A wire changing method of a motor stator wire forming apparatus

Abstract

This application discloses a wire changing method for a motor stator wire forming equipment, relating to the field of flat wire motor stator manufacturing technology. The method includes welding the tail end of a previous coil of copper wire to the head end of a new coil of copper wire, connecting the two coils into a continuous copper wire. The weld protrusion is then ground and trimmed. The ground weld and its adjacent areas are then sprayed with color to form a color-marked segment on the surface of the continuous copper wire. The continuous copper wire is then fed into the machine. A color detection mechanism scans the surface of the copper wire in real time. When a color-marked segment is detected, a trigger signal is generated. The PLC controller calculates the delay trigger time based on this trigger signal, the feed speed, and the physical axial distance, and controls a cutting mechanism to cut and remove the continuous copper wire containing the color-marked segment. This invention effectively reduces copper wire waste during the wire changing process, achieves automatic identification and removal of waste segments during continuous wire feeding, and ensures processing continuity.

Description

Technical Field

[0001] This application relates to the field of flat wire motor stator manufacturing technology, and in particular to a method for changing the wire in a motor stator wire forming equipment. Background Technology

[0002] The stator wire forming process is a core step in the manufacturing of flat wire motors, mainly used to process flat copper wire into stator winding hairpins. Currently, most mainstream wire forming equipment adopts highly integrated automated equipment solutions, which typically have multiple process modules arranged sequentially along the wire feeding direction, such as uncoiling, straightening, paint removal, wire feeding, and cutting and forming.

[0003] During continuous production, when a coil of copper wire is exhausted and needs to be replaced, the existing equipment operating mechanism results in significant material waste. This is mainly due to the structural principle of the automated wire forming equipment, where a fixed physical distance exists between the wire feeding mechanism that drives the copper wire and the front-end cutting mechanism. When the tail end of the old coil of copper wire detaches from the coil and the primary straightening section and enters the wire feeding mechanism, it gradually loses its subsequent physical propulsion and clamping force as it passes through the mechanism because there is no longer any wire connecting it. At this point, the section of copper wire remaining between the wire feeding mechanism and the front-end cutting mechanism cannot continue to be smoothly conveyed forward to complete subsequent processing.

[0004] To restore the equipment to normal operation and connect new copper wire coils, operators must pull out the entire section of copper wire stuck in the equipment channel and discard it as waste. This passive cleaning operation, caused by the spacing between equipment stations, results in significant raw material loss per wire change, increasing manufacturing costs. Simultaneously, the downtime for manual material extraction and re-threading disrupts the original processing rhythm, reducing the overall production efficiency of the wire forming equipment. Summary of the Invention

[0005] The purpose of this invention is to provide a method for changing the wire coil in an automatic stator wire forming equipment for motors. This method addresses the problem that when changing copper wire coils in an automatic stator wire forming equipment for motors, the spatial distance between the processing stations prevents continuous wire feeding of the previous coil, resulting in excess copper wire being cut off and discarded as scrap. This leads to copper waste and a decrease in production continuity due to downtime for wire changing.

[0006] This invention provides the following solution:

[0007] The first aspect of this invention provides a method for changing the stator wire in a motor stator wire forming device, comprising:

[0008] The tail end of the previous coiled copper wire is welded to the head end of the new coiled copper wire to connect the previous coiled copper wire and the new coiled copper wire into a continuous copper wire.

[0009] The protrusions at the weld joints of continuous copper wires are ground and repaired to obtain the repaired weld joints.

[0010] The repaired solder joints and their adjacent areas are sprayed with color to form color-marked sections on the surface of the continuous copper wire.

[0011] Drive the continuous copper wire feed and scan the surface color of the continuous copper wire in real time during the feeding process;

[0012] When a color-marked segment is detected by the scan, a trigger signal is generated;

[0013] Based on the trigger signal, the control cutting mechanism cuts and discards the continuous copper wire containing the color-marked segment.

[0014] Preferably, the tail end of the previous coil of copper wire is welded to the head end of the new coil of copper wire, including:

[0015] The tail end of the previous coiled copper wire and the head end of the new coiled copper wire are aligned and positioned in a special mold of the welding module.

[0016] The welding module applies instantaneous mechanical pressure to a special mold, causing the contact surfaces of the previously wound copper wire and the newly wound copper wire to undergo plastic deformation and be squeezed together.

[0017] Preferably, applying instantaneous mechanical pressure to a special mold via a welding module includes:

[0018] The welding module uses a cam mechanism to apply instantaneous pressure of 500 to 800 atmospheres to a special mold, causing the pure copper metal lattices at the ends of the pre-coiled copper wire and the newly coiled copper wire to approach each other at room temperature and form intergranular bonds. This mechanical force induces plastic flow in the pure copper metal matrix, displacing the surface oxide film and insulating layer, achieving metallic bonding of the pure copper material. This process meets the tensile strength requirements of subsequent wire feeding processes without the need for external heat sources or auxiliary flux.

[0019] Preferably, the protrusions at the weld joints of the continuous copper wire are ground and trimmed, including: physically grinding the protrusions by calling the grinding execution end of the trimming marking module; and verifying and controlling the dimensions of the physical contour of the grinding area so that the cross-sectional dimension of the ground weld area is not greater than the cross-sectional dimension of the original copper wire substrate. By controlling the cross-section of the welding area, the necessary mechanical clearance space is provided for the continuous copper wire to pass through the guide channel inside the forming equipment.

[0020] Preferably, the ground solder joints and their adjacent areas are spray-painted to form color-marked segments on the surface of the continuous copper wire, including:

[0021] Determine the specific extension lengths of the weld point and its front and rear ends as the spraying operation area;

[0022] Using a trimming and marking module, a specific marking medium is used to uniformly spray the spraying area to form a high-contrast color marking segment that differs from the optical reflection characteristics of the continuous copper wire surface.

[0023] Preferably, the specific extension length is 50 mm, and the specific marking medium is black synthetic resin ink. By using black ink to form a low-reflectivity coating on the surface of the continuous copper wire, a difference in optical reflection characteristics from the original insulating varnish is established, thereby providing an objective judgment benchmark for subsequent optical inspection agencies to determine the condition.

[0024] Preferably, the surface color of the continuous copper wire during the feeding process is scanned in real time, and a trigger signal is generated when a color marker segment is detected during the scan, including:

[0025] The surface of a continuous copper wire passing through the detection area is optically scanned online using a color detection mechanism located at the calibration mechanism.

[0026] When the intensity of reflected light received by the color detection mechanism drops below the preset optical recognition threshold, it is determined that a color mark segment has been identified, and the state is reversed through the internal hardware circuit of the color detection mechanism to generate a trigger signal in the form of a level signal.

[0027] Preferably, based on a trigger signal, the cutting mechanism is controlled to cut and discard the continuous copper wire containing the color-marked segment, including:

[0028] The PLC controller receives the trigger signal and obtains the current copper wire feed speed and the physical axial distance between the scanning detection point of the color detection mechanism and the cutting edge of the cutting mechanism.

[0029] Based on the copper wire feed speed and physical axial distance, calculate the delay trigger time for the color mark segment to reach the cutting mechanism;

[0030] When the timer reaches the delay trigger duration, the PLC controller sends an action command to the cutting mechanism to drive the cutting die to cut and physically separate the continuous copper wire containing the color-marked segment.

[0031] As an alternative identification method, the surface color of the continuous copper wire during the feeding process is scanned in real time, and a trigger signal is generated when a color marker segment is detected, including:

[0032] The industrial camera included in the color detection mechanism is used to acquire a real-time surface image stream of the continuous copper wire during the feeding process;

[0033] The image processing logic is used to analyze whether there is a specific black pixel cluster area in the surface image stream that corresponds to the color marker segment;

[0034] If a specific black pixel cluster exists, the color marker segment is identified, and a trigger signal is generated and sent to the PLC controller.

[0035] A second aspect of the present invention provides a motor stator wire forming device, comprising:

[0036] Opening book institutions;

[0037] The welding module, located at the front end of the uncoiling mechanism, is used to weld the tail end of the previous coiled copper wire to the head end of the new coiled copper wire, so that the previous coiled copper wire and the new coiled copper wire are connected into a continuous copper wire.

[0038] The trimming and marking module is located behind the welding module. It is used to grind and trim the protrusions of the solder joints at the continuous copper wire welding point, and to spray color on the ground solder joints and their adjacent areas to form color marking segments on the surface of the continuous copper wire.

[0039] The forming and processing module includes a straightening mechanism, a paint removal mechanism, and a cutting mechanism arranged sequentially along the copper wire feeding direction;

[0040] The identification control module includes a color detection mechanism located at the straightening mechanism and a PLC controller that is communicatively connected to the color detection mechanism. The PLC controller is also communicatively connected to the cutting mechanism.

[0041] The color detection mechanism is used to scan the surface color of continuous copper wires in real time during the feeding process and generate a trigger signal when the color mark segment is detected during scanning;

[0042] The PLC controller is used to control the cutting mechanism to cut and discard continuous copper wires containing color-marked segments based on trigger signals.

[0043] The above solution achieves the following beneficial technical effects:

[0044] This application applies instantaneous mechanical pressure to the tail end of the previous coiled copper wire and the head end of the new coiled copper wire, causing the pure copper end face to undergo plastic deformation and be squeezed together to form a continuous copper wire. This allows the wire to cross the physical distance between the various processing stations inside the equipment, avoiding the problem of directly discarding large sections of tail material due to the inability to feed the wire continuously, thereby reducing the material loss caused by replacing copper wire coils.

[0045] This application achieves automatic optical identification of welding waste sections that no longer possess their original electrical properties by spraying a color-differentiated marking medium onto the ground solder joints and their surrounding area using a marking medium that is different in color from the original insulating varnish. This is achieved by combining the color detection mechanism set at the wiring channel with the color detection mechanism to capture the drop in reflected light intensity caused by the passing of the sprayed coating.

[0046] This application receives the detection trigger signal through a PLC controller and calculates the delayed trigger time by combining the real-time copper wire feed speed and the physical distance from the detection point to the cutting edge. In conjunction with the front-end photoelectric recognition, the equipment can cut off and remove waste sections without stopping the machine and with continuous wire feeding, thus maintaining the continuity of the stator processing process. Attached Figure Description

[0047] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0048] Figure 2 This is a schematic diagram of the workflow of the present invention.

[0049] The components include: 1. Unwinding mechanism; 2. Welding module; 3. Trimming and marking module; 4. Straightening mechanism; 5. Paint removal mechanism; 6. Cutting mechanism; and 7. Color detection mechanism. Detailed Implementation

[0050] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0051] See attached document Figure 1 This invention provides a motor stator wire forming device, comprising:

[0052] Welding module 2, located at the front end of uncoiling mechanism 1, is used to connect the tail end of the previous coiled copper wire to the head end of the new coiled copper wire;

[0053] The trimming and marking module 3 is located behind the welding module 2 and is used to grind and trim the solder joints and spray color on the surface of the copper wire.

[0054] The forming and processing module includes a straightening mechanism 4, a paint removal mechanism 5, and a cutting mechanism 6 arranged sequentially along the copper wire feeding direction;

[0055] The identification control module includes a color detection mechanism 7 located at the straightening mechanism 4 and a PLC controller that is communicatively connected to the color detection mechanism 7. The PLC controller is communicatively connected to the cutting mechanism 6.

[0056] See attached document Figure 2 This invention provides a method for changing the stator wire in a motor stator wire forming equipment, comprising the following steps:

[0057] S100, connect the end of the front coiled copper wire to the beginning of the new coiled copper wire by connecting the welding module 2, so that the front coiled copper wire and the new coiled copper wire are connected as one.

[0058] S200, using the trimming and marking module 3 to grind and trim the solder joint protrusions generated at the welding point of the two coils of copper wire, so that the cross-sectional dimension of the solder joint area after grinding is not greater than the cross-sectional dimension of the original copper wire substrate.

[0059] S300, using the trimming and marking module 3, sprays the polished solder joints and their adjacent areas to form color marking segments on the copper wire surface;

[0060] S400, start the automatic wire forming equipment to feed the wire, and the color detection mechanism 7 in the identification control module scans the surface color of the copper wire passing through the detection area in real time.

[0061] S500: When the color detection mechanism 7 identifies a color mark segment, it generates a trigger signal and sends it to the PLC controller.

[0062] After receiving the trigger signal, the S600 PLC controller will control the cutting mechanism 6 in the molding and processing module to cut off the color-marked segment containing the weld point and remove it from the production line.

[0063] In this embodiment, the step S100 of connecting the tail end of the previous coiled copper wire to the head end of the new coiled copper wire by connecting it to the welding module 2 may specifically include the following sub-steps.

[0064] In actual line changeover operations, sub-step S101 is typically executed, pausing the automatic wire forming equipment's feeding action and introducing the exhausted end of the previous coil of copper wire and the beginning of the new coil of copper wire to be replaced into the working area of ​​welding module 2. As a preferred method, welding module 2 employs a cold welding machine. The end of the previous coil of copper wire is aligned with the beginning of the new coil of copper wire, and then placed into a dedicated mold inside the cold welding machine for positioning and contact.

[0065] After the wire end positioning is completed, sub-step S102 is initiated, and welding module 2 is activated. An internal cam mechanism applies instantaneous mechanical pressure to a dedicated mold, causing plastic deformation and direct compression bonding between the contact surfaces of the previously coiled copper wire and the newly coiled copper wire. In the principle of cold-press welding, under sufficiently large mechanical force, the local stress at the contact interface of two metals exceeds the yield strength of the materials, resulting in intense plastic flow. This plastic flow can break up and displace the surface oxide film or insulating layer, exposing the fresh pure copper metal substrate and allowing them to come into close contact. When the contact distance reaches the range of interatomic attraction, a strong metallic bond can be formed. Based on the material characteristics of flat copper wire, the cam mechanism is typically set to generate an instantaneous pressure of 500 to 800 standard atmospheres during operation. The value of this pressure range is mainly determined by the yield strength of the copper material itself and the wire diameter. Too low a pressure will result in a weak cold-welded interface, while too high a pressure can easily damage the mold or cause the wire to break due to excessive compression. Mechanical pressure is concentrated on the contact surfaces of the two copper wires through a specialized mold, causing the pure copper metal lattices at both ends to approach each other and form intergranular bonds at room temperature. This connection method requires no external heat source, no filler, and no auxiliary flux. The specific mechanical configuration of the cam mechanism inside the cold welding machine and the clamping design of the specialized mold can be conventionally selected and adjusted according to the specifications of the copper wire by those skilled in the art. Its mechanical transmission and clamping structure are well-known technologies in the field and will not be elaborated upon here.

[0066] Sub-step S103 is then executed to release the instantaneous pressure applied by welding module 2 and open the special mold, thus removing the continuous copper wire that has been joined together. In the manufacturing scenario used in this embodiment, the applicable size range for the width of flat copper wire by the cold welding machine is generally between 3 and 6 mm. Relevant tests show that after cold pressing and extrusion bonding, the pull-out force at the joint area between the previously coiled copper wire and the newly coiled copper wire can reach about 450 N. This pull-out strength can usually meet the tensile tension requirements of the subsequent copper wire passing through the various wire feeding mechanisms in the forming processing module, which helps to prevent the copper wire from breaking during continuous feeding.

[0067] It should be noted that, without changing the core objective of continuously joining the two independent coils of copper wire end-to-end, the technical implementation of welding module 2 can be equivalently replaced. For example, as another feasible implementation, welding module 2 can also be configured as a TIG welding device or a laser welding device. When using a TIG welding device, the heat generated by the tungsten inert gas arc melts the ends of adjacent copper wires to form a molten pool and solidifies the connection; when using a laser welding device, a high-energy-density laser beam irradiates the copper wire joint area to achieve material fusion. All of the above different welding schemes can achieve a rigid connection between the two coils of copper wire, which are foreseeable equivalent implementations of the technical solution of this invention.

[0068] In this embodiment, the step S200 of using the trimming marking module 3 to grind and trim the solder joint protrusions generated at the welding point of the two coils of copper wire may specifically include the following sub-steps.

[0069] After the aforementioned cold-press welding operation, the joint area of ​​the two coils of copper wire usually experiences outward extrusion due to the plastic flow of pure copper metal, forming metal flash or geometric protrusions that exceed the original wire contour. To eliminate these dimensional interferences, sub-step S201 is executed in the specific implementation, calling the grinding execution end in the trimming mark module 3 to physically grind the protruding area. As a preferred method, the grinding execution end uses a portable grinding wheel. Through manual operation or robotic arm-assisted positioning, the grinding surface of the portable grinding wheel is aligned with the flash position of the joint section for cutting and grinding, gradually removing the metal excess that exceeds the outer contour of the substrate.

[0070] After the basic grinding is completed, the dimensions of the ground area need to be further verified. This involves executing sub-step S202 to verify and control the physical contour of the ground area until it meets the threshold requirements for entering subsequent processes. In the physical architecture of the automated forming equipment, the subsequent forming processing module contains multiple sets of straightening guide rollers and paint removal cutting dies. The guide clearances of these mechanical components are usually set based on the nominal dimensions of the original copper wire substrate. If the local dimensions of the welding section are too large, it can easily cause mechanical interference during equipment operation.

[0071] In practical grinding scenarios, it is common practice to grind the solder joint area to a negative tolerance state, slightly below the original copper wire substrate dimensions. Since the copper insulation varnish of this welded section and its surrounding area is damaged during welding and grinding, and its actual cross-section and resistivity change, this section of wire is discarded as scrap in subsequent processes. Therefore, the slight reduction in its actual cross-sectional area during the finishing stage does not affect the electrical performance or mechanical strength of the final stator product. Based on this physical characteristic, moderately increasing the grinding amount is not only easier to achieve in terms of process operation, but also, by maintaining the aforementioned dimensional relationships, usually provides the necessary mechanical clearance space for the welded section to smoothly pass through various narrow guide channels inside the forming module, which helps reduce the probability of mechanical jamming of the copper wire during continuous feeding.

[0072] For the selection of specific motor power, setting of abrasive mesh size, and basic dimensional inspection methods for portable grinding machines, those skilled in the art can make conventional settings based on the material hardness of flat copper wire and the on-site working space. These are well-known technologies in the field and will not be elaborated here.

[0073] In this embodiment, the step S300 of using the trimming marking module 3 to spray the ground weld point and its adjacent areas may specifically include the following sub-steps.

[0074] After grinding and finishing, considering that the insulating varnish at the weld joint has been damaged and the physical properties of the wire have changed, this section of copper wire is essentially no longer suitable for manufacturing the stator hairpin winding of a motor. To enable subsequent automated equipment to identify this waste material as it passes through, sub-step S301 is executed to determine the spraying area of ​​the finishing marking module 3. When the copper wire is continuously fed, photoelectric detection equipment typically requires a certain response time to capture surface features. Based on this principle, the spraying area is not limited to the physical weld point itself, but covers the entire weld point and extends to both ends. As a preferred approach, the spraying range is determined to be the physical weld point and an area 50mm before and after it. Maintaining this specific extension length is primarily to allow a relatively generous time window for subsequent electrical signal triggering, thereby helping to reduce the risk of the color detection mechanism 7 missing detection due to an excessively short marking section.

[0075] Based on the determined spraying range, sub-step S302 is further executed, selecting a specific marking medium to cover the copper wire surface of this area. In this embodiment, the operator uses a portable spray can as the spraying tool and selects synthetic resin ink as the spraying material to uniformly spray the designated area. Since the insulating varnish on the surface of conventional flat copper wire is mostly brown or yellow, in order to establish a high-contrast optical feature that is easy for machines to recognize, the color of the synthetic resin ink used is specifically set to black. The black resin ink can form a continuous low-reflectivity coating locally on the copper wire, creating a difference from the optical reflection characteristics of the original copper wire surface. This obvious color difference constitutes the objective physical benchmark for the color detection mechanism 7 to determine the state.

[0076] As long as the marking material can form a stable color band on the copper substrate surface, those skilled in the art can also use other high-contrast coatings with significant color differences to replace the black synthetic resin ink. These coating color replacements based on actual production line conditions are all foreseeable equivalent implementations of the technical solution of this invention. Regarding the internal air pressure setting of the portable spray can and the basic atomization film-forming mechanism of the coating, those skilled in the art can handle these matters based on conventional industrial knowledge; they are well-known technologies in the field and will not be elaborated upon here.

[0077] In this embodiment, the step S400, in which the automatic wire forming equipment is started to feed the wire and the color detection mechanism 7 in the identification control module performs real-time scanning of the surface color of the copper wire passing through the detection area, may specifically include the following sub-steps.

[0078] After completing the grinding and spraying operations in the solder joint area, the main drive system of the automatic wire forming equipment needs to be started to restore the production line's operating rhythm. Two coils of copper wire, connected as a single unit, are continuously fed into the forming module at a set feed speed under the traction of the wire feeding mechanism. To effectively capture scrap sections during the copper wire feeding process, sub-step S401 is executed, allowing the fed copper wire to pass through a specific detection area, and the surface of the copper wire is continuously monitored using a color detection mechanism 7 located therein. As a preferred embodiment, the color detection mechanism 7 employs a color mark sensor, which is fixedly installed in the straightening mechanism 4 inside the forming module. Because the straightening mechanism 4 has multiple sets of guide wheels for flattening the wire, the copper wire is mechanically constrained when passing through this area, typically maintaining a relatively stable linear motion posture. Placing the color mark sensor here allows its optical detection window to maintain a relatively constant detection distance from the copper wire surface, which physically helps reduce detection errors caused by wire vibration.

[0079] As the copper wire smoothly passes through the detection area, it naturally transitions to sub-step S402, where the color detection mechanism 7 performs online optical scanning and identification of the surface features of the copper wire. Under normal wire feeding conditions, the light beam emitted by the color mark sensor illuminates the surface of the copper wire with its original color insulating varnish, and the receiver captures the reflected light signal within a normal reference range. As feeding continues, when the black color-marked segment, after being sprayed with color, reaches the detection spot of the color mark sensor, the black resin coating absorbs most of the incident light. This optical absorption characteristic causes a decrease in the intensity of the light beam reflected back to the sensor. The processing circuit inside the color mark sensor compares the change in reflected light intensity in real time. When the change exceeds a preset optical recognition threshold, it serves as the basis for determining that the copper wire currently passing through the detection area is no longer normal wire, thus completing the online physical identification of the color-marked segment. It should be noted that the aforementioned preset optical recognition threshold is typically calibrated based on the physical difference between the reflectivity of the original copper wire surface insulating varnish and the reflectivity of the black marking coating to ensure reliable differentiation between normal wire and marked waste.

[0080] It should be noted that there are multiple feasible engineering implementation approaches for the identification mechanism of surface spray color features. Without departing from the technical principles of this invention, the color detection mechanism 7 can also adopt visual inspection technology as an equivalent alternative. For example, an industrial camera can be set as the detection front end to acquire the surface image stream of the fed copper wire in real time, and the presence of specific black pixel clusters in the image can be analyzed through the underlying image processing logic. This non-contact detection method based on machine vision can usually also achieve automatic identification of marked solder joints and is a foreseeable equivalent implementation of the technical solution of this invention. As for the hardware architecture of the photoelectric conversion circuit inside the color mark sensor, the specific calibration method of the sensitivity threshold, and the image grayscale extraction algorithm in conventional visual inspection, those skilled in the art can perform routine adjustments according to the ambient lighting conditions. The basic photoelectric sensing and image recognition principles are well-known technologies in this field and will not be elaborated here.

[0081] In this embodiment, the step S500 of generating a trigger signal and sending it to the PLC controller when the color detection mechanism 7 identifies a color mark segment may specifically include the following sub-steps.

[0082] During the preceding continuous scanning process, once the surface of the copper wire passing through the detection area switches from normal insulating varnish to a black coating, the amount of light received by the color mark sensor decreases. Based on the abrupt change in physical light intensity during photoelectric conversion, the device executes sub-step S501, where the hardware circuitry inside the color detection mechanism 7 reverses the state and generates a trigger signal. Preferably, the color mark sensor contains photoelectric conversion components and a corresponding comparator circuit. When the intensity of the captured reflected light drops below a preset optical recognition threshold, the voltage signal generated by the photoelectric conversion crosses the comparator's flip threshold, driving the output stage circuit to generate a step-level signal. This level signal typically manifests as a high-level or low-level pulse lasting for a certain period, essentially constituting a hardware trigger signal used to notify the external control system of the discovery of a waste section. It should be noted that the setting of this flip threshold is usually based on prior calibration tests: by measuring the reflected voltage of the normal copper wire surface and the absorbed voltage of the black mark section, the difference between the two is extracted, and an appropriate safety margin is set to determine the comparator's trigger reference. This helps prevent false triggering caused by minor fluctuations in ambient stray light.

[0083] After acquiring the trigger pulse, to achieve electrical connection and remote control, the color detection mechanism 7 transmits the trigger signal to the PLC controller in the recognition control module in real time through a preset electrical communication link, thus proceeding to sub-step S502. Considering the electromagnetic interference caused by the operation of high-power servo motors in automated forming equipment, the communication connection between the sensor and the PLC controller typically uses a shielded signal cable for physical hard-wired transmission. This direct connection method helps reduce signal delay on the transmission path and suppress external interference. Without changing the core technical logic of signal transmission, if the aforementioned color detection mechanism 7 adopts visual detection technology as an equivalent implementation, the corresponding trigger signal can also be sent to the PLC controller via industrial fieldbus protocols such as Ethernet or Profinet. These different data interaction methods can usually also deliver the recognition result to the main control unit, which is a foreseeable equivalent implementation of the technical solution of this invention.

[0084] After the signal is sent to the control terminal, the input port of the PLC controller receives the trigger signal and converts it into an internally processable logic state, i.e., executing sub-step S503. Specifically, the high-speed input module of the PLC controller, upon capturing the level transition edge (such as rising or falling edge) of the trigger signal, immediately responds to a hardware interrupt and writes the Boolean state of the trigger event into a specific internal register address. At this time, the underlying program of the PLC controller uses the change in the register state as a condition variable to complete the logical switch from the normal power supply monitoring state to the waste removal intervention state, thereby providing the necessary data foundation for subsequent linkage with downstream actuators.

[0085] For the specific configuration of the color mark sensor output stage circuit (e.g., NPN or PNP type open collector output), the grounding wiring specifications of the industrial shielded cable, and the electrical isolation and filtering design of the PLC controller input port, those skilled in the art can perform conventional matching based on the overall electrical architecture of the field control cabinet. Its basic electrical communication control is a well-known technology in the field and will not be elaborated here.

[0086] In this embodiment, the step S600, in which the PLC controller controls the downstream actuator to cut and remove the marked waste section based on the received trigger signal, may specifically include the following sub-steps.

[0087] After the PLC controller completes the switch from regular wire feeding monitoring to waste removal intervention, considering the fixed physical distance between the installation position of the color detection mechanism 7 and the execution station of the downstream cutting mechanism 6, the abnormal marked waste segment continues to be conveyed forward even when the sensor sends a trigger signal. To compensate for this spatial difference, the system executes sub-step S601, where the PLC controller determines the delayed triggering timing of the cutting action based on preset control logic. Specifically, the controller's internal processing program comprehensively calls the current wire feed speed parameters and the physical axial distance between the scanning detection point of the color detection mechanism 7 and the cutting edge of the cutting mechanism 6. This distance value is usually physically measured during equipment manufacturing or commissioning and written into the system as a fixed parameter. By combining the above-set distance with the real-time feed speed, the PLC controller can calculate the time difference required for the marked waste segment to move from being detected to reaching the cutter, and thus set it as the delayed triggering duration for cutting.

[0088] After completing the timing matching described above, the process proceeds to sub-step S602 as the feed continues. When the system timer reaches the set delay trigger duration, the PLC controller sends an action command to the cutting mechanism 6 in the forming processing module. The cutting mechanism 6, preferably, employs a pneumatically or hydraulically driven cutting die. When the marked scrap section just reaches below the cutter, the cutting die responds to the control signal from the solenoid valve and quickly presses down, physically separating the entire scrap section, including the physical solder joints and the extended markings, from the continuous copper wire entity through a preset scrap cutting action. This distance- and speed-based delay matching mechanism helps to accurately cut off defective connection sections while continuously feeding wire without stopping the machine.

[0089] After the waste section is sheared and separated, sub-step S603 is immediately carried out. The welding waste section, which has lost its original mechanical constraint of the wire, usually falls directly into the waste collection tank below by its own gravity and is thus removed. After confirming that the waste has been removed and the cutting die has been reset, the PLC controller continues to maintain the normal feed command of the wire feeding mechanism, and the equipment resumes the conventional hairpin winding cutting and forming process for subsequent normal copper wire.

[0090] It should be noted that the implementation of the position tracking logic can be equivalently replaced without departing from the technical principles of this invention. For example, in addition to time-based delay calculation, the PLC controller can also collect real-time operating data of the wire feeding mechanism, convert the aforementioned physical axial distance into an equivalent target conveying volume, and trigger the cutting command by comparing the actual conveying volume with the target conveying volume. This conventional control scheme can also achieve the matching of the cutting position and is a foreseeable equivalent implementation of the technical solution of this invention. As for the specific cylinder selection, mechanical guiding structure of the cutting die, and basic sheet metal layout of the waste trough inside the cutting mechanism 6, those skilled in the art can perform conventional assembly based on the wire hardness and the available space. The design of its mechanical actuators is well-known in the field and will not be elaborated here.

[0091] Specific application examples:

[0092] Taking one of the company's stator products as an example, the wire coil is replaced 10-12 times per shift. Each wire coil replacement can save 4.3 meters of copper wire loss, which means 44-52 meters of copper wire are saved per shift.

Claims

1. A method for changing the wire in a motor stator wire forming device, characterized in that, include: The tail end of the previous coiled copper wire is welded to the head end of the new coiled copper wire to connect the previous coiled copper wire and the new coiled copper wire into a continuous copper wire. The protrusions at the weld joints of the continuous copper wires are ground and repaired to obtain the repaired weld joints. The polished solder joints and their adjacent areas are sprayed with color to form color-marked sections on the surface of the continuous copper wire. Drive the continuous copper wire to feed and feed the wire, and scan the surface color of the continuous copper wire in real time during the feeding process; When the color-marked segment is detected by the scan, a trigger signal is generated; Based on the trigger signal, the cutting mechanism (6) is controlled to cut and remove the continuous copper wire containing the color mark segment.

2. The method for changing the stator wire in a motor stator wire forming device according to claim 1, characterized in that, The process of welding the end of the previous coil of copper wire to the beginning of the new coil of copper wire includes the following steps: The tail end of the previous coiled copper wire and the head end of the new coiled copper wire are aligned and positioned in the special mold of the welding module (2); The welding module (2) applies instantaneous mechanical pressure to the special mold, causing the contact end face of the pre-coiled copper wire and the new coiled copper wire to undergo plastic deformation and be squeezed together.

3. The method for changing the stator wire in a motor stator wire forming device according to claim 2, characterized in that, Applying instantaneous mechanical pressure to the special mold via the welding module (2) includes the following steps: The cam mechanism inside the welding module (2) applies an instantaneous pressure of 500 to 800 standard atmospheres to the special mold, causing the pure copper metal lattice at the end of the pre-coiled copper wire and the new-coiled copper wire to approach each other at room temperature and form intercrystalline bonding.

4. The method for changing the stator wire in a motor stator wire forming device according to claim 1, characterized in that, Grinding and smoothing the protruding solder joints at the continuous copper wire welds includes the following steps: The grinding execution end of the trimming mark module (3) is called to physically grind the weld point protrusion; The physical contour of the grinding area is dimensionally verified and controlled to ensure that the cross-sectional dimension of the grinding solder joint area is not greater than the cross-sectional dimension of the original copper wire substrate.

5. The method for changing the stator wire in a motor stator wire forming device according to claim 4, characterized in that, The process of spraying color onto the ground solder joints and their adjacent areas to form color-marked segments on the surface of the continuous copper wire includes the following steps: The specific extension lengths before and after the weld point are defined as the spraying operation area; Using the trimming marking module (3), a specific marking medium is used to uniformly spray the spraying operation area to form a high-contrast color marking segment that differs from the optical reflection characteristics of the continuous copper wire surface.

6. The method for changing the wire in a motor stator wire forming device according to claim 5, characterized in that, The specific extension length is 50 mm, and the specific marking medium is black synthetic resin ink.

7. The method for changing the wire in a motor stator wire forming device according to claim 1, characterized in that, The surface color of the continuous copper wire during the feeding process is scanned in real time, and a trigger signal is generated when the color mark segment is identified during the scan, including: The surface of the continuous copper wire passing through the detection area is optically scanned online using a color detection mechanism (7) located at the alignment mechanism (4); When the intensity of reflected light received by the color detection mechanism (7) drops below the preset optical recognition threshold, it is determined that the color mark segment has been identified, and the state is reversed through the hardware circuit inside the color detection mechanism (7) to generate the trigger signal in the form of a level signal.

8. The method for changing the stator wire in a motor stator wire forming device according to claim 7, characterized in that, Based on the trigger signal, the cutting mechanism (6) is controlled to cut and remove the continuous copper wire containing the color mark segment, including the following steps: The PLC controller receives the trigger signal and obtains the current copper wire feed speed and the physical axial distance between the scanning detection point of the color detection mechanism (7) and the cutting edge of the cutting mechanism (6). Based on the copper wire feed speed and the physical axial distance, calculate the delay trigger time for the color mark segment to run to the cutting mechanism (6); When the timer reaches the delay trigger duration, the PLC controller sends an action command to the cutting mechanism (6) to drive the cutting die to cut and physically separate the continuous copper wire containing the color mark segment.

9. The method for changing the wire in a motor stator wire forming device according to claim 1, characterized in that, The surface color of the continuous copper wire during the feeding process is scanned in real time, and a trigger signal is generated when the color mark segment is identified during the scan, including: The surface image stream of the continuous copper wire during the feeding process is acquired in real time using an industrial camera included in the color detection mechanism (7); The image processing logic is used to analyze whether there is a specific black pixel cluster area in the surface image stream that corresponds to the color mark segment; If the specific black pixel cluster area exists, the color marker segment is identified, and the trigger signal is generated and sent to the PLC controller.

10. A motor stator wire forming device, characterized in that, include: Opening mechanism (1); The welding module (2) is located at the front end of the uncoiling mechanism (1) and is used to weld the tail end of the front coiled copper wire to the head end of the new coiled copper wire so that the front coiled copper wire and the new coiled copper wire are connected as a continuous copper wire. The trimming and marking module (3) is located behind the welding module (2) and is used to grind and trim the protrusion of the weld point at the continuous copper wire welding point, and to spray color on the ground weld point and its adjacent areas before and after, so as to form a color marking segment on the surface of the continuous copper wire. The forming and processing module includes a straightening mechanism (4), a paint removal mechanism (5), and a cutting mechanism (6) arranged sequentially along the copper wire feeding direction. The identification control module includes a color detection mechanism (7) located at the straightening mechanism (4) and a PLC controller that is communicatively connected to the color detection mechanism (7). The PLC controller is communicatively connected to the cutting mechanism (6). The color detection mechanism (7) is used to scan the surface color of the continuous copper wire in real time during the feeding process, and generate a trigger signal when the color mark segment is detected during the scan. The PLC controller is used to control the cutting mechanism (6) to cut and remove the continuous copper wire containing the color mark segment based on the trigger signal.

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