A wear-resistant commutator segment and manufacturing method thereof

Abstract

The present invention discloses a wear-resistant commutator segment and a manufacturing method, which relates to the technical field of commutator segment manufacturing, including two connecting plates, an external unit arranged inside the two connecting plates, and a fixing unit arranged between the two connecting plates for fixing copper wires; the external unit includes a connecting component arranged on the left and right sides of the connecting plate, and a linkage component arranged on the front and rear sides of the connecting plate; the fixing unit includes a limit seat fixedly connected between the two connecting plates, a placement groove opened inside the limit seat, and a limit assembly arranged inside the placement groove. The present invention is a wear-resistant commutator segment and a manufacturing method, which improves the application range and convenience of the commutator segment, ensures the stable connection of multiple commutator segments, and optimizes the fixing effect of the copper wire.

Description

Technical Field

[0001] The invention relates to the technical field of commutator segment manufacturing, and in particular to a wear-resistant commutator segment and a manufacturing method thereof. Background Art

[0002] The commutator is a circular shape with several commutator segments connected to each tap on the rotor. Two electrodes called brushes are connected to the outside to contact them, and only two of them are contacted at the same time. The commutator segments are generally made of long strips of silver-copper alloy.

[0003] After searching the publication (announcement) number: CN110739592A, a commutator segment for commutator and its production equipment are disclosed, which relates to the technical field of commutator, and aims to solve the problem that the commutator segment is squeezed outwards by pressure on both sides of the hook portion during the hook bending process to produce bulges and burrs. The key points of its technical solution are that it includes a segment body and a hook portion, the segment body includes a contact block and a clamping block, the contact block is provided with a connecting block along its length direction, the connecting block is provided with a connecting piece along the vertical direction, and the end of the connecting piece away from the contact block is fixedly connected with the clamping block along its length direction, the contact block, the connecting block, the connecting piece and the clamping block are fixedly connected, and the two ends of the connecting block, the connecting piece and the clamping block jointly form a clamping groove; one end of the contact block along its length direction is fixedly connected to the hook portion, and the two ends of the hook portion along its width direction are provided with deformation grooves, and the two deformation grooves penetrate the upper and lower end surfaces of the hook portion, which can effectively solve the problem that the commutator segment is squeezed outwards by pressure on both sides of the hook portion during the hook bending process to produce bulges and burrs.

[0004] Although the above scheme can effectively solve the problem that the two sides of the hook of the commutator segment are squeezed outward due to pressure during the bending process to produce protrusions and burrs, the commutator segment often needs to be fitted on the commutator when working on the commutator, and multiple commutators need to be stably connected together. The heights of various commutators are different, so the heights of the commutator segments used are also different. It is necessary to select commutator segments of various heights, which makes the use process cumbersome, and the fixing effect of the copper wire is not good enough, which easily causes the copper wire to loosen during the subsequent rotation process. Summary of the invention

[0005] The main purpose of the present invention is to provide a wear-resistant commutator segment and a manufacturing method. By setting up an external unit, the problem of needing to stably connect multiple commutators together is solved. The heights of the multiple commutators are different, so the heights of the commutator segments used are also different. It is necessary to select commutator segments of various heights, which leads to the problem of cumbersome use process. By setting up a fixing unit, the problem of insufficient fixing effect on the copper wire, which easily causes the copper wire to loosen during the subsequent rotation process is solved.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A wear-resistant commutator segment comprises two connecting plates, an external connection unit arranged inside the two connecting plates, and a fixing unit arranged between the two connecting plates for fixing a copper wire;

[0008] The external connection unit includes connection components arranged on the left and right sides of the connection plate, and linkage components arranged on the front and rear sides of the connection plate;

[0009] The fixing unit comprises a limiting seat fixedly connected between two connecting plates, a placement groove opened inside the limiting seat, and a limiting component arranged inside the placement groove.

[0010] Preferably, the connection assembly in the external unit includes a limiting groove provided on one of the left and right sides of the connection plate, an extension groove connected to one side of the limiting groove, a second elastic column provided inside the extension groove, a second spring provided on the surface of the second elastic column, a plug-in column fixedly connected to one side of the second elastic column, a convex groove connected to the front and rear sides of the limiting groove, a first elastic column provided inside the convex groove, a first spring provided on the surface of the first elastic column, a convex column fixedly connected to one end of the first elastic column, and a circular hole provided inside the convex column;

[0011] One end of the convex column extends to the inside of the limiting groove, and the plug-in column is matched with the circular hole, and the length of the connecting plate at the top end is greater than the length of the connecting plate at the bottom end.

[0012] Preferably, the connection assembly in the external unit further includes a connection column fixedly connected to the other left and right sides of the connection plate, wear-resistant grooves opened on the upper and lower sides of the connection column, and a connecting groove vertically connected to one side of the wear-resistant groove.

[0013] Preferably, one end of the convex column in the external unit connection assembly is matched with the wear-resistant groove, and one end of the plug-in column is matched with the connecting groove.

[0014] Preferably, the linkage assembly in the external unit includes a trapezoidal groove opened inside the front and rear sides of the connecting plate, a movable groove connected to the two sides of the trapezoidal groove, a third elastic column arranged inside the movable groove, a third spring arranged on the surface of the third elastic column, a push block fixedly connected to one side of the third elastic column, a rectangular groove connected to the upper and lower sides of the trapezoidal groove, a fourth elastic column fixedly connected to one of the rectangular grooves, a fourth spring arranged on the surface of the fourth elastic column, and a clamping plate fixedly connected to one end of the fourth elastic column.

[0015] Preferably, the linkage assembly in the external unit further comprises a special-shaped plate arranged inside the trapezoidal groove, a flexible layer symmetrically arranged inside the special-shaped plate, a clamping groove arranged on four sides of the special-shaped plate, and a through hole symmetrically arranged inside the special-shaped plate;

[0016] The special-shaped plate is symmetrically composed of two trapezoidal plates, and the four sides of the special-shaped plate all have a certain curvature.

[0017] Preferably, the clamping plate in the external unit extends to the inside of the rectangular groove through the corresponding through hole, and the pushing block is flush with the corresponding clamping groove.

[0018] Preferably, the external connection unit further comprises grooves provided on the front and rear sides of the connection plate, an external connection plate provided on the other end of the special-shaped plate, and a locking column fixedly connected to the bottom end of the external connection plate;

[0019] The bottom end of the locking column is engaged with the corresponding groove.

[0020] Preferably, the limiting assembly in the fixing unit includes a partition plate fixedly connected to the middle of the placement groove, a plurality of fifth elastic columns fixedly connected to both sides of the partition plate, a fifth spring arranged on the surface of the fifth elastic column, a moving plate fixedly connected to one end of the fifth elastic column, and a sliding plate fixedly connected to both ends of one side of the moving plate;

[0021] One end of the sliding plate extends to the interior of the housing of the limiting seat.

[0022] A method for manufacturing a wear-resistant commutator segment comprises the following steps:

[0023] Step 1: Connect the two connecting plates and the limit seat together to form a commutator segment;

[0024] Step 2: Insert one end of the special-shaped plate into the trapezoidal groove according to the use requirements, use the push block and the clamping plate to limit the movement of the special-shaped plate, and connect the other set of connecting plates to the special-shaped plate;

[0025] Step 3: You can also bend the special-shaped plate, connect the external plate to the bent end of the special-shaped plate, and then use a locking column to connect the external plate and the connecting plate.

[0026] Furthermore, in step 1, the adaptive neural fuzzy inference system ANFIS is introduced to dynamically adjust the height of the commutator segments according to the sensor data. Through the combination of fuzzy logic and neural network, the automatic classification and matching of commutator segments of different heights is realized to improve the selection accuracy and efficiency; the specific process is as follows:

[0027] 1. Sensor Configuration

[0028] 1. Sensor type:

[0029] Height sensor: used to measure the height of the connecting plate and the limit seat;

[0030] Thickness sensor: used to measure the thickness of the connecting plate and the limit seat;

[0031] Ultrasonic detector: Different materials have different reflection and transmission characteristics to ultrasound, so ultrasonic detectors are used to detect materials;

[0032] 2. Sensor installation:

[0033] Height sensors and thickness sensors are installed on the manufacturing production line to collect the dimension data of the connecting plate and the limit seat in real time;

[0034] The ultrasonic detector is installed on the conveyor belt of the limit seat to detect the material characteristics of the limit seat;

[0035] 2. Data Collection and Preprocessing

[0036] 1. Collect data:

[0037] Collects height, thickness and material type data from sensors;

[0038] Store the data in the database, and perform data cleaning and normalization for subsequent algorithm training;

[0039] 3. Establishment of Adaptive Neuro-Fuzzy Inference System ANFIS Model

[0040] 1. Input layer:

[0041] Input features: Connecting plate height;

[0042] Input feature x2: connecting plate thickness;

[0043] Input feature x3: stopper material type;

[0044] 2. Improved fuzzy processing:

[0045] Use Gaussian kernel function as membership function

[0046]

[0047] in, is the i-th input variable x i The membership degree of i is the center position of the Gaussian membership function, σ i is the width parameter of the Gaussian membership function;

[0048] 3. Multi-head self-attention mechanism:

[0049] Input feature matrix X:

[0050] X=[x1,x2,x3]

[0051] Among them, X is the input feature matrix, which contains all input variables;

[0052] Calculate the attention mechanism:

[0053] Q=XW Q

[0054] K=XW K

[0055] V=XW V

[0056]

[0057] Among them, d is the dimension of the input feature; Q is the query matrix, which is obtained by the input feature matrix X through the weight matrix W Q Linear transformation; K is the key matrix, which is obtained by input feature matrix X through weight matrix W K Obtained by linear transformation; V is the value matrix, which is obtained by input feature matrix X through weight matrix W V Linear transformation yields; d k is the dimension of the key matrix K; Attention(Q,K,V) is the calculation formula of the attention mechanism, which calculates the similarity between the query matrix Q and the key matrix K, and performs weighted average on the value matrix V;

[0058] Fuzzy rules:

[0059] Set the initial fuzzy rules:

[0060] R1: Ifx1isA 11 andx2isA 12 andx3is 13 theny1

[0061] =2x1+3x2+0.5x3+1

[0062] Among them, R j is the jth fuzzy rule; A ij is the fuzzy set of the i-th input variable in the j-th rule; y1: is the output of rule R1, which is the result obtained after fuzzification and fuzzy reasoning based on the input features x1, x2, x3;

[0063] Reasoning process:

[0064] Calculate the activation of each rule:

[0065]

[0066] Among them, w j The activation degree of the jth fuzzy rule is calculated by the product of the membership degrees of the input variables;

[0067] Output layer calculation:

[0068] Calculate the weighted output:

[0069]

[0070] Among them, y is the weighted output, which is obtained by the weighted average of all fuzzy rules; f j (x) is the output linear function of the jth rule; m is the total number of rules;

[0071] Among them, f j (x) is a linear function:

[0072]

[0073] Among them, p j0 ,p ji is the parameter of the linear function; i represents the index of the input variable; j represents the index of the fuzzy rule;

[0074] 4. Parameter optimization:

[0075] Use the Adam optimization algorithm to optimize the parameters and minimize the mean square error:

[0076]

[0077] Among them, L is the loss function, which is used to measure the model prediction value y k With the true value The difference between

[0078] Parameter update rules of Adam optimization algorithm:

[0079] (1) Gradient estimation:

[0080]

[0081] Among them, g t is the current gradient; is the gradient at time step t, representing the loss function L with respect to the parameter θ t The partial derivative of θ t is the model parameter at the tth iteration;

[0082] (2) Momentum estimation:

[0083] m t =β1m t-1 +(1-β1)g t

[0084] (3) Second-order momentum estimation:

[0085]

[0086] Among them, m t is the first-order momentum estimate of the gradient; vt is the second-order momentum estimate of the gradient; β1 and β2 are the momentum decay rates, which are used to control the smoothness of the momentum update;

[0087] (4) Deviation correction:

[0088]

[0089] in, is the bias-corrected first-order momentum estimate; is the bias-corrected second-order momentum estimate;

[0090] (5) Parameter update:

[0091]

[0092] Among them, θ t is the model parameter at the tth iteration; θ t+1 is the parameter vector at time step t+1; α is the learning rate, which controls the step size of parameter update; ∈ is a small constant to prevent division by zero;

[0093] 4. Achieve Control

[0094] 1. Data input:

[0095] In actual production, sensors collect data on the height, thickness and material type of the connecting plate and the limit seat in real time and input them into the ANFIS model;

[0096] 2. Reasoning and selection:

[0097] The ANFIS model infers the input data and outputs the best combination of connecting plate and limit seat.

[0098] 3. Actual operation:

[0099] According to the combined results output by the ANFIS model, the automated robot assembles the appropriate connecting plates and limit seats to form commutator segments.

[0100] Compared with the prior art, the present invention has the following beneficial effects:

[0101] 1. In the present invention, through the arrangement of the special-shaped plate and the connecting plate, if the commutator is relatively high and the height of the commutator segment does not meet the use requirements, one end of the special-shaped plate can be inserted into the trapezoidal groove. When one end of the special-shaped plate fits with one side of the trapezoidal groove, the elastic force of the third elastic column and the third spring drives the push block to move, so that the push block enters the interior of the clamping groove. At the same time, the fourth elastic column and the fourth spring drive the clamping plate to descend, pass through the through hole and enter the interior of another rectangular groove, thereby fixing half of the special-shaped plate. Similarly, the corresponding connecting plate in the other commutator segment is connected to the other half of the special-shaped plate to form a new higher commutator segment, thereby improving the application range and convenience of use of the commutator segment.

[0102] 2. In the present invention, through the setting of the limit groove and the connecting column, the corresponding connecting plates of the two commutator segments can be close to each other, so that the connecting column extends into the corresponding limit groove. In the process of the connecting column entering the limit groove, the connecting column will first squeeze the convex column, so that the second elastic column and the second spring will contract, and at the same time the plug-in column enters the wear-resistant groove through the connecting groove. When the side of the connecting column is completely fitted with the limit groove, one end of the convex column enters the wear-resistant groove, and at the same time the plug-in column enters the inside of the circular hole. Since the length of the connecting plate at the top is greater than the length of the connecting plate at the bottom, it can be ensured that the two connecting plates on the commutator segment can be stably connected to the connecting plates on other commutators.

[0103] 3. In the present invention, by setting the external plate and the locking column, half of the special-shaped plate can be connected to the connecting plate, and then the other half of the special-shaped plate is bent and connected to the external plate, and then the external plate and the connecting plate are connected together with the locking column, which can be suitable for different commutators.

[0104] 4. In the present invention, through the setting of the fixing unit, the copper wire is located between the two commutator segments, and the movable plate and the sliding plate can be driven to move under the elastic force of the fifth elastic column and the fifth spring, so that the distance between two adjacent movable plates will be reduced, and the two movable plates will squeeze the sides of the copper wire, thereby optimizing the fixing effect of the copper wire.

[0105] 5. In the present invention, the adaptive neural fuzzy inference system ANFIS is introduced to automatically identify and select the appropriate combination of the connecting plate and the limit seat. The Gaussian membership function and multi-head self-attention mechanism can be used to more accurately classify and match the commutator segments of different heights, reducing the tedious steps of manual selection and improving work efficiency.

[0106] 6. In the present invention, the combination selection of the connection plate and the limit seat is adjusted in real time through the adaptive learning ability of the ANFIS model. Combined with the multi-head self-attention mechanism and the Adam optimization algorithm, it is possible to dynamically optimize parameters during the production process, improve the adaptability and response speed of the model, and ensure that the commutator can achieve the best performance under various conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0107] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention;

[0108] Figure 2 It is a cross-sectional view of the limiting seat in the present invention;

[0109] Figure 3 It is a schematic diagram of the three-dimensional structure of the special-shaped plate in the present invention;

[0110] Figure 4 is a transverse cross-sectional view of the connecting plate of the present invention;

[0111] Figure 5 For the present invention Figure 4 A schematic diagram of the structure enlargement in the middle;

[0112] Figure 6 For the present invention Figure 4 A magnified schematic diagram of the structure at B in the middle;

[0113] Figure 7 is a vertical cross-sectional view of the connecting plate of the present invention;

[0114] Figure 8 It is a schematic diagram of the three-dimensional structure of the present invention connected with the connecting column and the external connecting plate;

[0115] Fig. 9 It is a flow chart of the intelligent algorithm in the present invention.

[0116] In the figure:

[0117] 1. Connecting plate;

[0118] 2. External unit; 201. Snap-on groove; 202. Special-shaped plate; 203. Flexible layer; 204. Through hole; 205. Trapezoidal groove; 206. Limiting groove; 207. Connecting column; 208. First elastic column; 209. First spring; 210. Plug-in column; 211. Second elastic column; 212. Second spring; 213. Groove; 214. Third spring; 215. Third elastic column; 216. Push block; 217. Active groove; 218. Convex column; 219. Wear-resistant groove; 220. Connecting groove; 221. Fourth spring; 222. Fourth elastic column; 223. Snap-on plate; 224. Rectangular groove; 225. Locking column; 226. External plate;

[0119] 3. Fixed unit; 301. Limit seat; 302. Partition plate; 303. Moving plate; 304. Fifth spring; 305. Fifth elastic column; 306. Placement slot; 307. Sliding plate. DETAILED DESCRIPTION

[0120] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0121] Example 1

[0122] like Figure 1-8 As shown, a wear-resistant commutator segment includes two connecting plates 1, an external connection unit 2 disposed inside the two connecting plates 1, and a fixing unit 3 disposed between the two connecting plates 1 for fixing a copper wire;

[0123] The external unit 2 includes connection components arranged on the left and right sides of the connection plate 1, and linkage components arranged on the front and rear sides of the connection plate 1;

[0124] The fixing unit 3 includes a limiting seat 301 fixedly connected between the two connecting plates 1 , a placement groove 306 opened inside the limiting seat 301 , and a limiting component arranged inside the placement groove 306 .

[0125] The connection assembly in the external unit 2 includes a limiting groove 206 provided on one of the left and right sides of the connection plate 1, an extension groove connected to one side of the limiting groove 206, a second elastic column 211 provided inside the extension groove, a second spring 212 provided on the surface of the second elastic column 211, a plug-in column 210 fixedly connected to one side of the second elastic column 211, a convex groove connected to the front and rear sides of the limiting groove 206, a first elastic column 208 provided inside the convex groove, a first spring 209 provided on the surface of the first elastic column 208, a convex column 218 fixedly connected to one end of the first elastic column 208, and a circular hole provided inside the convex column 218;

[0126] One end of the convex column 218 extends to the inside of the limiting groove 206, and the plug-in column 210 is matched with the circular hole, and the length of the top connecting plate 1 is greater than the length of the bottom connecting plate 1.

[0127] The connection assembly in the external unit 2 also includes a connection column 207 fixedly connected to the other left and right sides of the connection plate 1, wear-resistant grooves 219 opened on the upper and lower sides of the connection column 207, and a connecting groove 220 vertically connected to one side of the wear-resistant groove 219.

[0128] One end of the convex column 218 in the connecting assembly of the external unit 2 is matched with the wear-resistant groove 219 , and one end of the plug-in column 210 is matched with the connecting groove 220 .

[0129] The corresponding connecting plates 1 of the two commutator segments can be close to each other, so that the connecting column 207 extends into the corresponding limiting groove 206. When the connecting column 207 enters the limiting groove 206, the connecting column 207 will first squeeze the convex column 218, so that the second elastic column 211 and the second spring 212 will shrink, and the plug-in column 210 will enter the wear-resistant groove 219 through the connecting groove 220. When the side surface of the connecting column 207 is completely fitted with the limiting groove 206, one end of the convex column 218 enters the wear-resistant groove 219, and the plug-in column 210 enters the inside of the circular hole. Since the length of the top connecting plate 1 is greater than that of the bottom connecting plate 1, it can be ensured that the two connecting plates 1 on the commutator segment can be stably connected to the connecting plates 1 on other commutators.

[0130] The linkage assembly in the external unit 2 includes a trapezoidal groove 205 opened inside the front and rear sides of the connecting plate 1, a movable groove 217 connected to the two sides of the trapezoidal groove 205, a third elastic column 215 arranged inside the movable groove 217, a third spring 214 arranged on the surface of the third elastic column 215, a push block 216 fixedly connected to one side of the third elastic column 215, a rectangular groove 224 connected to the upper and lower sides of the trapezoidal groove 205, a fourth elastic column 222 fixedly connected to the inside of one of the rectangular grooves 224, a fourth spring 221 arranged on the surface of the fourth elastic column 222, and a clamping plate 223 fixedly connected to one end of the fourth elastic column 222.

[0131] The linkage assembly in the external unit 2 further includes a special-shaped plate 202 disposed inside the trapezoidal groove 205, a flexible layer 203 symmetrically disposed inside the special-shaped plate 202, a clamping groove 201 disposed on four sides of the special-shaped plate 202, and a through hole 204 symmetrically disposed inside the special-shaped plate 202;

[0132] The special-shaped plate 202 is symmetrically composed of two trapezoidal plates, and the four sides of the special-shaped plate 202 have a certain curvature.

[0133] The clamping plate 223 in the external unit 2 extends to the inside of the rectangular slot 224 through the corresponding through hole 204 , and the pushing block 216 is flush with the corresponding clamping slot 201 .

[0134] If the commutator is relatively high and the height of the commutator segment does not meet the use requirements, one end of the special-shaped plate 202 can be inserted into the trapezoidal groove 205. When one end of the special-shaped plate 202 fits against one side of the trapezoidal groove 205, the elastic force of the third elastic column 215 and the third spring 214 drives the push block 216 to move, so that the push block 216 enters the inside of the clamping groove 201. At the same time, the fourth elastic column 222 and the fourth spring 221 drive the clamping plate 223 to descend, pass through the through hole 204 and enter the inside of another rectangular groove 224, thereby fixing half of the special-shaped plate 202. Similarly, the corresponding connecting plate 1 in the other commutator segment is connected to the other half of the special-shaped plate 202 to form a new higher commutator segment, thereby improving the application range and convenience of use of the commutator segment.

[0135] The external unit 2 further includes grooves 213 formed on the front and rear sides of the connecting plate 1, an external plate 226 disposed at the other end of the special-shaped plate 202, and a locking column 225 fixedly connected to the bottom end of the external plate 226;

[0136] The bottom end of the locking column 225 is engaged with the corresponding groove 213 .

[0137] The limiting assembly in the fixing unit 3 includes a partition plate 302 fixedly connected to the middle of the placement groove 306, a plurality of fifth elastic columns 305 fixedly connected to both sides of the partition plate 302, a fifth spring 304 arranged on the surface of the fifth elastic column 305, a moving plate 303 fixedly connected to one end of the fifth elastic column 305, and a sliding plate 307 fixedly connected to both ends of one side of the moving plate 303;

[0138] One end of the sliding plate 307 extends to the inside of the housing of the limiting seat 301 .

[0139] The copper wire is located between the two commutator segments, and the fifth elastic column 305 and the fifth spring 304 can drive the moving plate 303 and the sliding plate 307 to move, so that the distance between two adjacent moving plates 303 is reduced, and the two moving plates 303 squeeze the side of the copper wire, thereby optimizing the fixing effect of the copper wire;

[0140] A method for manufacturing a wear-resistant commutator segment comprises the following steps:

[0141] Step 1: Connect the two connecting plates 1 and the limit seat 301 together to form a commutator segment; introduce the adaptive neural fuzzy inference system ANFIS to dynamically adjust the height of the commutator segment according to the sensor data. Through the combination of fuzzy logic and neural network, the automatic classification and matching of commutator segments of different heights can be realized to improve the selection accuracy and efficiency; the specific process is:

[0142] 1. Sensor Configuration

[0143] 1. Sensor type:

[0144] Height sensor: used to measure the height of the connecting plate and the limit seat;

[0145] Thickness sensor: used to measure the thickness of the connecting plate and the limit seat;

[0146] Ultrasonic detector: Different materials have different reflection and transmission characteristics to ultrasonic waves. Ultrasonic detectors are used to detect materials. Commonly used limit seat materials are detected by the detector to form historical data.

[0147] 2. Sensor installation:

[0148] Height sensors and thickness sensors are installed on the manufacturing production line to collect the dimension data of the connecting plate and the limit seat in real time;

[0149] The ultrasonic detector is installed on the conveyor belt of the limit seat to detect the material characteristics of the common limit seat, thereby forming historical data; or measure the conductivity (or spectral characteristics) of the material by means of conductivity (or spectral analysis) measurement to determine the material type.

[0150] 2. Data Collection and Preprocessing

[0151] 1. Collect data:

[0152] Collects height, thickness and material type data from sensors;

[0153] Store the data in the database, and perform data cleaning and normalization for subsequent algorithm training;

[0154] 3. Establishment of Adaptive Neuro-Fuzzy Inference System ANFIS Model

[0155] 1. Input layer:

[0156] Input features: Connecting plate height;

[0157] Input feature x2: connecting plate thickness;

[0158] Input feature x3: stopper material type;

[0159] 2. Improved fuzzy processing:

[0160] Use Gaussian kernel function as membership function

[0161]

[0162] in, is the i-th input variable x i The membership degree of i is the center position of the Gaussian membership function, σ i is the width parameter of the Gaussian membership function;

[0163] 3. Multi-head self-attention mechanism:

[0164] Input feature matrix X:

[0165] X=[x1,x2,x3]

[0166] Among them, X is the input feature matrix, which contains all input variables;

[0167] Calculate the attention mechanism:

[0168] Q=XW Q

[0169] K=XW K

[0170] V=XW V

[0171]

[0172] Among them, d is the dimension of the input feature; Q is the query matrix, which is the input feature matrix X through the weight matrix W Q Linear transformation; K is the key matrix, which is obtained by input feature matrix X through weight matrix W K Obtained by linear transformation; V is the value matrix, which is obtained by input feature matrix X through weight matrix W V Linear transformation yields; d k is the dimension of the key matrix K; Attention(Q,K,V) is the calculation formula of the attention mechanism, which calculates the similarity between the query matrix Q and the key matrix K, and performs weighted average on the value matrix V;

[0173] Fuzzy rules:

[0174] Set the initial fuzzy rules:

[0175] R1: Ifx1isA 11 andx2isA 12 andx3is 13 theny1

[0176] =2x1+3x2+0.5x3+1

[0177] Among them, R j is the jth fuzzy rule; A ij is the fuzzy set of the i-th input variable in the j-th rule; y1: is the output of rule R1, which is the result obtained after fuzzification and fuzzy reasoning based on the input features x1, x2, x3;

[0178] Reasoning process:

[0179] Calculate the activation of each rule:

[0180]

[0181] Among them, w j The activation degree of the jth fuzzy rule is calculated by the product of the membership degrees of the input variables;

[0182] Output layer calculation:

[0183] Calculate the weighted output:

[0184]

[0185] Among them, y is the weighted output, which is obtained by the weighted average of all fuzzy rules; f j (x) is the output linear function of the jth rule; m is the total number of rules;

[0186] Among them, f j (x) is a linear function:

[0187]

[0188] Among them, p j0 ,p ji is the parameter of the linear function; i represents the index of the input variable; j represents the index of the fuzzy rule;

[0189] 4. Parameter optimization:

[0190] Use the Adam optimization algorithm to optimize the parameters and minimize the mean square error:

[0191]

[0192] Among them, L is the loss function, which is used to measure the model prediction value y k With the true value The difference between

[0193] Parameter update rules of Adam optimization algorithm:

[0194] (1) Gradient estimation:

[0195]

[0196] Among them, g t is the current gradient; is the gradient at time step t, representing the loss function L with respect to the parameter θ t The partial derivative of θ t is the model parameter at the tth iteration;

[0197] (2) Momentum estimation:

[0198] m t =β1m t-1 +(1-β1)g t

[0199] (3) Second-order momentum estimation:

[0200]

[0201] Among them, m t is the first-order momentum estimate of the gradient; v t is the second-order momentum estimate of the gradient; β1 and β2 are the momentum decay rates, which are used to control the smoothness of the momentum update;

[0202] (4) Deviation correction:

[0203]

[0204] in, is the bias-corrected first-order momentum estimate; is the bias-corrected second-order momentum estimate;

[0205] (5) Parameter update:

[0206]

[0207] Among them, θ t is the model parameter at the tth iteration; θ t+1 is the parameter vector at time step t+1; α is the learning rate, which controls the step size of parameter update; ∈ is a small constant to prevent division by zero;

[0208] 4. Achieve Control

[0209] 1. Data input:

[0210] In actual production, sensors collect data on the height, thickness and material type of the connecting plate and the limit seat in real time and input them into the ANFIS model;

[0211] 2. Reasoning and selection:

[0212] The ANFIS model infers the input data and outputs the best combination of connecting plate and limit seat.

[0213] 3. Actual operation:

[0214] According to the combined results output by the ANFIS model, the automated robot assembles the appropriate connecting plates and limit seats to form commutator segments.

[0215] Numerical case analysis:

[0216] Connecting plate height x1: 10mm

[0217] Connecting plate thickness x2: 5mm

[0218] Limit seat material type x3:1

[0219] Fuzzy processing:

[0220] Apply Gaussian membership functions to height x1, thickness x2, and material type x3 respectively:

[0221]

[0222] Attention mechanism calculation:

[0223] Input feature matrix X:

[0224] X=[10,5,1]

[0225] Q=XW Q ,K=XW K ,V=XW V

[0226] Calculate the attention mechanism:

[0227]

[0228] Fuzzy rule activation degree:

[0229] Activation of rule R1:

[0230]

[0231] Weighted output calculation:

[0232] f1(x)=2x1+3x2+0.5x3+1

[0233]

[0234] Parameter optimization:

[0235] The Adam optimization algorithm is used to update the parameters to ensure that the model is gradually optimized in multiple iterations to achieve the best performance.

[0236] Step 2: insert one end of the special-shaped plate 202 into the trapezoidal groove 205 according to the use requirements, use the push block 216 and the clamping plate 223 to limit the movement of the special-shaped plate 202, and connect another group of connecting plates 1 to the special-shaped plate 202;

[0237] Step 3: The special-shaped plate 202 may be bent, and then the external plate 226 may be connected to the bent end of the special-shaped plate 202 , and then the locking column 225 may be used to connect the external plate 226 and the connecting plate 1 .

[0238] Example 2

[0239] like Figure 1-8 As shown, a wear-resistant commutator segment includes two connecting plates 1, an external connection unit 2 disposed inside the two connecting plates 1, and a fixing unit 3 disposed between the two connecting plates 1 for fixing a copper wire;

[0240] The external unit 2 includes connection components arranged on the left and right sides of the connection plate 1, and linkage components arranged on the front and rear sides of the connection plate 1;

[0241] The fixing unit 3 includes a limiting seat 301 fixedly connected between the two connecting plates 1 , a placement groove 306 opened inside the limiting seat 301 , and a limiting component arranged inside the placement groove 306 .

[0242] The connection assembly in the external unit 2 includes a limiting groove 206 provided on one of the left and right sides of the connection plate 1, an extension groove connected to one side of the limiting groove 206, a second elastic column 211 provided inside the extension groove, a second spring 212 provided on the surface of the second elastic column 211, a plug-in column 210 fixedly connected to one side of the second elastic column 211, a convex groove connected to the front and rear sides of the limiting groove 206, a first elastic column 208 provided inside the convex groove, a first spring 209 provided on the surface of the first elastic column 208, a convex column 218 fixedly connected to one end of the first elastic column 208, and a circular hole provided inside the convex column 218;

[0243] One end of the convex column 218 extends to the inside of the limiting groove 206, and the plug-in column 210 is matched with the circular hole, and the length of the top connecting plate 1 is greater than the length of the bottom connecting plate 1.

[0244] The connection assembly in the external unit 2 also includes a connection column 207 fixedly connected to the other left and right sides of the connection plate 1, wear-resistant grooves 219 opened on the upper and lower sides of the connection column 207, and a connecting groove 220 vertically connected to one side of the wear-resistant groove 219.

[0245] One end of the convex column 218 in the connecting assembly of the external unit 2 is matched with the wear-resistant groove 219 , and one end of the plug-in column 210 is matched with the connecting groove 220 .

[0246] The linkage assembly in the external unit 2 includes a trapezoidal groove 205 opened inside the front and rear sides of the connecting plate 1, a movable groove 217 connected to the two sides of the trapezoidal groove 205, a third elastic column 215 arranged inside the movable groove 217, a third spring 214 arranged on the surface of the third elastic column 215, a push block 216 fixedly connected to one side of the third elastic column 215, a rectangular groove 224 connected to the upper and lower sides of the trapezoidal groove 205, a fourth elastic column 222 fixedly connected to the inside of one of the rectangular grooves 224, a fourth spring 221 arranged on the surface of the fourth elastic column 222, and a clamping plate 223 fixedly connected to one end of the fourth elastic column 222.

[0247] The linkage assembly in the external unit 2 further includes a special-shaped plate 202 disposed inside the trapezoidal groove 205, a flexible layer 203 symmetrically disposed inside the special-shaped plate 202, a clamping groove 201 disposed on four sides of the special-shaped plate 202, and a through hole 204 symmetrically disposed inside the special-shaped plate 202;

[0248] The special-shaped plate 202 is symmetrically composed of two trapezoidal plates, and the four sides of the special-shaped plate 202 have a certain curvature.

[0249] Half of the special-shaped plate 202 can be connected to the connecting plate 1, and then the other half of the special-shaped plate 202 can be bent and connected to the external plate 226, and then the external plate 226 and the connecting plate 1 can be connected together with the locking column 225, which can be suitable for different commutators.

[0250] The clamping plate 223 in the external unit 2 extends to the inside of the rectangular slot 224 through the corresponding through hole 204 , and the pushing block 216 is flush with the corresponding clamping slot 201 .

[0251] The external unit 2 further includes grooves 213 formed on the front and rear sides of the connecting plate 1, an external plate 226 disposed at the other end of the special-shaped plate 202, and a locking column 225 fixedly connected to the bottom end of the external plate 226;

[0252] The bottom end of the locking column 225 is engaged with the corresponding groove 213 .

[0253] The limiting assembly in the fixing unit 3 includes a partition plate 302 fixedly connected to the middle of the placement groove 306, a plurality of fifth elastic columns 305 fixedly connected to both sides of the partition plate 302, a fifth spring 304 arranged on the surface of the fifth elastic column 305, a moving plate 303 fixedly connected to one end of the fifth elastic column 305, and a sliding plate 307 fixedly connected to both ends of one side of the moving plate 303;

[0254] One end of the sliding plate 307 extends to the inside of the housing of the limiting seat 301 .

[0255] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A wear-resistant commutator segment, comprising two connecting plates, characterized in that: It also includes an external connection unit disposed inside the two connection plates, and a fixing unit disposed between the two connection plates for fixing the copper wire; The external connection unit includes connection components arranged on the left and right sides of the connection plate, and linkage components arranged on the front and rear sides of the connection plate; The fixing unit includes a limiting seat fixedly connected between the two connecting plates, a placement groove opened inside the limiting seat, and a limiting component arranged inside the placement groove; The connecting assembly in the external unit includes a limiting groove provided on one side of the connecting plate, an extension groove connected to one side of the limiting groove, a second elastic column provided inside the extension groove, a second spring provided on the surface of the second elastic column, a plug-in column fixedly connected to one side of the second elastic column, a convex groove connected to the front and rear sides of the limiting groove, a first elastic column provided inside the convex groove, a first spring provided on the surface of the first elastic column, a convex column fixedly connected to one end of the first elastic column, and a circular hole provided inside the convex column; One end of the convex column extends into the interior of the limiting groove, and the plug-in column is matched with the circular hole; The linkage assembly in the external unit includes a trapezoidal groove opened inside the front and rear sides of the connecting plate, a movable groove connected to the two sides of the trapezoidal groove, a third elastic column arranged inside the movable groove, a third spring arranged on the surface of the third elastic column, a push block fixedly connected to one side of the third elastic column, a rectangular groove connected to the upper and lower sides of the trapezoidal groove, a fourth elastic column fixedly connected to the inside of one of the rectangular grooves, a fourth spring arranged on the surface of the fourth elastic column, and a clamping plate fixedly connected to one end of the fourth elastic column.

2. A wear-resistant commutator segment according to claim 1, characterized in that: The connection assembly in the external unit also includes a connection column fixedly connected to the other left and right sides of the connection plate, wear-resistant grooves opened on the upper and lower sides of the connection column, and a connecting groove vertically connected to one side of the wear-resistant groove.

3. A wear-resistant commutator segment according to claim 2, characterized in that: One end of the convex column in the external unit connection assembly is matched with the wear-resistant groove, and one end of the plug-in column is matched with the communication groove.

4. The wear-resistant commutator segment according to claim 1, characterized in that: The linkage assembly in the external unit also includes a special-shaped plate arranged inside the trapezoidal groove, a flexible layer symmetrically arranged inside the special-shaped plate, a clamping groove arranged on four sides of the special-shaped plate, and a through hole symmetrically arranged inside the special-shaped plate.

5. A wear-resistant commutator segment according to claim 4, characterized in that: The clamping plate in the external unit extends to the inside of the rectangular groove through the corresponding through hole, and the pushing block is flush with the corresponding clamping groove.

6. A wear-resistant commutator segment according to claim 5, characterized in that: The external connection unit also includes grooves provided on the front and rear sides of the connection plate, an external connection plate provided on the other end of the special-shaped plate, and a locking column fixedly connected to the bottom end of the external connection plate; The bottom end of the locking column is engaged with the corresponding groove.

7. The wear-resistant commutator segment according to claim 6, characterized in that: The limiting assembly in the fixing unit includes a partition plate fixedly connected to the middle of the placement groove, a plurality of fifth elastic columns fixedly connected to both sides of the partition plate, a fifth spring arranged on the surface of the fifth elastic column, a moving plate fixedly connected to one end of the fifth elastic column, and a sliding plate fixedly connected to both ends of one side of the moving plate; One end of the sliding plate extends to the interior of the housing of the limiting seat.

8. A method for manufacturing a wear-resistant commutator segment, which is applied to the wear-resistant commutator segment according to claim 1, characterized in that: The following steps are involved: Step 1: Connect the two connecting plates and the limit seat together to form a commutator segment; Step 2: Insert one end of the special-shaped plate into the trapezoidal groove according to the use requirements, use the push block and the clamping plate to limit the movement of the special-shaped plate, and connect the other set of connecting plates to the special-shaped plate; Step 3: bend the special-shaped plate, connect the external plate to the bent end of the special-shaped plate, and then use a locking column to connect the external plate and the connecting plate.

9. A method for manufacturing a wear-resistant commutator segment according to claim 8, characterized in that: In step 1, the adaptive neural fuzzy inference system ANFIS is introduced to dynamically adjust the height of the commutator segments according to the sensor data. Through the combination of fuzzy logic and neural network, the automatic classification and matching of commutator segments of different heights is realized to improve the selection accuracy and efficiency. The specific process is as follows:

1. Sensor Configuration 1. Sensor type: Height sensor: used to measure the height of the connecting plate and the limit seat; Thickness sensor: used to measure the thickness of the connecting plate and the limit seat; Ultrasonic detector: Different materials have different reflection and transmission characteristics to ultrasound, so ultrasonic detectors are used to detect materials; 2. Sensor installation: Height sensors and thickness sensors are installed on the manufacturing production line to collect the dimension data of the connecting plate and the limit seat in real time; 2. Data Collection and Preprocessing 1. Collect data: Collects height, thickness and material type data from sensors; Store the data in the database, and perform data cleaning and normalization for subsequent algorithm training; 3. Establishment of Adaptive Neuro-Fuzzy Inference System ANFIS Model 1. Input layer: Input features: Connecting plate height; Input feature x2: connecting plate thickness; Input feature x3: stopper material type; 2. Improved fuzzy processing: Use Gaussian kernel function as membership function in, is the i-th input variable x i The membership degree of i is the center position of the Gaussian membership function, σ i is the width parameter of the Gaussian membership function; 3. Multi-head self-attention mechanism: Input feature matrix X: X=[x1,x2,x3] Among them, X is the input feature matrix, which contains all input variables; Calculate the attention mechanism: Q=XW Q K=XW K V=XW V Among them, d is the dimension of the input feature; Q is the query matrix, which is obtained by the input feature matrix X through the weight matrix W Q Linear transformation; K is the key matrix, which is obtained by input feature matrix X through weight matrix W K Obtained by linear transformation; V is the value matrix, which is obtained by input feature matrix X through weight matrix W V Linear transformation yields; d k is the dimension of the key matrix K; Attention(Q,K,V) is the calculation formula of the attention mechanism, which calculates the similarity between the query matrix Q and the key matrix K, and performs weighted average on the value matrix V; Fuzzy rules: Set the initial fuzzy rules: R1:Ifx1isA 11 andx2isA 12 andx3isA 13 theny1 =2x1+3x2+0.5x3+1 Among them, R j is the jth fuzzy rule; A ij is the fuzzy set of the i-th input variable in the j-th rule; y1: is the output of rule R1, which is the result obtained after fuzzification and fuzzy reasoning based on the input features x1, x2, x3; Reasoning process: Calculate the activation of each rule: Among them, w j The activation degree of the jth fuzzy rule is calculated by the product of the membership degrees of the input variables; Output layer calculation: Calculate the weighted output: Among them, y is the weighted output, which is obtained by the weighted average of all fuzzy rules; f j (x) is the output linear function of the jth rule; m is the total number of rules; Among them, f j (x) is a linear function: Among them, p j0 ,p ji is the parameter of the linear function; i represents the index of the input variable; j represents the index of the fuzzy rule; 4. Parameter optimization: Use the Adam optimization algorithm to optimize the parameters and minimize the mean square error: Among them, L is the loss function, which is used to measure the model prediction value y k With the true value The difference between Parameter update rules of Adam optimization algorithm: (1) Gradient estimation: Among them, g t is the current gradient; is the gradient at time step t, representing the loss function L with respect to the parameter θ t The partial derivative of θ t is the model parameter at the tth iteration; (2) Momentum estimation: m t =β1m t-1 +(1-β1)g t (3) Second-order momentum estimation: Among them, m t is the first-order momentum estimate of the gradient; v t is the second-order momentum estimate of the gradient; β1 and β2 are the momentum decay rates, which are used to control the smoothness of the momentum update; (4) Deviation correction: in, is the bias-corrected first-order momentum estimate; is the bias-corrected second-order momentum estimate; (5) Parameter update: Among them, θ t is the model parameter at the tth iteration; θ t+1 is the parameter vector at time step t+1; α is the learning rate, which controls the step size of parameter update; ∈ is a small constant to prevent division by zero; 4. Achieve Control 1. Data input: In actual production, sensors collect data on the height, thickness and material type of the connecting plate and the limit seat in real time and input them into the ANFIS model; 2. Reasoning and selection: The ANFIS model infers the input data and outputs the best combination of connecting plate and limit seat.

3. Actual operation: According to the combined results output by the ANFIS model, the automated robot assembles the appropriate connecting plates and limit seats to form commutator segments.

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