Modular brushless motor assembling system

Abstract

The invention discloses a modular brushless motor assembly system, and belongs to the technical field of brushless motor assembly. Comprising a stator assembling system, a rotor assembling system, an end cover assembling system and a controller assembling system, a stator module is fixed in a shell module through the stator assembling system, the shell module assembled with the stator module is taken away through the rotor assembling system, and a rotor module is fixed in the shell module; the end cover assembling system takes away the shell module assembled with the stator module and the rotor module and installs the end cover module at an opening of the shell module, and the controller assembling system takes away the shell module assembled with the stator module, the rotor module and the end cover module and conveys the controller module. Finally, the controller module is installed on the outer side of the shell module by a worker, and the controller module and the stator module are connected; the assembly system applied to the modularized brushless motor can achieve the purpose of semi-automatic assembly of the brushless motor.

Description

Technical Field

[0001] The invention relates to the technical field of brushless motor assembly, in particular to a modular brushless motor assembly system. Background Art

[0002] The brushless DC motor consists of a motor body and a driver. Brushless motors have the advantages of high efficiency, high reliability, and low noise, and have been widely used in many fields. However, the traditional assembly method of brushless motors is usually complicated and requires professional technicians to operate. In addition, errors are prone to occur during the assembly process, affecting the performance and quality of the motor. Summary of the invention

[0003] The object of the present invention is to provide a modular brushless motor assembly system to solve the problems raised in the above background technology.

[0004] In view of the above problems, the technical solution proposed by the present invention is: A modular brushless motor assembly system, including a stator assembly system, a rotor assembly system, an end cover assembly system, and a controller assembly system; The stator assembly system includes a shell module warehouse, a first conveying module, a first clamping module, a stator module warehouse, a second conveying module, a second clamping module, a first positioning module, a first assembly table, a first fixing module, a clamp, a heating module, and a cooling module. The shell module is stored in the shell module warehouse. The first conveying module conveys the shell module. The first clamping module clamps the shell module conveyed by the first conveying module to the first assembly table. The first fixing module fixes the shell module on the first assembly table. The stator module warehouse stores a stator module. The second conveying module conveys the stator module. The second clamping module clamps the stator module conveyed by the second conveying module to the shell module on the first assembly table. The second clamping module adjusts the position of the stator module in the shell module on the first assembly table according to the first positioning module. The heating module heats the shell module and the stator module on the first assembly table. The clamp fixes the stator module on the first assembly table in the shell module. The cooling module cools the shell module and the stator module fixed together. As a preferred technical solution of the present invention, an assembly box is installed on the top surface of the first assembly table, and the top surface of the assembly box is open. The heating module and the cooling module are both installed in the first assembly table. The top surface of the first assembly table is provided with a plurality of air holes that pass through the bottom surface of the assembly box. The heating module is a heater, and the cooling module is a cooler.

[0005] Specifically, the housing module is a modular housing, that is, the housing, heat sink, junction box, and mounting frame are pre-installed together, and the stator module is a modular stator, that is, the stator core, stator winding, electronic commutator, insulating material, and fixing components are pre-installed together.

[0006] Specifically, the first clamping module and the second clamping module can accurately place the shell module in the assembly box according to the preset program and the pre-input coordinates. The first fixing module is in the assembly box, which automatically fixes the shell module and accurately places the stator module in the shell module. At the same time, the first positioning module measures the distance between the stator module and the shell module. The second clamping module adjusts the position of the stator module according to the measurement result of the first positioning module so that its axis and the axis of the shell module are on the same straight line. The heat generated by the heater enters the assembly box through the air holes. After the temperature in the assembly box reaches the set temperature, it is maintained for a period of time to fully soften the shell module and the stator module. The clamp-type clamp is also in the assembly box, and the clamp-type clamp is used to pressurize the outside of the shell module so that the shell module and the stator module are tightly combined together. The low temperature generated by the cooler enters the assembly box through the air holes to cool the shell module and the stator module.

[0007] As a preferred technical solution of the present invention, the first fixing module, the second fixing module and the third fixing module are all three-jaw chucks, the top surfaces of the second assembly table and the third assembly table are both provided with openings, and the jaws of the three-jaw chucks are around the openings.

[0008] The rotor assembly system includes a third clamping module, a rotor module bin, a third conveying module, a fourth clamping module, a second positioning module, a second assembly table, a press-fitting module, and a second fixing module. The third clamping module clamps the cooled shell module fixed with the stator module on the first assembly table to the second assembly table. The second fixing module fixes the shell module on the second assembly table. The rotor module bin stores a rotor module. The third conveying module conveys the rotor module. The fourth clamping module clamps the rotor module conveyed by the third conveying module to the shell module on the second assembly table. The fourth clamping module adjusts the position of the rotor module in the shell module on the second assembly table according to the second positioning module. The press-fitting module fixes the rotor module on the second assembly table in the shell module. As a preferred technical solution of the present invention, the press-fitting module is composed of a hydraulic system and a press head, and the press head is installed at the driving end of the hydraulic system.

[0009] Specifically, the rotor module is a modular rotor, that is, the permanent magnet, the rotor core, the main shaft, and the bearings are pre-installed together.

[0010] Specifically, one side of the shell module is open to the outside for assembling the stator module and the rotor module, and the other side is provided with a through hole for the main shaft of the rotor module to pass through. The third clamping module clamps the shell module with the stator module installed on the second assembly table. The through hole of the shell module is located above the opening. When assembling the rotor module, the main shaft of the rotor module can extend into the opening through the through hole, so that the second assembly table will not hinder the assembly of the rotor module. During assembly, the second fixing module fixes the shell module, and the fourth clamping module places the rotor module in the shell module. At the same time, the second positioning module measures the distance between the rotor module and the shell module. The fourth clamping module adjusts the position of the rotor module according to the measurement result of the second positioning module so that its axis and the axis of the shell module are on the same straight line. The pressure head is pressed on the top surface of the stator module, and the hydraulic system applies pressure to the pressure head so that the bearing of the rotor module is fixed in the shell module and the main shaft of the rotor module extends out of the shell module.

[0011] The end cap assembly system includes a fifth clamping module, an end cap module bin, a fourth conveying module, a sixth clamping module, a third positioning module, a third assembly table, a third fixing module, a tightening module, and a feeding module. The fifth clamping module clamps the housing module fixed with the stator module and the rotor module on the second assembly table to the third assembly table. The third module fixes the housing module on the third assembly table. The end cap module bin stores the end cap module. The fourth conveying module conveys the end cap module. The sixth clamping module adsorbs the end cap module conveyed by the fourth conveying module to the opening of the housing module on the third assembly table. The sixth clamping module adjusts the position of the end cap module at the opening of the housing module on the third assembly table according to the third positioning module. A plurality of screws are stored in the feeding module. The feeding module conveys the screws to the tightening module. The tightening module uses screws to fix the end cap module and the housing module together. As a preferred technical solution of the present invention, the feeding module is a vibration plate, and the tightening module is an automatic screw feeding and tightening machine.

[0012] Specifically, the end cover module is a modular end cover, that is, the end cover, the seal, and the fixing hole are pre-installed.

[0013] Specifically, one side of the shell module is open to the outside for assembling the stator module and the rotor module, and the other side is provided with a through hole for the main shaft of the rotor module to pass through. The fifth clamping module clamps the shell module with the stator module and the rotor module installed on the third assembly table. The through hole of the shell module is located above the opening, and the main shaft is located in the opening, so that the main shaft does not contact the third assembly table. During assembly, the third fixing module fixes the shell module, the sixth clamping module absorbs the end cover and places it in the opening of the shell module, the third positioning module controls the sixth clamping module to align the fixing hole with the threaded hole on the shell module, and the automatic screw feeding machine takes the screw from the vibration plate, passes the screw through the fixing hole and screws it into the threaded hole.

[0014] The controller assembly system includes a seventh clamping module, a controller module warehouse, a fifth conveying module, and an eighth clamping module. The seventh clamping module clamps the housing module fixed with the stator module, the rotor module, and the end cover module on the third assembly table to the fourth assembly table. The controller module is stored in the controller module warehouse. The fifth conveying module conveys the controller module. The eighth clamping module clamps the controller module conveyed by the fifth conveying module to the fourth assembly table.

[0015] Specifically, the controller module is a modular controller, that is, the main control chip, drive circuit, power circuit, sensor interface circuit, and communication interface circuit are pre-installed.

[0016] Specifically, the seventh clamping module clamps the shell module equipped with the stator module, the rotor module and the end cover module onto the fourth assembly table, and the eighth clamping module clamps the controller module onto the fourth assembly table. The assembler connects the cables of the controller module and the stator module together, and then installs the controller module on the shell module.

[0017] As a preferred technical solution of the present invention, the first conveying module, the second conveying module, the third conveying module, the fourth conveying module, and the fifth conveying module are one or more of a conveyor belt, a roller conveyor, and an automatic guided vehicle.

[0018] Specifically, the shell module, stator module, rotor module, end cover module and controller module are placed on the first conveying module, the second conveying module, the third conveying module, the fourth conveying module and the fifth conveying module manually or mechanically, and the shell module, stator module, rotor module, end cover module and controller module conveyed by the first conveying module, the second conveying module, the third conveying module, the fourth conveying module and the fifth conveying module are arranged vertically and do not contact each other.

[0019] As a preferred technical solution of the present invention, the first clamping module, the second clamping module, the third clamping module, the fourth clamping module, the fifth clamping module, the seventh clamping module, and the eighth clamping module are composed of a robotic arm and a robotic claw, and the robotic claw is installed at the execution end of the robotic arm; the sixth clamping module is composed of a robotic arm and an electric suction cup, and the electric suction cup is installed at the execution end of the robotic arm.

[0020] Specifically, the electric suction cup absorbs the center of the end cover module, and the end cover module is not clamped by a mechanical claw, which can prevent the mechanical claw from affecting the installation of the screws.

[0021] As a preferred technical solution of the present invention, the first positioning module, the second positioning module and the third positioning module are optical positioners, and the first positioning module, the second positioning module and the third positioning module are all installed on the robotic arm and close to the execution end of the robotic arm.

[0022] Compared with the prior art, the beneficial effects of the present invention are: the modular brushless motor assembly system assembles the stator module, the rotor module, and the end cover module in the shell module by automation, and assembles the controller module on the outside of the shell module by semi-automation, which can reduce the difficulty of assembling the brushless motor, reduce the demand for professional technicians, and improve the accuracy of assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A system block diagram of a modular brushless motor assembly system disclosed in an embodiment of the present invention. DETAILED DESCRIPTION

[0024] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0025] See also Figure 1The present invention provides a technical solution: a modular brushless motor assembly system, including a stator assembly system, the stator assembly system including a shell module warehouse, a first conveying module, a first clamping module, a stator module warehouse, a second conveying module, a second clamping module, a first positioning module, a first assembly table, a first fixing module, a clamp, a heating module, and a cooling module. The shell module warehouse stores a shell module, the first conveying module conveys the shell module, the first clamping module clamps the shell module conveyed by the first conveying module to the first assembly table, and the first fixing module fixes the shell module on the first assembly table. block, the stator module is stored in the stator module warehouse, the second conveying module conveys the stator module, the second clamping module clamps the stator module conveyed by the second conveying module into the shell module on the first assembly table, the second clamping module adjusts the position of the stator module in the shell module on the first assembly table according to the first positioning module, the heating module heats the shell module and the stator module on the first assembly table, the clamp-type clamp fixes the stator module on the first assembly table in the shell module, and the cooling module cools the shell module and the stator module fixed together.

[0026] According to an embodiment of the present invention, further, an assembly box is installed on the top surface of the first assembly table, the top surface of the assembly box is open, the heating module and the cooling module are both installed in the first assembly table, and a plurality of air holes penetrating the bottom surface of the assembly box are opened on the top surface of the first assembly table, the heating module is a heater, and the cooling module is a cooler.

[0027] In one embodiment of the present invention, further, the shell module is a modular shell, that is, the shell, heat sink, junction box, and mounting frame are pre-installed together, and the stator module is a modular stator, that is, the stator core, stator winding, electronic commutator, insulating material, and fixing components are pre-installed together.

[0028] An embodiment of the function of the present invention, further, the first clamping module and the second clamping module can accurately place the shell module in the assembly box according to a preset program and pre-input coordinates, the first fixing module is in the assembly box, and it automatically fixes the shell module and accurately places the stator module in the shell module, and at the same time the first positioning module measures the distance between the stator module and the shell module, the second clamping module adjusts the position of the stator module according to the measurement result of the first positioning module, so that its axis and the axis of the shell module are on the same straight line, the heat generated by the heater enters the assembly box through the air hole, and the temperature in the assembly box reaches the set temperature and is maintained for a period of time, so that the shell module and the stator module are fully softened, the clamp-type clamp is also in the assembly box, and the clamp-type clamp is used to pressurize the outside of the shell module, so that the shell module and the stator module are tightly combined together, and the low temperature generated by the cooler enters the assembly box through the air hole, so that the shell module and the stator module are cooled.

[0029] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] See also Figure 1 The present invention provides a technical solution: a method for using a modular brushless motor assembly system, including a rotor assembly system, wherein the rotor assembly system includes a third clamping module, a rotor module bin, a third conveying module, a fourth clamping module, a second positioning module, a second assembly table, a press-fitting module, and a second fixing module. The third clamping module clamps the cooled shell module fixed with the stator module on the first assembly table to the second assembly table, the second fixing module fixes the shell module on the second assembly table, the rotor module bin stores a rotor module, the third conveying module conveys the rotor module, the fourth clamping module clamps the rotor module conveyed by the third conveying module to the shell module on the second assembly table, the fourth clamping module adjusts the position of the rotor module in the shell module on the second assembly table according to the second positioning module, and the press-fitting module fixes the rotor module on the second assembly table in the shell module.

[0031] According to an embodiment of the present invention, further, the press module is composed of a hydraulic system and a pressing head, and the pressing head is installed at a driving end of the hydraulic system.

[0032] According to an embodiment of the present invention, further, the first fixing module, the second fixing module and the third fixing module are all three-jaw chucks, the top surfaces of the second assembly table and the third assembly table are both provided with openings, and the clamping jaws of the three-jaw chucks are around the openings.

[0033] According to an embodiment of the present invention, further, the rotor module is a modular rotor, that is, the permanent magnet, the rotor core, the main shaft and the bearing are pre-installed together.

[0034] According to an embodiment of the present invention, further, one side of the shell module is open to the outside for assembling the stator module and the rotor module, and the other side is provided with a through hole for the main shaft of the rotor module to pass through. The third clamping module clamps the shell module with the stator module installed on the second assembly table, and the through hole of the shell module is located above the opening. When assembling the rotor module, the main shaft of the rotor module can extend into the opening through the through hole, so that the second assembly table will not hinder the assembly of the rotor module. During assembly, the second fixing module fixes the shell module, and the fourth clamping module places the rotor module in the shell module. At the same time, the second positioning module measures the distance between the rotor module and the shell module. The fourth clamping module adjusts the position of the rotor module according to the measurement result of the second positioning module, so that its axis and the axis of the shell module are on the same straight line, the pressure head is pressed on the top surface of the stator module, and the hydraulic system applies pressure to the pressure head, so that the bearing of the rotor module is fixed in the shell module, and the main shaft of the rotor module extends out of the shell module.

[0035] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0036] See also Figure 1The present invention provides a technical solution: a method for using a modular brushless motor assembly system, comprising an end cap assembly system, wherein the end cap assembly system comprises a fifth clamping module, an end cap module bin, a fourth conveying module, a sixth clamping module, a third positioning module, a third assembly platform, a third fixing module, a tightening module, and a feeding module, wherein the fifth clamping module clamps the housing module fixed with the stator module and the rotor module on the second assembly platform to the third assembly platform, the third module fixes the housing module on the third assembly platform, the end cap module bin stores the end cap module, the fourth conveying module conveys the end cap module, the sixth clamping module adsorbs the end cap module conveyed by the fourth conveying module to the opening of the housing module on the third assembly platform, the sixth clamping module adjusts the position of the end cap module at the opening of the housing module on the third assembly platform according to the third positioning module, the feeding module stores a plurality of screws, the feeding module conveys the screws to the tightening module, and the tightening module uses screws to fix the end cap module and the housing module together; According to an embodiment of the present invention, further, the feeding module is a vibration plate, and the tightening module is an automatic screw feeding and tightening machine.

[0037] According to an embodiment of the present invention, further, the first fixing module, the second fixing module and the third fixing module are all three-jaw chucks, the top surfaces of the second assembly table and the third assembly table are both provided with openings, and the clamping jaws of the three-jaw chucks are around the openings.

[0038] According to an embodiment of the present invention, further, the end cover module is a modular end cover, that is, the end cover, the seal, and the fixing hole are pre-installed.

[0039] According to an embodiment of the present invention, one side of the shell module is open to the outside for assembling the stator module and the rotor module, and the other side is provided with a through hole for the main shaft of the rotor module to pass through. The fifth clamping module clamps the shell module with the stator module and the rotor module onto the third assembly table. The through hole of the shell module is located above the opening, and the main shaft is located in the opening, so that the main shaft does not contact the third assembly table. During assembly, the third fixing module fixes the shell module, the sixth clamping module absorbs the end cover and places it at the opening of the shell module, the third positioning module controls the sixth clamping module to align the fixing hole with the threaded hole on the shell module, and the automatic screw feeding machine takes the screw from the vibration plate, passes the screw through the fixing hole and screws it into the threaded hole.

[0040] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0041] See also Figure 1 The present invention provides a technical solution: a method for using a modular brushless motor assembly system, including a controller assembly system, the controller assembly system including a seventh clamping module, a controller module warehouse, a fifth conveying module, and an eighth clamping module, the seventh clamping module clamps the housing module fixed with the stator module, the rotor module, and the end cover module on the third assembly table to the fourth assembly table, the controller module is stored in the controller module warehouse, the fifth conveying module conveys the controller module, and the eighth clamping module clamps the controller module conveyed by the fifth conveying module to the fourth assembly table.

[0042] In one embodiment of the present invention, further, the controller module is a modular controller, that is, the main control chip, the drive circuit, the power circuit, the sensor interface circuit, and the communication interface circuit are pre-installed.

[0043] According to an embodiment of the present invention, further, the seventh clamping module clamps the shell module equipped with the stator module, the rotor module and the end cover module onto the fourth assembly table, and the eighth clamping module clamps the controller module onto the fourth assembly table. The assembler connects the cables of the controller module and the stator module together, and then installs the controller module on the shell module.

Claims

1. A modular brushless motor assembly system, characterized in that: Including stator assembly system, rotor assembly system, end cover assembly system, controller assembly system; The stator assembly system includes a shell module warehouse, a first conveying module, a first clamping module, a stator module warehouse, a second conveying module, a second clamping module, a first positioning module, a first assembly table, a first fixing module, a clamp, a heating module, and a cooling module. The shell module is stored in the shell module warehouse. The first conveying module conveys the shell module. The first clamping module clamps the shell module conveyed by the first conveying module to the first assembly table. The first fixing module fixes the shell module on the first assembly table. The stator module warehouse stores a stator module. The second conveying module conveys the stator module. The second clamping module clamps the stator module conveyed by the second conveying module to the shell module on the first assembly table. The second clamping module adjusts the position of the stator module in the shell module on the first assembly table according to the first positioning module. The heating module heats the shell module and the stator module on the first assembly table. The clamp fixes the stator module on the first assembly table in the shell module. The cooling module cools the shell module and the stator module fixed together. The rotor assembly system includes a third clamping module, a rotor module bin, a third conveying module, a fourth clamping module, a second positioning module, a second assembly table, a press-fitting module, and a second fixing module. The third clamping module clamps the cooled shell module fixed with the stator module on the first assembly table to the second assembly table. The second fixing module fixes the shell module on the second assembly table. The rotor module bin stores a rotor module. The third conveying module conveys the rotor module. The fourth clamping module clamps the rotor module conveyed by the third conveying module to the shell module on the second assembly table. The fourth clamping module adjusts the position of the rotor module in the shell module on the second assembly table according to the second positioning module. The press-fitting module fixes the rotor module on the second assembly table in the shell module. The end cap assembly system includes a fifth clamping module, an end cap module bin, a fourth conveying module, a sixth clamping module, a third positioning module, a third assembly table, a third fixing module, a tightening module, and a feeding module. The fifth clamping module clamps the housing module fixed with the stator module and the rotor module on the second assembly table to the third assembly table. The third module fixes the housing module on the third assembly table. The end cap module bin stores the end cap module. The fourth conveying module conveys the end cap module. The sixth clamping module adsorbs the end cap module conveyed by the fourth conveying module to the opening of the housing module on the third assembly table. The sixth clamping module adjusts the position of the end cap module at the opening of the housing module on the third assembly table according to the third positioning module. A plurality of screws are stored in the feeding module. The feeding module conveys the screws to the tightening module. The tightening module uses screws to fix the end cap module and the housing module together. The controller assembly system includes a seventh clamping module, a controller module warehouse, a fifth conveying module, and an eighth clamping module. The seventh clamping module clamps the housing module fixed with the stator module, the rotor module, and the end cover module on the third assembly table to the fourth assembly table. The controller module is stored in the controller module warehouse. The fifth conveying module conveys the controller module. The eighth clamping module clamps the controller module conveyed by the fifth conveying module to the fourth assembly table.

2. A modular brushless motor assembly system according to claim 1, characterized in that: The first conveying module, the second conveying module, the third conveying module, the fourth conveying module, and the fifth conveying module are one or more of a conveyor belt, a roller conveyor, and an automatic guided vehicle.

3. A modular brushless motor assembly system according to claim 1, characterized in that: The first clamping module, the second clamping module, the third clamping module, the fourth clamping module, the fifth clamping module, the seventh clamping module and the eighth clamping module are composed of a robotic arm and a robotic claw, and the robotic claw is installed at the execution end of the robotic arm. The sixth clamping module is composed of a robotic arm and an electric suction cup, and the electric suction cup is installed at the execution end of the robotic arm.

4. A modular brushless motor assembly system according to claim 3, characterized in that: The first positioning module, the second positioning module and the third positioning module are optical positioners, and the first positioning module, the second positioning module and the third positioning module are all installed on the mechanical arm and close to the execution end of the mechanical arm.

5. The modular brushless motor assembly system according to claim 1, characterized in that: The first fixing module, the second fixing module and the third fixing module are all three-jaw chucks, the top surfaces of the second assembly table and the third assembly table are both provided with openings, and the clamping jaws of the three-jaw chucks are around the openings.

6. A modular brushless motor assembly system according to claim 1, characterized in that: An assembly box is installed on the top surface of the first assembly table, and the top surface of the assembly box is open. The heating module and the cooling module are both installed in the first assembly table. The top surface of the first assembly table is provided with a plurality of air holes that pass through the bottom surface of the assembly box. The heating module is a heater, and the cooling module is a cooler.

7. A modular brushless motor assembly system according to claim 1, characterized in that: The press module is composed of a hydraulic system and a press head, and the press head is installed at the driving end of the hydraulic system.

8. A modular brushless motor assembly system according to claim 3, characterized in that: The feeding module is a vibration plate, and the tightening module is an automatic screw feeding and tightening machine.

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