Flat copper wire stator hairpin paint film visual inspection system

Abstract

The present invention discloses a paint film visual inspection system for stator hairpins of flat copper wires, comprising a first conveyor belt unit and a second conveyor belt unit extending along the same horizontal extension line, wherein a first conveying surface on the first conveyor belt unit and a second conveying surface on the second conveyor belt unit can both convey the hairpin-shaped flat copper wire; a first CCD image camera and a second CCD image camera are respectively installed above the first conveying surface and the second conveying surface; the structure of the present invention can turn over the hairpin-shaped flat copper wire during transportation, thereby realizing double-sided inspection of the hairpin-shaped flat copper wire and improving the accuracy and reliability of the inspection.

Description

Technical Field

[0001] The invention belongs to the field of flat copper wire stator detection. Background Art

[0002] As the name implies, the flat wire motor uses flat copper wire in the stator winding. First, the winding copper wire is made into several hairpin-like shapes (such as Figure 1 ), insert it into the stator slot, and then weld the end of the hairpin at the other end. The insulation performance of the hairpin-shaped flat copper wire is achieved by the paint film on the outer surface. Whether the paint film on the outer surface of the hairpin-shaped flat copper wire is complete directly affects the service life of the motor. Therefore, the hairpin-shaped flat copper wire can be monitored by using a CCD image detector to check whether the flat wire paint film has scratches, wrinkles, paint leakage and other defects, so as to prevent the motor insulation problem caused by the quality defects of the flat wire; and the hairpin-shaped flat copper wire has only one side facing up during the transmission process, and the camera cannot capture both sides of the hairpin-shaped flat copper wire, which causes limitations in detection. Summary of the invention

[0003] Purpose of the invention: In order to overcome the deficiencies in the prior art, the present invention provides a visual inspection system for the paint film of a flat copper wire stator hairpin capable of double-sided inspection.

[0004] Technical solution: To achieve the above-mentioned purpose, the paint film visual inspection system of the flat copper wire stator hairpin of the present invention comprises a first conveyor belt unit and a second conveyor belt unit extending along the same horizontal extension line, and the first conveying surface on the first conveyor belt unit and the second conveying surface on the second conveyor belt unit can both convey the hairpin-shaped flat copper wire; the first CCD image camera and the second CCD image camera are respectively installed above the first conveying surface and the second conveying surface;

[0005] A transfer mechanism is provided between the first conveyor belt unit and the second conveyor belt unit; the transfer mechanism comprises a fixedly installed horizontal motor, the axis of the output shaft of the motor is perpendicular to the extension direction of the first conveyor belt unit / the second conveyor belt unit; a clamping transfer arm is fixedly connected to the side of the output shaft of the motor;

[0006] The rotation of the output shaft can drive the clamping transfer arm to clamp the hairpin-shaped flat copper wire at the transmission end of the first conveyor belt unit, and transfer the clamped hairpin-shaped flat copper wire to the transmission starting point of the second conveyor belt unit.

[0007] Furthermore, the clamping transfer arm includes a support arm perpendicular to the output shaft, the root of the support arm is fixedly connected to the output shaft, the end of the support arm is vertically connected to a horizontal fixed clamp, and a movable clamp is arranged parallel to the side of the fixed clamp close to the output shaft; it also includes a disk coaxially fixed to the end of the output shaft, a linear push rod motor is fixedly mounted on the disk, the push rod end of the linear push rod motor is fixedly connected to the movable clamp, and the linear push rod motor drives the movable clamp to move gradually closer to or away from the fixed clamp through the push rod, and a hairpin-shaped flat copper wire can be clamped between the movable clamp and the fixed clamp.

[0008] Furthermore, a guide arm parallel to the fixed clamp is vertically connected to the middle of the bracket arm; a push rod guide hole is provided in the middle of the guide arm, and the push rod moves through the push rod guide hole; two guide column holes are provided on both sides of the guide arm; two guide columns are also vertically connected to the movable clamp, and the two guide columns move through the two guide column holes respectively.

[0009] Furthermore, the motor is a stepping motor.

[0010] Furthermore, the height at which the axis of the output shaft is located is flush with the height at which the first conveying surface / the second conveying surface is located.

[0011] Furthermore, it also includes a dark box, in which a light source is arranged, the first conveyor belt unit and the second conveyor belt unit, the first CCD image camera, the second CCD image camera and the transfer mechanism are all located in the dark box, an entrance and an exit are respectively arranged at both ends of the dark box, and the conveying starting point of the first conveyor belt unit and the conveying end of the second conveyor belt unit pass through the entrance and the exit respectively.

[0012] Beneficial effects: The structure of the present invention can turn over the hairpin-shaped flat copper wire during transportation, thereby realizing double-sided detection of the hairpin-shaped flat copper wire and improving the accuracy and reliability of the detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Attached Figure 1 Schematic diagram of the hairpin-shaped flat copper wire structure to be tested.

[0014] Attached Figure 2 is a schematic diagram of the overall first structure of the device;

[0015] Attached Figure 3 is a second overall structural schematic diagram of the device;

[0016] Attached Figure 4 is a cross-sectional view of the device;

[0017] Attached Figure 5 This is a schematic diagram of the structure of the device after the external dark box is hidden;

[0018] Attached Figure 6 This is a schematic diagram of the structure after the clamping transfer arm releases the card-shaped flat copper wire;

[0019] Attached Figure 7 This is a schematic diagram of the structure after the clamping transfer arm clamps the hairpin-shaped flat copper wire. DETAILED DESCRIPTION

[0020] The present invention will be further described below in conjunction with the accompanying drawings.

[0021] As attached Figures 1 to 7 The paint film visual inspection system for the flat copper wire stator hairpin shown in the figure comprises a first conveyor belt unit 3 and a second conveyor belt unit 4 extending along the same horizontal extension line, and a first conveying surface 3.1 on the first conveyor belt unit 3 and a second conveying surface 4.1 on the second conveyor belt unit 4 can both convey the hairpin-shaped flat copper wire 1; a first CCD image camera 9 and a second CCD image camera 10 are respectively installed above the first conveying surface 3.1 and the second conveying surface 4.1;

[0022] A transfer mechanism is arranged between the first conveyor belt unit 3 and the second conveyor belt unit 4; the transfer mechanism includes a fixedly mounted horizontal motor 11. In order to improve the rotation accuracy, the motor 11 of the present embodiment is a stepping motor, and the axis of the output shaft 12 of the motor 11 is perpendicular to the extension direction of the first conveyor belt unit 3 / the second conveyor belt unit 4; the side of the output shaft 12 of the motor 11 is fixedly connected with a clamping transfer arm 8; the height at which the axis of the output shaft 12 of the present embodiment is located is flush with the height at which the first conveying surface 3.1 / the second conveying surface 4.1 is located.

[0023] The rotation of the output shaft 12 can drive the clamping transfer arm 8 to clamp the hairpin-shaped flat copper wire 1 at the conveying end of the first conveyor belt unit 3 and transfer the clamped hairpin-shaped flat copper wire 1 to the conveying starting point of the second conveyor belt unit 4 .

[0024] The clamping and transporting arm 8 includes a support arm 16 that is perpendicular to the output shaft 12, the root of the support arm 16 is fixedly connected to the output shaft 12, the end of the support arm 16 is vertically connected to a horizontal fixed clamp 17, and a movable clamp 15 is arranged in parallel on the side of the fixed clamp 17 close to the output shaft 12; it also includes a disc 13 coaxially fixed to the end of the output shaft 12, a linear push rod motor 21 is fixedly installed on the disc 13, the end of the push rod 20 of the linear push rod motor 21 is fixedly connected to the movable clamp 15, the linear push rod motor 21 drives the movable clamp 15 to move gradually closer to or away from the fixed clamp 17 through the push rod 20, and the hairpin-shaped flat copper wire 1 can be clamped between the movable clamp 15 and the fixed clamp 17.

[0025] A guide arm 22 parallel to the fixed clamp strip 17 is vertically connected to the middle of the bracket arm 16; a push rod guide hole 23 is provided through the middle of the guide arm 22, and the push rod 20 moves through the push rod guide hole 23; two guide column holes 18 are provided on both sides of the guide arm 22; two guide columns 19 are also vertically connected to the movable clamp strip 15, and the two guide columns 19 move through the two guide column holes 18 respectively.

[0026] In order to create a more stable optical environment and prevent changes in ambient brightness from affecting the detection results, the present embodiment also includes a dark box 2, in which a light source is arranged, a first conveyor belt unit 3 and a second conveyor belt unit 4, a first CCD image camera 9, a second CCD image camera 10 and a transfer mechanism are all located in the dark box 2, and an entrance 5 and an exit 6 are respectively arranged at both ends of the dark box 2, and the conveying starting point of the first conveyor belt unit 3 and the conveying end of the second conveyor belt unit 4 pass through the entrance 5 and the exit 6 respectively.

[0027] The operation process and working principle of this device are as follows:

[0028] The hairpin-shaped flat copper wires 1 to be inspected are placed horizontally one by one at the conveying starting point of the first conveyor belt unit 3. At this time, the hairpin-shaped flat copper wires 1 conveyed on the first conveying surface 3.1 are recorded as the hairpin-shaped flat copper wires 1.1 facing upward. Then, the first CCD imaging camera 9 captures the hairpin-shaped flat copper wires 1.1 facing upward conveyed on the first conveying surface 3.1. After the first CCD imaging camera 9 obtains the image of the hairpin-shaped flat copper wires 1.1 facing upward conveyed on the first conveying surface 3.1, the image processing system replaces the human eye to judge whether the paint film on the hairpin-shaped flat copper wires 1.1 facing upward has defects such as scratches, wrinkles, and paint leakage.

[0029] When the hairpin-shaped flat copper wire 1.1 facing upward on the first conveying surface 3.1 is conveyed to the conveying end of the first conveyor belt unit 3, the rotation of the output shaft 12 drives the clamping transfer arm 8 to rotate to the upper side of the conveying end of the first conveyor belt unit 3, and at this time, the movable clamping bar 15 and the fixed clamping bar 17 are flush with the first conveying surface 3.1. At this time, the hairpin-shaped flat copper wire 1.1 facing upward at the conveying end of the first conveyor belt unit 3 is between the movable clamping bar 15 and the fixed clamping bar 17. At this time, the linear push rod motor 21 is started, and then the push rod 20 drives the movable clamping bar 15 to move gradually close to the fixed clamping bar 17 until the movable clamping bar 15 and the fixed clamping bar 17 clamp the hairpin-shaped flat copper wire 1.1 facing upward;

[0030] At this time, the output shaft 12 is controlled to rotate 180° clockwise, so that the clamping transfer arm 8 rotates to the upper side of the conveying end of the second conveyor belt unit 4, and the movable clamping strip 15 and the fixed clamping strip 17 are flush with the second conveying surface 3.1. At this time, the clamped hairpin-shaped flat copper wire 1.1 with the front side facing upward will rotate 180° along the output shaft 12 with the clamping transfer arm 8, thereby turning the hairpin-shaped flat copper wire 1.1 with the front side facing upward into the hairpin-shaped flat copper wire 1.2 with the back side facing upward; then the linear push rod motor 21 is started, so that the push rod 20 drives the movable clamping strip 15 to move gradually away from the fixed clamping strip 17, until the movable clamping strip 15 and the fixed clamping strip 17 release and loosen the hairpin-shaped flat copper wire 1.2 with the back side facing upward (such as Figure 6 );

[0031] Then, the hairpin-shaped flat copper wire 1.2 with the back side facing upward is conveyed on the second conveying surface 3.1, and then the second CCD imaging camera 10 photographs the hairpin-shaped flat copper wire 1.2 with the back side facing upward conveyed on the second conveying surface 4.1. After the second CCD imaging camera 10 obtains the image of the hairpin-shaped flat copper wire 1.2 with the back side facing upward conveyed on the second conveying surface 4.1, the image processing system replaces the human eye to judge whether there are defects such as scratches, wrinkles, paint leakage, etc. on the paint film of the hairpin-shaped flat copper wire 1.2 with the back side facing upward.

[0032] The above detection process can be automated without the need for an image system, and the image data captured by the first CCD image camera 10 and the second CCD image camera 10 can also be magnified and displayed on a display screen for manual monitoring.

[0033] The above are only preferred embodiments of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A paint film visual inspection system for a flat copper wire stator hairpin, comprising a first conveyor belt unit (3) and a second conveyor belt unit (4) extending along the same horizontal extension line, wherein a first conveying surface (3.1) on the first conveyor belt unit (3) and a second conveying surface (4.1) on the second conveyor belt unit (4) can both convey the hairpin-shaped flat copper wire (1); a first CCD image camera (9) and a second CCD image camera (10) are respectively mounted above the first conveying surface (3.1) and the second conveying surface (4.1); Features: A transfer mechanism is provided between the first conveyor belt unit (3) and the second conveyor belt unit (4); the transfer mechanism comprises a fixedly mounted horizontal motor (11), the axis of the output shaft (12) of the motor (11) being perpendicular to the extension direction of the first conveyor belt unit (3) / the second conveyor belt unit (4); a clamping transfer arm (8) is fixedly connected to the side of the output shaft (12) of the motor (11); The rotation of the output shaft (12) can drive the clamping and transporting arm (8) to clamp the hairpin-shaped flat copper wire (1) at the end of the conveying on the first conveyor belt unit (3), and transport the clamped hairpin-shaped flat copper wire (1) to the starting point of the conveying on the second conveyor belt unit (4); The clamping and transporting arm (8) comprises a support arm (16) perpendicular to the output shaft (12), the root of the support arm (16) being fixedly connected to the output shaft (12), the end of the support arm (16) being vertically connected to a horizontal fixed clamping strip (17), and a movable clamping strip (15) being arranged in parallel on a side of the fixed clamping strip (17) close to the output shaft (12); and further comprises a disk (13) coaxially fixed to the end of the output shaft (12), a linear push rod motor (21) being fixedly mounted on the disk (13), the end of a push rod (20) of the linear push rod motor (21) being fixedly connected to the movable clamping strip (15), the linear push rod motor (21) driving the movable clamping strip (15) to move gradually closer to or away from the fixed clamping strip (17) through the push rod (20), and the hairpin-shaped flat copper wire (1) can be clamped between the movable clamping strip (15) and the fixed clamping strip (17); The middle of the support arm (16) is vertically connected to a guide arm (22) parallel to the fixed clamping strip (17); a push rod guide hole (23) is provided through the middle of the guide arm (22), and the push rod (20) movably passes through the push rod guide hole (23); two guide column holes (18) are provided through the two sides of the guide arm (22); and two guide columns (19) are vertically connected to the movable clamping strip (15), and the two guide columns (19) movably pass through the two guide column holes (18) respectively; It also comprises a dark box (2), wherein a light source is arranged in the dark box (2), the first conveyor belt unit (3) and the second conveyor belt unit (4), the first CCD image camera (9), the second CCD image camera (10) and the transfer mechanism are all located in the dark box (2), an entrance (5) and an exit (6) are respectively arranged at two ends of the dark box (2), and the conveying starting point of the first conveyor belt unit (3) and the conveying end of the second conveyor belt unit (4) pass through the entrance (5) and the exit (6) respectively; The hairpin-shaped flat copper wires (1) to be inspected are placed horizontally one by one at the conveying starting point of the first conveyor belt unit (3), and the hairpin-shaped flat copper wires (1) conveyed on the first conveying surface (3.1) are recorded as the hairpin-shaped flat copper wires (1.1) with their front sides facing upwards, and then the first CCD imaging camera (9) captures the hairpin-shaped flat copper wires (1.1) conveyed on the first conveying surface (3.1) with their front sides facing upwards, and then after the first CCD imaging camera (9) obtains the image of the hairpin-shaped flat copper wires (1.1) conveyed on the first conveying surface (3.1) with their front sides facing upwards, the image processing system determines whether there are defects in the paint film on the hairpin-shaped flat copper wires (1.1) with their front sides facing upwards; When the hairpin-shaped flat copper wire (1.1) facing upward and being transported on the first transport surface (3.1) is transported to the transport end of the first conveyor belt unit (3), the rotation of the output shaft (12) drives the clamping transfer arm (8) to rotate to the upper side of the transport end of the first conveyor belt unit (3), and at this time, the movable clamping strip (15) and the fixed clamping strip (17) are flush with the first transport surface (3.1). At this time, the hairpin-shaped flat copper wire (1.1) facing upward and being at the transport end of the first conveyor belt unit (3) is located between the movable clamping strip (15) and the fixed clamping strip (17). At this time, the linear push rod motor (21) is started, so that the push rod (20) drives the movable clamping strip (15) to move gradually closer to the fixed clamping strip (17) until the movable clamping strip (15) and the fixed clamping strip (17) clamp the hairpin-shaped flat copper wire (1.1) facing upward; At this time, the output shaft (12) is controlled to rotate 180° clockwise, so that the clamping transfer arm (8) rotates to the upper side of the conveying end of the second conveyor belt unit (4), and the movable clamping strip (15) and the fixed clamping strip (17) are flush with the second conveying surface (3.1). At this time, the clamped hairpin-shaped flat copper wire (1.1) facing upward will rotate 180° along the output shaft (12) along the clamping transfer arm (8), thereby changing the hairpin-shaped flat copper wire (1.1) facing upward to the hairpin-shaped flat copper wire (1.2) facing upward. Then, the linear push rod motor (21) is started, so that the push rod (20) drives the movable clamping strip (15) to move gradually away from the fixed clamping strip (17), until the movable clamping strip (15) and the fixed clamping strip (17) are released to release the hairpin-shaped flat copper wire facing upward. The hairpin-shaped flat copper wire (1.2) with its back side facing upward is then conveyed on the second conveying surface (3.1), and then the second CCD image camera (10) captures the hairpin-shaped flat copper wire (1.2) conveyed on the second conveying surface (4.1) with its back side facing upward. After the second CCD image camera (10) obtains an image of the hairpin-shaped flat copper wire (1.2) conveyed on the second conveying surface (4.1) with its back side facing upward, the image processing system determines whether there are any defects in the paint film on the hairpin-shaped flat copper wire (1.2) with its back side facing upward.

2. The paint film visual inspection system for the flat copper wire stator hairpin according to claim 1, Features: The motor (11) is a stepping motor.

3. The paint film visual inspection system for the flat copper wire stator hairpin according to claim 2, Features: The height at which the axis of the output shaft (12) is located is flush with the height at which the first conveying surface (3.1) / the second conveying surface (4.1) is located.

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