Automatic press-fitting system for rotor and spline shaft

Abstract

The invention relates to an automatic press-fitting system for a rotor and a spline shaft, which is characterized in that a laser sensor is used for detecting the reflected light intensity difference of a tooth crest and a tooth groove, and a PLC (Programmable Logic Controller) calculates the angular deviation of the spline shaft in real time based on a difference signal and generates a rotation instruction; after receiving the instruction, the servo motor drives the spline shaft to adjust at a certain increment angle; the suction cup tool sucks the rotor end face through a vacuum suction cup and moves to the position coaxial with the spline shaft; and the servo press drives the rotor to press with constant pressure, the PLC synchronously analyzes the press-in force and displacement, when the displacement reaches a preset range, it is judged that meshing succeeds, and when the displacement does not reach the preset range, it is judged that tooth crest interference occurs, and a reverse rotation correction process is triggered. The system can realize high-precision angle detection and dynamic correction, improves the one-time success rate of engagement of the spline shaft and the rotor, is suitable for precision assembly scenes such as a new energy automobile electric drive system and an industrial speed reducer, effectively reduces the manual intervention cost, and improves the production takt time stability.

Description

Technical Field

[0001] The present invention belongs to the technical field of electric drive component assembly, and more specifically, relates to an automatic press-fitting system for a rotor and a spline shaft. Background Art

[0002] In the field of mechanical manufacturing, the press-fitting of the rotor and the spline shaft is a key link in the assembly of electric drive components. The meshing accuracy of the spline shaft and the rotor directly affects the transmission efficiency and service life of the equipment. In the traditional press-fitting process, the meshing alignment and press-fitting are mainly completed by manual operation or semi-automatic equipment, but in actual application, there are the following problems and shortcomings: First, the traditional manual press-fitting requires workers to adjust the spline shaft angle by visual inspection or simple tools, and the meshing state depends on the operator's experience and judgment. Since the spline shaft tooth grooves and the rotor tooth shape need to be precisely aligned, manual adjustment is time-consuming and can easily lead to meshing failure due to operational errors. For example, when the tooth tops interfere, workers need to repeatedly try and error to adjust the angle, resulting in a longer production cycle. In addition, the skill differences between different operators in mass production can easily lead to quality fluctuations and increase the rework rate. 2. Existing semi-automatic press-fitting equipment, as described in patent application publication number CN117961478A, uses a servo motor to drive the gear rotation, combined with pressure feedback from a servo press, to find the critical point where pressure decreases during rotation to complete the press-fitting. Although this has achieved an improvement from manual to semi-automatic, the following problems and limitations still exist in actual applications: 1. Angle detection relies on a single pressure feedback and has insufficient anti-interference capability; 2. The correction strategy is fixed and lacks dynamic adaptability; 3. The meshing state determination relies on a single parameter, with a high risk of misjudgment; 4. Data traceability and process monitoring capabilities are limited.

[0003] These issues lead to low efficiency, poor quality consistency, and high maintenance costs in the existing press-fitting process. A solution that can achieve high-precision detection, adaptive correction, and data traceability is urgently needed to improve press-fitting automation and product reliability. Summary of the Invention

[0004] An object of the present invention is to address at least the above-mentioned drawbacks and to provide at least the advantages which will be described hereinafter.

[0005] The present invention provides an automated press-fitting system for a rotor and a spline shaft, one purpose of which is to solve the problems of low press-fitting process efficiency, high misjudgment rate of meshing state and low correction efficiency in traditional press-fitting processes.

[0006] The present invention provides a rotor and spline shaft automatic press-fitting system, the rotor and spline shaft automatic press-fitting system is characterized by comprising a servo press, a servo motor, a PLC controller, a laser sensor and a suction cup tooling; The laser sensor is arranged on the side of the spline shaft, and detects the difference in reflected light intensity between the tooth top and tooth groove of the spline shaft by emitting laser, and transmits the signal to the PLC controller; The PLC controller calculates the angle of the spline shaft according to the difference in reflected light intensity and generates a rotation instruction; The servo motor is connected to the spline shaft, receives a rotation instruction and drives the spline shaft to rotate; The suction cup fixture includes a vacuum suction cup, which absorbs the end face of the rotor and moves the rotor to a position coaxial with the spline shaft; The servo press drives the rotor to move toward the spline shaft and applies a constant pressure; When the pressing force reaches a preset pressure value, the PLC controller determines the meshing state according to whether the displacement is within a preset range: if the displacement reaches the preset range, it is determined to be meshing successfully; if the displacement does not reach the preset range, it is determined to be tooth top interference; When it is determined that there is tooth top interference, the PLC controller drives the spline shaft to rotate in the opposite direction and re-executes the press-fitting process.

[0007] Preferably, it also includes an anti-slip sheet; the anti-slip sheet is fixed to the end of the rotor, and its inner ring is provided with teeth matching the tooth shape of the spline shaft; when the rotor is engaged with the spline shaft, the teeth of the anti-slip sheet are embedded in the tooth grooves of the spline shaft.

[0008] Preferably, the logic of the PLC controller includes: After the initial press-fitting fails, the spline shaft is controlled to rotate in the opposite direction. During the rotation, the changes in the press-fitting force are monitored in real time. When the press-fitting force is less than the preset pressure value, the engagement is determined to be successful. The press-fitting force will be reconfirmed before the servo press is pressed to prevent misjudgment. The maximum angle of the rotating spline shaft is the angle corresponding to the single tooth pitch, which is 360° divided by the total number of teeth on the spline shaft. When the number of consecutive failures reaches a preset threshold, an alarm signal is triggered and the process is paused. The preset threshold can be 3 to 5 times.

[0009] Preferably, the end surface of the rotor is provided with a positioning boss; A guide groove matching the positioning boss is provided at the center of the suction cup fixture.

[0010] Preferably, the press-fitting process of the system includes: Adsorb the rotor and move it to the initial position; Use a laser sensor to detect the angle of the spline shaft and adjust the spline shaft to the target angle; Drive the servo press to press the rotor; Determine the meshing results based on the indentation force curve and displacement curve; If the determination fails, rotate the spline shaft in the opposite direction and repeat the process.

[0011] Preferably, the data of the pressing force curve is stored in a storage module of the PLC controller; The storage module records the peak pressure, displacement and timestamp of each press-fitting; The data is transmitted to a host computer via industrial Ethernet, and the host computer generates a press-fitting qualified rate statistical report.

[0012] Preferably, the servo press is connected to the rotor via a suction cup fixture; The front end of the suction cup tooling is provided with a pressure sensor and a displacement sensor, the pressure sensor is rigidly connected to the pressure head of the servo press, and the displacement sensor is fixed on the side of the pressure head; When the servo press drives the rotor to press-fit, the pressure sensor collects the pressing force signal in real time and generates a pressing force curve, and the displacement sensor collects the linear displacement of the press head in real time and generates a displacement curve; The signals of the pressure sensor and displacement sensor are transmitted to the PLC controller through the analog module; The PLC controller determines the meshing state according to the displacement difference when the pressure in the pressing force curve reaches a preset pressure value.

[0013] Preferably, the specific logic of the PLC controller driving the spline shaft to rotate in the opposite direction is: When it is determined to be tooth addendum interference, the PLC controller calculates the deviation between the current angle of the spline shaft and the target angle based on the difference in reflected light intensity detected by the laser sensor; The deviation value ranges from 0.5° to 5°; The PLC controller generates a reverse rotation command to drive the servo motor to use the absolute value of the deviation as the rotation angle correction value; The corrected spline shaft angle must make the reflected light intensity difference signal meet the preset tooth groove alignment threshold.

[0014] Preferably, the preset cogging alignment threshold is that the fluctuation amplitude of the reflected light intensity difference signal detected by the laser sensor is less than 3% to 8% of the full scale of the sensor; if the sensor range is 0-1000mV, the cogging alignment threshold is that the fluctuation value of the reflected light intensity difference signal is ≤±30mV to ±80mV; When the fluctuation amplitude of the reflected light intensity difference signal is within the range of 3% to 8%, the PLC controller determines that the tooth groove of the spline shaft is aligned with the rotor tooth profile; The PLC controller controls the servo motor to stop rotating by comparing the real-time reflected light intensity difference signal with the threshold range, and triggers the servo press to re-execute the pressing process.

[0015] Preferably, the calculation logic of the deviation value includes: The target angle is the theoretical angle when the rotor tooth profile is completely aligned with the spline shaft tooth groove; The deviation value is the difference between the real-time angle and the theoretical angle. The calculation formula of the deviation value is: Δθ=θ 实时 -θ 理论 ; When the absolute value of the deviation Δθ is greater than or equal to 0.5° and less than or equal to 5°, it is determined to be a valid deviation and a reverse rotation correction is triggered.

[0016] The present invention has at least the following beneficial effects: This invention uses collaborative data collection from pressure and displacement sensors to correlate press force and displacement changes, eliminating the limitations of single-parameter judgment. This solves the problem in traditional press-fitting processes, which lacks real-time force-displacement coupled monitoring, leading to a high rate of misjudgment of meshing status and potential damage to the rotor or spline shaft.

[0017] This invention ensures that the spline shaft rotation angle strictly matches the actual assembly error by calculating the angular deviation in real time and dynamically adjusting the correction amount. This addresses the problem in traditional error correction methods where fixed-angle rotation (such as single tooth pitch) cannot adapt to the dynamic changes in the actual spline shaft angular deviation, resulting in increased repeated adjustments or secondary interference.

[0018] The present invention solves the problem of insufficient alignment accuracy during the dynamic correction process by quantifying the tooth groove alignment threshold range.

[0019] The present invention solves the nonlinear conversion problem between the reflected light intensity difference signal and the true angle by dynamically calibrating the voltage-angle mapping relationship, thereby improving the deviation calculation accuracy.

[0020] Other advantages, objectives and features of the present invention will be reflected in part from the following description and will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a schematic diagram of the press-fitting system for the rotor and spline shaft according to the present invention; Figure 2 This is a schematic diagram of the implementation of the rotor and spline shaft automatic press-fitting system of the present invention; Figure 3 This is a flow chart of an implementation form of the rotor and spline shaft automatic press-fitting system of the present invention; Among them, the rotor 1; the anti-slip plate 2; the spline shaft 3; the servo motor 4, the suction cup tooling 5, the servo press 6, the frame 7, and the laser sensor 8. DETAILED DESCRIPTION

[0022] The present invention is further described in detail below with reference to the embodiments so that those skilled in the art can implement the invention with reference to the description.

[0023] It should be noted that the experimental methods described in the following embodiments are conventional methods unless otherwise specified, and the reagents and materials are commercially available unless otherwise specified. In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "set" should be understood in a broad sense, for example, they can be fixedly connected or set, or detachably connected or set, or integrally connected or set. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances. The orientations or positional relationships indicated by the terms "transverse", "longitudinal", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc. are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0024] See also Figure 1 、 Figure 2 and Figure 3 As shown, according to an implementation of the present invention, it includes a servo press 6, a servo motor 4, a PLC controller, a laser sensor 8 and a suction cup tooling 5; the laser sensor 8 is arranged on the side of the spline shaft 3 and fixed on the frame 7, and the laser sensor 8 detects the difference in reflected light intensity by emitting laser to the tooth top and tooth groove surface of the spline shaft, and converts the light intensity signal into an electrical signal and transmits it to the PLC controller; the PLC controller calculates the current angle of the spline shaft according to the received reflected light intensity difference signal, and generates a spline shaft rotation instruction; the servo motor 4 is connected to the spline shaft 3, receives the rotation instruction of the PLC controller, and drives the spline shaft to rotate at an incremental angle of 0.5° to 3°; the suction cup tooling includes 6 vacuum suction cups with a suction force of 80N to 120N, and the vacuum suction cups adsorb the end face of the rotor 1 , move the rotor 1 to a position coaxial with the spline shaft; the servo press 6 is connected to the suction cup tooling 5, driving the rotor 1 to move toward the spline shaft 3 at a speed of 5mm / s to 15mm / s; when the rotor contacts the spline shaft, the servo press applies a constant pressure of 500N to 700N, and collects the pressing force curve and displacement curve in real time; the PLC controller judges the engagement state by the displacement when the pressure value in the pressing force curve reaches 500N to 700N: if the displacement is 3mm to 8mm, it is judged to be meshing successfully; if the displacement is 0.5mm to 2.5mm, it is judged to be tooth top interference; when it is judged to be tooth top interference, the PLC controller sends a reverse rotation command to the servo motor, drives the spline shaft to rotate 0.5° to 3° in the opposite direction, and restarts the servo press to execute the pressing process.

[0025] According to another implementation of the present invention, the judgment logic of the pressing force curve includes: when the pressing force reaches a preset pressure value, the meshing state is determined based on whether the displacement is within a preset range; for example, the PLC controller determines the meshing state based on the displacement when the pressure value in the pressing force curve reaches 500N to 700N: if the displacement is 3mm to 8mm, it is determined to be meshing successfully; if the displacement is 0.5mm to 2.5mm, it is determined to be tooth top interference; Alternatively, based on the positive correlation between displacement and time when the speed is constant, the judgment is made: when the time for the pressing force to increase from 0N to 500N to 700N is less than 0.5s, it is judged as tooth top interference; when the time for the pressing force to increase from 0N to 500N to 700N is greater than 1s and less than 3s, it is judged as successful meshing.

[0026] The sampling frequency of the displacement curve is 100 Hz to 200 Hz, and the displacement accuracy is ±0.02 mm.

[0027] According to another embodiment of the present invention, the vacuum cups of the suction cup fixture are evenly distributed around the circumference, with the central angle between adjacent cups being 60°. The suction surface of the vacuum cups is made of rubber with a hardness of Shore A50 to Shore A70. The vacuum cups are connected to a vacuum pump via a solenoid valve, and the vacuum pump has a negative pressure of -60kPa to -80kPa. The servo press has a repeatability accuracy of ±0.01mm to ±0.05mm; the servo motor has a rotation angle feedback accuracy of ±0.1° to ±0.3°; the laser sensor has a detection distance of 10mm to 50mm, and a spot diameter of 0.1mm to 0.3mm.

[0028] One implementation works as follows: A laser sensor (detection distance 10-50mm, spot diameter 0.1-0.3mm) emits laser light at the tooth tops and tooth grooves of the spline shaft. The difference in reflected light intensity between the tooth tops (high reflectivity) and tooth grooves (low reflectivity) generates an electrical signal and transmits it to a PLC controller. The PLC receives the light intensity signal and uses an algorithm to calculate the current angle of the spline shaft. If the current angle deviates from the target angle, a rotation command (incremental angle 0.5°-3°) is generated. A servo motor (rotation angle feedback accuracy ±0.1°-0.3°) receives the command and drives the spline shaft to rotate by the specified increment. The detection and adjustment cycle is repeated until the reflected light intensity difference signal meets the tooth groove alignment requirements. A suction cup fixture (six vacuum cups, suction force 80-120N) grasps the rotor end face, aligns with the rotor's positioning bosses through guide grooves, and moves it coaxially with the spline shaft. A servo press (with a repeatability of ±0.01-0.05mm) drives the rotor toward the spline shaft at a speed of 5-15mm / s. After contact, a constant pressure of 500-700N is applied, and real-time force and displacement curves are collected (sampling frequency 100-200Hz, displacement accuracy ±0.02mm). Engagement is successful when the pressure reaches 500-700N and the displacement is 3-8mm. A tooth tip interference is detected when the pressure reaches 500-700N and the displacement is 0.5-2.5mm. If interference is detected, the PLC drives the spline shaft to rotate 0.5-3° in the opposite direction, restarting the servo press and continuing the press-fit process until engagement is successful or an alarm is triggered after 3-5 consecutive failures.

[0029] This invention uses a laser sensor to calculate angular deviation (accuracy ±0.1°) in real time based on differences in reflected light intensity, replacing traditional mechanical positioning or manual adjustment to avoid cumulative errors. 0.5° to 3° incremental rotation and reverse correction adapt to actual spline shaft assembly deviations, reducing the number of repeated adjustments. The collaborative judgment of the press-in force curve (pressure threshold) and the displacement curve (displacement range) reduces the false positive rate and avoids erroneous operations caused by a single parameter.

[0030] According to another implementation of the present invention, the anti-slip plate 2 can be fixed to the end of the rotor 1 and connected by bolts or welding. The shape of the teeth on the inner ring of the anti-slip plate can be designed to be an involute tooth shape that fully matches the tooth groove of the spline shaft to ensure that the teeth are embedded in the tooth groove after engagement. During assembly, the anti-slip plate can be installed at the center of the rotor end face and aligned with the rotor axis. The gap between the teeth and the tooth groove can be achieved by adjusting the tooth top height of the teeth. A gap that is too large will cause the anti-slip plate to be unable to effectively limit, and a gap that is too small may increase the assembly resistance. During assembly, after the teeth are embedded in the tooth groove of the spline shaft, it is necessary to ensure that the rotor and the spline shaft are not loose axially. The thickness of the anti-slip plate can be selected according to the rotor load requirements. Thicker anti-slip plates are suitable for high torque scenarios, and thinner ones are suitable for light load scenarios. The hardness of the material must take into account both strength and toughness to avoid deformation or breakage of the teeth during the press-fitting process. The clearance between the latching teeth and the tooth grooves can range from 0.05mm to 0.15mm. The anti-slip plate is 2mm to 5mm thick and made of spring steel with a hardness of HRC40 to HRC50. The working process is as follows: After press-fitting, the anti-slip plate moves with the rotor to the spline shaft meshing position. The latching teeth engage the spline shaft tooth grooves under the pressure of the servo press, with the clearance controlled within the range of 0.05mm to 0.15mm. The anti-slip plate adapts to slight deviations in the spline shaft tooth grooves through elastic deformation of the spring steel, ensuring no axial play after meshing.

[0031] According to another implementation of the present invention, when the initial press-fit fails, the PLC controller can calculate the single-tooth pitch angle of the spline shaft. For example, if the spline shaft has 24 teeth, the single-tooth pitch angle is 15°. The servo motor can receive PLC instructions and drive the spline shaft to rotate in the opposite direction by a correction angle, with the correction angle ≤ a maximum angle of 15°. During rotation, the press-fit force is dynamically monitored in real time. Engagement is determined to be successful when the press-fit force is less than a preset pressure value and the displacement reaches a preset range. The press-fit force is reconfirmed before the servo press to prevent misjudgment. The rotation angle accuracy can be controlled within a range of ±0.1° to ±0.3°. The single-tooth pitch angle can be 15° (24 teeth), 12° (30 teeth), or 7.2° (50 teeth). The servo motor is directly connected to the spline shaft via a coupling and mounted on a side bracket of the press-fit system. The PLC controller can record the number of press-fit failures in real time. When the number of consecutive failures reaches a preset threshold (e.g., 3, 4, or 5), the PLC can trigger an audible and visual alarm and pause the press-fit process. Alarm signals can be output to an external alarm device via a relay module. The consecutive failure threshold can be set to three, four, or five times. The audible and visual alarm can be a combination of an industrial-grade three-color light and a buzzer. The alarm device can be mounted on the operation panel or on the top of the machine for easy observation. The PLC controller can be programmed with logic to receive real-time data from the pressure and displacement sensors. When a press failure is detected, the PLC automatically generates a rotation command and sends it to the servo motor driver. After the corrected command is executed, the system automatically restarts the press process. The PLC control cabinet housing can be constructed of cold-rolled steel or aluminum alloy to meet dust and heat dissipation requirements. The pressure sensor can be a piezoelectric sensor, and the displacement sensor can be a magnetic or optical grating sensor. The PLC control cabinet is installed at the rear of the machine, and the sensor signal cables are connected to the PLC input module via shielded cable. In the event of a press failure, the PLC records the number of failures and calculates the single-tooth pitch angle. The servo motor then rotates the spline shaft by the corresponding angle (corrected angle) to initiate a second press. If three to five consecutive failures occur, the PLC triggers an alarm and pauses the process, awaiting manual intervention. Single-tooth pitch rotation adapts to spline shafts with different numbers of teeth to avoid excessive or insufficient angle correction; the continuous failure alarm mechanism prevents equipment component wear due to repeated incorrect operations; PLC and sensor collaborative control improves system response speed and correction accuracy.

[0032] According to another implementation of the present invention, the positioning boss can be cylindrical or rectangular, with a height of 1 mm, 2 mm, or 3 mm. The positioning boss can be located at the geometric center of the rotor end face and formed by turning or milling. It can be made of 45-gauge steel or 304 stainless steel, with a hardened surface for enhanced wear resistance. The diameter of the positioning boss can be 0.05 mm to 0.1 mm smaller than the guide groove to ensure guide clearance. The positioning boss can be machined on a CNC lathe or machining center. The positioning boss must be strictly coaxial with the rotor axis, with an error within ±0.02 mm. The guide groove can be designed as a groove that matches the shape of the positioning boss, with a depth slightly greater than the height (e.g., 1.5 mm to 3.5 mm). The inner wall of the guide groove can be machined with a bevel or arc transition to reduce assembly resistance. The suction cup tooling can be made of aluminum alloy or engineering plastic, and the guide groove is formed by precision wire cutting or electro-spark machining. The diameter of the guide groove can be 0.05 mm, 0.08 mm, or 0.1 mm larger than the positioning boss. The inner wall of the guide groove can be hard chrome plated or sprayed with a ceramic coating to improve wear resistance. The guide groove is located at the center of the suction cup fixture and is coaxial with the vacuum chuck. The clearance between the locating boss and the guide groove can be controlled within a range of 0.02mm to 0.1mm. Excessive clearance can cause rotor misalignment, while too small a clearance can cause binding. During assembly, the coaxiality of the boss and guide groove must be checked with a dial indicator to ensure an error of no more than ±0.03mm. The clearance can be adjusted to 0.05mm, 0.07mm, or 0.1mm. A pneumatic gauge or laser alignment tool can be used to check the clearance. The suction cup fixture is bolted to the front end of the servo press and rigidly connected to the press head. The vacuum cup grips the rotor end face, and the locating boss engages the guide groove. The servo press drives the suction cup fixture to move, and the guide groove guides the rotor to maintain coaxiality with the spline shaft. During the press-fit process, the clearance between the locating boss and the guide groove ensures no radial misalignment of the rotor, improving press-fit accuracy. The coordinated design of the positioning boss and guide groove simplifies the rotor alignment process and reduces manual adjustment time; standardized clearance control adapts to rotors of different sizes and improves system versatility; wear-resistant materials and precision machining extend the service life of the guide groove and reduce maintenance frequency.

[0033] According to another implementation of the present invention, the suction cup fixture can use 6 vacuum suction cups with a suction force range of 80N to 120N. After adsorbing the rotor end face, it is driven by a servo motor to move to the initial position. The initial position can be set to 10mm to 20mm away from the end face of the spline shaft. The movement speed of the suction cup fixture can be controlled within the range of 5mm / s to 10mm / s to avoid positioning deviation caused by inertia. The adsorption holding time can be set to 0.5s, 1s or 1.5s to ensure adsorption stability. The vacuum pump can use a dry rotary vane vacuum pump, and the negative pressure value is set to -60kPa to -80kPa. The suction cup fixture is installed at the front end of the servo press through a linear guide rail and is rigidly connected to the pressure head. The laser sensor can be installed on the side bracket of the spline shaft, the detection distance is set to 20mm to 30mm, and the spot diameter is 0.3mm to 0.5mm. After receiving the reflected light intensity difference signal, the PLC controller calculates the deviation between the current angle of the spline shaft and the target angle. If the deviation exceeds ±0.5°, a servo motor drives the spline shaft to rotate in increments of 0.5° to 3° until the deviation is eliminated. The angle adjustment response time can be controlled within 0.2s to 0.5s. The laser sensor housing can be made of aluminum alloy, with internal optical components made of quartz glass. The laser sensor is fixed to the side of the spline shaft via an adjustable bracket and connected to the PLC controller via a shielded cable. A servo press drives the rotor to press against the spline shaft at a speed of 5mm / s to 15mm / s, applying a constant pressure of 500N to 700N. A pressure sensor collects the pressing force signal in real time, and a displacement sensor records the displacement of the press head. The PLC determines the meshing status based on preset thresholds: if the displacement reaches 3mm to 8mm when the pressure reaches 600N, the meshing is considered successful; if the displacement is less than 2.5mm, it is considered a tooth tip interference. The final press-fit displacement can be set to 8mm, 10mm, or 12mm. The pressure sensor can be a piezoelectric sensor, and the displacement sensor can be a magnetic linear encoder. The pressure sensor is integrated into the servo press's ram, and the displacement sensor is mounted to the side of the ram. If a tooth top interference is detected, the PLC generates a reverse rotation command, driving the spline shaft to rotate 0.5° to 3° before restarting the press process. If three to five consecutive failures occur, an alarm is triggered and the process is paused. The correction angle can be dynamically adjusted based on real-time deviations to avoid secondary interference caused by a fixed correction amount. The reverse rotation speed can be set to 1° / s, 2° / s, or 3° / s. The servo motor coupling can be made of stainless steel or high-strength nylon. The servo motor is flange-mounted at the drive end of the spline shaft and communicates with the PLC controller via a bus. The operating process is as follows: a suction cup fixture attracts the rotor and moves it to its initial position. A laser sensor detects the spline shaft angle. The servo motor adjusts the spline shaft to the target angle, and the servo press initiates the press process. The pressing force and displacement data are transmitted in real time to the PLC to determine the meshing status. If a failure occurs, the spline shaft rotates in the reverse direction to correct the angle, and the system automatically restarts the press process.

[0034] According to another implementation of the present invention, a PLC controller can be integrated with a storage module with selectable storage capacities of 32GB, 64GB, or 128GB. The CPU1518-4PN / DP from the Siemens S7-1500 series is recommended. The storage module can be set to cyclic overwrite mode, retaining the last 30 to 90 days of press-fit data. The storage frequency can be set to 100 or 200 times per second, synchronized with the displacement sensor's sampling frequency. The data storage period can be set to 30, 60, or 90 days. The storage module can use an industrial-grade SD card or solid-state drive. The storage medium can be NAND flash memory or 3D TLC chips. The storage module can be installed in an expansion slot of the PLC controller and connected to the CPU via a data bus. During each press-fit process, the storage module records peak pressure (e.g., 500N to 700N), displacement (e.g., 3mm to 8mm), and a timestamp (accurate to milliseconds). The timestamp format can comply with the ISO8601 standard, including date, hour, minute, second, and millisecond. Data records can be stored by batch or device number. Timestamp accuracy can be set to 1ms, 5ms, or 10ms. Piezoresistive pressure sensors can be used as pressure sensors, and linear scales can be used as displacement sensors. The pressure sensor is integrated into the servo press head, while the displacement sensor is mounted on a fixed bracket on the side of the head. The industrial Ethernet module supports ModbusTCP or Profinet protocols, and the data transmission rate can be set to 100Mbps or 1Gbps. The host computer software can generate daily, weekly, or monthly reports based on an SQL database. These reports include pass rate, failure type distribution, and press parameter trend analysis. The data transmission interval can be set to 1 minute, 5 minutes, or real-time. The industrial Ethernet switch can be unmanaged or lightweight managed. Cat5e or Cat6 shielded twisted pair Ethernet cables can be used. The industrial Ethernet module can be installed in the PLC control cabinet, and the host computer workstation can be deployed in the workshop monitoring room. During the press-fitting process, pressure sensors and displacement sensors collect data in real time and transmit it to the PLC; the PLC storage module records the pressure peak, displacement, and timestamp at a set frequency, and stores them as structured data; the industrial Ethernet module transmits the data to the host computer periodically or in real time, and the host computer software automatically parses the data and generates statistical reports; operators use the reports to analyze the press-fitting qualification rate trend, optimize process parameters, or troubleshoot equipment anomalies.

[0035] According to another implementation of the present invention, the suction cup fixture can be equipped with 6 vacuum suction cups, with a suction force range set to 80N to 120N. The pressure sensor can be installed at the connection between the front end of the suction cup fixture and the servo press head, and be rigidly connected to the head. The displacement sensor can be fixed to a bracket on the side of the head to detect the linear displacement of the head. The suction cup fixture can be made of aluminum alloy or engineering plastic, and the surface is anodized to enhance wear resistance. The range of the pressure sensor can be set to 0N to 1000N, and the range of the displacement sensor can be set to 0mm to 20mm. The pressure sensor can be a strain gauge sensor, and the displacement sensor can be a magnetostrictive linear displacement sensor. The pressure sensor is embedded in the flange at the front end of the suction cup fixture, and the displacement sensor is fixed to the mounting base on the side of the head by bolts. The signals of the pressure sensor and displacement sensor can be transmitted to the PLC controller via a 4-20mA or 0-10V analog module. The sampling frequency of the analog module can be set to 100Hz to 200Hz, matching the output frequency of the sensor. Shielded twisted-pair cable can be used for signal cables to reduce the impact of electromagnetic interference on data accuracy. The analog module's resolution can be set to 12, 14, or 16 bits. The signal cable's outer sheath can be made of PVC or polyurethane to adapt to industrial environments. The analog module can be installed in the expansion slot of the PLC control cabinet, and the sensor signal cable is connected to the module input via an aviation plug. The PLC controller can preset a pressure threshold (e.g., 500N to 700N) and a displacement difference range (e.g., 3mm to 8mm). When the pressure reaches the threshold, the PLC compares the current displacement with the preset range. If the displacement is within 3mm to 8mm, engagement is considered successful; if the displacement is less than 2.5mm, it is considered a tooth tip interference. This determination triggers subsequent corrections or alarms. The displacement difference tolerance can be set to ±0.5mm, ±1mm, or ±1.5mm. PLC controllers can support multi-channel analog inputs. The decision logic in the PLC program is written in ladder diagrams or structured text and stored in the controller's non-volatile memory. The operating process is as follows: a servo press drives the suction cup fixture to press against the spline shaft. A pressure sensor collects the indentation force signal in real time, and a displacement sensor records the displacement of the indenter. An analog module converts the sensor signal into a digital signal and transmits it to the PLC controller. The PLC triggers the displacement difference calculation based on a preset pressure threshold (e.g., 600N). If the displacement is within the range of 3mm to 8mm, the meshing is determined to be successful. If the displacement is insufficient, the PLC determines it to be a tooth top interference and initiates the reverse rotation correction process. The present invention's coordinated determination of both pressure and displacement parameters reduces the risk of misjudgment of a single signal and improves the accuracy of meshing state detection. The modular suction cup fixture and sensor integration simplify equipment maintenance and upgrades.

[0036] According to another implementation of the present invention, the laser sensor can detect the difference in reflected light intensity between the spline shaft tooth top and tooth groove, and the signal range can be set to 0-1000mV. The PLC controller can calculate the difference between the real-time angle and the theoretical angle (Δθ=θ 实时 -θ 理论 The valid deviation value range is limited to 0.5° to 5°. Exceeding this range indicates a system abnormality. The deviation value can be set to 1°, 2°, or 3° as a typical correction value. The laser sensor can be a diffuse reflection photoelectric sensor, and the PLC controller can support floating-point arithmetic. The laser sensor is mounted 10 mm to 30 mm to the side of the spline shaft using an adjustable bracket, and the signal cable is connected to the PLC analog input module. The servo motor receives pulses or analog commands from the PLC to drive the spline shaft in reverse rotation. The correction angle can be set based on the absolute value of the deviation value (e.g., 1.5° or 2.5°), and the rotation speed can be set from 1° / s to 5° / s. The servo motor's rotation accuracy can be controlled within a range of ±0.1° to ±0.3°. The reverse rotation speed can be set to 2° / s, 3° / s, or 4° / s. The servo motor coupling can be made of stainless steel or polyurethane to reduce transmission backlash. The servo motor is flange-mounted to the drive end of the spline shaft, and the encoder feedback signal is connected to the PLC's high-speed counter module. After correction is complete, the laser sensor re-detects the reflected light intensity difference signal. If the signal fluctuation amplitude is less than 8% of the full scale (e.g., ≤80mV), the PLC determines that the tooth-slot alignment is successful; otherwise, a second correction is triggered. The verification process can be completed within 0.1s to 0.3s, ensuring the continuity of the press-fit process. The tooth-slot alignment threshold can be set to 5%, 6%, or 7% of the full scale. The signal filtering circuit can use an RC low-pass filter with a cutoff frequency set between 10Hz and 50Hz. The filter circuit is integrated into the front end of the PLC analog input module, and the signal ground is connected to the equipment ground terminal. In the event of press-fit failure, the laser sensor detects the spline shaft angle, and the PLC calculates the real-time angle deviation Δθ (e.g., 2.3°). The PLC generates a reverse rotation command, driving the servo motor to rotate 2.3° to correct the spline shaft angle. After correction, the laser sensor re-detects the reflected light intensity difference signal. If the fluctuation amplitude is ≤80mV (8% of the full scale), the alignment is determined to be successful and the press-fit process is restarted. If the threshold is still not met, the PLC attempts to correct the alignment again using the new deviation value until success or an alarm is triggered.

[0037] The present invention adapts to actual assembly errors through dynamic deviation calculation and correction, avoiding secondary interference caused by fixed angle adjustment; the reflected light intensity threshold verification improves the reliability of angle alignment and reduces the number of invalid corrections; the closed-loop control logic enhances the system's adaptability and is suitable for high-precision spline shaft press-fitting scenarios.

[0038] According to another implementation of the present invention, the full-scale range of the laser sensor can be set to 0-1000mV, and the tooth-slot alignment threshold can correspond to ±30mV to ±80mV (3%-8%). The threshold range can be set to multiple levels (e.g., 5%, 6%, and 7%) via the PLC program to accommodate different spline shaft accuracy requirements. The threshold can be set to 5% (±50mV), 6% (±60mV), or 7% (±70mV). The laser sensor can be a high-resolution diffuse reflection type, and the PLC controller can support multi-threshold logic. The sensor optical window can be made of quartz glass or sapphire glass to reduce the impact of surface scratches. The laser sensor is mounted on the side of the spline shaft using an adjustable bracket, maintaining a vertical distance of 10mm to 20mm from the tooth top detection surface. The PLC controller collects the reflected light intensity signal in real time and smoothes signal fluctuations using a moving average algorithm (window size of 5-10 sampling points). Successful tooth-slot alignment is determined when the signal fluctuation amplitude is below the threshold for 3-5 consecutive sampling periods. The signal sampling frequency can be set to 100Hz, 150Hz, or 200Hz. The signal processing module can be a PLC with an FPGA or a stand-alone signal conditioner. The signal conditioner is integrated into the PLC control cabinet, and a shielded cable connects the sensor to the PLC. If alignment is successful, the PLC sends a start command to the servo press, and the press process continues from the current position. If the threshold is not met, the PLC triggers a secondary correction command, adjusting the spline shaft angular deviation by 50% to 70% as a correction. The secondary correction can be set to 50%, 60%, or 70% of the original deviation. The servo press can be equipped with a position hold function to ensure press continuity. The servo press control signal cable is connected to the PLC output module via an aviation connector. The theoretical angle θtheoretical can be pre-stored in the PLC and calculated based on the number of spline shaft teeth and the rotor tooth profile. The real-time angle θ is obtained in real time by mapping the voltage signal from the laser sensor to a calibration curve. The calibration curve can be piecewise linearized (with calibration points every 0.5°). The calibration curve segment interval can be set to 0.5°, 1°, or 2°. The calibration equipment can use a high-precision indexing stage (resolution ±0.01°). Calibration data is stored in the PLC's non-volatile memory and supports online updates. The effective range of the deviation value Δθ can be set from 0.5° to 5°. Exceeding this range indicates a system fault (such as sensor offset or mechanical jamming). The PLC records the number of limit violations, triggering a maintenance alarm after 3 to 5 consecutive violations. The limit violation alarm threshold can be set to 3, 4, or 5 times. The alarm module can be equipped with a combination of a three-color indicator and a buzzer. The alarm device is prominently mounted on the equipment's operation panel for quick response. Nonlinear compensation of the voltage-angle mapping relationship can be achieved using a lookup table or polynomial fitting. For example, within the range of 0° to 5°, a voltage value is assigned for every 0.5°. The PLC interpolates the angle based on the real-time voltage lookup table. The polynomial fitting order can be set to 2nd, 3rd, or 4th order.The spline shaft used for calibration can be made of 45 steel or tool steel with a hardened surface. The spline shaft used for calibration is installed on a special fixture, maintaining a fixed detection distance from the laser sensor. The working process is as follows: the laser sensor detects the difference signal of the reflected light intensity of the spline shaft, and the PLC calculates the real-time angle θrealtime; based on the difference Δθ between θrealtime and θtheoretical, it determines whether it is within the valid deviation range (0.5°≤|Δθ|≤5°); if valid, the PLC drives the servo motor to rotate in the opposite direction by the absolute value of Δθ to correct the spline shaft angle; after correction, the reflected light intensity signal is re-detected. If the fluctuation amplitude is ≤ the threshold (such as ±60mV), the alignment is determined to be successful and the press-fitting is restarted; if Δθ exceeds the valid range or continuous correction fails, the system alarm is triggered and the process is suspended.

[0039] The threshold grading setting of the present invention improves the flexibility of alignment judgment and adapts to different working conditions; nonlinear signal compensation reduces angle calculation errors and improves the accuracy of deviation correction; the effective deviation range is limited to prevent invalid corrections and reduce the risk of equipment abnormality; the closed-loop control process ensures the stability and repeatability of the pressing process.

[0040] The specific steps of the laser angle detection and dynamic correction algorithm of the present invention are as follows: 1. Initial baseline setup (performed when the system is first installed) Step 1: Use computer CAD software to calculate the angle (for example, 0°) that the spline shaft tooth groove should be at when the rotor and spline shaft are perfectly engaged. Store this angle in the PLC controller and name it the theoretical angle.

[0041] Step 2: Control the servo motor to rotate the spline shaft to the theoretical angle position, use the laser sensor to detect the light intensity signal reflected by the tooth groove at this time (for example, 520mV), and store this voltage value in the PLC and name it the reference voltage.

[0042] 2. Real-time workflow (executed before each press) Step 3: The laser sensor continuously scans the spline shaft surface (200 times per second). After detecting the reflected voltage signal, the PLC averages the five consecutive sampling values ​​to eliminate random interference.

[0043] Step 4: The PLC identifies the peaks (corresponding to the tooth tops, where the voltage is more than 30% higher than the reference value) and troughs (corresponding to the tooth grooves, where the voltage is more than 30% lower than the reference value) in the signal.

[0044] Calculate the time difference between two adjacent wave peaks (for example, 0.0208 seconds), and combine the motor speed and the total number of spline shaft teeth to calculate the cycle time from one tooth peak to the next peak (referred to as tooth cycle).

[0045] Step 5: Record the time point when the latest peak appears (for example, 10.254 seconds).

[0046] Subtract the theoretical alignment time recorded in step 2 (e.g., 10.250 seconds) from the current peak time to obtain the time difference (e.g., 0.004 seconds).

[0047] Divide the time difference by the tooth period to obtain the phase difference ratio (e.g. 0.004÷0.0208≈0.192).

[0048] The phase difference ratio multiplied by the angle of a single tooth (=360°÷total number of teeth) is the angular deviation (e.g. 0.192×15°=2.88°).

[0049] 3. Dynamic correction judgment Step 6: If the angle deviation is between 0.5° and 5°: The PLC commands the servo motor to rotate the spline shaft in the opposite direction by the deviation angle value (for example, 2.88°).

[0050] If the angle deviation is less than 0.5°, it is determined to be aligned and no correction is made.

[0051] If the angle deviation exceeds 5°: the device alarm is triggered (indicating mechanical failure).

[0052] Step 7: Re-test the reflected voltage after correction: If the difference between the current voltage and the reference voltage is ≤ 5% of the sensor range (for example, the difference is ≤ 50mV when the range is 1000mV), the tooth slot alignment is successful.

[0053] Otherwise, return to step 3 and retest.

[0054] Working example (24-tooth spline shaft scenario): initialization: The theoretical angle was set to 0°, and the reference voltage was recorded as 520 mV (at this time, the spline shaft tooth groove was facing the laser).

[0055] Real-time detection: The latest peak time detected is: 10.254 seconds (theoretical alignment time: 10.250 seconds).

[0056] Tooth period = 0.0208 seconds (motor 120 rpm, 24 teeth).

[0057] Time difference = 0.004 seconds, phase difference ratio = 0.004 / 0.0208≈0.192, angle deviation = 0.192×15°=2.88°.

[0058] Correction Implementation: The PLC controls the servo motor to rotate the spline shaft in the opposite direction by 2.88°.

[0059] Alignment Verification: After correction, the detection voltage = 535mV, and the difference with the reference voltage 520mV = 15mV.

[0060] The sensor range is 1000mV, 5% range = 50mV, 15mV < 50mV, and the alignment is successful! Example scenario: The laser sensor, PLC control logic, and suction cup tooling are integrated into the existing equipment (CN117961478A) to form the press-fitting system of the present invention.

[0061] Install a laser sensor on the side of the spline shaft (detection distance 10~50mm, spot diameter 0.1~0.3mm); Add a pressure sensor (±0.02mm accuracy) and a displacement sensor (100~200Hz sampling frequency) to the front end of the servo press; Replace the original gripping mechanism with a suction cup tooling (6 vacuum suction cups, suction force 80~120N).

[0062] The PLC controller is embedded with a light intensity difference signal processing algorithm, collaboratively determines the pressing force-displacement curve, and sets the reverse rotation correction logic (deviation value 0.5°~5°).

[0063] During use, the suction cup fixture absorbs the rotor and moves it to a position coaxial with the spline shaft. The laser sensor emits laser light to the spline shaft tooth tops / tooth grooves and detects the reflected light intensity difference signal. The PLC calculates the current angle of the spline shaft based on the light intensity difference and generates a rotation command. The servo motor drives the spline shaft to rotate in increments of 0.5° to 3° until the light intensity signal meets the tooth groove alignment threshold (fluctuation amplitude ≤8% full scale). The servo press drives the rotor to press against the spline shaft at a speed of 5 to 15 mm / s, applying a constant pressure of 500 to 700 N. The pressing force curve and displacement curve are collected in real time to determine the engagement state: when successful: the displacement is 3 to 8 mm, and the pressing force rise time is 1 to 3 seconds; when the tooth top interferes: the displacement is 0.5 to 2.5 mm, and the pressing force rise time is <0.5 seconds.

[0064] If it is determined to be tooth tip interference, the PLC calculates the angle deviation (Δθ = real-time angle - theoretical angle) and drives the spline shaft to rotate in the opposite direction by the absolute value of Δθ (0.5°~5°); After 3-5 consecutive failures, an alarm is triggered, the process is suspended, and a fault report is generated. The storage module records the peak pressure, displacement, and timestamp of each press. This data is transmitted to the host computer via industrial Ethernet, and a pass rate report (such as the daily press success rate) is generated.

[0065] Test Trial 1. Test subjects: Spline shaft: module 2.0, number of teeth 24, material 45 steel; Rotor: External spline module 2.0, material 40Cr, surface hardening treatment; Test samples: 50 pieces per group, a total of 3 groups [existing technology group (CN117961478A), system group of the present invention, and manual operation group].

[0066] 2. Test environment: Temperature: 20±5°C; Humidity: 50±10%RH; Vibration: ≤0.1g (simulating an industrial workshop environment).

[0067] 3. Test methods and steps (1) Angle detection accuracy test method: Fix the spline shaft on the indexing table (resolution ±0.01°) and rotate it in 0.5° steps; Use laser sensor to collect reflected light intensity signal, and PLC to calculate angle; Compare the angle calculated by PLC with the actual angle of the indexing table and calculate the error.

[0068] Data collection: Repeat the measurement 10 times for each angle point and record the error value (Δθ = |θ calculated - θ actual |).

[0069] (2) Test method for press-fitting efficiency and number of corrections: The three groups of samples were press-fitted using the existing technology, the system of the present invention, and manual operation respectively; Record single pressing time, number of corrections and total time; Successful press-fitting criteria: displacement 3~8mm, press-fitting force 600±50N.

[0070] Data collection: Pressing time (from adsorption to completion of pressing); Number of corrections (number of reverse rotations); Total time (including correction time).

[0071] (3) Qualification rate and data traceability test method: The press-fitting results of the three groups of samples were visually inspected and three-dimensional coordinates were measured (coaxiality ≤ 0.05 mm); The system group of the present invention exports the press-fitting data report through the host computer and analyzes the pressure-displacement curve; Statistics on the qualification rate and fault type distribution of each group.

[0072] 4. The experimental results are shown in Tables 1, 2 and 3.

[0073] Table 1: Angle detection accuracy From the results in Table 1, it can be seen that the average error of angle detection of the present invention is ≤0.05°, and the maximum error is ≤0.1°, which meets the accuracy requirement of ±0.1°.

[0074] Table 2: Comparison of press-fitting efficiency As can be seen from the results in Table 2, the total time consumption of the system group of the present invention is reduced by 65% ​​compared with the prior art group, and the number of corrections is also significantly reduced.

[0075] Table 3: Qualified rate and failure analysis Group Pass rate (%) Main fault types Existing Technology Group 87.3 Tooth tip interference and coaxiality deviation The system of the present invention 96.8 Coaxiality out of tolerance, sensor misjudgment Manual operation group 78.0 Tooth tip interference, insufficient press-in force The results in Table 3 show that the system combination of the present invention increased its qualification rate by 9.5%, and the tooth tip interference problem was essentially eliminated. The qualified rate increased to 96.8%, and the main fault was transformed from tooth tip interference to manageable coaxiality issues. The data traceability function enables rapid fault location (such as suction cup wear) and optimizes maintenance cycles, showing promising application prospects.

[0076] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiment. They can be applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily realized.

Claims

1. Rotor and spline shaft automatic press-fitting system, characterized by: Includes servo press, servo motor, PLC controller, laser sensor and suction cup tooling; The laser sensor is arranged on the side of the spline shaft, and detects the difference in reflected light intensity between the tooth top and tooth groove of the spline shaft by emitting laser, and transmits the signal to the PLC controller; The PLC controller calculates the angle of the spline shaft according to the difference in reflected light intensity and generates a rotation instruction; The servo motor is connected to the spline shaft, receives a rotation instruction and drives the spline shaft to rotate; The suction cup fixture includes a vacuum suction cup, which absorbs the end face of the rotor and moves the rotor to a position coaxial with the spline shaft; The servo press drives the rotor to move toward the spline shaft and applies a constant pressure; When the pressing force reaches a preset pressure value, the PLC controller determines the meshing state according to whether the displacement is within a preset range: if the displacement reaches the preset range, it is determined to be meshing successfully; if the displacement does not reach the preset range, it is determined to be tooth top interference; When it is determined that there is tooth top interference, the PLC controller drives the spline shaft to rotate in the opposite direction and re-executes the press-fitting process.

2. The system according to claim 1, wherein: Also includes anti-shedding sheet; The anti-dropout piece is fixed to the end of the rotor, and its inner ring is provided with a latching tooth matching the tooth profile of the spline shaft; When the rotor is engaged with the spline shaft, the teeth of the anti-slip plate are embedded in the tooth grooves of the spline shaft.

3. The system according to claim 1, wherein: The logic of the PLC controller includes: After the initial press-fitting fails, the spline shaft is controlled to rotate in the opposite direction. During the reverse rotation process, the change in the pressing force is monitored in real time. When the pressing force is less than the preset pressure value and the displacement reaches the preset range, the meshing is determined to be successful. The maximum angle of the rotating spline shaft is the angle corresponding to the single tooth pitch, which is 360° divided by the total number of teeth on the spline shaft. When the number of consecutive failures reaches a preset threshold, an alarm signal is triggered and the process is paused.

4. The system according to claim 1, wherein: The end surface of the rotor is provided with a positioning boss; A guide groove matching the positioning boss is provided at the center of the suction cup fixture.

5. The system according to claim 1, wherein: The press-fitting process of the system includes: Drive the servo press to press the rotor; Determine the meshing results based on the indentation force curve and displacement curve; If the determination fails, rotate the spline shaft in the opposite direction and repeat the process.

6. The system according to claim 5, characterized in that The data of the pressing force curve is stored in a storage module of a servo press remote control server or a PLC controller; The storage module records the peak pressure, displacement and timestamp of each press-fitting; The data is transmitted to a host computer via industrial Ethernet, and the host computer generates a press-fitting qualified rate statistical report.

7. The system according to claim 6, characterized in that The servo press is connected to the rotor via a suction cup fixture; The front end of the suction cup tooling is provided with a pressure sensor and a displacement sensor, the pressure sensor is rigidly connected to the pressure head of the servo press, and the displacement sensor is fixed on the side of the pressure head; When the servo press drives the rotor to press-fit, the pressure sensor collects the pressing force signal in real time and generates a pressing force curve, and the displacement sensor collects the linear displacement of the press head in real time and generates a displacement curve; The signals of the pressure sensor and displacement sensor are transmitted to the PLC controller through the analog module; The PLC controller determines the meshing state according to the displacement difference when the pressure in the pressing force curve reaches a preset pressure value.

8. The system according to any one of claims 1 to 7, characterized in that: The specific logic of the PLC controller driving the spline shaft to rotate in the opposite direction is: When it is determined to be tooth addendum interference, the PLC controller calculates the deviation between the current angle of the spline shaft and the target angle based on the difference in reflected light intensity detected by the laser sensor; The deviation value ranges from 0.5° to 5°; The PLC controller generates a reverse rotation command to drive the servo motor to use the absolute value of the deviation as the rotation angle correction value; The corrected spline shaft angle must make the reflected light intensity difference signal meet the preset tooth groove alignment threshold.

9. The system according to claim 8, characterized in that The preset tooth-slot alignment threshold is that the fluctuation amplitude of the reflected light intensity difference signal detected by the laser sensor is less than 3% to 8% of the full scale of the sensor; When the fluctuation amplitude of the reflected light intensity difference signal is within the range of 3% to 8%, the PLC controller determines that the tooth groove of the spline shaft is aligned with the rotor tooth profile; The PLC controller controls the servo motor to stop rotating by comparing the real-time reflected light intensity difference signal with the threshold range, and triggers the servo press to re-execute the pressing process.

10. The system according to claim 8, wherein: The calculation logic of the deviation value includes: The target angle is the theoretical angle when the rotor tooth profile is completely aligned with the spline shaft tooth groove; The deviation value is the difference between the real-time angle and the theoretical angle; When the absolute value of the deviation Δθ is greater than or equal to 0.5° and less than or equal to 5°, it is determined to be a valid deviation and a reverse rotation correction is triggered.

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