An electric driving rotor assembling tool and a method thereof

Abstract

The application discloses an electric driving rotor assembling tool and a using method thereof, and belongs to the technical field of rotor assembling tools, which comprises a driving motor, a servo press, an XY adjusting mechanism and an angular adjusting mechanism. The driving motor can drive the servo press and the whole tool to move up and down. A rotor clamping cylinder carries a rotor assembly to a specified position. A Z-direction pressure sensor feeds back a pressure value to a controller. The controller judges whether the angular adjusting mechanism needs to rotate counterclockwise by a specific angle. After rotation, the controller determines whether the servo press needs to continue pressure assembly according to the cycle number. The whole process is dynamically positioned by driving the linear motor in the direction of the XYZ sensor detection value real-time calculation. The application has the advantages of simple structure, low cost, pressure feedback dynamic positioning, improved assembly precision, reduced abnormal stress alarm frequency, improved production line efficiency and assembly quality.

Description

Technical Field

[0001] This invention belongs to the field of rotor assembly tooling technology, specifically an electrically driven rotor assembly tooling and its usage method. Background Technology

[0002] In the electric drive assembly line of the new energy industry, the rotor assembly is assembled into the reducer. This requires the rotor shaft splines to be aligned and inserted into the spline sleeve inside the reducer. Because the rotor assembly lacks angular positioning or its positioning is inaccurate, and the angular orientation of the spline sleeve inside the reducer is also random, the rotor assembly requires multiple adjustments to the angle and mating pressure to assemble the spline shaft into the spline sleeve. Before assembly, the rotor shaft splines are mostly in contact with the mating end face of the spline sleeve under certain pressure. This poses a risk of damaging the spline shaft or sleeve due to friction during key rotation. Furthermore, the friction can cause the reducer spline sleeve to rotate, preventing the spline shaft from being properly aligned and triggering a timeout alarm. Additionally, due to inherent errors in the production line's positioning pallet tooling, the entire assembly process relies on rigid fit. This results in the pressure-displacement curve of the press-fitting process frequently exceeding the preset window and exhibiting irregularity, severely impacting the production line's equipment uptime and product assembly quality.

[0003] Another assembly process in the industry involves using two industrial cameras to photograph the rotor assembly spline shaft and the reducer spline sleeve separately. The camera controller identifies angular deviations, and the control mechanism adjusts the rotor shaft angle to ensure that the rotor shaft spline aligns perfectly with the spline sleeve before pressing. However, due to the small inner diameter and deep location of the spline sleeve, and the need for additional mechanisms to prevent the spline sleeve from rotating after photography, existing cameras and their light sources are large, bulky, and complex to operate. The resulting image quality is unsatisfactory, the recognition rate is low, the hardware cost is too high, debugging is difficult, and the detection is unstable. Furthermore, this solution also fails to address the issue of irregular displacement and pressure curves during spline assembly, leaving no room for potential spline damage. Summary of the Invention

[0004] To address the above problems, this invention provides an electrically driven rotor assembly fixture and its usage method, including a drive motor, a servo press, an XY-axis adjustment mechanism, and an angular adjustment mechanism. The drive motor can drive the servo press and the fixture as a whole to move up and down. The rotor clamping cylinder carries the rotor assembly down to a designated position. The Z-axis pressure sensor feeds back the pressure value to the controller. The controller determines whether the angular adjustment mechanism needs to be rotated counterclockwise by a specific angle. After rotation, the controller determines whether the servo press needs to continue pressing based on the number of cycles. The entire process is dynamically positioned by the drive linear motor in real time based on the XYZ-axis sensor detection values. This invention has a simple structure, low cost, and dynamic positioning with pressure feedback, which can effectively improve assembly accuracy, reduce the frequency of abnormal force alarms, and thus improve production line efficiency and assembly quality.

[0005] The technical solution of this invention is as follows: an electrically driven rotor assembly fixture, comprising: a drive motor, a servo press, an XY-axis adjustment mechanism, and an angular adjustment mechanism; the drive motor is capable of driving the servo press and the fixture as a whole to move up and down.

[0006] The XY-axis adjustment mechanism includes a servo motor, a reducer, an X-axis linear motor, a Y-axis linear motor, a moving base plate, a linear slide rail, a structural gear connecting base plate, a driving gear, and a driven structural gear. The moving base plate is fixed on the slider of the linear slide rail. The Y-axis linear motor is located below the moving base plate, and the X-axis linear motor is located below the Y-axis linear motor and connected by a connecting plate. The structural gear connecting base plate is fixed to the lower side of the X-axis linear motor bearing. The lower side of the reducer is fixed on the structural gear connecting base plate, and the upper side of the reducer is connected to the servo motor. The driven structural gear is connected to the structural gear connecting base plate, and the driving gear meshes with the driven structural gear. The driving gear is fixed on the output spindle of the reducer.

[0007] The angular adjustment mechanism includes a rotating bracket, an angular locking base, a base lifting cylinder, a base slide rail, an angular floating base plate, a spring support assembly, a rotor positioning fixture, a rotor clamping cylinder, XY-axis pressure sensors, and Z-axis pressure sensors.

[0008] The rotating bracket is fixed to the lower side of the passive gear structure. Two sets of base slide rails are installed inside the rotating bracket. The slider of the base slide rail is fixed to the angular locking base. The piston rod of the base lifting cylinder is connected to the rotating bracket. The cylinder body of the base lifting cylinder is connected to the angular locking base. The upper end of the spring support assembly is connected to the rotating bracket. The lower end of the spring support assembly is fixed to the angular floating base plate. There is a Z-axis pressure sensor between the assemblies. The rotor positioning fixture is fixed to the angular floating base plate through the slide rail. XY-axis pressure sensors are installed between the rotating bracket and the angular floating base plate. The rotor clamping cylinder is fixed to the rotor positioning fixture.

[0009] Furthermore, there are two Y-axis linear motors, arranged in parallel below the moving base plate.

[0010] Furthermore, the angular adjustment mechanism also includes a counterweight, which is fixed on the rotor positioning fixture.

[0011] A method for using an electrically driven rotor assembly fixture, specifically as follows:

[0012] The rotor clamping cylinder carries the rotor assembly, and the tooling drives the rotor assembly to descend to the designated position. The servo press pushes the assembled tooling to move the rotor assembly downwards. The Z-axis pressure sensor feeds back the pressure value to the controller. The controller judges and identifies the pressure. If the pressure is greater than the set value, the controller controls the servo press to move upwards, and the angular adjustment mechanism rotates counterclockwise by 1 / 5a, where a is the included angle between adjacent spline teeth. After rotation, the controller judges the number of cycles. If the number of cycles is >5, the equipment fault alarm is triggered; if the number of cycles is ≤5, the servo press continues to move downwards. When the Z-axis pressure sensor... When the detected value is less than the set value, the servo press presses downwards. The XY-axis pressure sensor dynamically detects the pressure. The controller calculates the value in real time based on the XY-axis pressure sensor detection and drives the linear motor to dynamically position itself in the horizontal direction and continue pressing downwards. The controller collects data from the XY-axis pressure sensor in real time. If the force is unstable or continues to increase, the angular adjustment mechanism is unlocked, allowing the rotor shaft inside the spline sleeve to slide angularly with the spline sleeve. The press continues to press downwards. If the force is good, the press presses down to the final position and completes the pressing. If the force does not improve, the equipment alarms, and the quality assurance personnel confirm the product status on-site.

[0013] Furthermore, the specified position is 2mm above the spline of the reducer.

[0014] Furthermore, the downward movement distance is 4mm, and the upward movement distance is 4mm.

[0015] The beneficial effects of this invention are as follows:

[0016] This invention eliminates rotation during the press-in process, preventing friction or damage between the spline shaft and spline sleeve during assembly. The rotor positioning fixture uses four pressure sensors to provide pressure feedback. The industrial computer calculates the required offset of the XY-axis linear motor slide rails, which actively adjust their position to ensure the rotor assembly spline shaft, fixed by the assembly fixture, experiences minimal or uniform radial force during press-in, guaranteeing a consistent press-in curve. Furthermore, the fixture features angular floating functionality to address angular deviations caused by poor pallet interchangeability and inaccurate positioning, ensuring high-quality rotor assembly. This solution is simple in structure, low in cost, and features dynamic positioning with pressure feedback, effectively improving assembly accuracy and reducing the frequency of abnormal force alarms, thereby enhancing production line efficiency and assembly quality. Attached Figure Description

[0017] Figure 1 This is a simplified diagram of the press-fitting fixture.

[0018] Figure 2 This is a flowchart of the press-fit control process.

[0019] Figure 3 Simplified diagram I for adjusting the structure in the XY direction.

[0020] Figure 4 Simplified diagram II for adjusting the structure in the XY direction

[0021] Figure 5 Schematic diagram of the angular adjustment mechanism

[0022] In the picture:

[0023] 1. Drive motor; 2. XY axis adjustment mechanism; 3. Angle adjustment mechanism; 4. Servo press; 201. Servo motor; 202. Reducer; 203. X-axis linear motor; 204. Y-axis linear motor; 205. Moving base plate; 206. Linear slide rail; 207. Structural gear connecting base plate; 208. Driving gear; 209. Passive structural gear; 301. Rotary bracket; 302. Angle locking base; 303. Base lifting cylinder; 304. Base slide rail; 305. Angle floating base plate; 306. Spring support assembly; 307. Rotor positioning fixture; 308. Rotor clamping cylinder; 309. Counterweight; 310. XY axis pressure sensor; 311. Z-axis pressure sensor. Detailed Implementation

[0024] It should be noted that in the description of this invention, the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation.

[0025] In this invention, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; a connection can be a mechanical connection or an electrical connection; a link can be a direct connection or an indirect connection through an intermediate medium, and can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0026] An electrically driven rotor assembly fixture includes a drive motor 1, a servo press 4, an XY-axis adjustment mechanism 2, and an angular adjustment mechanism 3. The drive motor 1 drives the servo press 4 and the fixture as a whole to move up and down, generally to about 2mm above the spline position. The servo press 4 presses the rotor. The adjustment part of the assembly fixture includes the XY-axis adjustment mechanism 2 and the angular adjustment mechanism 3. The XY-axis adjustment mechanism 2 can feed back the value of the XY-axis pressure sensor 310 to the controller. The controller calculates the horizontal adjustment amount and drives the two sets of linear motors of the XY-axis adjustment mechanism 2 to move and dynamically position accordingly, ensuring the optimal force process of the fixture during pressing. If the adjustment is ineffective, the angular adjustment mechanism 3 is opened to complete the free pressing of the rotor shaft spline and spline sleeve.

[0027] Initially, the rotor clamping cylinder 308 carries the rotor assembly. The drive motor 1 drives the rotor assembly to descend to the designated position. The servo press 4 pushes the assembly fixture to carry the rotor assembly to continue moving downward by 4mm. The Z-axis pressure sensor 311 feeds back the pressure value to the controller. The controller judges and identifies the pressure. If the pressure is greater than the set value, it means that the rotor shaft and spline are not aligned, thus generating positive pressure. The controller controls the servo press 4 to move upward by 4mm. The angular adjustment mechanism 3 rotates counterclockwise by 1 / 5a (a is the included angle between adjacent spline teeth). After rotation, the controller judges the number of cycles. If it is ≤5 times, the press continues to move downward by 4mm. If it is >5 times, the equipment fault alarm is triggered. When the Z-axis pressure sensor 311 detects a value less than the set value, it indicates that the spline and spline sleeve are aligned. The press continues to press downwards. The XY-axis pressure sensor 310 dynamically detects the spline. The controller calculates the value of the XY-axis pressure sensor 310 in real time and drives the linear motor to dynamically position itself in the horizontal direction and continue pressing downwards. The controller collects data from the XY-axis pressure sensor 310 in real time. If the force is unstable or continues to increase, the angular adjustment mechanism 3 is unlocked, allowing the rotor shaft inside the spline sleeve to slide angularly with the spline sleeve. The press continues to press downwards. If the force is good, the press is pressed down to the desired position and the pressing is completed. If the force does not improve, the equipment alarms, and the quality assurance personnel confirm the product status on-site.

[0028] The XY-axis adjustment mechanism 2 includes a servo motor 201, a reducer 202, an X-axis linear motor 203, a Y-axis linear motor 204, a moving base plate 205, a linear slide rail 206, a structural gear connecting base plate 207, a driving gear 208, and a passive structural gear 209.

[0029] The movable base plate 205 is fixed on the slider of the linear slide rail 206. Two sets of Y-axis linear motors 204 are placed parallel to each other on the lower side of the movable base plate 205. The X-axis linear motor 203 is placed on the lower side of the Y-axis linear motor 204 and connected by a connecting plate. The structural gear connecting base plate 207 is fixed to the lower side of the bearing of the X-axis linear motor 203. The lower side of the reducer 202 is fixed to the structural gear connecting base plate 207. The upper side of the reducer 202 is connected to the servo motor 201. The passive structural gear 209 is connected to the structural gear connecting base plate 207. The active gear 208 meshes with the passive structural gear 209. The active gear 208 is fixed on the output spindle of the reducer 202.

[0030] The angular adjustment mechanism 3 includes a rotating bracket 301, an angular locking base 302, a base lifting cylinder 303, a base slide rail 304, an angular floating base plate 305, a spring support assembly 306, a rotor positioning fixture 307, a rotor clamping cylinder 308, a counterweight 309, an XY-axis pressure sensor 310, and a Z-axis pressure sensor 311.

[0031] The rotating bracket 301 is fixed to the lower side of the passive structure gear 209. Two sets of base slide rails 304 are installed inside the rotating bracket 301. The slider of the base slide rail 304 is fixed on the angular locking base 302. The piston rod of the base lifting cylinder 303 is connected to the rotating bracket 301. The cylinder body of the base lifting cylinder 303 is connected to the angular locking base 302. The upper end of the spring support assembly 306 is connected to the rotating bracket 301. The lower end of the spring support assembly 306 is fixed on the angular floating base plate 305. There is a Z-axis pressure sensor 311 between the assemblies. The rotor positioning fixture 307 is fixed to the angular floating base plate 305 through the slide rail. An XY-axis pressure sensor 310 is installed between the rotating bracket 301 and the angular floating base plate 305. The rotor clamping cylinder 308 and the counterweight 309 are respectively fixed on the rotor positioning fixture 307.

[0032] The rotor clamping cylinder 308 clamps the rotor, and the servo press 4 moves downward to the designated position, generally 2mm above the spline of the reducer. The servo press 4 drives the press head to move downward by 4mm. If the spline does not enter, the spring support assembly 306 spring is compressed, the Z-axis pressure sensor 311 exceeds the set value, the servo press 4 returns to the original position, the servo motor 201 rotates, driving the reducer 202, the drive gear 208 rotates with the reducer 202, and drives the passive structure gear 209 to rotate by 1 / 5a angle. At the same time, the angle adjustment mechanism 3 connected to the lower side rotates together with the passive structure gear 209. The servo press 4 continues to press downward by 4mm until the spline enters the spline sleeve. The Z-axis pressure sensor 311 is less than the set value. At this time, the XY-axis pressure sensor 310 is activated to monitor the pressure in real time. The controller 5 calculates and drives the X-axis linear motor 203 and the Y-axis linear motor 204 to drive the structure gear connecting base plate 207 to move horizontally. Thus, the XY-axis pressure sensor 310 knows the rotor dynamic adjustment and positioning to reduce the force during the rotor pressing process. If the force during the process is still abnormal, the abnormal state is fed back to the controller through the XY-axis pressure sensor 310 and the displacement relationship of the servo press 4. The controller drives the base lifting cylinder 303 to retract, the angular locking base 302 to rise, and the angular floating base plate 305, without the support of the angular locking base plate 302, can swing slightly in the angular direction under the tension of the spring support assembly 306. This allows the rotor to slide freely into the deceleration spline sleeve during the pressing process, thereby ensuring smooth pressing, improving assembly quality, reducing failure rate, and increasing production line capacity and equipment uptime.

[0033] Determine the included angle α between adjacent splines. The upper fixture with rotor assembly descends to 2mm above the end face of the spline sleeve, and continues to move downwards by 4mm. The pressure sensor of the upper fixture's Z-axis floating mechanism detects that the spline is not inserted into the spline sleeve. The upper fixture rises by 4mm, rotates by 1 / 5a angle, and then moves downwards by 4mm. The pressure sensor detects whether the spline is pressed in. If it is not pressed in, repeat the process of rising by 4mm and rotating by 1 / 5a angle four more times. If it still cannot be pressed in, an alarm is triggered. If it is pressed in, the radial pressure sensing system is activated. The sensor transmits the pressure data to the industrial control computer in real time. The industrial control computer uses calculation to control the linear motor slide rail to drive the rotor shaft positioning fixture to adjust its position, so that the pressing process is as stress-free as possible or the stress is evenly distributed. This prevents alarms from being triggered by local abnormal stress during the pressing process. This process does not involve rotation during the pressing process, thus avoiding friction or damage between the spline shaft and the spline sleeve during assembly.

[0034] It can interact with a PLC, collect pressure and displacement data, and perform logical operations or calculations. Equipped with a database, it can set thresholds through self-learning and data analysis to ensure stable press-fitting.

[0035] Relying on four pressure sensors inside the device, the radial force during rotor pressing can be measured in real time and fed back to the industrial control computer. The number mentioned in this solution is four, but not limited to four.

[0036] The XY linear motor is an overlapping XY linear motor that can achieve precise control in the horizontal direction of the structural gear connection base plate and can feed the position back to the industrial control computer to achieve closed-loop precise control and more timely response.

[0037] The springs in the spring support assembly are compressed by the gravity of the tooling, ensuring that the contact force between the rotor shaft and the spline is less than the weight of the tooling during press-fitting, thus reducing relative wear. When unlocking this mechanism, the angular floating base plate can achieve micro-angle adaptive adjustment to solve the problem of abnormal force caused by the difference in coaxiality between the upper and lower tooling.

[0038] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions, and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention, and within the spirit and principles of the present invention, should be included within the scope of protection of the present invention. Furthermore, all content not described in detail in this specification is prior art known to those skilled in the art.

[0039] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

Claims

1. An electrical drive rotor assembly tooling fixture, characterized by, The utility model relates to a kind of servo press and the positioning device thereof, including: driving motor, servo press, XY adjustment mechanism and angular adjustment mechanism, driving motor can drive servo press and tooling as a whole up and down movement, XY adjustment mechanism includes servo motor, speed reducer, X linear motor, Y linear motor, moving base plate, linear slide, structure gear connection base plate, driving gear and passive structure gear, moving base plate is fixed on the slider of linear slide, Y linear motor is set below moving base plate, X linear motor is set below Y linear motor, is connected by a connecting plate, structure gear connection base plate is fixed below X linear motor bearing, speed reducer is fixed on structure gear connection base plate below, servo motor is connected on speed reducer upside, passive structure gear is connected with structure gear connection base plate, driving gear is engaged with passive structure gear, driving gear is fixed on the output spindle of speed reducer;Angular adjustment mechanism includes rotating support, angular locking base, base lifting cylinder, base slide, angular floating base plate, spring support assembly, rotor positioning tool, rotor clamping cylinder, XY pressure sensor and Z pressure sensor, rotating support is fixed below passive structure gear, two sets of base slides are installed in rotating support, base slide slider is fixed on angular locking base, the piston rod of base lifting cylinder is connected rotating support, the cylinder body of base lifting cylinder is connected angular locking base, the upper end of spring support assembly is connected rotating support, the lower end of spring support assembly is fixed on angular floating base plate, and there is Z pressure sensor between components, rotor positioning tool is fixed by slide and angular floating base plate, XY pressure sensor is installed between rotating support and angular floating base plate, rotor clamping cylinder is fixed on rotor positioning tool, Y linear motor has two, it is arranged in parallel below moving base plate, angular adjustment mechanism further includes counterweight, counterweight is fixed on rotor positioning tool. ​ 2. A method of using an electrical drive rotor assembly tooling, characterized by, The method comprises the following steps: a rotor clamping cylinder of an electric driving rotor assembly tooling carries a rotor assembly, the tooling drives the rotor assembly to descend to a specified position, a servo press pushes the assembly tooling to carry the rotor assembly to move downward, a Z-direction pressure sensor feeds back a pressure value to a controller, the controller judges and identifies, if the pressure is greater than a set value, the controller controls the servo press to move upward, an angular adjustment mechanism counterclockwise rotates 1 / 5a, a is a spline adjacent tooth included angle, after rotation, the controller judges a cycle number, if the cycle number is greater than 5 times, the equipment fault alarm; if the cycle number is less than or equal to 5 times, the servo press continues to move downward, when the Z-direction pressure sensor detection value is less than the set value, the servo press presses downward, XY-direction pressure sensors dynamically detect, the controller calculates a driving linear motor in a horizontal direction dynamically and continues to press downward according to the XY-direction pressure sensor detection value, the controller real-time collects the XY-direction pressure sensor, if a stress state is unstable or continuously increases, the angular adjustment mechanism is unlocked, so that the rotor shaft entering the spline sleeve can slide angularly with the spline sleeve, the press continues to press downward, if the stress state is good, the press presses to a position and completes the press fitting, if the stress state is still not improved, the equipment alarms, a quality assurance site confirms a product state, the specified position is 2mm above a spline of a speed reducer, the downward moving distance is 4mm, and the upward moving distance is 4mm.

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