Flexible EPS motor stator manufacturing system and manufacturing method

Abstract

The invention discloses a flexible EPS motor stator manufacturing system and method, and relates to the technical field of automobile steering system brushless motor manufacturing, and the system comprises a core device module which comprises a plurality of devices with manual / automatic dual-mode operation capability, the working procedure module is used for executing the working procedures of insulation framework penetrating, engraving, winding, circle forming, welding, wire cutting and performance testing in stator manufacturing; the intelligent control module is in communication connection with the core equipment module and is used for switching equipment operation modes according to production task types, managing equipment parameters and realizing process collaboration; the process database module is in communication connection with the intelligent control module and is used for storing process parameters and detection data and realizing associated application of trial-production and mass production process parameters, and the trial-production equipment can be switched to a mass production mode when no trial-production task exists through a dual-mode operation design; the reject ratio of products is reduced through parameter recording and visual assistance in trial-manufacturing operation; the switching cost is reduced; and the process is continuously optimized.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of manufacturing technology of brushless motor for automobile steering system, in particular to a flexible EPS motor stator manufacturing system and manufacturing method. BACKGROUND

[0002] Electric power steering system (abbreviation EPS) is a kind of power steering system directly relying on motor to provide auxiliary torque, compared with traditional hydraulic power steering system HPS, EPS system has many advantages, EPS is mainly composed of torque sensor, speed sensor, motor, speed reduction mechanism and electronic control unit (ECU) etc.

[0003] In the existing EPS motor stator manufacturing, there are technical difficulties of disconnection between trial production and mass production: Trial production stage: small batch sample making relies on special equipment (such as custom winding mold, manual welding tool), uneven winding tension, welding point deviation and other problems lead to poor product consistency, and the special equipment is idle after trial production, the utilization rate is less than 30%; Mass production stage: production line is mainly automatic equipment with fixed process, which is only suitable for single model product, and cannot be compatible with multi-specification and small batch demand in trial production stage, resulting in high idle rate of production line (when there is no trial production task, the utilization rate of part of equipment is less than 50%); High switching cost: the parameters and tool clamps of trial production and mass production equipment need to be manually re-adjusted, the switching cycle is as long as 2-3 days, and the trial production data cannot be reused, resulting in long optimization cycle of mass production process. SUMMARY

[0004] The present application provides a flexible EPS motor stator manufacturing system and manufacturing method to solve the above problems.

[0005] To achieve the above purpose, the present application provides the following technical scheme: A flexible EPS motor stator manufacturing system, comprising: Core equipment module, containing multiple devices with manual / automatic dual mode operation ability, used for executing stator manufacturing processes of insulating framework, printing, winding, grouping, welding, cutting and performance testing; Intelligent control module, in communication connection with the core equipment module, used for switching device operation mode according to production task type (trial production / mass production), managing device parameters and realizing process cooperation; Process database module, in communication connection with the intelligent control module, used for storing process parameters, detection data and realizing the associated application of trial production and mass production process parameters.

[0006] On the basis of the above technical scheme, the present application further provides the following optional technical scheme: In an alternative, the winding machine and laser welding machine in the core equipment module are provided with dynamic process compensation units. The winding machine is equipped with a tension sensor. When the tension is manually adjusted, the tension fluctuation data (such as ±0.5N deviation) are collected in real time and a compensation curve is generated. In the subsequent winding step, the tension is adjusted by the motor to control the tension accuracy within ±0.1N. When the laser welding machine is manually operated, the vision system records the deviation (such as X / Y axis ±0.1mm) between the actual point and the theoretical point, automatically generates the coordinate compensation value, and pre-corrects the subsequent welding points to ensure the overall welding accuracy ≤±0.05mm.

[0007] Specifically, the vision system of the laser welding machine ensures the welding accuracy by the following steps: a) Record the deviation between the actual welding point and the theoretical coordinate in manual mode; b) Fit the deviation curve using the least squares method to generate compensation parameters; c) Call the compensation parameters to correct the welding path in automatic mode.

[0008] In an alternative, the process database module includes a process gene inheritance unit, which can: During trial production, automatically extract process parameter sequences with a qualified rate ≥90% as candidate genes; During mass production, use gene matching algorithms to screen trial production parameters that match the specifications of mass production products, generate initial parameters for mass production, and support iterative optimization based on first trial production data.

[0009] Specifically, a "trial production process gene library" is constructed, and key process parameters (such as winding tension curve, welding energy distribution) in the trial production stage are converted into "quantifiable process genes": During trial production, the system automatically extracts "effective process segments" (such as winding parameter sequences with a qualified rate ≥90%) for each batch of products, and marks them as "candidate genes"; When switching to mass production, there is no need for manual re-adjustment. The system uses a "gene matching algorithm" to screen trial production parameters that best match the specifications of mass production products (such as winding tension reference values for the same core diameter) from the gene library, directly generates initial parameters for mass production, and iteratively optimizes through first trial production data (iteration period shortened to within 1 hour).

[0010] In an alternative, the tooling for the process of threading the insulation skeleton and assembling the circle in the core equipment module is modular self-adaptive tooling, including telescopic positioning pins (adapted to stators with diameters of 50-120mm) and magnetic quick-change components, which can adapt to different diameter stators and are integrated with pressure sensors that can detect positioning deviations and trigger audible and visual prompts when the workpiece is manually placed.

[0011] Specifically, the telescopic positioning pin is driven by an electric push rod (stroke 50-120mm), and the telescopic amount is adjusted by the intelligent control module to realize automatic calibration of the positioning reference.

[0012] In an alternative, the intelligent control module comprises a dynamic capacity scheduling unit, which can: Monitor the capacity demand of trial / production tasks in real time and decompose the process cycle; In the gap between trial tasks, idle equipment is automatically allocated to production processes for small batch production, and a visual scheduling Gantt chart is generated.

[0013] Specifically, the system monitors the capacity demand of trial / production tasks in real time (e.g. 50 trial pieces for 3 hours, 1000 production pieces for 8 hours), and automatically decomposes the process cycle; When there is a gap between trial tasks (e.g. waiting for test results), idle equipment (e.g. winding machine) is automatically allocated to production processes for small batch production (e.g. 200 pieces), avoiding idle equipment; A visual scheduling Gantt chart is generated for operators to adjust priorities.

[0014] In an alternative, the accuracy of the vision system of the laser welding machine is ±0.02mm, and the positioning accuracy of the vision system ±0.02mm provides the basis for coordinate compensation, and finally realizes welding accuracy ≤±0.05mm through compensation algorithm, and in automatic mode, the position of the split core can be recognized and laser welding (power 100-300W, time 0.1-0.5s) is triggered, and in manual mode, the stored coordinate data can be directly used as the parameter reference of automatic mode.

[0015] The present application also provides a flexible EPS motor stator manufacturing method based on the above flexible EPS motor stator manufacturing system, comprising the following steps: Switch the manufacturing system to trial mode or production mode according to the type of production task; In trial mode, manual operation of the equipment is allowed and operation errors are corrected through the dynamic process compensation unit, and effective process parameters are extracted as candidate genes; In production mode, the adaptive gene parameters in the process database are called to automatically run the equipment, and the utilization rate of the equipment is optimized through dynamic capacity scheduling.

[0016] In an alternative, the trial operation process further comprises: Modular adaptive tooling is used for insulation skeleton installation and circle assembly, and the positioning deviation of the workpiece is ensured to be ≤0.5mm through pressure sensor feedback; After manual operation, the system automatically stores the process parameters and test results in the process database.

[0017] In an alternative, the mass production process further comprises: The intelligent control module inserts mass production small batch production between trial production task gaps based on the dynamic capacity scheduling unit. After the first product is detected to be qualified, the process database automatically updates the optimal parameters of the batch.

[0018] In an alternative, when the mode is switched, the process database completes the conversion of trial production parameters to mass production parameters within 5 minutes through a genetic matching algorithm, and the modular adaptive tooling only needs to be automatically calibrated and positioned without replacement. The genetic matching algorithm uses weighted Euclidean distance calculation: taking the stator diameter (weight 60%), the number of turns (weight 30%), and the wire diameter (weight 10%) as parameters, when the calculated value ≤ preset threshold, the similarity ≥ 85%.

[0019] Compared with the prior art, the beneficial effects of the present application are as follows: 1. Improved production line utilization: through dual-mode operation design, trial production equipment can be switched to mass production mode when there is no trial production task, solving the problem of idle equipment; 2. Significant improvement in process consistency: through parameter recording and visual assistance in trial production, product failure rate is reduced; 3. Reduced switching cost: intelligent switching mechanism shortens the conversion time from 2-3 days to 30 minutes for trial production and mass production; 4. Continuous process optimization: the analysis model based on the database can automatically recommend parameters, shortening the new product mass production introduction cycle. BRIEF DESCRIPTION OF DRAWINGS

[0020] Fig. 1 An architecture diagram of a flexible EPS motor stator manufacturing system is provided.

[0021] Fig. 2 A dynamic tension compensation flowchart of a winding machine in a flexible EPS motor stator manufacturing system is provided.

[0022] Fig. 3 A process gene matching and iterative optimization schematic diagram in a flexible EPS motor stator manufacturing system is provided. DETAILED DESCRIPTION

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs; the terminology used in the description herein is for describing particular embodiments only and is not intended to be limiting of the application; the use herein of terms such as "comprise", "have" and "include" or variations such as "comprises", "comprising", "containing", "having" and "includes" or variations such as "comprises", "comprising", "containing", "having" and "includes" are to be construed as open-ended, that is, meaning "including, but not limited to", and so on. The use herein of terms such as "first", "second" and the like does not imply a particular order but is used for the purpose of nomenclature only.

[0024] Reference herein to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the application. The appearances of the phrase that the phrase in various places in the specification are not necessarily all referring to the same embodiment, or are necessarily referring to different or alternative embodiments. It is explicitly and implicitly contemplated that embodiments described herein can be combined with each other.

[0025] Embodiments Reference is made to Figs. 1-3 In an embodiment of the application, a flexible EPS motor stator manufacturing system comprises: Core equipment module Contains 7 key equipment with integrated innovative functions, all with "manual / automatic" dual-mode operation capability: Self-adaptive winding machine: Equipped with tension sensor (sampling frequency 1 kHz) and dynamic compensation unit, when manually adjusting tension (range 0.5-5N), real-time acquisition of fluctuation data and generation of compensation curve, through servo motor fine adjustment to regulate tension (final accuracy ±0.1N); Stores 100+ winding programs, supports touch screen manual fine adjustment of turns (1-1000 turns) and wire diameter (0.1-1mm) parameters and automatic recording.

[0026] Intelligent laser welding machine: Integrates visual positioning system (accuracy ±0.02mm) and coordinate compensation unit, when manually point welding, real-time recording of deviation (X / Y axis) between actual point and theoretical value, automatic generation of compensation value (correction amount ±0.05mm); After calling the compensated parameters in automatic mode, the laser power is adjustable from 100-300W, and the welding time is 0.1-0.5s.

[0027] Modular self-adaptive tooling (for insulating skeleton threading and round assembly process): The main body uses telescopic positioning pins (diameter adjustment range 50-120mm) and magnetic quick-change components (replacement time <30s); Built-in pressure sensor (detection range 0-10N, accuracy ±0.1N), manual placement of workpieces, if the positioning deviation is ≥0.5mm, the audible and light alarm will be triggered.

[0028] Specifically, three sets of telescopic positioning pins are preferably arranged, the three sets of positioning pins are uniformly distributed along the circumference (with an included angle of 120°), and a stable "constraint circle" can be formed through three-point contact to ensure that the stator does not shake or deviate in the radial (diameter) direction. The telescopic positioning pin comprises an electric push rod and a positioning pin fixed to the telescopic end of the electric push rod. The pressure sensor is embedded in the top of the positioning pin and can be synchronously adjusted in the radial direction (e.g. simultaneously extended or retracted) through telescopic design, which is suitable for different diameter stators of 50-120mm, taking into account stability and compatibility. The stroke accuracy of the electric push rod is ≤±0.05mm, the thrust is ≥20N, and the response time is ≤50ms. The magnetic quick-change assembly is used in cooperation with the auxiliary positioning member of the insulating framework or the split core of the stator to achieve quick model change.

[0029] For example, in the process of "inserting the insulating framework" of the EPS motor stator, the insulating framework (plastic or paper component, preventing short circuit of winding) needs to be installed in the core slot; in the process of "grouping", the split core needs to be spliced into a whole circle, which may need temporary positioning block for alignment.

[0030] The specifications of these insulating frameworks or auxiliary positioning blocks vary with the stator model (such as different heights and slot numbers), and the magnetic quick-change assembly (installed on the tool base) can be strongly magnetically attached to the corresponding "adapted positioning block" (a special component matching the insulating framework / split core).

[0031] For example, when changing the stator model, the operator can quickly remove the old adapted positioning block (magnetic connection, no tools required), and attract the new positioning block (completed within 30 seconds), ensuring the accuracy of the auxiliary positioning when the insulating framework is inserted or the split core is grouped, and avoiding low efficiency or deviation caused by manual alignment.

[0032] Terminal welding machine: pulse welding technology (current 50-200A) is adopted, manual parameter input and storage are supported, and a parameter verification unit is provided (to prevent exceeding the process threshold).

[0033] Stator marking machine: compatible with φ50-φ120mm stator, automatically calls the marking program (depth 0.1-0.3mm), and supports parameter step adjustment (0.01mm / step) in manual mode.

[0034] Clamping and cutting machine: cutting stroke 5-20mm adjustable, automatically adjusts the clamping force (10-50N) according to the diameter of the stator in automatic mode.

[0035] Comprehensive performance test equipment: integrated resistance (±1 mΩ), insulation (500-2500V), temperature resistance (-40~125℃) test module, data automatic correlation process parameter storage.

[0036] (2) Intelligent control module New core innovation unit: Dynamic capacity scheduling unit: Real-time monitoring of process cycle of trial production / quantity production task (such as 50 pieces of trial production requiring 3 hours, 1000 pieces of quantity production requiring 8 hours); When there is a gap in trial production tasks (such as waiting for test results), automatically allocate idle equipment (such as winding machines) to quantity production processes to insert small batch production (such as 200 pieces); Generate a visual Gantt chart to support manual adjustment of task priority.

[0037] Mode switching unit: optimize parameter switching logic, complete device parameter loading within 5 minutes when switching from trial production to quantity production (80% shorter than traditional).

[0038] Abnormal early warning unit: add process parameter correlation check (such as warning when winding tension and wire diameter do not match).

[0039] (3) Process database module The core innovation lies in the process gene inheritance system: Gene extraction unit: during trial production, automatically select process parameter sequences with a pass rate of ≥90% (such as winding tension curve, welding energy distribution), and mark them as "candidate genes"; Gene matching unit: during quantity production, match candidate genes with a similarity of ≥85% from the gene library based on product specifications (diameter, number of turns, etc.) to generate initial parameters; The similarity between trial production parameters and quantity production specifications is calculated using the following formula: Where: d represents the actual measured diameter parameter; d0 represents the diameter parameter (reference value) during trial production; n represents the actual measured number of turns parameter; n0 represents the number of turns parameter (reference value) during trial production; w represents the actual measured wire diameter parameter; w0 represents the wire diameter parameter (reference value) during trial production; 0.6, 0.3, and 0.1 are the weight coefficients of diameter, number of turns, and wire diameter in similarity calculation, respectively; Iterative optimization unit: combined with first trial production data (such as insulation test results), complete parameter iteration within 1 hour (traditional 4 hours).

[0040] 3.3 Manufacturing method flow (1) Trial production process (≤50 pieces) Insulation skeleton: through the modular adaptive tool positioning, pressure sensor ensures deviation ≤0.5mm; Stator engraving: manually select the basic program, step adjustment engraving depth (0.01mm / step), system records parameters; Winding: manually input initial tension (such as 1.0N), dynamic compensation unit real-time correction fluctuation (±0.1N finally), record tension curve; Specifically, the compensation curve uses a cubic polynomial to fit the tension fluctuation data (sampling frequency 1kHz), and the servo motor adjusts once every 10ms according to the curve slope (adjustment amount ±0.02N), until the tension is stable within ±0.1N; Tension compensation curve is a cubic polynomial: Wherein, a0 represents the basic tension value, unit is Newton (N), value range is [0.8, 1.2]; a1 represents linear fluctuation coefficient, value range is [-0.5, 0.5]; a2 represents quadratic fluctuation coefficient, value range is [-0.1, 0.1]; a3 represents cubic fluctuation coefficient, value range is [-0.01, 0.01]; t is time variable (independent variable); Group circle & laser welding: visual system assisted positioning, manual trigger welding, coordinate compensation unit corrects point deviation (≤±0.05mm); Terminal welding: manually input current parameters (such as 150A), system checks rationality before execution; Performance test: equipment automatic detection, process database marks qualified parameters as "candidate gene".

[0041] (2) Production process of quantity products (≥1000 pieces) MES assigns tasks, intelligent control module switches to automatic mode; Process gene matching: the system calls trial production candidate genes with similarity ≥85%, generates initial parameters; First trial production: the equipment runs according to the initial parameters, the test data is fed back to the iterative optimization unit, and the optimal parameters are output within 1 hour; Batch production: dynamic production scheduling unit allocates equipment, trial production idle equipment is inserted into mass production process; Whole process monitoring: abnormal early warning unit real-time checks parameter correlation, ensures qualified rate ≥99%.

[0042] (3) Mode switching mechanism Parameter switching: process database completes candidate gene matching and parameter loading within 5 minutes; Tool adjustment: modular adaptive tooling does not need to be replaced, automatically calibrates positioning reference (time consumption <30s); Capacity linkage: the dynamic capacity scheduling unit generates a linkage plan to ensure that there is no idle equipment during the switching.

[0043] It should be noted that, for the foregoing embodiments, for the sake of simple description, they are all expressed as a series of action combinations, but those skilled in the art should know that the present application is not limited by the order of the described actions, because according to the present application, certain steps can be performed in other orders or simultaneously. Secondly, those skilled in the art should know that the embodiments described in the specification are all preferred embodiments, and the actions and modules involved are not necessarily necessary for the present application.

[0044] In the embodiments provided in the present application, it should be understood that the disclosed device can be implemented in other ways. For example, the device embodiments described above are only schematic. For example, the division of the above units is only a logical function division, and there can be another division manner in actual implementation. For example, a plurality of units or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the displayed or discussed mutual coupling or communication connection can be indirect coupling or communication connection through some interface, device or unit, and can be electrical, mechanical or other forms.

[0045] The units described as separate components above can or can not be physically separate, and the components shown as units can or can not be physical units, i.e. they can be located in one place, or can be distributed on a plurality of network units. Some or all of the units can be selected to achieve the purpose of the embodiment scheme according to actual needs.

[0046] The above embodiments are only used to illustrate the technical solutions of the present application, and not to limit the protection scope of the application. Obviously, the described embodiments are only some of the embodiments of the present application, not all the embodiments. Based on these embodiments, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of the present application. Although the present application has been described in detail with reference to the above embodiments, those skilled in the art can still make some modifications or adjustments to the features of the embodiments in the present application without conflict, such as mutual combination, deletion or other adjustments, so as to obtain different other technical solutions which do not deviate from the concept of the present application in essence. These technical solutions also belong to the scope of the present application.

Claims

1. A flexible EPS motor stator manufacturing system, characterized by, The application relates to a manufacturing system for manufacturing a stator, which comprises a core equipment module, an intelligent control module and a process database module. The core equipment module comprises a plurality of devices capable of manual / automatic dual-mode operation, which are used to perform the processes of insulation skeleton threading, marking, winding, assembling, welding, wire cutting and performance testing in stator manufacturing. The intelligent control module is in communication connection with the core equipment module, and is used for switching the device operation mode according to the production task type, managing the device parameters and realizing process cooperation. The process database module is in communication connection with the intelligent control module, and is used for storing process parameters and detection data and realizing the associated application of trial production and mass production process parameters.

2. The flexible EPS motor stator manufacturing system of claim 1, wherein, The winding machine and the laser welding machine in the core equipment module are provided with dynamic process compensation units. The winding machine is provided with a tension sensor, and when the tension is manually adjusted, the tension fluctuation data are collected in real time and a compensation curve is generated, the tension is adjusted through a motor, and the tension accuracy is controlled within + / -0.1N. When the laser welding machine is manually operated, the vision system records the deviation between the actual point and the theoretical point, automatically generates a coordinate compensation value, and ensures that the overall welding accuracy is less than or equal to + / -0.05mm.

3. The flexible EPS motor stator manufacturing system of claim 1, wherein, The process database module comprises a process gene inheritance unit, which can: During trial production, process parameter sequences with a qualified rate greater than or equal to 90% are automatically extracted as candidate genes; During mass production, trial production parameters that are suitable for mass production product specifications are screened through a gene matching algorithm, mass production initial parameters are generated, and iterative optimization based on trial production data is supported.

4. The flexible EPS motor stator manufacturing system of claim 1, wherein, The tooling for the processes of insulation skeleton threading and assembling in the core equipment module is modular self-adaptive tooling, which comprises telescopic positioning pins and magnetic quick-change components, and is integrated with a pressure sensor, which can detect positioning deviation and trigger an audible and visual prompt when the workpiece is manually placed.

5. The flexible EPS motor stator manufacturing system of claim 1, wherein, The intelligent control module comprises a dynamic production capacity scheduling unit, which can: Real-time monitor the production capacity demand of trial production / mass production tasks and decompose the process beat; During the trial production task gap, idle devices are automatically allocated to mass production processes for small-batch production, and a visual scheduling Gantt chart is generated.

6. The flexible EPS motor stator manufacturing system of claim 2, wherein, The vision system of the laser welding machine has an accuracy of + / -0.02mm, can recognize the position of the split core in the automatic mode and trigger the laser welding, and the stored coordinate data in the manual mode can be directly used as the parameter reference of the automatic mode.

7. The method of claim 1-6, wherein the method of manufacturing a flexible EPS motor stator manufacturing system is characterized by, The application relates to a manufacturing system for manufacturing a stator, which comprises a core equipment module, an intelligent control module and a process database module. In the trial production mode, manual operation of the device is allowed, and the operation error is corrected through the dynamic process compensation unit, and effective process parameters are extracted as candidate genes; In the mass production mode, adaptive gene parameters in the process database are called to automatically operate the device, and the utilization rate of the device is optimized through the dynamic production capacity scheduling. The trial production process further comprises:

8. The method of claim 7, wherein the step of forming the flexible EPS motor stator further comprises the step of: The modular self-adaptive tooling is used for insulation skeleton threading and assembling, and the positioning deviation of the workpiece is ensured to be less than or equal to 0.5mm through pressure sensor feedback; ​ After manual operation is completed, the system automatically stores the process parameters and detection results in the process database. The mass production process further comprises:

9. The method of claim 7, wherein the step of forming the flexible EPS motor stator further comprises the step of: The intelligent control module inserts mass production small-batch production in the trial production task gap based on the dynamic production capacity scheduling unit; ​ After the first product detection is qualified, the process database automatically updates the optimal parameters of the batch. ​ 10. The method of claim 7, wherein the flexible EPS motor stator is manufactured by the steps of: The mode switching is completed by the process database through a gene matching algorithm within 5 minutes to convert the trial parameters to the mass production parameters, and the modular adaptive tooling only needs to be automatically calibrated and positioned without replacement. ​

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