X-pin stator post-welding visual inspection system

Abstract

The invention discloses an X-pin stator post-welding visual inspection system, which relates to the technical field of X-pin motor stator welding inspection equipment, and comprises an X-pin stator, a stator base and a visual inspection part, according to the welding spot characteristic of the X-pin stator of the flat wire motor, the proper 3D line laser camera is adopted to capture the welding spots of the motor stator in the visual field and generate the 3D image, so that the welding spots of the X-pin stator are accurately judged, and the debugging cost is saved; unqualified welding spots after welding can be accurately and efficiently recognized, defects such as welding skips and explosion welding can be overcome, so that outflow of unqualified stators is reduced, and unnecessary loss is avoided; the detection level of the welding quality of the flat wire motor stator is remarkably improved, and the requirements of the new energy automobile industry for high-efficiency and high-reliability motors are met; the perfect welding spot detection logic and the powerful deep learning function of the detection software judge the states of all welding spots in the visual field through a deep learning algorithm and various program logic processes, and different welding spot positions and various welding spot numbers of different product models can be compatible.

Description

Technical Field

[0001] The invention relates to the technical field of X-pin motor stator welding detection equipment, in particular to an X-pin stator post-welding visual detection system. Background Art

[0002] With the rapid development of the new energy vehicle market, flat wire motors have gradually become the first choice for new energy vehicle drive motors due to their high power density, high efficiency and excellent heat dissipation performance. In the manufacturing process of flat wire motors, stator welding is one of the key processes. The welding of X-pin stator products mainly adopts laser welding technology, which melts copper at high temperature to form solder joints to achieve electrical connection of the windings. However, there is a significant difference between the welding of X-pin stators and U-pin stators. There is no molten ball in the state after welding and the appearance change is not obvious, which brings challenges to the detection of welding quality.

[0003] Traditional motor stator welding quality inspection mainly relies on manual visual inspection, which is inefficient, inconsistent, and susceptible to operator fatigue and subjective judgment, resulting in high missed detection and misjudgment rates. In addition, existing automated inspection equipment is often difficult to adapt to the needs of high-speed production lines and lacks the ability to accurately identify welding defects, especially defects such as missed welding and blown welding that may occur during X-pin stator welding.

[0004] In order to improve the efficiency and accuracy of welding quality inspection, the industry has begun to explore the use of visual inspection technology to identify welding defects in recent years. For example, through 2D or 3D visual systems, combined with advanced image processing algorithms, welds can be inspected quickly and accurately. However, at present, the post-weld inspection technology for X-pin stators in China is almost blank and lacks mature solutions.

[0005] In the prior art, visual inspection is used to identify solder joints with unqualified welding quality and solder joints with leaks. Laser welding is mainly used for welding X-pin stators of flat wire motors for new energy vehicles. The laser is used to melt the copper wire of the X-pin stator flat wire at high temperature to form solder joints, thereby realizing the electrical connection of the windings. The welding of X-pin stators is different from that of U-pin stators. There is no molten ball after welding, and there is no obvious change in appearance. Currently, unqualified solder joints after laser welding are mainly divided into leaks and blown solder joints. It is difficult to accurately and efficiently detect the welding quality of X-pin stators after welding using conventional visual inspection methods, so it is difficult to control the outflow of unqualified stators, which will cause unnecessary losses. In addition, there are currently few mass production lines for X-pin motor stators in China, and there is almost no post-weld inspection of X-pin motor stators. Summary of the invention

[0006] The purpose of the present invention is to provide an X-pin stator post-weld visual inspection system to solve the problem of lack of accurate and efficient post-weld inspection of X-pin motor stators in the prior art mentioned in the above background technology.

[0007] To achieve the above object, the present invention provides the following technical solution: a visual inspection system for X-pin stator after welding, which is used to inspect the X-pin stator after laser welding, and comprises the following steps: Step 1: The X-pin stator to be inspected is fed to the inspection device through the feeding line, and then placed on the stator base and fixed in position by the handling device. Then, the X-pin stator is moved to the bottom of the visual inspection part by the driving of the moving motor on the stator base to prepare for visual inspection; Step 2: The X-pin stator rotates at a constant speed in the field of view of the visual hardware of the visual inspection unit. The visual inspection unit collects photos and transmits them to the controller through the signal line. The controller has built-in inspection software, which processes and analyzes the images and outputs the inspection results in the form of communication; Step 3: The qualified X-pin stator is transferred to the feeding line through the transport device and transported to the next production process; the unqualified X-pin stator is transferred to the laser repair welding device through the transport device, and the test result of step 2 is communicated to the laser repair welding device, and the laser repair welding device performs repair welding on the unqualified copper wire welding points according to the test result; Step 4: After the repair welding is completed, the X-pin stator is transferred to the stator base through the transport device and step 1 is repeated. The welds after the repair welding are inspected. The X-pin stators that pass the inspection are transferred to the conveying line through the transport device and transported to the next production process; the X-pin stators that fail the inspection repeat the repair welding operation of step 3. After the repair welding is completed, step 1 is repeated until the welding is qualified.

[0008] Preferably, the X-pin stator includes a stator core, the inner wall of which is evenly provided with a plurality of stator core slots penetrating up and down, and multiple layers of hairpin-shaped flat copper wires are passed through the slots, one end of the flat copper wire that is bent is a crown end, and the end that needs to be welded is a welding end.

[0009] Preferably, the stator base includes a horizontally arranged base plate, two mutually parallel guide rails are arranged on the top surface of the base plate, a base slide plate that can slide along the axial direction is jointly arranged on the two guide rails through sliders, and the base slide plate is also connected to a moving motor arranged on the base plate; a rotating mechanism is arranged at the center of the base slide plate, a rotating base plate is arranged on the top surface of the rotating mechanism, three T-shaped slide grooves are evenly arranged along the radial direction on the top surface of the rotating base plate, and a guide positioning block is arranged in each T-shaped slide groove, and the three guide positioning blocks can be used to position and place X-pin stators of different specifications through synchronous adjustment.

[0010] Preferably, the rotating mechanism includes an inner clamping motor, the shaft of the clamping motor is connected to a horizontally arranged spiral drive disk, a spiral groove is arranged on the top surface of the spiral drive disk and is meshed with three guide positioning blocks at the same time, and drives the three guide positioning blocks to approach or move away from the center of the circle synchronously, so that it can be used for positioning support of X-pin stators of various specifications; a rotating motor is also arranged on the outer side of the rotating mechanism, through which the rotating motor can drive the rotating base plate and the inner clamping motor to rotate synchronously, thereby driving the X-pin stator to rotate synchronously.

[0011] Preferably, the guide positioning block includes a guide slider arranged in the T-shaped slide groove, a card groove meshingly connected with the spiral drive disk is arranged on the bottom surface of the guide slider, an L-shaped stator bracket is arranged on the top surface, and a stator support plate extending inward is arranged on the inner side of the vertical upright plate of the stator bracket near the top, and the X-pin stator can be positioned and supported by the three stator support plates. During detection, the bottom end of the stator core is placed on the three stator support plates.

[0012] Preferably, the visual inspection unit includes a visual bracket, on which visual hardware is arranged, and a lens of the visual hardware is located above the welding end, so that the welding end after welding can be photographed and imaged; the visual hardware is connected to a controller via a signal line, and the controller has built-in inspection software that can process and analyze images and output the inspection results in the form of communications.

[0013] Preferably, the visual hardware adopts a 3D line laser camera.

[0014] Preferably, the detection software is combined with a deep learning software algorithm, and the welding points are trained and classified through deep learning. At present, the welding points of the flat copper wire of the X-pin stator are mainly divided into three states, namely qualified welding, leaking welding, and blown welding; the detection software can accurately judge the three states of the welding points after deep learning; the main detection logic of the software is: visual hardware collects pictures, weld detection and judgment, and outputs results.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The present invention aims at the welding point characteristics of the X-pin stator of the flat wire motor, uses a suitable 3D line laser camera to capture the motor stator welding points in the field of view and generate a 3D image, so as to accurately judge the welding points of the X-pin stator and save debugging costs; The present invention can accurately and efficiently identify unqualified welds after welding, including defects such as leaking welds and blown welds, thereby reducing the outflow of unqualified stators and avoiding unnecessary losses; It can significantly improve the inspection level of the flat wire motor stator welding quality and meet the demand of the new energy vehicle industry for high-efficiency and high-reliability motors; The detection software has perfect solder joint detection logic and powerful deep learning function. It uses deep learning algorithms and multiple program logic processes to determine the status of all solder joints in the field of view. It is compatible with different solder joint positions and multiple solder joint quantities of different product models. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the structure of the present invention; Figure 2 for Figure 1 Structural diagram; Figure 3 for Figure 2 A magnified view of middle; Figure 4 This is a partial enlarged view of the X-pin stator; Figure 5 Flow chart of visual inspection department; In the figure: X-pin stator-1, stator core-11, flat copper wire-12, crown end-13, welding end-14, stator base-2, base plate-21, guide rail-22, base slide-23, rotating mechanism-24, rotating base plate-25, T-shaped slide-26, guide positioning block-27, guide slide-271, stator bracket-272, stator support plate-273, visual inspection unit-3, visual bracket-31, visual hardware-32. DETAILED DESCRIPTION

[0017] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention are clearly and completely described below in conjunction with the accompanying drawings and specific embodiments.

[0018] Please refer to Figures 1 to 5 , Figure 1 It is a schematic diagram of the structure of the present invention; Figure 2 for Figure 1 Structural diagram; Figure 3 for Figure 2 A magnified view of middle; Figure 4This is a partial enlarged view of the X-pin stator; Figure 5 Schematic diagram of the visual inspection department process.

[0019] The present invention provides an X-pin stator post-welding visual inspection system, which is used for inspecting an X-pin stator after laser welding, and comprises the following steps: Step 1: The welded X-pin stator 1 to be inspected is fed to the inspection device through the feeding line, and then placed on the stator base 2 and positioned and fixed by the handling device, and then the X-pin stator 1 is moved to the bottom of the visual inspection part 3 by the driving of the moving motor on the stator base 2 to prepare for visual inspection; Step 2: The X-pin stator 1 rotates at a constant speed in the field of view of the visual hardware of the visual inspection unit 3. The visual inspection unit 3 collects photos and transmits them to the controller through the signal line. The controller has built-in inspection software, which processes and analyzes the images and outputs the inspection results in the form of communication; Step 3: The qualified X-pin stator 1 is transferred to the feeding line through the transport device and transported to the next production process; the unqualified X-pin stator 1 is transferred to the laser repair welding device through the transport device, and the test result of step 2 is communicated to the laser repair welding device, and the laser repair welding device performs repair welding on the unqualified copper wire welding points according to the test result; Step 4: After the repair welding is completed, the X-pin stator 1 is transferred to the stator base 2 through the transport device and step 1 is repeated. The welds after the repair welding are inspected. The X-pin stator 1 that passes the inspection is transferred to the conveying line through the transport device and transported to the next production process; the X-pin stator 1 that fails the inspection repeats the repair welding operation of step 3. After the repair welding is completed, step 1 is continued to be repeated until the welding is qualified.

[0020] The X-pin stator 1 can be positioned on a stator base 2 , and a visual inspection unit 3 is provided above the stator base 2 .

[0021] The X-pin stator 1 includes a stator core 11, and a plurality of stator core slots penetrating up and down are evenly arranged on the inner wall of the stator core 11, and multiple layers of hairpin-shaped flat copper wires 12 are inserted in the slots. One end of the flat copper wire 12 that is bent is a crown end 13, and the end that needs to be welded is a welding end 14.

[0022] The stator base 2 includes a horizontally arranged base plate 21, on the top surface of which two mutually parallel guide rails 22 are arranged, on which a base slide plate 23 which can slide along its axial direction is arranged through a slider, and the base slide plate 23 is also connected to a moving motor arranged on the base plate 21; a rotating mechanism 24 is arranged at the center of the base slide plate 23, on the top surface of the rotating mechanism 24 a rotating base plate 25 is arranged, on the top surface of the rotating base plate 25 three T-shaped slide grooves 26 are evenly arranged along its radial direction, and in each T-shaped slide groove 26 a guide positioning block 27 is arranged, and the three guide positioning blocks 27 can be used to position and place X-pin stators 1 of various specifications through synchronous adjustment.

[0023] The rotating mechanism 24 includes an inner clamping motor, the shaft of which is connected to a horizontally arranged spiral drive disk, a spiral groove is arranged on the top surface of the spiral drive disk and is meshed with three guide positioning blocks 27 at the same time, and drives the three guide positioning blocks 27 to synchronously approach or move away from the center of the circle, so that it can be used for positioning and supporting X-pin stators 1 of various specifications; a rotating motor is also arranged on the outer side of the rotating mechanism 24, and the rotating motor can drive the rotating base plate 25 and the inner clamping motor to rotate synchronously, thereby driving the X-pin stator 1 to rotate synchronously.

[0024] The guide positioning block 27 includes a guide slider 271 arranged in the T-shaped slide groove 26, a card groove meshing with the spiral drive disk is arranged on the bottom surface of the guide slider 271, and an L-shaped stator bracket 272 is arranged on the top surface, and a stator support plate 273 extending inward is arranged on the inner side of the vertical upright plate of the stator bracket 272 near the top, and the X-pin stator 1 can be positioned and supported by the three stator support plates 273. During detection, the bottom end of the stator core 11 is placed on the three stator support plates 273.

[0025] The visual inspection unit 3 includes a visual bracket 31, and a visual hardware 32 is arranged through the visual bracket 31. The lens of the visual hardware 32 is located above the welding end 14, so that the welding end 14 after welding can be photographed and imaged; the visual hardware 32 is connected to a controller through a signal line, and the controller has built-in detection software that can process and analyze images and output the detection results in a communication manner.

[0026] The visual hardware 32 uses a 3D line laser camera.

[0027] The detection software combines the software algorithm of deep learning, trains and classifies the solder joints through deep learning, restores the solder joint contours of the copper wire with a 3D line laser camera, and detects through the built-in visual software of the controller after taking images with the camera. The program debugging is flexible, and the program can be switched to be compatible with various solder joint positions and solder joint quantities of different products, and finally outputs the judgment data of all solder joints and the total judgment result of the stator; currently, the solder joints of the flat copper wire of the X-pin stator are mainly divided into three states, namely qualified welding, leaking welding, and blown welding; the detection software can accurately judge the three states of the solder joints after deep learning; the main detection logic of the software is: visual hardware 32 collects pictures, solder joint detection and judgment, and outputs results.

[0028] The present invention is aimed at the quality inspection of the X-pin stator after welding of the flat wire motor. It uses a 3D line scan camera to generate a 3D image of the motor stator welding end by selecting the most suitable camera group hardware. The built-in visual software of the controller is associated with the controller. It combines deep learning software algorithms, rigorous detection logic, and reasonable detection technology. Through machine vision deep learning and program logic flow, the state of all solder joints in the field of view is judged, and the quality of solder joints is classified. It solves the quality monitoring of Xpin after welding and is compatible with the quality of solder joints of different product models.

[0029] Although the embodiments of the present invention have been shown and described, it is obvious that the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, it can be understood by ordinary technicians in this field that all other embodiments obtained by making various changes, modifications, substitutions and variations to these embodiments without departing from the principles and spirit of the present invention and without making creative work, all belong to the scope of protection of the present invention.

Claims

1. An X-pin stator post-weld visual inspection system, used for inspecting X-pin stators after laser welding, characterized in that: The steps include: Step 1: The X-pin stator (1) to be inspected is fed to the inspection device through a feeding line, and then placed on the stator base (2) and positioned and fixed by a handling device, and then the X-pin stator (1) is moved to the bottom of the visual inspection part (3) by driving a moving motor on the stator base (2) to prepare for visual inspection; Step 2: The X-pin stator (1) rotates at a constant speed within the field of view of the visual hardware of the visual inspection unit (3). The visual inspection unit (3) collects photos and transmits them to the controller through a signal line. The controller has built-in inspection software. The inspection software processes and analyzes the images and outputs the inspection results in the form of communication. Step 3: The X-pin stator (1) that passes the inspection is transferred to the feeding line through the transport device and transported to the next production process; the X-pin stator (1) that fails the inspection is transferred to the laser repair welding device through the transport device, and the inspection result of step 2 is communicated to the laser repair welding device, and the laser repair welding device performs repair welding on the copper wire welding points that fail the inspection according to the inspection result; Step 4: After the repair welding, the X-pin stator (1) is transferred to the stator base (2) by the transport device and step 1 is repeated to inspect the welds after the repair welding. The X-pin stator (1) that passes the inspection is transferred to the conveying line by the transport device and transported to the next production process. The X-pin stator (1) that fails the inspection repeats the repair welding operation of step 3. After the repair welding is completed, step 1 is continued to be repeated until the welding is qualified.

2. The X-pin stator post-weld visual inspection system according to claim 1, characterized in that: The X-pin stator (1) comprises a stator core (11), the inner wall of the stator core (11) being evenly provided with a plurality of stator core slots penetrating vertically, and multiple layers of hairpin-shaped flat copper wires (12) being passed through the slots, one end of the flat copper wire (12) being bent being a crown end (13), and the other end to be welded being a welding end (14).

3. The X-pin stator post-weld visual inspection system according to claim 2, characterized in that: The stator base (2) comprises a horizontally arranged base plate (21), two mutually parallel guide rails (22) are arranged on the top surface of the base plate (21), a base slide plate (23) which can slide along the axial direction thereof is arranged on the two guide rails (22) via a slider, and the base slide plate (23) is also connected to a moving motor arranged on the base plate (21); a rotating mechanism (24) is arranged at the center of the base slide plate (23), a rotating base plate (25) is arranged on the top surface of the rotating mechanism (24), three T-shaped slide grooves (26) are evenly arranged on the top surface of the rotating base plate (25) along the radial direction thereof, and a guide positioning block (27) is arranged in each T-shaped slide groove (26), and the three guide positioning blocks (27) can be used to position and place X-pin stators (1) of various specifications through synchronous adjustment.

4. The X-pin stator post-weld visual inspection system according to claim 3 is characterized in that: The rotating mechanism (24) includes an inner clamping motor, the shaft of which is connected to a horizontally arranged spiral drive disk, a spiral groove being arranged on the top surface of the spiral drive disk and being meshed with three guide positioning blocks (27) at the same time, and driving the three guide positioning blocks (27) to synchronously approach or move away from the center of a circle, so that it can be used for positioning and supporting X-pin stators (1) of various specifications; a rotating motor is also arranged on the outer side of the rotating mechanism (24), and the rotating base plate (25) and the inner clamping motor can be driven to rotate synchronously by the rotating motor, thereby driving the X-pin stator (1) to rotate synchronously.

5. The X-pin stator post-weld visual inspection system according to claim 4, characterized in that: The guide positioning block (27) comprises a guide slider (271) arranged in the T-shaped slide groove (26); a groove meshing with the spiral drive disk is arranged on the bottom surface of the guide slider (271); an L-shaped stator bracket (272) is arranged on the top surface; a stator support plate (273) extending inward is arranged on the inner side of the vertical upright plate of the stator bracket (272) near the top; the X-pin stator (1) can be positioned and supported by the three stator support plates (273) together; during detection, the bottom end of the stator core (11) is placed on the three stator support plates (273).

6. The X-pin stator post-weld visual inspection system according to claim 5, characterized in that: The visual inspection unit (3) comprises a visual support (31), and visual hardware (32) is arranged via the visual support (31), wherein a lens of the visual hardware (32) is located above the welding end (14), so that the welding end (14) after welding can be photographed and imaged; the visual hardware (32) is connected to a controller via a signal line, and the controller has built-in inspection software capable of processing and analyzing images, and outputting the inspection results in a communication manner.

7. The X-pin stator post-weld visual inspection system according to claim 6, characterized in that: The visual hardware (32) uses a 3D line laser camera.

8. The X-pin stator post-weld visual inspection system according to claim 7, characterized in that: The detection software is combined with a deep learning software algorithm, and the welding points are trained and classified through deep learning. At present, the welding points of the flat copper wire of the X-pin stator are mainly divided into three states, namely qualified welding, leaking welding, and blown welding. The detection software can accurately judge the three states of the welding points after deep learning. The main detection logic of the software is: the visual hardware (32) collects pictures, detects and judges the welding points, and outputs the results.

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