保管时，可以对样品进行标记，从而便于识别上一盘检测样品和下一盘检测样品，不会产生混淆。
进一步地，第一切割位置与接头之间的距离以及第二切割位置与接头之间的距离均为10cm，第三切割位置与第一切割位置之间的距离为20cm-100cm。
在本发明的一些具体实施方式中，第一切割位置与第三切割位置之间的金属端子料带在作为检查样品时，剪切件50能够沿输送方向以第三切割位置为起点在每间隔距离s处剪切金属端子料带。可选地，将s设定为20cm，也就是说，在步骤S5中，以间隔20cm为切断长度对所述第一切割位置与所述第三切割位置之间的所述金属端子料带进行切割，切断数量范围可在2～4条内设定，并对切断的样品有序排列保管，便于检测样品性能。
可选地，当第一切割位置与第三切割位置之间的金属端子料带需要废弃时，可按间隔20cm为切断长度将金属端子料带切割，切断后废弃到废料桶中。
S6、对所述金属端子料带上位于运输方向上的两端的两个端部接头的上下游区域进行至少两次切割，两次切割位置分别位于两个所述端部接头的上游和下游。可选地，在检测到两个接头之间的长度小于5m时，以间隔20cm为切断长度，切断后废弃到废料桶中。同时当连续金属端子表面处理产品卷入收料盘30后，保护带多卷入3圈后，自动停止转动。
可选地，当第2个接头切断结束，再多余切断50cm，随后的表面处理产品自动卷入料盘的同时保护带也自动开始运行，做到在表面处理生产中有一个或多个接头时，也能全自动连续进行表面处理生产的目的。
S7、继续对所述金属端子料带进行收料，直至收料完成。
根据本发明实施例的全自动收料机100和自动收料方法至少具有以下优点：
(1)能够实现连续金属端子表面处理生产的高度自动化；
(2)在连续金属端子的连续表面处理生产过程中，大幅度降低人工所发生的操作失误，生产效率有极大的提高，降低了表面处理产品的不合格百分率，对连续金属端子表面处理产品质量的投诉也减少了许多，从而使连续金属端子的表面处理生产成本也得到了大 幅度降低。
(3)在连续金属端子的连续表面处理生产过程中，采用该全自动收料机100和自动收料方法可以使连续金属端子即使发生突发性的产品变形能够通过CCD检测设备准确无误检测到变形范围，自动剪切废弃变形产品，自动连续表面处理生产不会受到影响。
(4)在连续金属端子的连续表面处理生产过程中，当一盘表面处理产品有一个或多个接头时，只要检测到两个接头之间的长度小于5m，就能自动剪切和废弃该段产品，并且自动连续表面处理生产不会受到影响。
(5)在连续金属端子的调试表面处理生产条件时，采用该自动收卷方法和设备可以准确无误自动完成剪切收集表面处理测试样品；大幅度减少调试时间，使生产效率得到极大提高；从而大幅度降低了表面处理的生产成本。
下面结合实施例具体描述根据本发明实施例的全自动收料机100以及全自动收料方法。
其中，本发明实施例中的连续金属端子可以是在端子的表面上析出镍金属后，然后再进行部分析出金，或钯，或钯镍，或铑钌，或银，或锡等形成表面处理产品；也可以是在金属端子的表面上析出铜金属后，再析出金属锡。
本发明实施例中的调试表面处理生产条件所用的牵引材料可以是铜合金带材或不锈钢带材也可以是供表面处理专用的薄塑料带材。
本发明实施例中的自动多层收卷机是本公司为适应表面处理产品自动收料方法而配套设计制作的多功能收料机设备。
实施例1
[原材料]
适用于连续金属端子表面上析出镍金属后，然后在其表面上再进行部分析出金，或部分析出钯，或钯镍，或铑钌，或银，或锡等形成的表面处理产品，但是此处的析出锡的产品不需要Reflow加热处理。因而牵引材料可以用与金属端子宽度相近的不必耐高温的薄塑料带材。
[表面处理条件调试]
将绕有薄塑料带材的圆盘设置在放料机盘上，拉出薄塑料带材穿过放料停止治具，绕过放料缓冲机的各个导轮，穿过表面处理生产线的每个处理工艺和每个供电轮和驱动轮；穿过画像检查CCD处理装置，然后绕过收料缓冲机的各个导轮，穿过收料停止治具，最后进入收料圆盘中并用胶带将薄塑料带材粘贴固定在圆盘上，并缠绕3周后确认薄塑料带材坚实牢固；该收料圆盘放置在自动收料设备的圆盘固定位置上。在放料停止治具处，剪断薄塑料带材，用订书钉3点定面的方法将连续金属端子和薄塑料带材牢固地钉在一起并用胶带将订书钉缠绕包紧密实以防酸碱溶液和电镀溶液的浸入而产生不良后果。启动表面处理设备缓慢运行，连续金属端子材料运行出5米后，停止表面处理设备的运行；在连续金属端子材料5米处剪断并用订书钉3点定面的方法将连续金属端子和薄塑料带材牢固地钉在一起并用胶带将订书钉缠绕包紧密实等待使用。
依据连续金属端子规定的表面处理条件，将前后各处理工艺和各电镀工艺的泵浦开启，各水洗用水和风刀用压力空气开启，确认各工艺的温度是否达到规定设定值，如果检查结果准确无误可以准备开机。启动电镀设备，当连续金属端子进入到电解槽时手动开启 相对应的整流器，而当电镀材料全部运行出电解槽时，关闭相对应的整流器；同样的整流器操作在镀镍金属时类同；此后的部分镀金工艺过程，连续金属端子的定位孔一定要与镀金治具的定位针位置相吻合，才能保证电镀的位置和电镀膜厚的质量。随后对该产品的镀锡区域进行前处理后，用浸入方式进行部分镀锡并进行后处理，最后进入产品的画像检查和自动收卷工艺。
当画像检查没有发生报警时，电镀产品和薄塑料带材的第一个接头被导轮检测到后，剪断该接头后薄塑料带材卷入盘中旋转马达自动停止，连续金属端子电镀调试材料剪切10段20cm废弃到废料桶中，然后按设定要求采集每条长20cm剪断4条检查样品，并按顺序排列保管；继续按20cm每条剪断调试表面处理端子并废弃，直到剪断后续的金属端子与薄塑料带材接头后，按停机按钮完成采集表面处理端子检查样品的操作。
[表面处理产品检查]
表面处理检查样品经检查人员，按表面处理外观是否正常，端子是否有变形，表面处理金属与金属材料之间的结合力是否达到要求，表面处理金属膜厚是否在产品规格范围内等规格要求进行检查。如果所有检查项目都符合规格要求，即可开始表面处理生产。如果有任何一项检查内容不符合规格要求，要从最初的准备[原材料]开始，到最后[表面处理产品检查]为止重新进行整个过程，这种重复过程直到所有检查内容全部符合产品规格为止。
[表面处理生产/收放料准备]
表面处理条件调试样品的检查全部符合规格要求后，将收料机处的卷盘中的薄塑料带材与表面处理设备中的薄塑料带材用订书钉3点定面的方法将连续金属端子和薄塑料带材牢固地钉在一起并用胶带将订书钉缠绕包紧密实；另外准备一个收料盘，将保护电镀产品的保护带材用胶带紧密粘贴在该收料盘中，已备收取连续金属端子表面处理产品使用。然后，将放料卷盘中的薄塑料带材剪断并与调试材料连续金属端子1米用订书钉3点定面的方法将连续金属端子和薄塑料带材牢固地钉在一起并用胶带将订书钉缠绕包紧密实；1米连续金属端子调试材料的另一端与生产材料盘中的连续金属端子用电焊机将连续金属端子和薄塑料带材牢固地焊接在一起，焊接时必须将前后金属端子的定位孔完全重叠以保证在镀金工艺与镀金治具的定位针位置完全吻合。
[表面处理生产/开始]
依据连续金属端子规定的表面处理条件，将前后各处理工艺和各表面处理工艺的泵浦开启，各水洗用水和风刀用压力空气开启，确认各工艺的温度是否达到规定设定值，如果检查结果准确无误可以准备开机。启动表面处理设备，当连续金属端子进入到电解槽时手动开启相对应的整流器，而当表面处理材料全部运行出电解槽时，关闭相对应的整流器；同样的整流器操作在镀镍金属时类同；此后的部分镀金工艺过程，连续金属端子的定位孔一定要与镀金治具的定位针位置相吻合，才能保证表面处理的位置和电镀膜厚的质量。随后对该产品的镀锡区域进行前处理后，用浸入方式进行部分镀锡并进行后处理，最后进入产品的画像检查和自动收卷工艺。
当画像检查没有发生报警时，调试材料连续金属端子1米和薄塑料带材的接头被导轮检测到以后，以接头为中心剪断20cm该接头，随后剪切电镀产品20cm端子4段并废弃到废料桶中，将调试材料端子与生产材料端子的接头20cm剪断废弃；紧接随后剪切100cm表面处理生产端子的检查样品并保管，连续金属端子表面处理产品自动被送入准备好的卷盘与 保护带夹缝中间，收料盘自动开启的同时保护带也运行，开始将连续金属端子的表面处理产品卷入盘中。
将收料处的卷有薄塑料带材的料盘取下换上空盘，用胶带将保护表面处理产品的保护带紧密粘贴在该收料盘中，已备收取下一盘连续金属端子表面处理产品使用。
在放料处，当前一盘连续金属端子从料盘中脱出并在接头连接位置被停止治具夹紧后迅速将下一盘连续金属端子产品与夹具处的连续金属端子用点焊机焊接牢固，将停止治具开关解除。通过这种方式连续金属端子产品的电镀生产能够得以连续不断持续进行。
随着表面处理生产的持续进行，如果画像检查没有发生报警，在连续金属端子产品两盘之间的接头前10cm处为切断终点，需要剪切电镀产品的品质检查用样品，该样品一条的切断长度100cm，当连续金属端子产品两盘之间的接头切除后，随之运行而来的是下一盘的连续金属端子表面处理产品，为了保证连续金属端子表面处理产品的质量，接头后的长100cm端子产品切断并存放到固定位置进行保管；该样品可供选择废弃也可作为检查样品确认产品质量，样品保管位置要有明确标记，能明确识别上一盘100cm和下一盘100cm不能混淆。下一卷连续金属端子表面处理产品自动被送入准备好的卷盘与保护带夹缝中间，收料盘自动开启，开始将连续金属端子的表面处理产品卷入盘中。
将收料处的卷有连续金属端子表面处理产品的料盘取下换上空盘，用胶带将保护表面处理产品的保护带紧密粘贴在该收料盘中，以备收取下一盘连续金属端子表面处理产品时使用。将收集的表面处理端子样品送检查室检查，检查结果无异常则继续生产；检查结果有异常时立即停机，排查异常原因解除异常后方可继续生产。
以此连续并且持续不断重复以上同样过程既能达到表面处理端子的全自动收料目的。
[表面处理生产/产品变形]
当连续金属端子电镀生产中发生端子变形异常时，变形端子产品通过CCD检测会发出警报，在变形产品前50cm处开始自动切断表面处理产品，以间隔20cm为切断长度，切断后废弃在废料桶中，同时无变形表面处理产品卷入料盘后，保护带多卷入3圈后，自动停止传动等待变形产品剪切结束后无变形电镀产品的卷入；变形产品过后再多余切断50cm，随后的表面处理产品自动卷入料盘的同时保护带也自动开始运行。
[表面处理生产/产品有接头]
当一盘表面处理产品有一个或多个接头时，自动检测到两个接头之间的长度小于5米，就能够以间隔20cm长度自动切断并废弃到废料桶中；同时切断后的表面处理产品卷入料盘后，保护带多卷入3圈后，自动停止转动；当第2个接头切断结束，再多余切断50cm，随后的表面处理产品自动卷入料盘的同时保护带也自动开始运行。
实施例2
[原材料]
适用于连续金属端子表面上镀镍金属后，然后在其表面上再进行部分析出金，或部分析出钯，或钯镍，或铑钌，或银，或锡等形成的表面处理产品，此处的镀锡产品需要Reflow加热处理。因而牵引材料必须用可以耐高温的铜合金或不锈钢带材。
[表面处理条件调试]
实施例1结束后，将收料处的产品盘换成卷有薄塑料带材的盘，并将其与表面处理 设备内的薄塑料带材用订书钉3点定面的方法将它们牢固地钉在一起并用胶带将订书钉缠绕包紧密实。
然后在放料处切断薄塑料带材并将其与薄不锈钢带材用订书钉3点定面的方法将它们牢固地钉在一起并用胶带将订书钉缠绕包紧密实。表面处理设备的所有处理溶液和表面处理溶液的泵浦不开启；水洗水以及风刀用压缩空气关闭不用。启动表面处理设备将薄不锈钢带材牵引通过整条电镀生产线到达收料处，剪断薄塑料带材与薄不锈钢带材的接头并将薄不锈钢带材用胶带固定到空盘，启动表面处理设备将薄不锈钢带材卷入到空盘3圈后停机。
在放料处，将薄不锈钢带材剪断并与调试用连续金属端子用订书钉3点定面的方法将它们牢固地钉在一起并用胶带将订书钉缠绕包紧密实。启动表面处理设备缓慢运行，连续金属端子材料运行出5米后，停止表面处理设备的运行；在连续金属端子材料5米处剪断并用订书钉3点定面的方法将连续金属端子和薄不锈钢带材牢固地钉在一起并用胶带将订书钉缠绕包紧密实等待使用。
依据连续金属端子规定的表面处理条件，除先将Reflow加热设备启动开始加热，经过15分钟Reflow炉膛内的温度达到电镀条件设定温度并趋于稳定以外，其它的所有准备工作和顺序与(实施例1)的相同。
启动表面处理设备，当调试用连续金属端子经过所有表面处理处理后，除通过Reflow加热设备所有的金属端子电镀产品从Reflow加热设备出口运行出来以后即可关闭Reflow加热设备的电源的操作以外，其它的所有操作方法和顺序与(实施例1)的相同。
[表面处理产品检查]
除了电镀锡Reflow加热处理后产品的性能要增加焊锡实验以外，其它的所有检查内容和方法与(实施例1)的相同。
[表面处理生产/收放料准备]
除了牵引带由薄不锈钢带材代替薄塑料带材，以及电镀条件由实施例1换为实施例2的以外，其它的所有内容与(实施例1)的相同。
[表面处理生产/开始]
除了牵引带由薄不锈钢带材代替薄塑料带材，以及电镀条件由实施例1换为实施例2的以外，其它的所有内容与(实施例1)的相同。
[表面处理生产/产品变形]
除了牵引带由薄不锈钢带材代替薄塑料带材，以及电镀条件由实施例1换为实施例2的以外，其它的所有内容与(实施例1)的相同。
[表面处理生产/产品有接头]
除了牵引带由薄不锈钢带材代替薄塑料带材，以及电镀条件由实施例1换为实施例2的以外，其它的所有内容与(实施例1)的相同。
实施例3
[原材料]
适用于连续金属端子表面上镀铜金属后，然后在其表面上再进行析出锡形成的表面处理产品，此处的镀锡产品需要Reflow加热处理。因而牵引材料必须用可以耐高温的铜合金或不锈钢带材。
[表面处理条件调试]
除在连续金属端子表面上镀铜金属以外，其它的所有操作方法和顺序与(实施例2)的相同。
[表面处理产品检查]
除在连续金属端子表面上镀铜金属以外，其它的所有操作方法和顺序与(实施例2)的相同。
[表面处理生产/收放料准备]
除在连续金属端子表面上镀铜金属以外，其它的所有操作方法和顺序与(实施例2)的相同。
[表面处理生产/开始]
除在连续金属端子表面上镀铜金属以外，其它的所有操作方法和顺序与(实施例2)的相同。
[表面处理生产/产品变形]
除在连续金属端子表面上镀铜金属以外，其它的所有操作方法和顺序与(实施例2)的相同。
[表面处理生产/产品有接头]
除在连续金属端子表面上镀铜金属以外，其它的所有操作方法和顺序与(实施例2)的相同。
总而言之，根据本发明实施例的全自动收料机100以及全自动收料方法以解决下列所述问题中的至少一个为研究开发目标。
(1)在连续金属端子的连续表面处理生产中的需求包括：
1)表面处理产品的自动剪切采集测试样品并保存，自动剪切接头并可将其废弃到废料桶中，自动更换收料盘，自动卷式收取产品；
2)对变形产品自动检测检出，自动剪切并废弃在废料桶中，并可以自动卷取无变形产品；
3)自动检测出不足5米的有两个接头的连续金属端子产品，自动剪切并废弃在废料桶中，可将切断接头后的电镀产品自动卷取到收料盘中。
(2)在调试产品表面处理条件时，需求包括：
4)所使用的金属牵引材料，要能在自动剪切采集测试样品后，如果金属牵引材料需要再利用时，自动剪断接头，并能将金属牵引用材料自动卷入料盘；
5)如果金属牵引用材料需要废弃时，能做到自动剪切全部金属牵引用材料并废弃在废料桶中。
根据本发明实施例的全自动收料机100以及全自动收料方法能够减小手工操作中的失误百分率，降低连续金属端子产品生产设备的停机次数，提高效率和质量，降低连续金属端子的生产成本。
在本说明书的描述中，参考术语“一个实施例”、“一些实施例”、“示意性实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特 点可以在任何的一个或多个实施例或示例中以合适的方式结合。
尽管已经示出和描述了本发明的实施例，本领域的普通技术人员可以理解：在不脱离本发明的原理和宗旨的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由权利要求及其等同物限定。

Claims (10)

  1. 一种全自动收料机，能够用于对金属端子料带进行连续收料形成料盘，所述金属端子料带具有沿其输送方向延伸的至少一个接头，其特征在于，所述全自动收料机包括：
    机体；
    收料盘，所述收料盘设于所述机体，所述收料盘能够收卷所述金属端子料带；
    检测机构，所述检测机构设于所述机体且能够获取在预设距离内的接头数量；
    剪切件，所述剪切件设于所述机体且能够剪切所述金属端子料带，所述剪切件位于所述收料盘与所述检测机构之间；
    控制器，所述控制器分别与所述检测机构和所述剪切件相连以根据所述检测机构检测到的接头数量控制所述剪切件对所述金属端子料带进行剪切，其中，在所述预设距离内的接头数量为一个时，所述控制器控制所述剪切件切断所述一个接头两侧的所述金属端子料带，在所述预设距离内的接头数量为两个以上时，所述控制器控制所述剪切件切断所述预设距离内的第一个接头邻近所述收料盘所在位置的一侧的所述金属端子料带以及所述预设距离内的最后一个接头背向所述收料盘所在位置的一侧的所述金属端子料带。
  2. 根据权利要求1所述的全自动收料机，其特征在于，还包括：
    CCD检测器，所述CCD检测器设于所述机体且能够检测所述金属端子料带中的金属端子的变形情况，所述控制器与所述CCD检测器相连以根据检测到的变形情况控制所述剪切件切断变形的所述金属端子两侧的所述金属端子料带。
  3. 根据权利要求1所述的全自动收料机，其特征在于，所述机体上设有收料位置与下料位置，所述收料盘的数量为两个以上，两个所述收料盘沿上下方向间隔开分布，每个所述收料盘能够在所述收料位置与所述下料位置之间可活动。
  4. 根据权利要求1所述的全自动收料机，其特征在于，所述剪切件被构造成在所述预设距离内的接头数量为一个时对所述金属端子料带上接头的上下游区域进行至少三次切割，其中，第一切割位置和第二切割位置分别位于接头的上游和下游，第三切割位置在位于所述第一切割位置的上游。
  5. 根据权利要求1所述的全自动收料机，其特征在于，所述剪切件被构造成在所述预设距离内的接头数量为多个时对所述金属端子料带上位于运输方向上的两端的两个端部接头的上下游区域进行至少两次切割，两次切割位置分别位于两个所述端部接头的上游和下游。
  6. 一种全自动收料机的全自动收料方法，能够用于对金属端子料带进行连续收料形成料盘，所述金属端子料带具有沿其输送方向延伸的至少一个接头，其特征在于，所述方法包括以下步骤：
    S1、判断全自动收料机是否满足正式生产条件；
    S2、在满足正式生产条件时，进行生产，在不满足正式生产条件时，调试生产条件，在生产条件合格时进行生产；
    S3、检测所述金属端子料带上是否有变形的金属端子，在有变形的金属端子时切除变形的金属端子，在无变形的金属端子时进行收料；
    S4、检测所述金属端子料带上的预设距离内是否有接头，并在所述金属端子料带上具有一个接头时执行步骤S5，在所述金属端子料带上具有多个接头时执行步骤S6；
    S5、对所述金属端子料带上接头的上下游区域进行至少三次切割，其中，第一切割位置 和第二切割位置分别位于接头的上游和下游，第三切割位置在位于所述第一切割位置的上游；
    S6、对所述金属端子料带上位于运输方向上的两端的两个端部接头的上下游区域进行至少两次切割，两次切割位置分别位于两个所述端部接头的上游和下游；
    S7、继续对所述金属端子料带进行收料，直至收料完成。
  7. 根据权利要求6所述的全自动收料方法，其特征在于，步骤S1包括：
    S11、将要调试表面处理条件的金属端子料带的前端与高度相等的金属牵引材料连接成一体成为前接头，调试金属端子料带的后端与高度相等的金属牵引材料连接成一体成为后接头；
    S12、将所述金属端子料带进行表面处理；
    S13、沿输送方向将所述前接头的至少一部分的前方与所述后接头的至少一部分的后方之间的所述金属端子料带切断，切断的一部分所述金属端子料带作为检测样品，检查检测样品的表面处理性能，在不符合要求时重复步骤S11。
  8. 根据权利要求7所述的全自动收料方法，其特征在于，在步骤S13中，在所述金属牵引材料需要再利用时，沿输送方向将所述前端与对应的所述金属牵引材料之间的连接位置与所述后端与对应的所述金属牵引材料之间的连接位置之间的所述金属端子料带切断，并将所述前接头对应的金属牵引材料卷入所述料盘，将所述后接头对应的金属牵引材料卷入至属牵引材料盘，在所述金属牵引材料需要废弃时，沿输送方向将所述前接头的前方与所述后接头的后方之间的所述金属端子料带切断。
  9. 根据权利要求6所述的全自动收料方法，其特征在于，在步骤S4中，所述预设距离为5m，在步骤S5中，所述第一切割位置和所述第二切割位置与所述接头之间的距离为10cm，所述第三切割位置与所述第一切割位置之间的距离为20cm-100cm。
  10. 根据权利要求6所述的全自动收料方法，其特征在于，在步骤S5中，以间隔20cm为切断长度对所述第一切割位置与所述第三切割位置之间的所述金属端子料带进行切割。
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CN115616173A (zh) * 2022-10-21 2023-01-17 北京市农产品质量安全中心 一种用于动物源性产品安全评价分析仪及其方法
CN116594329A (zh) * 2023-04-13 2023-08-15 东莞市永兴机电工程有限公司 分条机自动控制系统
CN116594329B (zh) * 2023-04-13 2024-04-09 东莞市永兴机电工程有限公司 分条机自动控制系统

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