Stator forming coil expansion test control system and method

Abstract

The present invention discloses a stator forming coil expansion test control system and method, which includes at least three test channels: a stretching-bending channel, a torsion-bending channel and a stretching-twist-bending channel, and mutually independent stretching heads, torsion heads and bending heads as loading heads, wherein the stretching head or torsion head or bending head is combined; the upper computer stores or can access software programs; the software program is set to perform different parameter settings according to different test conditions, and controls the motor controller according to the parameter settings and conditions, and collects data for test analysis; the test conditions at least include: coordinated stretching-bending test conditions, coordinated torsion-bending test conditions, coordinated torsion-stretching test conditions, and coordinated torsion-stretching-bending test conditions. In order to realize frequent and efficient batch implementation of coil expansion experiments, clarify the influence of different test parameters such as load, displacement, deformation and different processing sequences on the expansion effect of stator forming coils.

Description

Technical Field

[0001] The invention belongs to the technical field of permanent magnet traction motor stator coil forming, and in particular relates to a stator forming coil expansion test device system and a control method. Background Art

[0002] As a key component of permanent magnet traction motors, the complexity of the stator forming coil expansion process directly affects the accuracy of each coil size, which in turn affects the effectiveness of subsequent process flows. The manufacturing of stator forming coils requires complex coil expansion processes and quality control. Figure 1 As shown, the shuttle coil 500 needs to be formed into a three-dimensional geometric diamond coil, including the main parts of the straight edge 1, the transition edge 2, the transition fillet 3, and the nose end 4. The transition edge 2, the transition fillet 3, and the nose end 4 have curved and twisted features, and there is a stretched straight edge 1 in the middle. The expansion process directly affects the dimensional accuracy of the coil and the effective implementation of the subsequent assembly process.

[0003] The manufacturing expansion of stator forming coils still relies on the empirical parameters of existing forming equipment. This traditional method has obvious defects such as insufficient geometric accuracy of manufactured products, low consistency, and low efficiency of process parameter adjustment. Since the expansion process is limited by experience, the pass rate of finished product dimensional accuracy is not high, resulting in many finished products requiring secondary repairs to meet the use standards. Existing expansion equipment fails to provide comprehensive theoretical guidance for the expansion process of stator forming coils, limiting the improvement of production efficiency and pass rate. Therefore, it is necessary to design a variety of tests to clarify the expansion mechanism, optimize the coil expansion process, and improve production efficiency and dimensional accuracy.

[0004] However, the expansion machine can only achieve the tensile displacement and angular deformation of the coil by driving the motor using a position loop control. There is no way to consider the real-time impact of tensile load, bending load and deformation on the coil in the processing project. The true value of load, displacement and deformation cannot be mapped in the coil processing, and the error transmission, error accumulation and compensation error of mechanical equipment cannot be considered. The processing error is large, it is difficult to ensure the manufacturing accuracy of the coil, and it is impossible to consider the impact of different processing sequences and processes on the coil.

[0005] In order to meet the universal requirements, the current traditional mechanical test bench has a fixed size for the test specimens. The various ways of specimen size are usually related to the stroke of the action end and the fixed design size, making it difficult to test the sizes of multiple materials of the same type. In particular, the stator forming coil includes a straight part and a nose part, which is a complex irregular torsion and stretching structure, and it is impossible to perform a variety of complex expansion tests on the traditional mechanical test bench.

[0006] Moreover, it is difficult to achieve integrated control of the above two existing systems, and it is impossible to test the simulation of multiple working conditions at the same time, such as torsional bending conditions. It is also impossible to adapt to the needs of frequent adjustment of test parameters such as load, displacement, and deformation, and it is difficult to meet the current batch testing and design assistance tasks. Summary of the invention

[0007] In order to solve the above problems, it is urgently necessary to design a stator forming coil expansion test control system and method to realize frequent and efficient batch implementation of coil expansion experiments, and to explore the influence of different load, displacement, deformation and other test parameters and different processing sequences on the stator forming coil expansion mechanism, so as to improve the actual coil expansion production efficiency and improve the qualified rate of finished products.

[0008] The purpose of this application is to provide a solution to the above technical problems. The present invention adopts the following technical solutions:

[0009] A stator forming coil expansion test control system, characterized by comprising:

[0010] At least three test channels are included: a twisting-bending channel for forming the coil nose end and a stretching-bending channel for three-point or four-point pressing to form a transition edge and / or a straight edge; the twisting-bending channel includes a mutually independent twisting head and a bending head as loading heads, and the bending head is configured to be combined with an independent stretching head as a loading head of the stretching-bending channel;

[0011] The three loading heads are configured to form a torsion-bending-stretching channel by combining them when needed. Each motor can be controlled independently. In the combined test of the three working conditions, a stretching-torsion test can be formed first.

[0012] The sensors include a torque angle sensor arranged on the twisting head, a tension sensor arranged on the stretching head, a pressure sensor arranged on the bending head, and a displacement sensor arranged in the stretching direction and the bending expansion direction;

[0013] A central controller is connected to each sensor and each servo motor controller of the twisting head, the stretching head and the bending head, and is in communication connection with a host computer, and the host computer stores or has access to a software program;

[0014] The software program is configured to perform different parameter settings according to different test conditions, and to control the motor controller according to the parameter settings and the conditions, and to collect sensor and motor data for test analysis;

[0015] The test conditions include at least: tensile test conditions, torsion test conditions, bending test conditions, coordinated tensile-bending test conditions, coordinated torsion-bending test conditions, coordinated torsion-tensile test conditions, and coordinated torsion-tensile-bending test conditions.

[0016] In the above technical solution, the twisting head and the stretching head are provided with accommodating grooves capable of accommodating the coil nose end and the straight portion, and the bending head is provided with at least one convex top suitable for contacting the test piece in a vertical direction to form a pressure point.

[0017] In the above technical solution, each test condition is set to associate the corresponding sensor according to the measured physical quantity, and simultaneously associate the corresponding loading head and the servo motor as the bending motor, the stretching motor and the torsion motor to achieve closed-loop control for the set physical quantity.

[0018] In the above technical scheme, in the tensile test condition, the coordinated tensile-bending test condition, the coordinated torsion-tensile test condition, and the coordinated torsion-tensile-bending test condition, the tensile motor is arranged to operate according to the position control closed loop to achieve the target length.

[0019] In the above technical scheme, in the bending test conditions, coordinated stretching-bending test conditions, coordinated torsion-bending test conditions and coordinated torsion-stretching-bending test conditions, a bending motor is provided to achieve the target span extension according to a position control closed loop.

[0020] In the above technical solution, the above target span extension is set to be pressed down or pulled up in a direction perpendicular to a line connecting the loading heads at both horizontal ends of the specimen.

[0021] In the above technical solution, the bending motor realizes the target span extension in the vertical or horizontal direction perpendicular to the line connecting the loading heads at the two horizontal ends of the specimen.

[0022] In the above technical scheme, in the torsion test condition, the coordinated torsion-bending test condition, the coordinated torsion-tensile test condition, and the coordinated torsion-tensile-bending test condition, a torsion motor is provided to achieve the target angle torsion according to the torque control closed loop.

[0023] In the above technical scheme, during the collaborative combination test conditions, after the servo motor reaches the set displacement or angle value according to the set time, the servo motor stops running and maintains the current displacement or angle value until the set loading time is reached, and the value in the sensor is read; at the same time or in a manner that changes with the order of the servo motor's actions, the chuck connected to another servo motor is loaded to reach the set displacement or angle, the motor stops running and maintains the current position until the set loading time is reached, and then the motor returns to the initial position, and the sensor value after the specimen is deformed is read; finally, the specimen is directly unloaded from the chuck, and the deformation amount of the specimen after different test sequences is measured.

[0024] At the same time, the present invention protects a stator forming coil expansion test control method, which is characterized by using the above-mentioned stator forming coil expansion test control system.

[0025] At the same time, other working conditions of the system and method of the present invention are listed as follows:

[0026] (1) Torsion test conditions:

[0027] The torsion motor reaches the set torque value according to the time set on the host computer, stops running and maintains the current torque value until the set loading time is reached, and reads the angle value in the torque angle sensor; then the tester loosens the torsion chuck and directly unloads the specimen, uses the measuring instrument to measure the deformation angle of the specimen after torsion unloading and records the data.

[0028] (2) Tensile test conditions

[0029] The stretching motor reaches the set tension value according to the time set on the host computer, and the stretching motor stops running and maintains the current position until the set loading time is reached, and the value in the grating ruler displacement sensor is read; then the test personnel loosen the stretching chuck and directly unload the specimen. The length of the specimen after unloading is measured by the measuring instrument, and the expansion data is recorded.

[0030] (3) Bending test conditions

[0031] The bending motor loads and drives the electric cylinder or other linear motion mechanism to make the specimen coil contacted by the bending head reach the set bending deflection. The bending motor stops running and maintains the current position until the set loading time is reached. Then the bending motor returns to the initial position, reads the laser displacement sensor value, and obtains the expansion test data.

[0032] (4) Coordinated tensile-bending test conditions

[0033] After the stretching motor reaches the tension value according to the set time, the stretching motor stops running and maintains the current position until the set loading time is reached, and the value in the grating ruler displacement sensor is read; at the same time, or the order with the stretching motor can be adjusted, the bending motor loads and drives the electric cylinder or other linear motion mechanism to reach the set test bending deflection, and the bending motor stops running and maintains the current position until the set loading time is reached; then the bending motor returns to the initial position and reads the value of the laser displacement sensor under the specimen; finally, the tester releases the stretching head and directly unloads the specimen. The deformation data of the specimen after unloading of the stretching expansion is measured by the measuring instrument and the data is recorded.

[0034] (5) Synergistic torsion-bending test conditions

[0035] After the torsion motor reaches the set torque value at the set time, the torsion motor stops running and maintains the current torque value until the set loading time is reached, and the value in the torque angle sensor is read; at the same time, the second servo electric cylinder reaches the bending deflection, the second servo electric cylinder stops running and maintains the current position until the set loading time is reached; then the second servo electric cylinder returns to the initial position, and reads the value of the laser displacement sensor under the specimen; then the tester loosens the torsion chuck and directly unloads the specimen, and uses a measuring instrument to measure the deformation data of the specimen after torsion unloading and records the data.

[0036] (6) Coordinated tension-torsion test conditions

[0037] After the tensile motor reaches the tension value according to the set time, the torsion motor stops running and maintains the current position until the set loading time is reached, and the value in the grating scale displacement sensor is read; at the same time, after the torsion motor reaches the bending deflection, the torsion motor stops running and maintains the current position until the set loading time is reached; then the torsion motor returns to the initial position and reads the value of the laser displacement sensor under the specimen; then the tester loosens the tensile chuck and directly unloads the specimen. The deformation data after tensile unloading is measured by the measuring instrument and the data is recorded.

[0038] (7) Synergistic torsion-tension-bending test conditions

[0039] The torsion motor reaches the set torque value according to the time set on the host computer, the torsion motor stops running and maintains the current torque value until the set loading time is reached, and the angle value in the torque angle sensor is read; at the same time, or the sequence can be adjusted, after the stretching motor reaches the tension value according to the set time, the stretching motor stops running and maintains the current position until the set loading time is reached, and the value in the grating scale displacement sensor is read; at the same time, or the sequence with the stretching motor can be adjusted, after the bending motor loads and drives the electric cylinder or other linear motion mechanism to reach the set test bending deflection, the bending motor stops running and maintains the current position until the set loading time is reached; then the bending motor returns to the initial position and reads the value of the laser displacement sensor under the specimen.

[0040] In the above-mentioned collaborative mode, stretching, torsion and bending can be carried out simultaneously or in turn to carry out different degrees of expansion tests. After each test, the influence of different degrees of expansion on the coil is examined according to the current load and coil deformation, the test process and parameters are optimized, and the optimal design parameters are achieved.

[0041] In the above process, the central controller sends the test parameters and test mode from the host computer to the motor controller. The motor controller controls the servo motor to move according to the established speed, position and torque, and collects the data of the servo motor and sensor according to the preset collection cycle. The collected data is uniformly uploaded to the host computer according to the preset sending cycle for test result processing.

[0042] At the same time, during the test process, the test system is diagnosed and processed for abnormalities based on the data fed back to the central controller by the servo motor, torque angle sensor, tension sensor and laser displacement sensor, and the time of the abnormal diagnosis result is recorded. Finally, all the data is sent to the host computer.

[0043] The host computer software of the host computer can select different test conditions for parameter setting. The host computer sends the parameters to the central controller, which converts the received parameters and sends them to the servo motor controller to control the speed, position and torque of the servo motor. The process includes:

[0044] S1, using the upper computer software to select the test conditions to be performed, the selectable test conditions include tensile test conditions, torsion test conditions, bending test conditions, tensile-bending test conditions, torsion-bending test conditions, and the test conditions to be set include: tension value, time to reach the target tension value, loading time under the target tension value, torque value, time to reach the target torque value, loading time under the target torque value, bending deflection, and loading time under the target bending deflection;

[0045] S2, the host computer and the central controller communicate via Ethernet for data transmission. The central controller program has a reserved address for receiving the parameters set in step S1;

[0046] S3, the data received in step S2 is calculated inside the central controller, the decimal number is converted into a hexadecimal number or a value with a time dimension, and then sent to the servo motor controller.

[0047] Compared with the prior art, the beneficial effects of this application are:

[0048] 1. The present invention integrates the three single working condition test modules of stretching, torsion and bending and the composite working condition test modules of stretching-bending, torsion-bending and stretching-torsion, which have good interchangeability and convenience of module combination. The control system has a simple structure, higher precision through closed-loop control, more accurate results, more collected parameters, and is conducive to multi-model analysis.

[0049] 2. The present invention can set experimental parameters through the host computer, plan different tests, realize multi-channel data acquisition of six physical parameters such as tension, tensile displacement, torque, angle, bending force, bending disturbance, etc., and acquire and display data in the test process in real time, which is easy to operate; it overcomes the problem that the general mechanical platform cannot be applied to the special shape of the coil and the test requirements cannot be met. The whole detection process has a high degree of automation, which meets the test requirements of the stator forming coil under various working conditions and promotes the development of permanent magnet traction motor manufacturing technology for rail transit.

[0050] 3. The present invention is more suitable for operators to obtain test structures efficiently and accurately in a short time through the input end and the display end, and to conduct large-scale tests efficiently, quickly and frequently, which can effectively reduce the test cost, quickly explore the expansion mechanism of a certain expansion process, and reduce the time cost. It avoids the huge cost of the direct processing test effect of the expansion machine and the defects of unstable and inaccurate test results afterwards.

[0051] 4. Compared with the prior art, the present invention can realize the coordinated control of torsion and bending, and can also realize the coordinated control of torsion and bending and stretching, and can quickly output and collect variables according to the test sequence and given variable control conditions. It is more suitable for key analysis of the nose end and transition part and different stages of the realization process of the coil comprehensive structure.

[0052] 5. The control system host computer adopts graphical interface and visual operation to simplify the operation steps, monitor the system status in real time, and extract and process the data of various physical quantities flexibly and quickly. It provides multi-dimensional data display of curve graphs and reports of displacement, load, time, deformation and other data. Through the operation monitoring and parameter setting data management module, the system operation status can be intuitively understood, which is convenient for timely adjustment of control parameters. The integrated fault diagnosis function can automatically detect problems and give solutions to help users quickly troubleshoot and improve the stability and reliability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

[0054] Figure 1 It is a schematic diagram of the structure of a formed coil from an initial state to an expanded state in the prior art.

[0055] Figure 2 The figure is the overall structure diagram of the stator forming coil expansion test control system implemented according to the present invention (Example 1).

[0056] Figure 3 This is a control logic diagram of the stator forming coil expansion test of the present invention.

[0057] Figure 4 It is a control flow chart of the present invention under different working modes.

[0058] Figure 5 The figure is the overall structure diagram of the stator forming coil expansion test control system implemented according to the present invention (Example 2).

[0059] Figure 6 This is the overall structural diagram of the stator forming coil expansion test control system according to the present invention (Example 3).

[0060] Figure 7 for Figure 6 Top view of the .

[0061] Figure 8 It is a structural diagram of the stretching and bending channel combination and the stretching head of the present invention.

[0062] Fig. 9 It is a schematic diagram of the process of bending and pressing a test piece by the bending head of the present invention under various working control modes (four-point pressing).

[0063] Fig.10 It is the working principle diagram of the stretching head of the present invention.

[0064] Fig.11 It is a schematic diagram of the twisting head structure of the present invention.

[0065] Fig.12 for Fig.11 Split diagram of .

[0066] Fig.13 It is a working schematic diagram of the coordinated stretching and bending working condition control mode of the present invention.

[0067] Fig.14 It is a schematic diagram of the working of the coordinated stretching-torsion-bending composite working condition of the present invention.

[0068] Fig.15 Schematic diagram before loading (a) and schematic diagram after loading (b) in the coordinated torsion-bending working condition control mode of the present invention.

[0069] Fig.16 It is a bending chuck for torsion-bending working condition of the present invention.

[0070] Fig.17 It is a working schematic diagram of the tensile and torsion coordinated test channel control mode of the present invention.

[0071] Fig.18 It is the operation interface of the host computer control system of the present invention. DETAILED DESCRIPTION

[0072] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Generally, the channels of the embodiments of the present application described and shown in the drawings here can be arranged and designed in various different configurations.

[0073] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for which protection is sought, but merely represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in the field without creative work are within the scope of protection of the present application.

[0074] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0075] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, or the positions or positional relationships in which the product of the application is usually placed when in use. They are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific position, be constructed and operated in a specific position, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0076] In addition, the terms "horizontal", "vertical", "overhanging" and the like do not mean that the components are required to be absolutely horizontal or overhanging, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0077] In the description of this application, it should also be noted that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0078] In the present application, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0079] The features and performance of the present application are further described in detail below in conjunction with the embodiments.

[0080] Embodiment 1:

[0081] The system implemented according to the present invention includes a host computer and three independent test channels, such as Figure 2-18 shown.

[0082] (1) Host computer

[0083] The host computer of this embodiment communicates with the central controller (preferably the central controller is a PLC controller, and can also be other central controllers with data and command interaction) through Ethernet, reads data in the central controller and sends commands to the central controller. The host computer software can be used to select the working conditions of the test device, including tensile test conditions, torsion test conditions, bending test, tensile-bending test conditions, and tensile-bending test conditions, and set the relevant parameters of different working conditions. The input data is sent to the parameter address reserved inside the central controller program. The central controller converts the received data and then sends it to the servo motor controller, thereby allowing the servo motor to operate as required; the host computer software inside the host computer analyzes and processes the read test data to obtain tables and line graphs (such as Fig.18 ).

[0084] In addition, the host computer software is also used for system self-check after power-on. During the test, the test system is diagnosed and processed for abnormalities based on the data fed back to the central controller by the servo motor, torque angle sensor, tension sensor and laser displacement sensor, and the time of the abnormal diagnosis results is recorded. Finally, all data is sent to the host computer.

[0085] (2) Test channel

[0086] There are at least three test channels, and the three most representative channels are selected for introduction.

[0087] Test channel 1 (stretching-bending channel) includes stretching motor driver, stretching motor encoder and stretching motor, planetary reducer, coupling connection, ball screw module, stretching mobile base, tension sensor, stretching mobile chuck and other components; a laser displacement sensor is installed under the specimen, and the first servo bending electric cylinder, the first bending electric cylinder and the bending chuck and other components are installed on the gantry above the specimen;

[0088] Test channel 2 (torsion-bending channel) includes a torsion motor driver, a torsion motor encoder and a torsion motor, a planetary reducer, a coupling connection, a torque angle sensor, a torsion head and other components. A laser displacement sensor is installed below the test piece, and the first servo bending electric cylinder, the first servo bending electric cylinder and the bending chuck and other components are installed on the gantry above the test piece.

[0089] Test channel three (stretching-torsion-bending channel) includes torsion motor driver, torsion motor encoder, torsion motor, planetary reducer, coupling connection, torque angle sensor, torsion chuck, stretching motor, ball screw module, stretching mobile base, tension pressure sensor, grating scale displacement sensor, stretching mobile chuck and other components; first bending electric cylinder, laser displacement sensor, bending chuck and other components. Each servo motor can be controlled independently, and the stretching-torsion test can be formed first in the joint test of three working conditions;

[0090] The servo motor controller and the servo electric cylinder are both connected to the central controller. The sensor and the central controller complete data reading through the Modbus RTU RS485 communication protocol. The central controller reads the sensor data according to the set cycle; the servo motor controller and the servo electric cylinder complete data exchange with the central controller through Ethernet connection.

[0091] When conducting a combined working condition test, multiple parameters such as the maximum load value, the time to reach the maximum load, the maximum holding time, and the maximum displacement value are set in the upper computer software. The upper computer sends the set parameters to the central controller. The corresponding parameter address is reserved in the central controller program to receive the parameters, and the dimensionless time parameters are converted into dimensioned time parameters. The parameters to be sent to the servo controller are converted into hexadecimal numbers. After all the parameters are converted, they are sent to the servo controller to control the operation of the servo motor. When the servo motor reaches the load value according to the set time, the servo motor stops running and maintains the current position until the set loading time is reached, and the value in the displacement sensor is read. At the same time, after the servo motor drives the chuck to reach the set displacement or angle, the servo motor stops running and maintains the current position until the set loading time is reached. Then the servo motor drives the transmission part back to the initial position and reads the sensor value after the specimen is deformed. Then the tester releases the chuck and directly unloads the specimen. The deformation data of the specimen after unloading is measured by the measuring instrument. Finally, the central controller sends the collected sensor data to the upper computer software, and the upper computer software analyzes and processes these data to obtain a table and a line chart.

[0092] according to Figure 3 and Figure 4 The control flow chart of the present invention has the following implementation modes:

[0093] (1) Torsion test conditions

[0094] The torsion motor reaches the set torque value according to the time set on the host computer, stops running and maintains the current torque value until the set loading time is reached, and reads the angle value in the torque angle sensor; then the tester loosens the torsion chuck and directly unloads the specimen, uses the measuring instrument to measure the deformation angle of the specimen after torsion unloading and records the data.

[0095] (2) Tensile test conditions

[0096] The stretching motor reaches the set tension value according to the time set on the host computer, and the stretching motor stops running and maintains the current position until the set loading time is reached, and the value in the grating ruler displacement sensor is read; then the test personnel loosen the stretching chuck and directly unload the specimen. The length of the specimen after unloading is measured by the measuring instrument, and the expansion data is recorded.

[0097] (3) Bending test conditions

[0098] The bending motor loads and drives the electric cylinder or other linear motion mechanism to make the specimen coil contacted by the bending head reach the set bending deflection. The bending motor stops running and maintains the current position until the set loading time is reached. Then the bending motor returns to the initial position, reads the laser displacement sensor value, and obtains the expansion test data.

[0099] (4) Coordinated tensile-bending test conditions

[0100] After the stretching motor reaches the tension value according to the set time, the stretching motor stops running and maintains the current position until the set loading time is reached, and the value in the grating ruler displacement sensor is read; at the same time, or the order with the stretching motor can be adjusted, the bending motor loads and drives the electric cylinder or other linear motion mechanism to reach the set test bending deflection, the bending motor stops running and maintains the current position until the set loading time is reached; then the bending motor returns to the initial position and reads the value of the laser displacement sensor under the specimen; finally, the tester releases the stretching head and directly unloads the specimen. The length of the specimen after unloading of the stretching expansion is measured by a measuring instrument and the data is recorded.

[0101] (5) Synergistic torsion-bending test conditions

[0102] After the torsion motor reaches the set torque value at the set time, the torsion motor stops running and maintains the current torque value until the set loading time is reached, and the value in the torque angle sensor is read; at the same time, the second servo electric cylinder reaches the bending deflection, the second servo electric cylinder stops running and maintains the current position until the set loading time is reached; then the second servo electric cylinder returns to the initial position, and reads the value of the laser displacement sensor under the specimen; then the tester loosens the torsion chuck and directly unloads the specimen, uses a measuring instrument to measure the deformation angle of the specimen after torsion unloading and records the data.

[0103] (6) Coordinated tension-torsion test conditions

[0104] After the tensile motor reaches the tension value according to the set time, the torsion motor stops running and maintains the current position until the set loading time is reached, and the value in the grating ruler displacement sensor is read; at the same time, after the torsion motor reaches the tensile displacement, the torsion motor stops running and maintains the current position until the set loading time is reached; then the torsion motor returns to the initial position and reads the value of the specimen grating ruler sensor; then the tester loosens the tensile chuck and directly unloads the specimen. The length and torsion angle of the specimen after tensile unloading are measured by measuring instruments, and the data is recorded.

[0105] (7) Synergistic torsion-tension-bending test conditions

[0106] The torsion motor reaches the set torque value according to the time set on the host computer, the torsion motor stops running and maintains the current torque value until the set loading time is reached, and the angle value in the torque angle sensor is read; at the same time, or the sequence can be adjusted, after the stretching motor reaches the tension value according to the set time, the stretching motor stops running and maintains the current position until the set loading time is reached, and the value in the grating scale displacement sensor is read; at the same time, or the sequence with the stretching motor can be adjusted, after the bending motor loads and drives the electric cylinder or other linear motion mechanism to reach the set test bending deflection, the bending motor stops running and maintains the current position until the set loading time is reached; then the bending motor returns to the initial position and reads the value of the laser displacement sensor under the specimen.

[0107] Embodiment 2:

[0108] In Example 1 and other embodiments, the test channel of the present invention can also be as follows Figure 5-12 Configure as shown.

[0109] The control system is integrated in the control assembly 40, and includes a control unit, an input unit, and an output unit; the signal transceiver end of the control unit is connected to the signal transceiver end of the signal processing unit, and the control unit is used to receive and process sensor data and send motor control signals; the signal output end of the input unit is connected to the signal input end of the control unit, and the input unit is used to convert user operations into control signals and send them to the control unit; the signal output end of the control unit is connected to the signal input end of the output unit, and the output unit is used to display the data output by the control unit to the user;

[0110] The control unit includes a control circuit, which includes a motor control circuit and a sensor control circuit; the motor control circuit includes a servo motor control circuit and an electric cylinder control circuit, the servo motor control circuit host computer 4, the central controller 5 and the V90 driver 6, the servo motor control circuit is used to perform position control, speed control and torque control on the stretching motor 101 and the torsion motor 201, and the electric cylinder control circuit is used to perform position control, speed control and torque control on the electric cylinder 303.

[0111] The signal processing unit includes a data acquisition circuit and a filtering circuit; the signal input end of the filtering circuit is connected to the signal output end of the sensor, and the signal output end of the filtering circuit is connected to the analog-to-digital conversion interface of the data acquisition circuit, and the filtering circuit is used to smooth the signal input to the data acquisition circuit; the signal transceiver end of the data acquisition circuit is connected to the signal transceiver end of the host computer 4, and the data acquisition circuit is used to send sensor data to the host computer and receive control signals from the host computer.

[0112] See also Figures 6 to 12The mechanical assembly 10 includes a basic platform 100 with a T-slot, a stretching channel 1, a torsion channel 2, and a bending channel 3; the control assembly 40 includes a signal processing unit and a control unit; and the power supply is used to provide driving force to the entire device;

[0113] The working surface of the basic platform 100 with T-slots is placed horizontally; a set of parallel slots is provided on the upper surface of the basic platform 100, which is used to pass T-bolts 600 with feet and fix various special brackets on the basic platform 100. The longitudinal direction along the T-slot is the left-right direction; the direction perpendicular to the surface of the basic platform 100 is the up-down direction.

[0114] The stretching channel, the torsion channel and the bending channel can be designed separately, or they can be arranged in combination of two or all three. Figure 5 and 6 The structure includes a stretching-bending channel and a torsion-bending channel. Figure 5 The middle curved channel is arranged horizontally or vertically. Figure 6 The middle curved channel is arranged vertically.

[0115] The stretching channel includes a stretching motor 101, a stretching motor fixed seat 102, a first planetary reducer 103, a first coupling 104, a guide rail slider module base 105, a guide rail slider module 106, a stretching chuck moving end base 107, a stretching moving end chuck 109, a tension sensor 108, a grating scale displacement sensor 110, a grating scale fixed bracket 111, a stretching chuck fixed end base 113, and a stretching fixed end chuck 112.

[0116] The stretching motor fixing base 102, the guide rail slider module base 105, the grating ruler fixing bracket 111, and the stretching chuck fixing end base 113 are fixed on the basic platform 100 with T-bolts respectively;

[0117] The stretching motor 101 is connected to the servo motor fixing seat 102, and the servo motor fixing seat 102 is used to fix the stretching motor 101 on the basic platform 100; the stretching motor 101 is used to provide torque to the guide rail slider module 106; the input end of the first planetary reducer 103 is connected to the stretching motor 101, and the output end of the first planetary reducer 103 is connected to the guide rail slider module 106, and the first planetary reducer 103 is used to provide a constant reduction ratio for the stretching motor 101; the first coupling 104 is used to connect the output of the first planetary reducer 103 The guide rail slider module 106 is connected to the guide rail slider module base 104, and the guide rail slider module 106 is used to convert the rotation output by the stretching motor 101 into a linear movement of the mobile platform of the guide rail slider module 106; the special chuck for stretching includes a stretching movable end chuck 109 and a stretching fixed end chuck 112, and the special chuck for stretching is used to clamp the material to be tested for stretching test; the stretching movable end chuck 109 is connected to the tension sensor 108, and the stretching fixed end chuck 112 is connected to the stretching chuck fixed end base 113.

[0118] The guide rail slider module base 105 is used to fix the guide rail slider module 106 on the basic platform 100; the grating scale fixing bracket 111 is used to fix the grating scale displacement sensor 110 on the basic platform 100; the stretching chuck moving end base 107 is fixed to the moving platform 1061 of the guide rail slider module 106 with fasteners, and is used to fix the tension sensor 108 and the stretching moving end chuck 109; the stretching chuck moving end base 107 is used to fix the stretching moving end chuck 109 on the moving platform of the guide rail slider module 106; the stretching chuck fixed end base 113 is used to fix the stretching fixed end chuck 112 on the basic platform 100.

[0119] The grating scale displacement sensor 110 is arranged on the guide rail slider module 106, wherein the two ends of the long grating (scale grating) are respectively mounted on two grating scale fixing brackets 111, and the short grating (indicator grating) is mounted on the moving platform of the guide rail slider module 106. The grating scale displacement sensor 110 is used to measure the elongation of the material; the stretching channel tension sensor 108 is mounted on the base of the moving end of the stretching chuck and connected to the stretching moving chuck, and is used to measure the tension applied to the material during stretching.

[0120] like Figure 8 The two wedges 1091 of the stretching movable end chuck 109 and the stretching fixed end chuck 112 are clamped, and the two force arms on the wedges 1091 are rotated to push the wedges to lock, and the rectangular block 1092 is tightened on the specimen 700 by screws to prevent the specimen 700 from loosening during the stretching process.

[0121] In the torsion channel, the torsion motor fixing seat 202, the angle torque sensor bracket 206, the torsion end chuck bracket 207, the torsion chuck fixed end base 207, the angle torque sensor bracket 206 and the torsion chuck fixed end base 207 are respectively fixed on the basic platform 100 with special T-bolts 500, and are respectively used to fix the servo motor 201, the angle torque sensor 205, the torsion chuck support seat 208, and the torsion fixed end chuck 210.

[0122] The stretching movable end chuck 109 and the stretching fixed end chuck 112 are installed at the same horizontal height; the output shaft of the torsion motor 201, the output shaft of the second planetary reducer 203, the output shaft of the angle torque sensor 205, the center of the torsion action end chuck 209 and the center of the torsion fixed end chuck 210 are installed on the same horizontal straight line and parallel to the working surface of the base platform 100.

[0123] The torsion motor 201 is connected to the servo motor fixing seat 202, and the torsion motor 201 provides torque; the input end of the second planetary reducer 203 is connected to the torsion motor 201, and the output end of the second planetary reducer 202 is connected to the angle torque sensor 205, and the planetary reducer 203 is used to provide a constant reduction ratio for the servo motor 201; the coupling 204 is used to connect the output end of the planetary reducer 203 and the input end of the angle torque sensor 205; the angle torque sensor 205 is a part of the transmission structure, and the output end of the angle torsion sensor is connected to the torsion chuck through a key; the special torsion chuck includes a torsion action end chuck 206 and a torsion fixed end chuck 210, and the special torsion chuck is used to clamp the material to be tested for torsion testing; the torsion action end chuck 209 is connected to the angle torque sensor 205 through a key, and the torsion fixed end chuck 210 is connected to the torsion chuck fixed end base 207.

[0124] The angle torque sensor bracket 206 is used to fix the angle torque sensor 205 on the base platform 100; the torsion end chuck bracket 207 is used to fix the torsion chuck support seat 208 on the base platform 100; the torsion chuck support seat 208 is used to limit the radial range of motion of the torsion chuck; the torsion chuck fixed end base 207 is used to fix the torsion fixed end chuck on the base platform 100.

[0125] The angle torque sensor 205 is disposed between the output end of the second planetary reducer 202 and the torsion chuck, and is fixed on the base platform 100 by an angle torque sensor bracket 206. The angle torque sensor 205 is used to measure the torsion angle and torque of the material to be tested.

[0126] like Figure 11-12The torsion chuck support seat 208 is used to limit the radial movement of the torsion action end chuck 209. The torsion chuck support seat 208 is divided into two parts, the upper and lower parts. The clamping holes in the upper block 2081 and the lower block 2082 form a complete circle; the diameter of the circle should be slightly smaller than the diameter of the outer circle of the torsion action end chuck 209, and a graphite wool filler 213 is arranged in the gap between the two. The graphite wool filler 213 is in direct contact with the outer edge of the torsion action end chuck 209 for lubrication, preventing rigid contact from aggravating wear and reducing transmission errors, and ensuring that the friction between the graphite wool filler 213 and the outer edge of the torsion action end chuck 209 is small enough.

[0127] like Fig.11 As shown, the torsion chuck zero return limit device 212 has a proximity switch 2120 arranged on the torsion chuck support seat 208. When the proximity end 2121 on the torsion action end chuck 209 is rotated to reach the proximity switch 2120, it is limited to reset the angle of the torsion chuck back to the original position.

[0128] There are many types of clamps for tension and compression channels and torsion channels, including clamps for clamping straight edges (such as Figure 8 ), and a chuck (such as a chuck having a receiving groove for accommodating the initial folded state of the coil and the nose end portion) Figure 15-17 ).

[0129] like Figure 5-6 The bending channel in this embodiment has two action ends (one of which is redundant), with the same components and loading methods, and is placed vertically with the stretching channel and the torsion channel respectively. In practice, only one bending channel can be set for sharing.

[0130] The bending channel includes a gantry 301, a power module 302 with a drive motor and a third planetary reducer, an electric cylinder 303, a pressure sensor 304, a bending pressure head 305, a laser displacement sensor bracket 306, and a laser displacement sensor 307. The electric cylinder 303 is a lead screw and nut telescopic channel. Here, the electric cylinder 303 can also be replaced by a servo cylinder, a hydraulic cylinder, or other precision linear device.

[0131] The linear motion mechanism where the bending press head 305 is located is installed on the gantry 301 to ensure that the push rod of the electric cylinder 303 is perpendicular to the plane of the basic platform 100; adjust the installation position of the laser displacement sensor bracket 306 to ensure that the emission and receiving points of the laser displacement sensor 307 are located directly below the electric cylinder push rod.

[0132] You can also Figure 4 As shown, the curved channel can be arranged parallel to the base platform. The curved pressure head 305 is arranged horizontally, and the pushing direction is parallel to the base platform 100 and perpendicular to the stretching direction or the center line of the torsion clamp. The gantry 301 is also arranged parallel to the base platform 100.

[0133] Regardless of the setting direction, the driving device and structure are the same. The electric cylinder 303 is connected to the gantry 301, and the electric cylinder 303 is used to push the four-point bending pressure head to feed and move; the four-point bending special pressure head is connected to the pressure sensor 304, and the four-point bending special pressure head is used to perform four-point bending on the material to be tested.

[0134] The laser displacement sensor bracket 306 is used to fix the laser displacement sensor 307 on the basic platform 100; the gantry 301 is used to vertically fix the electric cylinder 303 above the basic platform 100; the basic platform 100 is used to place the components of this channel.

[0135] The pressure sensor 304 is installed on the push rod of the electric cylinder 303 and is connected to the bending pressure head 305. The pressure sensor 304 is used to measure the pressure applied to the material when it is bent. The laser displacement sensor 307 is set directly below the material to be tested and is fixed on the basic platform 100 by the laser displacement sensor bracket 306. The laser displacement sensor 307 is used to measure the vertical downward pressure distance of the bending of the material to be tested.

[0136] like Fig. 9 The changing state of the four-point pressing of the test piece 700 by using the two-point bending pressure head 305 is shown. The structure of the bending pressure head 305 can be seen, including the physical center of the balance plate vertically connected to the output end of the power output module of the linear motion, two rib-shaped convex tops 3051 are axially symmetrically arranged below the balance plate with the physical center of the balance plate as the midpoint, or a rib-shaped convex top 3051 is arranged in the center, and the convex top 3051 is arranged along the direction of pressure expansion or lifting, and the outer edge of the lowest part maintains a thickness suitable for contact with the coil. The convex top 3051 is arranged to be fixed on the balance plate or adjusted in position by T-bolts 600.

[0137] According to different bending requirements, different bending heads can be replaced, or the distance between the two rib-shaped convex tops can be adjusted to achieve one-point force application or two-point force application at different distances, thus ensuring the replaceability of the device.

[0138] The test device is installed as follows:

[0139] By fixing the basic platform 100 and adjusting the anchor bolts, ensure that the plane of the basic platform 100 is in a horizontal position;

[0140] The stretching motor fixing base 102, the guide rail slider module base 105, the grating ruler fixing bracket 111, the stretching chuck fixed end base 113, the torsion motor fixing base 202, the angle torque sensor bracket 206, the torsion end chuck bracket 207, the torsion chuck fixed end base 207, the laser displacement sensor bracket 105 and the gantry 301 are fixed on the basic platform 100 by fasteners and special fixing brackets;

[0141] Fix the base platform 100 and adjust the anchor bolts to ensure that the plane of the base platform 100 is in a horizontal position;

[0142] The stretching chuck movable end base 107 is fixed on the movable platform of the guide rail slider module 106 by tightening bolts;

[0143] The tension sensor 108 is fixed to the base 107 of the moving end of the tensile chuck by fasteners;

[0144] The output end of the first planetary reducer 103 is connected to the screw input end of the guide rail slider module 106 through the first coupling 104;

[0145] Fix the tension fixing end clamp 112 on the tension sensor 108 by tightening bolts;

[0146] Fix the angle torque sensor 205 on the angle torque sensor bracket 206 by tightening bolts;

[0147] Fix the graphite wool filler to the inner wall of the torsion chuck support seat 208 by tightening bolts;

[0148] Fix the lower half of the torsion chuck support seat 208 to the torsion end chuck bracket 207 by tightening bolts;

[0149] Place the torsion action end chuck 204 in the circular groove in the lower half of the torsion action end chuck, and connect the torsion action end chuck 204 to the angle torque sensor 205 through a key;

[0150] Fix the upper part of the torsion chuck support seat 208 to the lower part of the torsion chuck support seat 208 by tightening bolts;

[0151] Fix the electric cylinder 303 on the gantry 301 by tightening bolts;

[0152] Fix the tension and compression sensor 302 on the push rod of the electric cylinder 303 by tightening bolts;

[0153] Fix the bending pressure head 305 on the pressure sensor 304 by tightening bolts;

[0154] Connecting the signal transceiver end of the data acquisition circuit to the signal transceiver end of the control unit;

[0155] Connecting the signal output terminal of the input unit to the signal input terminal of the control unit;

[0156] Connect the signal output terminal of the control unit to the signal input terminal of the output unit.

[0157] During the test, electromagnetic wire with polyimide film layer was selected, and the manufacturing process of the expansion machine was analyzed to calculate the specimen size using the equivalent principle. The electromagnetic wire was processed as the test specimen (such as Figure 1 shuttle coil).

[0158] The test control method using the above permanent magnet traction motor stator forming coil expansion test device comprises the following steps:

[0159] S1: Clamp the specimen. Clamp the specimen at the tensile end. First, clamp the specimen in the fixed end fixture. Adjust the screw feed accurately through the operation interface so that the distance between the two fixtures at the tensile end can meet the coil length. Then tighten the tightening handle of the tensile fixture to fix and clamp the specimen. At the torsion end, move the fixed end fixture to adjust to the appropriate length of the specimen, and tighten the torsion fixture tightening bolts;

[0160] S2: expansion test, input control parameters to the control unit through the input unit, and the control unit sends the control parameters to each component in the device through the signal processing unit;

[0161] S3: Data analysis and processing. The system outputs data such as tensile force F1 at the stretching end, thrust F2 at the bending end, tensile displacement D1, bending deflection D2, torque T, torque loading time t1, torque holding time t2, thrust loading time t3, thrust holding time t4, rotation angle θ, etc. The user analyzes the data.

[0162] S21: Tensile test, e.g. Figure 6 and 10 ,as well as Figure 3-4 , the specific steps are:

[0163] S211: Adjust the stretching end channel, and adjust the ball screw feed amount by jogging the servo motor in manual mode, so that the distance between the two clamps at the stretching end can approximately meet the coil length, and mark the ball screw scale. The distance between the ball screw limit end and the fixed end is used as the initial length L0 of the coil, and the ball screw moves from the limit end to the motor end to perform stretching movement;

[0164] S212: Clamp the test piece. First, clamp the test piece in the fixture at the fixed end of the stretching channel. Calculate the motor rotation angle through the lead screw lead to accurately control the screw feed amount on the upper computer operation interface so that the distance between the two fixtures at the stretching end can meet the coil length. Then tighten the tightening handle of the stretching fixture to fix and clamp the test piece. During this process, ensure that the test piece material is parallel to the plane of the special test bench;

[0165] S213: Install the extensometer at about the middle of the specimen. The distance marked on the extensometer is L. e , mark the original gauge length L with a thin line e .

[0166] S214: Set the test force zero point. After the test loading chain is assembled and before the two ends of the specimen are clamped, the zero point of the force measurement system should be set.

[0167] S215: Specimen clamping, use the tensile end clamp to clamp the specimen, ensure that the clamped specimen is subjected to axial tension and reduce bending. In order to obtain a straight specimen and ensure that the specimen is horizontally aligned with the clamp, a pre-tension corresponding to no more than 5% of the specified strength may be applied;

[0168] S216: Conduct the test, control the motor drive to perform the stretching action through the host computer, load slowly and evenly, obtain the yield load value, record it to calculate the yield point stress value, pay attention to observe the slip phenomenon in the yield stage, after the yield stage, the loading speed can be accelerated;

[0169] S217: Tensile test and data acquisition. The servo motor drive is controlled through the upper computer operation interface. The actuator generates axial tension to deform the specimen. The displacement is measured by the grating ruler through the software interface. The tension F1, displacement D1, loading time t1, holding time t2, and coil length L are calculated. c As control variables, two of the control variables are set, and the displacement is set as the monitoring response. When the specimen is stretched to the set displacement, the motor is controlled to stop rotating and brake to maintain the load, and the stretching displacement S1 is observed;

[0170] S218: Data analysis and processing, the system outputs tension F1, displacement S1, loading time t1, holding time t2, coil length L c The user analyzes the data.

[0171] S22: Torsion test, e.g. Figure 3-4 , the specific steps are:

[0172] S221: Adjust the torsion end fixture, loosen the fastening screws under the torsion end fixing fixture, and adjust the distance between the two fixtures to be larger than the initial length L of the specimen through the sliding guide rail. c .

[0173] S222: Install the specimen, insert the specimen into the action end torsion fixture parallel to the table, make its axis coincide with the center axis of the chuck, ensure that the specimen remains straight during the test, and turn the handle to tighten; then adjust the distance of the slide rail to meet the coil length requirement, insert the other end of the specimen into the fixed end fixture, tighten the fixed end mounting screws, and tighten the fixed end fixture handle to clamp the specimen; after placing the specimen into the chuck of the testing machine, rotate the rotatable chuck at a suitable constant speed until the specimen reaches the specified torsion angle α;

[0174] S223: Start the motor and control the output torque and angle control range through the host computer operation interface;

[0175] S224: Torsion springback data collection; control the motor drive through the host computer operation interface; the actuator generates a rotational motion to cause the specimen to twist and deform, and the torque and rotation angle thresholds are monitored through the software interface; the torque T, loading time t1, holding time t2, rotation angle θ, coil length L c As control variables; set two of the control variables; set the torque and angle as monitoring responses. When the specimen is twisted to the preset angle α, control the motor to stop working until the brake is engaged, maintain the load, change the control time, and observe the torsion value. At this time, the specimen is twisted to a certain extent. After maintaining the load, perform torque unloading, control the motor to rotate in the opposite direction, observe the change in torque value, and stop the motor when the torque value is 0. After unloading, read the change angle β.

[0176] S225: data analysis and processing, torque T, loading time t1, holding time t2, rotation angle θ;

[0177] S23: Bend test, e.g. Figure 3-4 , 9, the specific steps are:

[0178] S231: Adjust the fixture, fix the specimen through the stretching end, and adjust the ball screw feed amount through the servo motor manual mode, so that the distance between the two fixtures at the stretching end can approximately meet the coil length, and the distance between the ball screw limit end and the fixed end is used as the initial length L0 of the coil;

[0179] S232: Install the specimen, insert the multiple layers of the specimen into the actuating end tensile fixture perpendicular to the table, turn the handle to tighten the chuck, adjust the distance of the tensile actuating end to meet the coil length requirement, insert the other end of the specimen into the fixed end fixture, tighten the fixed end fixture handle to clamp the specimen;

[0180] S223: The specimen is subjected to bending moment during the bending process, and the thrust generated at the bending end is constant and does not rotate; by adjusting the distance between the convex tops on the bending fixture or the number of installations, force is applied at one or two points of the specimen to perform three-point bending or four-point bending;

[0181] S234: Mark the initial gauge length S0 of the coil and control the electric cylinder drive through the upper computer operation interface;

[0182] S235: Adjust the bending end fixture, manually adjust the distance between the two acting pressure heads on the four-point bending special fixture, and then align the pressure head with the marking point by adjusting the position of the electric cylinder bracket;

[0183] S236: Bending test data collection, start the motor, control the electric cylinder drive through the host computer operation interface, the actuating end generates radial displacement to cause the specimen to bend; monitor the displacement measured by the grating ruler through the software interface, and convert the thrust F2, bending deflection D2, loading time t1, holding time t2, coil length L cAs control variables, two of the control variables are set, and the displacement is set as the monitoring response; when the specimen bends to the specified displacement, the motor is controlled to stop rotating and brake, load is maintained, the control time is changed, and the bending deflection D2 is observed;

[0184] S237: Data analysis and processing, system output thrust F2, bending deflection D2, loading time t1, holding time t2, coil length L c And other data information, analyze the data;

[0185] S24: Tensile-bending test, e.g. Figure 3-4 , 8 and 13, the specimen is subjected to bending moment during the stretching process. The tensile-bending test has load timing, and the test conditions include: stretching first and then bending, bending first and then stretching, and stretching and bending at the same time;

[0186] Stretch-bending process, such as Figure 8 As shown, the specimen clamping method is that the side of the specimen 700 is clamped by two wedges 1091 of the stretching movable end clamp 109 and the stretching fixed end clamp 112, the wedges are rotated and pushed to lock by two force arms on the wedges 1091, and the rectangular block 1092 is tightened on the specimen 700 by screws to prevent the end of the specimen 700 from warping up during the bending process.

[0187] S241: The working condition of stretching first and then bending includes the following steps: starting the test, the process of clamping the specimen and the method of applying the load are the same as those in the tensile test; the loading process and method are the same as those in the bending test, the tensile displacement and the bending deflection are set as monitoring responses, the stretching action is performed first, when the specimen reaches the specified displacement, the motor is controlled to stop working and brake, the load is maintained, and the stretching displacement D1 is observed; then the bending action is performed, when the specimen is bent to the specified displacement, the motor is controlled to stop working and brake, the load is maintained, and the bending deflection D2 is observed; the loading sequence is determined by the actual working conditions.

[0188] S242: The bending-then-stretching working condition includes the following steps: setting the stretching displacement and the bending deflection as monitoring responses, first performing the bending action, and when the specimen is bent to the specified displacement, controlling the motor to stop working and brake to maintain the load, and observing the bending deflection amount D2; then performing the stretching action, and when the specimen is stretched to the specified displacement, controlling the motor to stop working and brake to maintain the load, and observing the stretching displacement D1; the loading sequence is determined by the actual working conditions.

[0189] S243: Simultaneous stretching and bending conditions, including the following steps:

[0190] The bending-before-stretching working condition includes the following steps: the upper computer interface sets the corresponding loading rate and load of stretching-bending, and the loading time is kept consistent, so that the fixture applies the load to the time at the same time. The stretching displacement and bending deflection are set as monitoring responses, and the stretching and bending actions are performed simultaneously. When the specimen is bent to the specified displacement, the motor is controlled to stop working until the brake is engaged, the load is maintained, and the bending deflection D2 is observed; when the specimen is stretched to the specified displacement, the motor is controlled to stop working until the brake is engaged, the load is maintained, and the stretching displacement D1 is observed;

[0191] S244: Data analysis and processing, data variables tension F1, tensile displacement D1, loading time t1, holding time t2, coil length L c , thrust F2, bending deflection D2 and other data, the user analyzes the data;

[0192] S25: Torsion-bending test, e.g. Figure 3-4 , 15 and 16 show the schematic diagram of the torsion-bending condition before loading (a) and the schematic diagram of the torsion-bending condition after loading (b), wherein the specimen is subjected to bending moment during the torsion process. The torsion-bending test has load timing, and the test conditions include: torsion first and then bending, bending first and then torsion, and torsion and bending at the same time. The specimen is subjected to bending moment during the torsion process, and the thrust generated at the bending end is constant and does not rotate; by adjusting the distance between the convex tops on the bending fixture or the number of installations, force is applied at one or two points of the specimen to perform three-point bending or four-point bending.

[0193] The torsion-bending condition can be used as follows Fig.16 The structure shown is used as a clamp 3001 at both ends of the specimen during bending pressure loading. The specimen is tightened relatively close from two directions by screws in the vertical and horizontal directions on the clamp (the movable clamp block is clamped by the screws in the vertical direction, and a protective layer can be provided on the screw head to protect the specimen). The clamp 3001 locks the straight edge of the specimen, and the bending loading head 305 bends the specimen to form a straight edge, which extends downward from the opening at the bottom of the clamp 3001 to the pressing position of the bending loading head. When the torsion end rotates, the specimen is warped to form a transition edge structure, thereby avoiding twisting and twisting during torsion. The torsion and bending sequence can be adjusted, and a clamp 3001 of this structure can be used.

[0194] S251: Torsion followed by bending working condition, including the following steps: during the test process, the clamping process of the specimen in the tensile test is the same as the load application method; the loading process and method of the specimen in the bending test are the same, the torsion angle and the bending deflection are set as monitoring responses, when the specimen is twisted to a preset angle α, the motor is controlled to stop working until the brake is engaged, the load is maintained, the control time is changed, and the torsion value is observed; the bending end feeding operation is performed; when the specimen is bent to a specified displacement, the motor is controlled to stop working until the brake is engaged, the load is maintained, the control time is changed, and the bending deflection amount D2 is observed;

[0195] S252: The bending-then-torsion working condition includes the following steps: During the test, the clamping process and load application method of the specimen in the tensile test are the same; the loading process and method of the specimen in the bending test are the same, and the torsion angle and bending deflection are set as monitoring responses. First, the bending action is performed. When the specimen is bent to the specified displacement, the motor is controlled to stop working until the brake is engaged, the load is maintained, the control time is changed, and the bending deflection D2 is observed; then the torsion action is performed. When the specimen is twisted to the preset angle α, the motor is controlled to stop working until the brake is engaged, the load is maintained, the control time is changed, and the torque value is observed;

[0196] S253: Simultaneous torsion and bending conditions: The upper computer interface sets the corresponding loading rate and load of torsion-bending, and the loading time is kept consistent, so that the fixture applies load to time at the same time. Perform torsion-bending actions at the same time. When the specimen is bent to the specified displacement, the motor is controlled to stop working until the brake is engaged, the load is maintained, the control time is changed, and the bending deflection D2 is observed; when the specimen is twisted to the preset angle α, the motor is controlled to stop working until the brake is engaged, the load is maintained, the control time is changed, and the torque value is observed.

[0197] S254: Data analysis and processing, data variables include torque T, bending thrust F2, bending deflection D2, loading time t1, holding time t2, rotation angle θ, coil length L c Users analyze the data.

[0198] S261: Torsion followed by tension, including the following steps: During the test, the bolts on the T-slot of the entire torsion assembly (except the base of the fixed end of the torsion chuck) are removed, and the entire assembly is fixed to the T-slot at the tension end, forming a tension-torsion composite condition. The height of the fixture is adjusted so that the height of the specimen clamped on the two fixtures remains consistent.

[0199] The clamping process and load application method of the specimen in the tensile and torsion tests are the same; the loading process and method of the specimen in the tensile test are the same, and the torsion angle and tensile displacement are set as monitoring responses. When the specimen is twisted to the preset angle γ, the motor is controlled to stop to maintain the load, change the control time, and observe the torsion value; the tensile end feed operation is performed; when the specimen is bent to the specified displacement, the motor is controlled to stop working until the brake is applied, the load is maintained, the control time is changed, and the tensile displacement D3 is observed;

[0200] S262: first stretch and then twist condition. The operation steps are the same as the first twist and then bend condition. The loading sequence is first stretching and then bending. There is a time sequence between the two conditions.

[0201] S263: simultaneous stretching and bending condition, the operation steps are the same as the torsion-first-then-bending condition, and the loading sequence is to perform torsion and bending actions simultaneously;

[0202] S264: Data analysis and processing. The data variables include torque T3, tensile force F3, tensile displacement D3, loading time t1, holding time t2, rotation angle γ and other data. The data are analyzed.

[0203] Embodiment 3:

[0204] When the three combined tests of tension, torsion and bending are performed, Figure 3-4 ,and Fig.14 The structural combination test channels are controlled and different performance parameters are obtained by changing different test sequences for comparison.

[0205] Embodiment 4:

[0206] Tensile and torsion test channels, such as Figure 3-4 ,and Fig.17 The structural combination test channel is controlled, the twisting head 109 and the twisting head 209 clamp 700, the twisting head 109 and the twisting head 209 are in Figure 3 and 4 The control is realized under the process, and different performance parameters are obtained by changing the order of different test specimens 700 for comparison.

[0207] The embodiments described above are part of the embodiments of the present application, rather than all of the embodiments. The detailed description of the embodiments of the present application is not intended to limit the scope of the present application for protection, but merely represents the selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present application.

Claims

1. A stator forming coil expansion test control system, characterized in that include: At least three test channels are included: a stretching-bending channel, a torsion-bending channel, and a stretching-twist-bending channel. Each channel is provided with a mutually independent loading head, wherein the bending loading head is provided to be combined with the stretching loading head and / or the torsion loading head to form different test conditions; the torsion loading head and the stretching loading head are provided with a receiving groove capable of accommodating the coil nose end and the straight portion, and the bending loading head is provided with at least one convex top suitable for contacting the test piece in a vertical direction to form a pressure point; The sensors include a torque angle sensor arranged on the twisting head, a tension sensor arranged on the stretching head, a pressure sensor arranged on the bending head, and a displacement sensor arranged in the stretching direction and the bending expansion direction; A central controller is connected to each sensor and each servo motor controller of the loading head, and is in communication connection with a host computer, and the host computer stores or has access to a software program; The software program is configured to perform different parameter settings according to different test conditions, and to control each motor controller according to the parameter settings and conditions, and to collect sensor and motor data for test analysis and display; the test conditions at least include: coordinated stretching-bending test conditions, coordinated torsion-bending test conditions, coordinated torsion-stretching test conditions, and coordinated torsion-stretching-bending test conditions.

2. The stator forming coil expansion test control system according to claim 1 is characterized in that Each test condition is set to associate the corresponding sensor according to the measured physical quantity, and simultaneously associate the corresponding loading head and servo motor to achieve closed-loop control for the set physical quantity.

3. The stator forming coil expansion test control system according to claim 1 is characterized in that In the tensile test condition, the coordinated tensile-bending test condition, the coordinated torsion-tensile test condition, and the coordinated torsion-tensile-bending test condition, the tensile motor is set to operate according to the position control closed loop to achieve the target length.

4. The stator forming coil expansion test control system according to claim 1 is characterized in that In the bending test conditions, coordinated stretching-bending test conditions, coordinated torsion-bending test conditions and coordinated torsion-stretching-bending test conditions, a bending motor is set to achieve the target span extension according to a position control closed loop.

5. The stator forming coil expansion test control system according to claim 4 is characterized in that The target span extension is set to be a downward extension or a upward extension in a direction perpendicular to a line connecting the loading heads at both ends of the specimen.

6. The stator forming coil expansion test control system according to claim 4 is characterized in that The bending motor realizes the target span extension in the vertical or horizontal direction perpendicular to the connection line of the loading heads at both ends of the specimen.

7. The stator forming coil expansion test control system according to claim 1 is characterized in that In the torsion test conditions, coordinated torsion-bending test conditions, coordinated torsion-tensile test conditions, and coordinated torsion-tensile-bending test conditions, a torsion motor is provided to achieve a target angle torsion according to a torque control closed loop.

8. The stator forming coil expansion test control system according to claim 1 is characterized in that During the collaborative working condition, after the servo motor drives the loading head to reach the set displacement or angle according to the set time, the motor stops running and maintains the current displacement or angle value until the set loading time is reached, and the value in the sensor is read; at the same time or in a manner that changes with the order of the servo motor's actions, the loading head connected to another servo motor is loaded to reach the set displacement or angle, and the other servo motor stops running and maintains the current position until the set loading time is reached, and then drives the other servo motor back to the initial position, and reads the sensor value after the specimen is deformed; finally, the specimen is directly unloaded from the chuck, and the deformation of the specimen after different test sequences is measured.

9. A stator forming coil expansion test control method, characterized in that A stator forming coil expansion test control system as described in any one of claims 1 to 8 is adopted.

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