Automated assembly tooling for ceramic ball commutators

Abstract

The present invention belongs to the technical field of commutator assembly and processing, and specifically relates to automated assembly tooling for ceramic bead commutators. It comprises an upper shell, an inner shell and an outer shell; the upper shell is fixedly connected to the inner shell, and is characterized in that: an ejection mechanism is provided inside the inner shell; the ejection mechanism comprises an iron rod; feed rods are evenly distributed on the outer ring of the iron rod; the top of the feed rod is concave inward in an arc shape and fits with the ceramic beads; an anti-slip layer is provided on the top of each feed rod that contacts the ceramic beads; the overall height of each feed rod is higher than the iron rod. The present invention has the characteristics of being able to position the commutator, load the ceramic beads, press-fit, and flip the commutator, and the entire process does not require manual operation, has a high degree of automation, and effectively guarantees the overall quality of the commutator while improving production efficiency.

Description

Technical Field

[0001] The invention belongs to the technical field of commutator assembly and processing, and particularly relates to an automated assembly tool for a ceramic bead commutator. Background Art

[0002] The commutator is a crucial component in the armature of DC and AC commutator motors. It reverses the direction of rotation during motor rotation, ensuring long-term, sustained motor rotation. As an essential component in industry, transportation, national defense, and everyday life, motors are used in nearly every sector of the national economy. As a core component of motors, the commutator has seen increasing demand alongside the industry's growth.

[0003] Ceramic bead commutator is a commutator with better performance and has been gradually promoted and used in China. However, in the processing of ceramic bead commutator, most of the time, the ceramic beads are placed between the copper sheets of the commutator by manual operation. After placement, the ends of the copper sheets need to be struck again to bend the copper sheets to fix the ceramic beads. The above operation will have the following problems: 1. After the ceramic beads are placed, the spacing and gaps between the ceramic beads and the two sides of the copper sheets are uneven, and they cannot be accurately positioned; 2. When the copper sheets are struck, they will be misaligned or the ceramic beads in front of the copper sheets will fall off, increasing the difficulty of assembly; 3. The production and assembly process is very inefficient, and the quality of the commutator cannot be guaranteed, which is not conducive to production and use.

[0004] Therefore, it is very important to design an automated assembly tool for ceramic bead commutators that can position the commutator, load ceramic beads, press and flip the commutator without manual operation throughout the process, with a high degree of automation, which can effectively ensure the overall quality of the commutator while improving production efficiency.

[0005] For example, the Chinese patent document with application number CN201920752962.0 describes a commutator assembly machine, which is provided with a divider and a turntable on the assembly table. Multiple tooling is evenly placed on the turntable along the circumference. The outer side of the turntable is provided with a pressure ring feeding structure, multiple pole piece feeding mechanisms, a skeleton feeding mechanism, a skeleton pressing mechanism and a commutator unloading mechanism in sequence from front to back along the circumference. A rotating mechanism is provided under the turntable for driving the upper tooling to rotate relative to the turntable when the turntable stops. The pressure ring is placed into the tooling through the pressure ring feeding structure. The turntable rotates to transfer the pressure ring to the first pole piece feeding mechanism to install the first pole piece, and then to the next pole piece feeding mechanism. The position of the pressure ring without a pole piece is driven by the rotating mechanism to the assembly position and then the pole piece is installed. After all the pole pieces are installed in sequence, the skeleton is installed by the skeleton feeding mechanism and the skeleton pressing mechanism. The commutator unloading mechanism removes the commutator from the tooling. Although the assembly efficiency is high, its disadvantage is that it is not suitable for the assembly of ceramic bead commutators. Summary of the Invention

[0006] The present invention aims to overcome the problems in the prior art of existing commutator assembly tooling, such as poor positioning accuracy, great assembly difficulty, and unguaranteed product quality. The present invention provides an automated assembly tooling for ceramic bead commutators that can position the commutator, load ceramic beads, press-fit, and flip the commutator without manual operation throughout the entire process. The tooling has a high degree of automation, improves production efficiency, and effectively ensures the overall quality of the commutator.

[0007] In order to achieve the above-mentioned object of the invention, the present invention adopts the following technical solutions:

[0008] An automated assembly tool for a ceramic bead commutator includes an upper shell, an inner shell, and an outer shell; the upper shell is fixedly connected to the inner shell, and an ejection mechanism is provided inside the inner shell; the ejection mechanism includes an iron rod; feed rods are evenly distributed on the outer ring of the iron rod; the top of the feed rod is concave inward in an arc shape and fits with the ceramic beads; an anti-slip layer is provided on the top of each feed rod where it contacts the ceramic beads; and the overall height of each feed rod is higher than the iron rod.

[0009] The device of the present invention can automatically load the ceramic beads in the commutator. While loading, it can also knock the copper sheet so that the copper sheet is bent toward the side of the ceramic bead to tighten the ceramic bead, thereby reducing the operator's multiple operations on a single commutator and greatly improving production efficiency. Specifically, the commutator without ceramic beads is placed between the air claws and one end of the commutator is placed against the top plate and the limiting mechanism on the lower surface of the top plate is inserted into the gap between the adjacent copper sheets for preliminary positioning. After the positioning is completed, the pneumatic telescopic column drives the ejection mechanism to move downward to the discharge port of the material channel, so that the ceramic beads roll into the arc-shaped groove on the top of the feed rod. The pneumatic telescopic column rises rapidly to fill the ceramic beads between the adjacent copper sheets of the commutator. At the same time, the iron rod also knocks and bends the commutator copper sheet to further fix the ceramic beads. The above design can complete the feeding of ceramic beads and the bending of copper sheets at the same time, simplifying the production process and ensuring the overall quality of the commutator. The height difference between the feed rod and the iron rod is set based on the actual situation of the commutator. The copper sheet is bent at the moment the ceramic beads are fed into the commutator. After bending, the feed rod and the bent part will not interfere with each other.

[0010] Preferably, air grippers are symmetrically provided on both sides of the upper shell; a pressure sensor is provided on the air grippers; one end of the air grippers is connected to a driver; a telescopic rod is provided above the driver; the driver and the telescopic rod are both installed on the side walls of the upper shell; and a top plate is connected to the top of the upper shell.

[0011] The air grippers designed on both sides of the upper shell are used to grab and fix the commutator to prevent the commutator from being displaced during operation. The sensor on the air gripper is electrically connected to the limit mechanism. After the air gripper clamps the commutator, the sensor senses the force and transmits it to the limit mechanism. The positioning pin in the limit mechanism will retract. In order to facilitate the flipping of the commutator and the convenience of installing ceramic beads on the other side of the commutator, the telescopic rod will drive the top plate and the limit mechanism to rise to the appropriate position to facilitate the flipping of the commutator. After the commutator flips, the telescopic rod will reset.

[0012] Preferably, the driver is a drive motor; the output end of the drive motor is connected to the air gripper. The driver is used to control the flipping of the air gripper. Because ceramic beads need to be embedded on both sides of the commutator, after one side is embedded and bent, the flipping of the commutator is driven by the flipping of the air gripper.

[0013] Preferably, a limiting mechanism is installed on the lower surface of the top plate; the limiting mechanism includes a cylinder, the movable end of the cylinder is connected to a fixed disk; the lower surface of the fixed disk is plugged with positioning pins; the positioning pins are arranged in a ring, and the diameter of the positioning pins is smaller than the gap between the commutator copper sheets. The limiting mechanism is used to position the commutator so that the spacing between the copper sheets in the inserted commutator corresponds to the feed rod in the lower ejection mechanism, facilitating the loading of ceramic beads. Specifically, before placing the commutator into the air gripper, the operator needs to align the gap between the commutator copper sheets with the positioning pins and snap them into position. After positioning is completed, the air gripper clamps the commutator. When the sensor on the air gripper senses that the commutator is clamped, it sends a signal to the limiting mechanism, and the positioning pins in the limiting mechanism retract with the cylinder, facilitating the flipping of the commutator.

[0014] Preferably, the outer side of the outer shell is provided with a number of feed boxes equal to the number of feeding rods; a vibrator is provided inside the feed box; a material channel is provided on the side wall of the outer shell; one side of the material channel is connected to the bottom of the feed box, and the other side is connected to the inner shell.

[0015] The inner shell of the feed box stores ceramic beads and is automatically loaded through a material channel. The size of the material channel can only pass one ceramic bead. At the same time, a vibrator is set to prevent blockage and play an auxiliary role in feeding.

[0016] Preferably, the bottom of the material channel is inclined; the connection between the inner shell and the material channel is inclined. The above design is for the convenience of feeding.

[0017] Preferably, at least three sets of pneumatic telescopic columns are provided below the ejection mechanism. These columns are used to assist the ejection mechanism and are provided in three sets to ensure stability during operation. During feeding, the columns retract, driving the ejection mechanism downward so that the top of the ejector rod is flush with the bottom of the material channel, enabling automatic feeding.

[0018] Preferably, the distance between the feed rod of the ejection mechanism and the inner shell is smaller than the radius of the ceramic beads. The distance between the feed rod and the inner shell will not cause the ceramic beads to fall to the bottom of the inner shell, nor will the feed rod scrape the side wall of the inner shell.

[0019] Compared with the prior art, the present invention has the following beneficial effects: (1) the device of the present invention performs preliminary positioning of the commutator through a limiting mechanism, and after positioning is completed, it is further fixed by an air claw, and the ejection mechanism loads the ceramic beads and bends the commutator copper sheet, and fixes the loaded ceramic beads. The entire process has a high degree of automation, simplifies the production process, and effectively maintains the overall quality of the commutator while improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a schematic diagram of the internal structure of an automated assembly tool for a ceramic bead commutator according to the present invention;

[0021] Figure 2 A schematic structural diagram of the ejection mechanism of the present invention;

[0022] Figure 3 It is a structural schematic diagram of the limiting mechanism in the present invention.

[0023] In the figure: upper shell 1, limit mechanism 2, cylinder 21, fixed plate 22, positioning pin 23, ejector plate 3, driver 4, air claw 5, pressure sensor 6, feed box 7, ejection mechanism 8, iron rod 81, feed rod 82, anti-slip layer 83, material channel 9, inner shell 10, outer shell 11, pneumatic telescopic column 12, ceramic beads 13, telescopic rod 14. DETAILED DESCRIPTION

[0024] To more clearly illustrate the embodiments of the present invention, specific embodiments of the present invention will be described below with reference to the accompanying drawings. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings and other embodiments can be obtained based on these drawings without inventive efforts.

[0025] Example:

[0026] like Figures 1 to 3 As shown, the present invention provides an automated assembly tool for a ceramic bead commutator, comprising an upper shell 1, an inner shell 10 and an outer shell 11. The upper shell and the inner shell are connected at a connection point via screws. An ejection mechanism 8 is provided inside the inner shell. The ejection mechanism comprises an iron rod 81. Feed rods 82 are evenly distributed around the outer ring of the iron rod. The top of the feed rod is concave inward in an arc shape and fits with the ceramic beads 13. An anti-slip layer 83 is provided at the contact portion between the top of the feed rod and the ceramic beads. The overall height of the feed rod is higher than that of the iron rod.

[0027] The device of the present invention can automatically load the ceramic beads in the commutator. While loading, it can also knock the copper sheet so that the copper sheet is bent toward the side of the ceramic bead to tighten the ceramic bead, thereby reducing the operator's multiple operations on a single commutator and greatly improving production efficiency. Specifically, the commutator without ceramic beads is placed between the air claws and one end of the commutator is placed against the top plate and the limiting mechanism on the lower surface of the top plate is inserted into the gap between the adjacent copper sheets for preliminary positioning. After the positioning is completed, the pneumatic telescopic column drives the ejection mechanism to move downward to the discharge port of the material channel, so that the ceramic beads roll into the arc-shaped groove on the top of the feeding rod. The pneumatic telescopic column rises rapidly to fill the ceramic beads between the adjacent copper sheets of the commutator. At the same time, the iron rod also knocks and bends the copper sheets to further fix the ceramic beads. The above design can complete the feeding of ceramic beads and the bending of copper sheets at the same time, simplifies the production process, and ensures the overall quality of the commutator. The height difference between the feeding rod and the iron rod is set based on the actual situation of the commutator, and the copper sheet is bent at the moment the ceramic beads are fed into the commutator.

[0028] Air grippers 5 are symmetrically positioned on either side of the upper housing, each equipped with a pressure sensor 6. One end of the gripper is connected to a driver 4, and a telescopic rod 14 is positioned above the driver. Both the driver and the telescopic rod are mounted on the side walls of the upper housing, and a top plate 3 is connected to the top of the upper housing. The air grippers on either side of the upper housing are used to grasp and secure the commutator, preventing displacement during operation. The sensors on the grippers are electrically connected to a limiter mechanism. After the grippers clamp the commutator, the force sensed by the sensors is transmitted to the limiter mechanism, causing the positioning pins within the limiter mechanism to retract. To facilitate flipping the commutator and installing ceramic beads on the other side, the telescopic rods raise the top plate and limiter mechanism to the appropriate position during flipping. Once the commutator is flipped, the telescopic rods reset.

[0029] The driver is a motor whose output is connected to the gripper. The driver is used to control the gripper's flipping. Because ceramic beads need to be embedded on both sides of the commutator, the commutator flips when the gripper flips after embedding the beads on one side.

[0030] The lower surface of the top plate is equipped with a limit mechanism 2, which includes a cylinder 21. The movable end of the cylinder is connected to a fixed disk 22. The lower surface of the fixed disk is plugged with positioning pins 23. The positioning pins are arranged in a ring and have a diameter smaller than the gap between the commutator copper sheets. The limit mechanism is used to position the commutator so that the spacing between the copper sheets in the inserted commutator corresponds to the feed rod in the ejection mechanism below, facilitating the loading of ceramic beads. Before placing the commutator into the air gripper, the operator needs to align the gap between the commutator copper sheets with the positioning pins and snap them into position. After positioning is completed, the air gripper clamps the commutator. When the sensor on the air gripper senses that the commutator is clamped, it sends a signal to the limit mechanism. The positioning pins in the limit mechanism will retract with the cylinder, facilitating the flipping of the commutator.

[0031] The outer shell is equipped with a feed box 7, the same number as the feed rods 82, and a vibrator inside the feed box. The side wall of the outer shell is opened with a material channel 9, which is connected to the bottom of the feed box on one side and to the inner shell on the other side. The ceramic beads stored in the inner shell of the feed box are automatically loaded through the material channel. The material channel is large enough to pass only one ceramic bead, and a vibrator is installed to prevent clogging and play an auxiliary role in feeding.

[0032] The bottom of the material channel is tilted, and the connection between the inner shell and the material channel is also tilted. The above design is for the convenience of feeding.

[0033] A pneumatic telescopic column 13 is provided below the ejection mechanism, and there are at least three sets of pneumatic telescopic columns. The pneumatic telescopic columns are used to boost the ejection mechanism, and are designed in three sets to ensure the stability of the device during operation.

[0034] The distance between the ejector rod and the inner shell is smaller than the radius of the ceramic bead. The distance between the ejector rod and the inner shell must not cause the ceramic bead to fall to the bottom of the inner shell, nor will the ejector rod scrape the side wall of the inner shell.

[0035] The specific working process of the present invention is as follows:

[0036] Place the commutator without ceramic beads between the pneumatic grippers, with one end of the commutator against the top plate and the limit mechanism on the bottom surface of the top plate inserted into the gap between the adjacent copper sheets of the commutator for preliminary positioning. After positioning is completed, the pneumatic grippers clamp the commutator, and the pressure sensor senses the force and transmits it to the limit mechanism. The positioning pin in the limit mechanism automatically retracts, and the pneumatic telescopic column drives the ejection mechanism downward to the discharge port of the material channel, causing the ceramic beads to roll into the arc-shaped groove at the top of the feed rod. The pneumatic telescopic column rises rapidly to embed the ceramic beads between the adjacent copper sheets of the commutator. At the same time, the iron rod also knocks and bends the copper sheets, further fixing the ceramic beads. After the above steps are completed, the telescopic rod of the upper shell will drive the top plate and limit mechanism to rise to the appropriate position. The driver will drive the pneumatic grippers to flip 180°, and the ceramic bead loading and bending steps will be repeated.

[0037] The device of the present invention performs preliminary positioning of the commutator through a limiting mechanism, and after positioning is completed, it is further fixed by an air claw. The ejection mechanism loads ceramic beads and bends the commutator copper sheet, and fixes the loaded ceramic beads. The entire process has a high degree of automation, simplifies the production process, and effectively maintains the overall quality of the commutator while improving production efficiency.

[0038] The above description is only a detailed description of the preferred embodiments and principles of the present invention. For ordinary technicians in this field, based on the ideas provided by the present invention, there may be changes in the specific implementation methods, and these changes should also be considered as the scope of protection of the present invention.

Claims

1. An automated assembly tool for a ceramic bead commutator, comprising an upper housing, an inner housing, and an outer housing; the upper housing is fixedly connected to the inner housing, and is characterized in that: The inner shell is provided with an ejection mechanism; the ejection mechanism comprises an iron rod; feed rods are evenly distributed on the outer ring of the iron rod; the top of the feed rod is concave inward in an arc shape and fits with the ceramic beads; the top of each feed rod is provided with an anti-slip layer at the part that contacts the ceramic beads; the overall height of each feed rod is higher than the iron rod; Air grippers are symmetrically provided on both sides of the upper housing; a pressure sensor is provided on the air grippers; one end of the air grippers is connected to a driver; a telescopic rod is provided above the driver; the driver and the telescopic rod are both mounted on the side walls of the upper housing; a top plate is connected to the top of the upper housing; The driver adopts a driving motor; the output end of the driving motor is connected to the air gripper; The lower surface of the top plate is provided with a limiting mechanism; the limiting mechanism comprises a cylinder, the movable end of the cylinder is connected to a fixed disk; the lower surface of the fixed disk is plugged with positioning pins; the positioning pins are arranged in a ring, and the diameter of the positioning pins is smaller than the gap between the commutator copper sheets; The commutator without ceramic beads is placed between the air claws, and one end of the commutator is placed against the top plate and the limit mechanism on the lower surface of the top plate is inserted into the gap between the adjacent copper sheets of the commutator for preliminary positioning. After the positioning is completed, the air claws clamp the commutator, and the pressure sensor senses the force and transmits it to the limit mechanism. The positioning pin in the limit mechanism automatically retracts, and the pneumatic telescopic column drives the ejection mechanism downward to the discharge port of the material channel, so that the ceramic beads roll into the arc-shaped groove at the top of the feed rod. The pneumatic telescopic column rises rapidly to embed the ceramic beads between the adjacent copper sheets of the commutator. At the same time, the iron rod also knocks and bends the copper sheet to further fix the ceramic beads. After the fixation is completed, the telescopic rod of the upper shell drives the top plate and the limit mechanism to rise to the appropriate position, and the driver drives the air gripper to turn 180 degrees, and the ceramic bead loading and bending steps are carried out again.

2. The automated assembly tool for ceramic bead commutator according to claim 1, characterized in that: The outer side of the outer shell is provided with a feed box with the same number as the feed rods; a vibrator is provided inside the feed box; the side wall of the outer shell is provided with a material channel; one side of the material channel is connected to the bottom of the feed box, and the other side is connected to the inner shell.

3. The automated assembly tool for ceramic bead commutator according to claim 2, characterized in that: The bottom of the material channel is inclined; the connection point between the inner shell and the material channel is inclined.

4. The automated assembly tool for ceramic bead commutator according to claim 1, characterized in that: At least three groups of pneumatic telescopic columns are provided below the ejection mechanism.

5. The automated assembly tool for ceramic bead commutator according to claim 1, characterized in that: The distance between the feeding rod of the ejection mechanism and the inner shell is smaller than the radius of the ceramic bead.

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