Stator BUSBAR positioning and welding method

Abstract

The invention discloses a stator BUSBAR positioning and welding method. The stator BUSBAR positioning and welding method comprises a positioning step and a welding step. In the positioning step, three outer ends of the BUSBAR terminal are clamped and fixed on a BUSBAR terminal positioning tool, and then a welding part of the BUSBAR terminal and an end part of a flat copper wire of a stator product are manually adjusted to be aligned and attached; in the welding step, the height of a welding electrode bar is detected firstly, the height numerical value is fed back to a control system to guide the descending distance of a welding gun head during subsequent welding, and a welding part is obtained through photographing of a visual guiding unit during welding and fed back to the control system to guide welding operation of the welding gun head. The visual guide unit is also used as an appearance detection unit after welding; thus, the problems of attachment and dislocation prevention of the radially attached BUSBAR terminal and the end of the flat copper wire of the stator product are effectively solved, meanwhile, three outer ends of the BUSBAR are positioned, it is ensured that the height of the welding electrode bar reaches the standard during welding each time, intelligent and reliable welding is achieved, and the welding quality is effectively improved.

Description

Technical Field

[0001] The invention relates to the field of stator BUSBAR welding technology, in particular to a stator BUSBAR positioning and welding method. Background Art

[0002] When welding the ends of the stator flat copper wires to the stator busbar (also called BUSBAR), the stator busbar must first be placed on the top of the stator product, and multiple welding parts of the stator busbar must correspond to the ends of the stator flat copper wires, and then they are welded. In the resistance welding (or arc welding) welding equipment, it usually includes a frame and a welding gun head arranged on the frame, the welding gun head is arranged downward, and a welding electrode rod (such as a tungsten rod or a tungsten needle) extends downward from the bottom end of the welding gun head.

[0003] In the prior art, the welding equipment used for welding the ends of the stator flat copper wires to the stator busbars has some disadvantages: 1. The degree of automation is not high enough, there is more manual involvement, the labor cost is high, the processing efficiency is low, and the processing quality is inevitably affected by human errors.

[0004] 2. After multiple welding, the bottom of the welding electrode rod is prone to wear or foreign matter, resulting in a difference between the actual height of the welding electrode rod and the default height setting in the equipment system. During welding, the pressure of the welding electrode rod is prone to be too large or too small, resulting in poor welding, weak welding, surface cracks at the welding point, spatter, overburning, burn-through, sticking electrodes, accelerated electrode consumption and other undesirable phenomena, which also have a negative impact on the welding quality. In view of the above situation, in actual welding processing, the usual practice is to replace the welding electrode rod after a period of time or after completing the set welding workload to avoid a high welding defect rate. However, for the same welding electrode rod, in theory, except for the first debugging and setting the standard height, there is a possibility that the actual height of the welding electrode rod may be different from the default height setting in the equipment system during subsequent welding, which is not conducive to ensuring welding quality. Moreover, frequent replacement of welding electrode rods occupies the effective working time of the equipment, affects processing efficiency, and also increases the consumption cost of welding electrode rods.

[0005] 3. The motor armature and BUSBAR flat copper wire applicable to the prior art are arranged along the circumferential direction, and the bonding direction is circumferential, which cannot be applied to situations requiring radial bonding. In addition, although it realizes circumferential bonding, if the motor armature and the BUSBAR flat copper wire are misaligned in the radial direction (i.e., not aligned), it is difficult to solve the misalignment problem by simply inserting each pair of flat copper wires into a through hole. If each pair of flat copper wires is misaligned, it means that the bonding area is reduced and the stability of the welding joint is reduced.

[0006] 4. In the prior art, if the three outer ends of the BUSBAR are suspended and deformed, correction is required after the motor armature and the flat copper wire of the BUSBAR are welded, which may cause a negative impact on the welding point and require additional correction time, which will inevitably increase the production cost.

[0007] Therefore, it is necessary to study a new technical solution to solve the above problems. Summary of the invention

[0008] In view of this, the present invention aims to solve the deficiencies in the prior art, and its main purpose is to provide a stator BUSBAR positioning and welding method, which effectively solves the problem of fitting and preventing misalignment between the radially fitted BUSBAR terminal and the end of the flat copper wire of the stator product, while positioning the three outer ends of the BUSBAR and ensuring that the height of the welding electrode rod meets the standard each time welding, thereby realizing intelligent and reliable welding and effectively improving the welding quality.

[0009] To achieve the above purpose, the present invention adopts the following technical solutions: A stator BUSBAR positioning and welding method comprises the following steps: Step 1: Positioning step; Step 1 includes: Step 1-1, the stator loading jig with the stator product is transported to the BUSBAR installation station along the guide rail assembly and is lifted and positioned; Step 1-2: At the BUSBAR installation station, manually place the BUSBAR terminal positioning tool on the stator product; Step 1-3: manually place the BUSBAR terminal on the stator product, and clamp and fix the three outer ends of the BUSBAR terminal on the BUSBAR terminal positioning tooling; Step 1-4: Manually adjust the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product to align and fit them; Step 2, welding step; Step 2 includes: Step 2-1, the stator product with the BUSBAR terminal assembled and positioned is transported to the BUSBAR welding station along the guide rail assembly along with the stator loading fixture; Step 2-2, detecting the height of the welding electrode rod, and feeding back the height value to the control system to guide the lowering distance of the welding gun head during subsequent welding; Step 2-3: The stator product with BUSBAR terminals is assembled and positioned together with the stator loading fixture; Step 2-4: The automatic power supply unit is connected to the BUSBAR terminal positioning tooling to realize power supply; Step 2-5: Use the visual guidance unit to take pictures to obtain the welding position and feed back to the control system; Step 2-6, the control system guides the welding gun head to complete the welding of the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product one by one according to the feedback information of the visual guidance unit; Step 2-6: The visual guidance unit serves as a post-welding appearance inspection unit, and takes a CCD photo of the top of the stator product to inspect the appearance of the stator product.

[0010] As a preferred solution, the BUSBAR terminal positioning tooling includes a positioning plate, a stator bus carrier plate and a fixed pressing plate; the positioning plate is provided with a first positioning portion positioned with the stator product, the stator bus carrier plate is connected to the positioning plate, a plurality of first connecting holes are provided on the stator bus carrier plate, the fixed pressing plate is detachably pressed against the stator bus carrier plate, and a plurality of first positioning pins are provided on the bottom of the fixed pressing plate extending downward to extend downward into the corresponding first connecting holes; in step 1-2, the positioning plate and the stator bus carrier plate are positioned on the stator product, in step 1-3, the three outer ends of the BUSBAR terminal are placed correspondingly on the stator bus carrier plate, and then the fixed pressing plate is pressed against the stator bus carrier plate, so that the three outer ends of the BUSBAR terminal are clamped between the fixed pressing plate and the stator bus carrier plate.

[0011] As a preferred solution, in steps 1-4, an adjustment component is further provided on the BUSBAR terminal positioning tooling, the adjustment component includes a base and a plurality of clamping members arranged on the base, the base is provided with a second positioning portion positioned with the stator product and / or the positioning plate, the clamping member includes a push portion and an action portion for driving the push portion to radially displace; the action portion is manually controlled, and the push portion is used to align and fit the welding portion of the BUSBAR terminal with the end of the flat copper wire of the stator product.

[0012] As a preferred solution, a magnet is provided on the fixed pressing plate, and the magnet attracts the stator busbar carrier plate, so that multiple outer ends of the stator busbar are pressed between the fixed pressing plate and the stator busbar carrier plate.

[0013] As a preferred solution, in steps 1-4, a clamping plate is further arranged on the BUSBAR terminal positioning tooling, and a plurality of limiting grooves corresponding to the welding parts of the BUSBAR terminals and the ends of the flat copper wires of the stator products are arranged on the clamping plate, so that each pair of welding parts and ends are limited in the corresponding limiting grooves, so that the welding parts of the BUSBAR terminals are aligned and fitted with the ends of the flat copper wires of the stator products, and then the clamping plate is locked to the top of the BUSBAR terminal positioning tooling.

[0014] As a preferred embodiment, the base is provided with an avoidance groove for the end of the flat copper wire of the stator to be exposed upward, and the clamping parts are respectively arranged on the inner and outer sides of the avoidance groove, the pushing part of the inner clamping part is arranged to push radially outward, and the pushing part of the outer clamping part is arranged to push radially inward; the end of the pushing part has a clamping groove open in the pushing direction, the pushing part has a left clamping arm and a right clamping arm located on the left and right sides of the clamping groove, and the bottom end of the deep groove of the clamping groove has a pushing surface.

[0015] As a preferred solution, in step 2-2, the welding electrode rod height detection unit includes a fiber optic sensor, and the fiber optic sensor includes a fiber optic transmitter and a fiber optic receiver. The fiber optic transmitter and the fiber optic receiver are arranged opposite to each other at a distance, and a detection port for the welding electrode rod to extend into is formed between the fiber optic transmitter and the fiber optic receiver.

[0016] As a preferred solution, in step 2-6, the welding gun head is connected to a Z-axis lifting drive unit, which drives the welding gun head to move up and down, and the Z-axis lifting drive unit is connected to a translation drive unit, which drives the Z-axis lifting drive unit and the welding gun head to translate together; the translation drive unit includes an X-axis translation drive unit and a Y-axis translation drive unit, the X-axis translation drive unit drives the Z-axis lifting drive unit and the welding gun head to translate together along the X-axis, and the Y-axis translation drive unit drives the Z-axis lifting drive unit and the welding gun head to translate together along the Y-axis; the Y-axis translation drive unit is connected to the X-axis translation drive unit, and the Y-axis translation drive unit drives the X-axis translation drive unit, the Z-axis lifting drive unit and the welding gun head to translate together along the Y-axis; the control system controls the Z-axis lifting drive unit, the X-axis translation drive unit, and the Y-axis translation drive unit to work according to the feedback information of the visual guidance unit to guide the welding gun head to complete the welding of the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product one by one.

[0017] As a preferred solution, in step 2-4, the automatic power extraction unit includes a power extraction device, the power extraction device includes an automatically opening and closing power extraction clamp, the power extraction clamp is connected to a Y-axis translation cylinder, and the control system controls the movement of the Y-axis translation cylinder and the power extraction clamp.

[0018] As a preferred solution, the visual guidance unit is located on the side of the welding gun head, the shooting angle of the visual guidance unit is downward, and the visual guidance unit and the welding gun head are connected to the Z-axis lifting drive unit, so that the Z-axis lifting drive unit drives the visual guidance unit and the welding gun head to rise and fall together.

[0019] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, it can be seen from the above technical scheme that it is mainly through the setting of positioning steps and welding steps, wherein the positioning step is to manually place the BUSBAR terminal on the stator product, and clamp and fix the three outer ends of the BUSBAR terminal on the BUSBAR terminal positioning tooling, and then manually adjust the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product to align and fit them; During the welding step, the height of the welding electrode rod is first detected, and the height value is fed back to the control system to guide the lowering distance of the welding gun head during subsequent welding. During welding, the visual guidance unit is used to take pictures to obtain the welding position, and the pictures are fed back to the control system. The control system guides the welding gun head to complete the welding of the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product one by one according to the feedback information of the visual guidance unit. The visual guidance unit serves as an appearance inspection unit after welding, and takes a CCD picture of the top of the stator product to detect the appearance of the stator product. In this way, the fitting and anti-misalignment problems of the radially fitted BUSBAR terminal and the end of the flat copper wire of the stator product are effectively solved. At the same time, the three outer ends of the BUSBAR are positioned to reduce defects, eliminate the need for secondary correction after welding, and ensure that the height of the welding electrode rod meets the standard during each welding, effectively improving the welding quality.

[0020] In order to more clearly illustrate the structural features and effects of the present invention, the present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a step diagram of a stator BUSBAR positioning and welding method according to an embodiment of the present invention; Figure 2 It is a three-dimensional diagram of a stator BUSBAR welding station according to an embodiment of the present invention; Figure 3 It is a partial three-dimensional diagram of a stator BUSBAR welding station according to an embodiment of the present invention; Figure 4 yes Figure 3 Middle K-direction view; Figure 5 It is a three-dimensional diagram of the assembly of a welding electrode rod height detection unit and a power extraction clamp according to an embodiment of the present invention; Figure 6 It is an exploded view of a stator loading jig, a BUSBAR terminal positioning tool and an adjustment assembly according to an embodiment of the present invention; Figure 7 It is a diagram showing the application status of the stator loading jig, the BUSBAR terminal positioning tooling and the adjustment assembly according to an embodiment of the present invention; Figure 8 yes Figure 7A partial enlarged diagram of the middle A; Fig. 9 1 is an exploded view of a BUSBAR terminal positioning tool and an adjustment assembly according to an embodiment of the present invention; Fig.10 1 is a side view of a BUSBAR terminal positioning tool according to an embodiment of the present invention; Fig.11 is an exploded view of a BUSBAR terminal positioning tool according to an embodiment of the present invention; Fig.12 is a partial cross-sectional view of a BUSBAR terminal positioning tool according to an embodiment of the present invention (showing multiple outer ends of a stator busbar); Fig.13 is an exploded view of an adjustment assembly according to an embodiment of the present invention; Fig.14 It is a diagram showing the application status of a stator loading fixture, a BUSBAR terminal positioning tool and an adjustment component according to another embodiment of the present invention; Fig.15 is an exploded view of a stator loading fixture, a BUSBAR terminal positioning tool, and an adjustment assembly according to another embodiment of the present invention; Fig.16 It is a diagram showing the application status of a stator loading fixture, a BUSBAR terminal positioning tool, and an adjustment component according to another embodiment of the present invention.

[0022] Description of the accompanying drawings: frame H1, welding gun head H2, welding electrode rod H3, Z-axis lifting drive unit H4, X-axis translation drive unit H5, Y-axis translation drive unit H6, mounting frame H7, optical fiber transmitter H8, optical fiber receiver H9, detection port H10, first adjustment hole H11, optical fiber amplifier H12, stand H13, power supply device H14, power supply clamp H15, Y-axis translation cylinder H16, second adjustment hole H17, adapter plate H18, optical fiber sensor H19, third adjustment hole H20, BUSBAR terminal positioning tool 100, positioning plate 101, stator bus carrier plate 102, fixed pressing sheet 103, hook 104, elastic fastener 105, cushion block 106, first connecting hole 107, first positioning pin 1 08, pin 1081, screw 1082, magnet 109, first positioning portion 1011, adjustment assembly 200, base 201, avoidance groove 2011, clamping member 202, second positioning portion 203, clamping groove 204, left clamping arm 2041, right clamping arm 2042, push surface 2043, limit block 205, guide block 206, limit hole 2051, guide hole 2061, clamped portion 207, screw 2021, sliding block 2022, push piece 2023, stator product 300, end 301 of flat copper wire, outer end 400 of stator bus, through hole 401, welding portion 400' of stator bus, stator loading fixture 500, guide rail assembly 600, lifting unit 700, visual guide unit 800. DETAILED DESCRIPTION

[0023] Please refer to Figures 1 to 16 As shown, it shows the specific structure of various embodiments of the present invention.

[0024] In the description of the present invention, it should be noted that the directions or positional relationships indicated by the terms "up", "down", "left", "right", etc. are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present invention.

[0025] A stator BUSBAR positioning and welding method comprises the following steps: Step 1, positioning step; namely, positioning the BUSBAR terminal (also designated as sub-bus) on the stator product, which is completed at the BUSBAR terminal positioning station; Step 1, including: Step 1-1, the stator loading jig with the stator product is transported along the guide rail group to the BUSBAR installation station (the position sensor can be used to understand the position of the stator loading jig 500 in real time), and is lifted and positioned so that the stator loading jig is upwardly separated from the guide rail group and is suspended and stationary, and will not slide along the guide rail group due to the conveying drive; Step 1-2: At the BUSBAR installation station, manually place the BUSBAR terminal positioning tool on the stator product (for example, insert the BUSBAR terminal positioning tool into the top periphery of the stator product); Step 1-3: manually place the BUSBAR terminal on the stator product, and clamp and fix the three outer ends of the BUSBAR terminal on the BUSBAR terminal positioning tooling; Step 1-4: Manually adjust the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product to align and fit; after completion, descend to the guide rail assembly and continue to be transported to the stator BUSBAR welding station; Step 2, welding step; it is completed at the stator BUSBAR welding station. The BUSBAR terminal positioning station and the stator BUSBAR welding station are connected through a guide rail group to form an automatic conveying production line. Usually, the guide rail groups passing through the two stations are located at the same horizontal conveying height; Step 2, including: Step 2-1, the stator product with the BUSBAR terminal assembled and positioned is transported to the BUSBAR welding station along with the stator loading jig along the guide rail group (the position sensor can be used to understand the position of the stator loading jig 500 in real time); the position sensor feeds back the position information, and the control system starts to detect the height of the welding electrode rod; Step 2-2, detecting the height of the welding electrode rod, and feeding back the height value to the control system to guide the lowering distance of the welding gun head during subsequent welding; Step 2-3: The stator product with the BUSBAR terminal is assembled and positioned together with the stator loading jig, so that the stator loading jig is upwardly separated from the guide rail group and is suspended and stationary, and will not slide along the guide rail group due to the action of the conveying drive; Step 2-4, the automatic power supply unit is connected to the BUSBAR terminal positioning tooling to realize power supply (for example, the power supply clamp is used to clamp the clamping part of the BUSBAR terminal positioning tooling); Step 2-5: Use the visual guidance unit to take pictures to obtain the welding position and feed back to the control system; Step 2-6, the control system guides the welding gun head to complete the welding of the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product one by one according to the feedback information of the visual guidance unit; Step 2-6: The visual guidance unit is used as a post-welding appearance inspection unit to take a CCD photo of the top of the stator product to inspect the appearance of the stator product. At this point, the stator product flows out of the stator BUSBAR welding station along the guide rail assembly.

[0026] Specifically, the BUSBAR terminal positioning station is provided with a frame, a guide rail group extending along the X-axis is provided in the frame, and a stator loading fixture capable of conveying along the X-axis direction of the guide rail group is provided on the guide rail group; the guide rail group includes two guide rails spaced and arranged in parallel along the Y-axis direction, and a space is reserved between the two guide rails, and a lifting unit, such as a lifting cylinder, is provided below the space; the guide rail group passes through both ends of the frame along the X-axis direction as a material inlet and a material outlet, so that the BUSBAR terminal positioning station can be easily connected with other workstations and is suitable for automated production.

[0027] The stator BUSBAR welding station is mainly used for welding stator products, specifically welding the ends of the stator flat copper wires to the stator busbars. The stator BUSBAR welding station includes: a frame H1, a welding device, a welding electrode height detection unit, a stator welding tool, an automatic power supply unit, a visual guidance unit 800, and a control system.

[0028] Similarly, a guide rail group 600 extending along the X-axis direction is provided in the frame H1, and a stator loading fixture 500 capable of conveying along the X-axis direction of the guide rail group 600 is provided on the guide rail group 600; the guide rail group 600 includes two guide rails spaced apart and arranged in parallel along the Y-axis direction, and a space is reserved between the two guide rails, and a lifting unit 700, such as a lifting cylinder, is arranged below the space; the guide rail group 600 passes through both ends of the frame along the X-axis direction as an inlet and an outlet, so that the stator BUSBAR welding station can be easily connected with other stations and is suitable for automated production.

[0029] The welding device includes a welding gun head H2, which is arranged downward, and a welding electrode rod H3 extends downward from the bottom end of the welding gun head H2; the welding gun head H2 is connected to a Z-axis lifting drive unit, which drives the welding gun head H2 to move up and down, and the Z-axis lifting drive unit is connected to a translation drive unit, which drives the Z-axis lifting drive unit and the welding gun head H2 to move together. Specifically in this embodiment: in the welding device, the translation drive unit drives the Z-axis lifting drive unit H4 to move together with the Z-axis lifting drive unit H4 and the welding gun head H2. In this embodiment, the translation drive unit includes an X-axis translation drive unit H5 and a Y-axis translation drive unit H6. The X-axis translation drive unit H5 drives the Z-axis lifting drive unit H4, and the Z-axis lifting drive unit H4 and the welding gun head H2 to translate along the X-axis direction. The Y-axis translation drive unit H6 drives the Z-axis lifting drive unit H4, and the Z-axis lifting drive unit H4 and the welding gun head H2 to translate along the Y-axis direction. The Y-axis translation drive unit H6 is connected to the X-axis translation drive unit H5, and the Y-axis translation drive unit H6 drives the X-axis translation drive unit H5, the Z-axis lifting drive unit H4, and the welding gun head H2 to translate along the Y-axis direction. In actual design, the Z-axis lifting drive unit H4, the X-axis translation drive unit H5, and the Z-axis lifting drive unit H4 can all use cylinders or motors (such as motor linear modules).

[0030] The welding electrode rod height detection unit is used to detect the bottom end height of the welding electrode rod H3. The welding electrode rod height detection unit includes a fiber optic sensor H19, which includes a mounting frame H7 and a fiber optic transmitter H8 and a fiber optic receiver H9 respectively mounted on the mounting frame H7. The fiber optic transmitter H8 and the fiber optic receiver H9 are arranged opposite to each other at a left-right spacing, and a detection port H10 is formed between the fiber optic transmitter H8 and the fiber optic receiver H9 for the welding electrode rod H3 of the welding gun head H2 to extend downward. The fiber optic transmitter H8 and the fiber optic receiver H9 are respectively mounted on the mounting frame H7, and the position of the mounting frame H7 can be adjusted up and down. In this embodiment, a first adjustment hole H11 extending vertically is provided on the mounting frame H7 to adjust the vertical installation height of the mounting frame H7, and then adjust the height of the fiber optic transmitter H8 and the fiber optic receiver H9. The fiber optic sensor is connected to a fiber optic amplifier H12, such as an FX-551-2 amplifier. The fiber optic amplifier H12 is connected to the control system. An RFID system may also be provided on the frame H1, and the RFID system is connected between the welding electrode rod height detection unit and the control system. For example, the optical fiber amplifier H12 is connected to the control system through the RFID system. Through the setting of the RFID system, information can be read instantly, which is convenient and fast, and is not affected by the working environment of the welding equipment, has a long service life, and has good reliability. The frame H1 is connected to a stand H13, and the mounting frame H7 is installed on the top of the stand H13. A power supply device H14 is also provided on the top of the stand H13, and the power supply device H14 and the optical fiber sensor are staggered from each other along the X-axis direction to avoid mutual interference. The power supply device H14 includes an automatically opened and closed power supply clamp H15 (a pair of clamping claws of the power supply clamp is driven by a clamping claw cylinder), and the power supply clamp H15 is connected to a Y-axis translation cylinder H16, which is installed on the top of the stand H13. The Y-axis translation cylinder H16 drives the power supply clamp H15 to translate along the Y-axis relative to the stand H13. The Y-axis translation cylinder H16 can adjust the position along the X-axis at the top of the stand H13. Specifically, a second adjustment hole H17 extending left and right can be provided on the top of the stand H13 to adjust the locking position of the Y-axis translation cylinder H16 in the second adjustment hole H17. The top of the stand H13 is connected with an adapter plate H18, which can be adjusted along the Y axis relative to the top of the stand H13. The adapter plate H18 is provided with a third adjustment hole H20 extending forward and backward, and the second adjustment hole H17 is provided on the adapter plate H18. The power taking device H14 is installed on the adapter plate H18; Before welding, the height of the welding electrode rod H3 is detected first, and the height value is fed back to the control system, which recalculates the target height of the welding electrode rod H3 to guide the Z-axis lifting drive unit H4 to drive the welding gun head H2 to descend during subsequent welding, so that the welding electrode rod H3 is lowered to the target height to ensure welding quality. It can be seen that before welding, the target height is refreshed and recalculated by the welding electrode rod height detection unit based on the actual situation of the welding electrode rod H3, avoiding the negative impact on welding quality caused by height differences due to wear at the bottom of the welding electrode rod H3 or other factors.

[0031] The stator welding tool is used to position the ends of the stator's flat copper wire and the stator busbar. The stator welding tool is used to weld the ends of the flat copper wire of the motor stator to the stator busbar, and includes a BUSBAR terminal positioning tool 100 and an adjustment component 200. The BUSBAR terminal positioning tool 100 also refers to the terminal tool, which is used to be sleeved on the stator product 300 to fix the subsequently installed stator busbar (also referred to as the BUSBAR terminal). The adjustment component 200 is used to adjust and correct the ends of the stator busbar and the stator's flat copper wire to prevent misalignment and make them fit more tightly, which is convenient for welding and is conducive to improving welding quality and yield; among them: The BUSBAR terminal positioning tool 100 includes a positioning plate 101, a stator bus carrier plate 102 and a fixed pressure plate 103; the positioning plate 101 is provided with a first positioning portion that is positioned with the stator product, and the first positioning portion can be integrally connected to the positioning plate 101, or it can be an additional assembled accessory as the first positioning portion 1011, for example: a pin structure (defined as a second positioning pin, which can adopt the same structure as the first positioning pin) is installed on the positioning plate 101.The positioning plate 101 is generally in the shape of an arc, such as a superior arc. The stator busbar carrier plate 102 is connected to the positioning plate 101. One end of the stator busbar carrier plate 102 can be hinged to one end of the arc of the positioning plate 101. The stator busbar carrier plate 102 can rotate relative to the hinge (rotate around the Z axis), and the other end of the stator busbar carrier plate 102 is provided with a hook portion 104. Correspondingly, an elastic fastener 105 is provided at the other end of the arc of the positioning plate 101, and the elastic fastener 105 is used to lock the hook portion 104; the bottoms of the positioning plate 101 and the stator busbar carrier plate 102 are respectively connected with a plurality of pads 106, which are convenient for multiple supports of the tray. The top of the column forms an abutment positioning, and the pad 106 is detachably arranged, and its material and shape can be flexibly arranged; a plurality of first connection holes 107 are arranged on the stator bus carrier 102, and the plurality of first connection holes 107 are arranged side by side with a spacing, which are arranged corresponding to the outer end 400 of the stator bus. Usually, the plurality of outer ends of the stator bus are reserved with through holes 401, and the bottom of the fixed pressing plate 103 is extended downwardly to be provided with a plurality of first positioning pins 108, which are used to extend downward into the corresponding through holes and the first connection holes 107, so as to achieve the positioning of the plurality of outer ends (for example, three) of the stator bus. The first positioning pin 108 can be integrally connected to the fixed pressing plate 1 03, it can also be an additional assembly accessory as the first locating pin 108. In comparison, the additional assembly accessory makes the structure of the fixed pressing plate 103 easier to process, and the accessories are optional and replaceable, which is more flexible. In this embodiment, the first locating pin 108 on the fixed pressing plate 103 is installed on the fixed pressing plate 103. The first locating pin 108 includes a pin 1081 and a screw 1082. The lower end of the pin is designed to be in the shape of a bullet head for easy insertion. The upper end of the pin has a step on the outside, and the upper end of the pin has an internal threaded hole on the inside. The fixed pressing plate 103 is provided with a plurality of second connecting holes, and the plurality of second connecting holes are arranged side by side at a spacing of 1 / 40. The first locating pin 108 is fixedly mounted on the fixing pressing plate 103; and a magnet 109 is provided on the fixing pressing plate 103 (for example, a magnet is provided at the bottom of the fixing pressing plate 103). The magnet 109 is used to attract the stator bus carrier plate 102, so that the multiple outer ends of the stator bus are pressed between the fixing pressing plate 103 and the stator bus carrier plate 102. The adjustment assembly 200 includes a base 201 and a plurality of clamping members 202 disposed on the base 201. The base 201 and the clamping members 202 are made of conductive materials. The base 201 has a clamping portion 207 for electrical connection. The base 201 can be a single component or a plurality of components assembled. The base 201 is provided with a second positioning portion 203 that is positioned with the stator product and / or the positioning plate 101. The second positioning portion 203 can be integrally connected to the base 201, or can be an additional assembly accessory as the first positioning portion, for example, a pin structure (defined as a third positioning pin, which can adopt the same structure as the first positioning pin 108) is installed on the base 201. In this embodiment, the third positioning pin is inserted into the reserved hole on the positioning plate 101 to form a positioning, which is equivalent to using the positioning plate 101 to realize the positioning of the base 201 relative to the stator product; the clamping member 202 includes a push portion and an action portion that drives the push portion to move radially forward and backward. The base 201 is provided with an avoidance groove 2011 for the ends of the flat copper wires of the stator to be exposed upward. The avoidance groove 2011 is roughly C-shaped to meet the exposure of multiple ends of the flat copper wires of multiple stators. The clamping members 202 are respectively arranged on the inner and outer sides of the avoidance groove 2011. The pushing portion of the inner clamping member 202 is radially pushed outward, while the pushing portion of the outer clamping member 202 is radially pushed inward. In the present embodiment, the pushing portions of the inner and outer clamping members 202 of a part are radially opposite to each other, and the pushing portions of the inner and outer clamping members 202 of another part are circumferentially staggered with each other. In this way, different pushing requirements of the ends of the flat copper wires of the stator and the welding portions of the stator bus are met. In actual use, some need to be adjusted to push outward, some need to be adjusted to push inward, and some need to be adjusted to push inward and outward at the same time, to ensure that the positions of the ends of the flat copper wires of the stator and the welding portions of the stator bus can be corrected and fitted, which is convenient for subsequent welding.The end of the push portion has a clamping groove 204 open toward the push direction, and the push portion has a left clamping arm 2041 and a right clamping arm 2042 located on the left and right sides of the clamping groove 204, and a push surface 2043 is provided at the bottom of the groove depth of the clamping groove 204. Usually, the clamping groove 204 is set through the top and bottom, so that the clamping groove 204 is used to prevent misalignment correction and clamping; the inner sides of the left clamping arm 2041 and the right clamping arm 2042 are provided with a guide inclined surface C1 and a fixed straight surface C2, and the guide inclined surface is along the groove depth direction of the clamping groove. It extends obliquely toward the middle of the groove, so that a gradually smaller guide correction opening D1 is formed between the guide inclined surfaces C1 of the left clamping arm 2041 and the right clamping arm 2042, and the shaping straight surface is connected to the inner end of the guiding inclined surface, and a shaping opening D2 is formed between the shaping straight surfaces C2 of the left clamping arm and the right clamping arm; for the situation where the pushing parts of the inner and outer clamping members 202 are arranged radially opposite to each other, the two clamping grooves 204 of the inner and outer clamping members 202 are staggered up and down; a limiting block 205 and a guide block 206 are arranged on the base 201, and a limiting hole 2051 is arranged in the limiting block 205 and radially penetrates the two ends of the limiting block 205, and a guide hole 2061 is arranged in the guide block 206 and radially penetrates the two ends of the guide block 206, and the limiting hole 2051 and the guide hole 2061 are arranged radially opposite to each other. The clamping member 202 includes a screw rod 2021, a sliding block 2022 and a push piece 2023. The rod portion of the screw rod 2021 is provided with an external thread 1 and a limiting boss 2. The rod portion passes through the limiting hole 2051. The limiting block 205 is limited between the nut portion 3 of the screw rod 2021 and the limiting boss 2. The nut portion 3 is exposed to the outside of the limiting block 205. The external thread 1 is provided on the side of the limiting boss 2 away from the nut 3. An internal thread 4 is provided at one radial end of the sliding block 2022, and the push piece 2023 is roughly Y-shaped. One radial end of the push piece 2023 is connected (e.g., detachably connected) to the other radial end of the sliding block 2022. More than one push piece 2023 can be connected to the same sliding block 2022. The external thread 1 of the rod and the internal thread 4 of the sliding block 2022 form a threaded connection, so that: when the nut 3 (the nut has an inner hexagonal hole for the tool to insert and rotate) is turned, since the screw rod 2021 cannot move radially, the external thread of the rod acts on the internal thread 4 of the sliding block 2022, and the sliding block 2022 moves radially, and the push piece 2023 moves radially along with it. It can be seen that in this embodiment, the nut 3 of the screw rod 2021 is used as the action part, and the push part is set at the other radial end of the push piece 2023;. Next, the use process of the stator welding tool of this embodiment is introduced: The stator product is placed on a tray (designated stator loading fixture 500) and transported along the production line (guide rail assembly 600). After being transported to the right place, the tray together with the stator product is lifted into place by a lifting unit 700 (such as a lifting cylinder); In this state, First, manually insert the BUSBAR terminal positioning tool 100 (including the positioning plate 101, the stator busbar carrier plate 102, and remove the fixing pressing plate 103) into the top of the stator product, the positioning plate 101 and the stator product are positioned, and the stator busbar carrier plate 102 is located at the periphery of the area where the end 301 of the flat copper wire of the stator product is located; Then, the stator busbar is manually placed on the stator product so that the welding portion 400' of the stator busbar is arranged correspondingly to the end portion 301 of the flat copper wire of the stator product 300, and the multiple outer ends of the stator busbar are located on the stator busbar carrier plate 102, and the through holes are arranged to be connected with the corresponding first connection holes 107 in a vertically corresponding manner; Then, the fixed pressing sheet 103 is assembled on the top of the multiple outer ends of the stator busbar, and the multiple first positioning pins 108 extend downward into the corresponding through holes 401 and the first connecting holes 107 to achieve the positioning of the multiple outer ends of the stator busbar, and the magnet 109 on the fixed pressing sheet 103 attracts the stator busbar carrier plate 102, so that the multiple outer ends of the stator busbar are pressed between the fixed pressing sheet 103 and the stator busbar carrier plate 102; Then, the adjustment assembly 200 is manually placed on the top of the stator product, the second positioning portion 203 of the base 201 is positioned in the reserved hole on the positioning plate 101, and the plurality of clamping pieces 202 correspond to the welding portion of the stator busbar and the end of the stator flat copper wire one by one; Finally, the action part is manually adjusted to drive the push part to move radially, so as to adjust and correct the welding part of the stator busbar and the end of the stator flat copper wire to solve the circumferential misalignment problem and make them close and fit radially; This state facilitates subsequent welding, so that the welding quality of the welding part of the stator bus and the end of the stator flat copper wire is better, and the multiple outer ends and the overall structure of the stator bus are corrected and shaped, which is beneficial to improving the quality of the stator product.

[0032] The automatic power supply unit is used to detachably connect the stator welding tooling to realize power supply; the automatic power supply unit includes a power supply device H14; the automatic power supply unit includes a power supply device arranged on the top of the stand, and the power supply device and the optical fiber sensor are staggered from each other along the X-axis. The power supply device includes an automatically opened and closed power supply clamp, the power supply clamp is connected to a Y-axis translation cylinder, the Y-axis translation cylinder is installed on the top of the stand, and the Y-axis translation cylinder drives the power supply clamp to translate relative to the stand along the Y-axis.

[0033] The visual guide unit 800 is used to take pictures toward the top of the stator product. The visual guide unit 800 includes a CCD. The visual guide unit 800 is located on the side of the welding gun head. The shooting angle of the visual guide unit 800 faces downward. The visual guide unit 800 and the welding gun head H2 are connected to the Z-axis lifting drive unit, so that the Z-axis lifting drive unit drives the visual guide unit 800 and the welding gun head H2 to rise and fall together. In addition, the visual guide unit 800 also serves as a post-welding appearance inspection unit.

[0034] The control system is connected to the Z-axis lifting drive unit, the translation drive unit, the welding electrode rod height detection unit, the automatic power supply unit and the visual guidance unit 800.

[0035] Next, the workflow of the stator BUSBAR welding station of this embodiment is introduced: 1. The stator loading jig 500 slides into position along the guide rail assembly 600 (the position sensor can be used to understand the position of the stator loading jig 500 in real time); 2. Detect the height of the welding electrode rod H3, and feed back the height value to the control system; (The control system recalculates the standard height of the welding electrode rod H3 to guide the Z-axis lifting drive unit H4 to drive the welding gun head H2 to descend during subsequent welding, so that the welding electrode rod H3 descends to the standard;) 3. The lifting cylinder lifts the stator loading fixture upward, so that the stator loading fixture 20 is separated from the guide rail group and is suspended and stationary, and will not slide along the X-axis of the guide rail group due to the action of the conveying drive; 4. The Y-axis translation cylinder drives the power-taking clamp to translate, and the power-taking clamp H15 clamps the clamped part 207 to achieve power taking; 5. The visual guidance unit 800 takes photos to obtain the welding position and feeds back to the control system; 6. The control system guides the welding device to move according to the feedback information from the visual guidance unit 800, and the welding gun head H2 completes the welding of the ends of the stator flat copper wires and the stator busbars one by one; 7. The visual guidance unit is used as an appearance inspection unit after welding. It takes CCD photos of the top of the stator product to inspect the appearance of the stator product.

[0036] Figure 14-16 As shown, it shows the structure of the BUSBAR terminal positioning tooling and adjustment components of the other two embodiments; it can be seen that in the present invention application, the BUSBAR terminal positioning tooling and adjustment components used in step 1 are not Figure 6-13 The other two embodiments of the BUSBAR terminal positioning tool and Figure 6-13The functions and structures of the BUSBAR terminal positioning tooling shown in the figure are basically the same. They all need to be positioned with the stator product and the three outer ends of the BUSBAR terminal need to be clamped and fixed. The main difference is that the three outer ends of the BUSBAR terminal are located at the bottom. In this way, the positioning plate 101' is located below the stator busbar carrier 102'. From top to bottom, they are: stator busbar carrier 102', three outer ends of the BUSBAR terminal, and positioning plate 101'. The adjustment component is the same as Figure 6-13 In the other two embodiments, the adjustment assembly shown in FIG. 1 is different from that shown in FIG. 1 , and the pressure plate is used to replace the pressure plate. Figure 6-13 The adjustment assembly shown in the figure is provided with a clamping plate 200' on the BUSBAR terminal positioning tooling, and a plurality of limiting grooves 201' corresponding to the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product are provided on the clamping plate 200', so that each pair of welding parts and ends are limited in the corresponding limiting grooves 201', so that the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product are aligned and fit, and then the clamping plate 200' is locked on the top of the BUSBAR terminal positioning tooling. Among them, Figure 14-15 The embodiment shown is suitable for stator products with relatively large height dimensions. The clamping portion 207 is arranged at the bottom or lower position of the positioning plate to facilitate matching with the automatic power extraction unit. Fig.16 The embodiment shown is suitable for stator products with relatively small height dimensions, and the clamping portion 207 is arranged on the top of the positioning plate to facilitate matching with the automatic power extraction unit.

[0037] The key point of the design of the present invention is that it is mainly arranged through the positioning step and the welding step, wherein the positioning step is to manually place the BUSBAR terminal on the stator product, and clamp and fix the three outer ends of the BUSBAR terminal on the BUSBAR terminal positioning tool, and then manually adjust the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product to align and fit them; During the welding step, the height of the welding electrode rod is first detected, and the height value is fed back to the control system to guide the lowering distance of the welding gun head during subsequent welding. During welding, the visual guidance unit is used to take pictures to obtain the welding position, and the pictures are fed back to the control system. The control system guides the welding gun head to complete the welding of the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product one by one according to the feedback information of the visual guidance unit. The visual guidance unit serves as an appearance inspection unit after welding, and takes a CCD picture of the top of the stator product to detect the appearance of the stator product. In this way, the fitting and anti-misalignment problems of the radially fitted BUSBAR terminal and the end of the flat copper wire of the stator product are effectively solved. At the same time, the three outer ends of the BUSBAR are positioned to reduce defects, eliminate the need for secondary correction after welding, and ensure that the height of the welding electrode rod meets the standard during each welding, effectively improving the welding quality.

[0038] The above description is only a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any slight modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A stator BUSBAR positioning and welding method, characterized in that: The steps include: Step 1: Positioning step; Step 1 includes: Step 1-1, the stator loading jig with the stator product is transported to the BUSBAR installation station along the guide rail assembly and is lifted and positioned; Step 1-2: At the BUSBAR installation station, manually place the BUSBAR terminal positioning tool on the stator product; Step 1-3: manually place the BUSBAR terminal on the stator product, and clamp and fix the three outer ends of the BUSBAR terminal on the BUSBAR terminal positioning tooling; Step 1-4: Manually adjust the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product to align and fit them; Step 2: welding step; Step 2 includes: Step 2-1, the stator product with the BUSBAR terminal assembled and positioned is transported to the BUSBAR welding station along the guide rail assembly along with the stator loading fixture; Step 2-2, detecting the height of the welding electrode rod, and feeding back the height value to the control system to guide the lowering distance of the welding gun head during subsequent welding; Step 2-3: The stator product with BUSBAR terminals is assembled and positioned together with the stator loading fixture; Step 2-4: The automatic power supply unit is connected to the BUSBAR terminal positioning tooling to realize power supply; Step 2-5: Use the visual guidance unit to take pictures to obtain the welding position and feed back to the control system; Step 2-6, the control system guides the welding gun head to complete the welding of the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product one by one according to the feedback information of the visual guidance unit; Step 2-6: The visual guidance unit serves as a post-welding appearance inspection unit, and takes a CCD photo of the top of the stator product to inspect the appearance of the stator product.

2. A stator BUSBAR positioning and welding method according to claim 1, characterized in that The BUSBAR terminal positioning tooling includes a positioning plate, a stator busbar carrier plate and a fixed pressing plate; a first positioning portion is arranged on the positioning plate for positioning with the stator product, the stator busbar carrier plate is connected to the positioning plate, a plurality of first connecting holes are arranged on the stator busbar carrier plate, the fixed pressing plate is detachably pressed against the stator busbar carrier plate, and a plurality of first positioning pins are arranged on the bottom of the fixed pressing plate extending downward to extend downward into the corresponding first connecting holes; in step 1-2, the positioning plate and the stator busbar carrier plate are positioned on the stator product, in step 1-3, the three outer ends of the BUSBAR terminal are placed on the stator busbar carrier plate accordingly, and then the fixed pressing plate is pressed on the stator busbar carrier plate, so that the three outer ends of the BUSBAR terminal are clamped between the fixed pressing plate and the stator busbar carrier plate.

3. A stator BUSBAR positioning and welding method according to claim 1 or 2, characterized in that In the steps 1-4, an adjustment component is further arranged on the BUSBAR terminal positioning tooling, the adjustment component includes a base and a plurality of clamping members arranged on the base, the base is provided with a second positioning portion positioned with the stator product and / or the positioning plate, the clamping member includes a push portion and an action portion for driving the push portion to radially displace; the action portion is manually controlled, and the push portion is used to align and fit the welding portion of the BUSBAR terminal with the end of the flat copper wire of the stator product.

4. A stator BUSBAR positioning and welding method according to claim 2, characterized in that A magnet is arranged on the fixed pressing plate, and the magnet attracts the stator busbar carrier plate, so that multiple outer ends of the stator busbar are pressed between the fixed pressing plate and the stator busbar carrier plate.

5. A stator BUSBAR positioning and welding method according to claim 1 or 2, characterized in that In the steps 1-4, a clamping plate is set on the BUSBAR terminal positioning tooling, and a plurality of limiting grooves corresponding to the welding parts of the BUSBAR terminal and the ends of the flat copper wires of the stator products are set on the clamping plate, so that each pair of welding parts and ends are limited in the corresponding limiting grooves, so that the welding parts of the BUSBAR terminals are aligned and fitted with the ends of the flat copper wires of the stator products, and then the clamping plate is locked to the top of the BUSBAR terminal positioning tooling.

6. A stator BUSBAR positioning and welding method according to claim 3, characterized in that The base is provided with an avoidance groove for the end of the flat copper wire of the stator to be exposed upward, and the clamping parts are respectively arranged on the inner and outer sides of the avoidance groove. The pushing part of the inner clamping part is set to push radially outward, while the pushing part of the outer clamping part is set to push radially inward; the end of the pushing part has a clamping groove open in the pushing direction, and the pushing part has a left clamping arm and a right clamping arm located on the left and right sides of the clamping groove, and the bottom end of the deep groove of the clamping groove has a pushing surface.

7. A stator BUSBAR positioning and welding method according to claim 1, characterized in that In the step 2-2, the welding electrode rod height detection unit includes a fiber optic sensor, and the fiber optic sensor includes a fiber optic transmitter and a fiber optic receiver. The fiber optic transmitter and the fiber optic receiver are arranged opposite to each other, and a detection port for the welding electrode rod to extend into is formed between the fiber optic transmitter and the fiber optic receiver.

8. A stator BUSBAR positioning and welding method according to claim 1, characterized in that In the steps 2-6, the welding gun head is connected to a Z-axis lifting drive unit, which drives the welding gun head to move up and down, and the Z-axis lifting drive unit is connected to a translation drive unit, which drives the Z-axis lifting drive unit and the welding gun head to translate together; the translation drive unit includes an X-axis translation drive unit and a Y-axis translation drive unit, the X-axis translation drive unit drives the Z-axis lifting drive unit and the welding gun head to translate together along the X-axis, and the Y-axis translation drive unit drives the Z-axis lifting drive unit and the welding gun head to translate together along the Y-axis; the Y-axis translation drive unit is connected to the X-axis translation drive unit, and the Y-axis translation drive unit drives the X-axis translation drive unit, the Z-axis lifting drive unit and the welding gun head to translate together along the Y-axis; the control system controls the Z-axis lifting drive unit, the X-axis translation drive unit, and the Y-axis translation drive unit to work according to the feedback information of the visual guidance unit to guide the welding gun head to complete the welding of the welding part of the BUSBAR terminal and the end of the flat copper wire of the stator product one by one.

9. A stator BUSBAR positioning and welding method according to claim 1, characterized in that In the steps 2-4, the automatic power taking unit includes a power taking device, the power taking device includes an automatically opening and closing power taking clamp, the power taking clamp is connected to a Y-axis translation cylinder, and the control system controls the movement of the Y-axis translation cylinder and the power taking clamp.

10. A stator BUSBAR positioning and welding method according to claim 8, characterized in that The visual guidance unit is located on the side of the welding gun head, the shooting angle of the visual guidance unit is downward, and the visual guidance unit and the welding gun head are connected to the Z-axis lifting drive unit, so that the Z-axis lifting drive unit drives the visual guidance unit and the welding gun head to rise and fall together.

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