X-pin flat wire motor stator welding quality detection system

Abstract

The invention discloses an X-pin flat wire motor stator welding quality detection system, and relates to the technical field of flat wire motor stator laser welding, a photoelectric sensor is used for collecting the optical signal intensity in the X-pin flat wire motor laser welding process, a threshold value of a detection signal is established by welding a normal product, the detection signal intensity is compared with the threshold value, and the X-pin flat wire motor stator welding quality is obtained. Whether the welding process is abnormal or not is judged; near-infrared light is irradiated to a sample through a fusion depth detection module, and light scattered and reflected by the sample is combined with reference light of an emission light path so as to detect the fusion depth; two detection modes are integrated on the same galvanometer, the equipment cost and the equipment space are saved, the welding quality is detected while welding is conducted, and the detection quality is guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of X-pin flat wire motor stator laser welding, in particular to an X-pin flat wire motor stator welding quality detection system. Background Art

[0002] With the rise of new energy vehicles in China, more and more domestic automobile manufacturers are pursuing innovation and improvement of new energy core technologies. As one of the core components of new energy vehicles, the production process of motors has received more and more attention. In the existing technology, in order to ensure welding quality and improve welding efficiency during the production of flat wire motors, laser welding is used to weld the motor stator flat wire; however, as one of the core welding processes, there is currently no effective solution for quality monitoring before, during and after X-pin welding.

[0003] The main reason is that due to the particularity of the flat wire motor stator structure and the diversity of flat wire gauges, when using traditional detection methods for quality control, there is often a high rate of missed or over-killing, and thus it is impossible to meet the high-efficiency and high-quality production requirements; therefore, solving the quality control problem of X-pin flat wire motor laser welding machine has become a top priority. Summary of the invention

[0004] The purpose of the present invention is to provide an X-pin flat wire motor stator welding quality inspection system to solve the problem that the traditional inspection means proposed in the above background technology have a high rate of missed or over-killing for laser welded flat wire motor stators and cannot meet the requirements of high efficiency and high quality production.

[0005] To achieve the above object, the present invention provides the following technical solutions: a system for detecting the welding quality of an X-pin flat wire motor stator, a method for synchronously detecting the laser welding quality when the X-pin flat wire motor stator is laser welded, comprising the following steps: Step 1: Place the X-pin flat wire motor stator to be welded on the positioning seat; Step 2: The laser emits laser light, and acts on the copper wire welding end of the flat wire motor stator through the optical fiber and the galvanometer module, and heats the copper wire to be welded at the copper wire welding end to form a molten pool, thereby completing the welding operation; Step 3: When using laser to weld the copper wire welding end of the flat wire motor stator, three lights with different wavelengths are generated and transmitted to the photoelectric sensor module through the galvanometer module, and the photoelectric sensor module converts the three optical signals into corresponding electrical signals to form signal thresholds; Step 4: Establish the threshold of the detection signal by welding normal products, compare the three optical signal intensities detected in step 3 with the threshold of the detection signal established by welding normal products, and determine whether there is any abnormality in the welding process; Step 5: At the same time as step 3 and step 4, the penetration detection module will synchronize the laser beam to emit light with a wavelength of 800nm ​​to 900nm to the welding pool at the welding end of the copper wire, and the welding pool will scatter and reflect the light with a wavelength of 800nm ​​to 900nm, and the scattered and reflected light will be transmitted to the penetration detection module via the galvanometer module; the penetration detection module will detect the received scattered and reflected light with the light of the emitted light path, and then detect the welding penetration; Step 6: Generate a curve chart with the test results of step 4 and step 5 in the same chart. The welding quality can be clearly judged through the curve chart.

[0006] Preferably, the three lights with different wavelengths are infrared light, visible light, and reflected light with a wavelength of 1060nm to 1080nm; An X-pin flat wire motor stator welding quality inspection system for implementing the above-mentioned inspection method includes a positioning seat and an X-pin flat wire motor stator placed thereon, a galvanometer module is arranged above the X-pin flat wire motor stator through a bracket, the galvanometer module is connected to a laser through an optical fiber, and a penetration detection module and a photoelectric sensor module are arranged on the side wall of the galvanometer module.

[0007] Preferably, the penetration detection module can emit near-infrared light, and irradiate the near-infrared light on the laser welding penetration of the copper wire welding end of the stator of the X-pin flat wire motor through the galvanometer module. The near-infrared light after reflection and scattering from the welding penetration is fed back to the penetration detection module via the galvanometer module.

[0008] Preferably, the penetration detection module detects the received scattered and reflected light and the light emitted from the emission light path, and obtains a one-dimensional signal in the depth direction by detecting the optical interference signal generated in this way, thereby detecting the welding penetration.

[0009] Compared with the prior art, the present invention has the following beneficial effects: The present invention innovatively uses light of different wavelengths for detection during laser welding of the X-pin flat wire motor stator, which has high detection efficiency; and fills the gap that there is no welding detection method for the previous X-pin flat wire motor stator, which is the first in the industry; Combining the two detection methods can improve detection efficiency and produce more accurate results; The two detection solutions are integrated into one set of galvanometer lenses, saving equipment cost and equipment space. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 It is a schematic diagram of the detection principle of the present invention; Figure 2 To detect qualified laser reflected light curve; Figure 3 To detect qualified infrared light curve; Figure 4 To detect qualified visible light curve; Figure 5 To detect unqualified laser reflected light curve; Figure 6 To detect unqualified infrared light curves; Figure 7 To detect unqualified visible light curve; In the figure: positioning seat-1, X-pin flat wire motor stator-2, galvanometer module-3, optical fiber-4, penetration depth detection module-5, photoelectric sensor module-6. DETAILED DESCRIPTION

[0011] 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.

[0012] Please refer to Figures 1 to 7 , Figure 1 It is a schematic diagram of the detection principle of the present invention; Figure 2 To detect qualified laser reflected light curve; Figure 3 To detect qualified infrared light curve; Figure 4 To detect qualified visible light curve; Figure 5 To detect unqualified laser reflected light curve; Figure 6 To detect unqualified infrared light curves; Figure 7 To detect unqualified visible light curve.

[0013] The present invention provides an X-pin flat wire motor stator welding quality detection system, which is used for synchronously detecting the laser welding quality of the X-pin flat wire motor stator during laser welding, and comprises the following steps: Step 1: Place the X-pin flat wire motor stator to be welded on the positioning seat; Step 2: The laser emits laser light, and acts on the copper wire welding end of the flat wire motor stator through the optical fiber and the galvanometer module, and heats the copper wire to be welded at the copper wire welding end to form a molten pool, thereby completing the welding operation; Step 3: When using laser to weld the copper wire welding end of the flat wire motor stator, three lights with different wavelengths are generated and transmitted to the photoelectric sensor module through the galvanometer module, and the photoelectric sensor module converts the three optical signals into corresponding electrical signals to form signal thresholds; Step 4: Establish the threshold of the detection signal by welding normal products, compare the three optical signal intensities detected in step 3 with the threshold of the detection signal established by welding normal products, and determine whether there is any abnormality in the welding process; Step 5: At the same time as step 3 and step 4, the penetration detection module will synchronize the laser beam to emit light with a wavelength of 800nm ​​to 900nm to the welding pool at the welding end of the copper wire, and the welding pool will scatter and reflect the light with a wavelength of 800nm ​​to 900nm, and the scattered and reflected light will be transmitted to the penetration detection module via the galvanometer module; the received scattered and reflected light and the light of the emitted light path will be detected by the penetration detection module, and the one-dimensional signal in the depth direction will be obtained by detecting the optical interference signal generated in this way, thereby detecting the welding penetration; Step 6: Generate a curve graph with the test results of step 4 and step 5 in the same chart. The welding quality can be clearly judged through the curve graph.

[0014] Step 6 will generate the attached Figure 2 To Attachment Figure 7 A curve diagram of Figure 2 To detect qualified laser reflected light curve, Figure 3 To detect qualified infrared light curves, Figure 4 To detect qualified visible light curve, Figure 5 To detect unqualified laser reflected light curves, Figure 6 To detect unqualified infrared light curves, Figure 7 To detect unqualified visible light curves, line A in each curve graph is the lower limit of the detection range, line B is the detection reference value, line C is the upper limit of the detection range, and line D is the detection result.

[0015] The detection device used to implement the above detection method includes a positioning seat 1 for positioning and placing an X-pin flat wire motor stator to be welded, an X-pin flat wire motor stator 2 is positioned and placed on the positioning seat 1, a galvanometer module 3 is arranged above the X-pin flat wire motor stator 2 through a bracket, the galvanometer module 3 is connected to the laser through an optical fiber 4, the laser emitted by the laser converges the laser on the copper wire welding end of the X-pin flat wire motor stator 2 through the optical fiber 4 and the galvanometer module 3, and the copper wire to be welded is heated at the copper wire welding end to form a molten pool, thereby completing the welding operation; A penetration detection module 5 and a photoelectric sensor module 6 are provided at the side wall of the galvanometer module 3. The penetration detection module 5 can emit near-infrared light, and the near-infrared light is irradiated on the laser welding penetration of the copper wire welding end of the X-pin flat wire motor stator 2 through the galvanometer module 3. The near-infrared light reflected and scattered by the welding penetration is fed back to the penetration detection module 5 through the galvanometer module 3. The received scattered and reflected light and the light of the emitted light path are detected by the penetration detection module 5. By detecting the optical interference signal generated in this way, a one-dimensional signal in the depth direction is obtained, and then the welding penetration is detected; When welding the copper wire of the X-pin flat wire motor stator 2 with laser, three lights with different wavelengths are generated, namely infrared light, visible light and reflected light with a wavelength of 1060nm to 1080nm, and the three lights are transmitted to the photoelectric sensor module 6 through the galvanometer module 3. After receiving the three lights, the photoelectric sensor module 6 converts the three lights into corresponding electrical signals to form signal thresholds.

[0016] The present invention innovatively uses light of different wavelengths for detection during laser welding of X-pin flat wire motor stators, thereby achieving high detection efficiency. It also fills the gap that there is no welding detection method for X-pin flat wire motor stators, which is an industry first. The two detection methods are combined with each other for detection, thereby achieving high detection efficiency and more accurate results. The two detection schemes are integrated into a set of galvanometer lenses, saving equipment cost and equipment space.

[0017] 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. A method for synchronously detecting the laser welding of an X-pin flat wire motor stator using an X-pin flat wire motor stator welding quality detection system, characterized in that: The following steps are involved: Step 1: Place the X-pin flat wire motor stator (2) to be welded on the positioning seat (1); Step 2: The laser emits laser light and applies the laser light to the copper wire welding end of the X-pin flat wire motor stator (2) through the optical fiber (4) and the galvanometer module (3), and heats the copper wire to be welded at the copper wire welding end to form a molten pool, thereby completing the welding operation; Step 3: In the process of using laser to weld the copper wire welding end of the X-pin flat wire motor stator (2), three lights with different wavelengths are generated and transmitted to the photoelectric sensor module (6) through the galvanometer module (3), and the photoelectric sensor module (6) converts the three optical signals into corresponding electrical signals to form signal thresholds; Step 4: Establish the threshold of the detection signal by welding normal products, compare the three optical signal intensities detected in step 3 with the threshold of the detection signal established by welding normal products, and determine whether there is any abnormality in the welding process; Step 5: At the same time as step 3 and step 4, the penetration detection module (5) will synchronize the laser beam to emit light with a wavelength of 800nm ​​to 900nm to the welding pool at the welding end of the copper wire, and the welding pool will scatter and reflect the light with a wavelength of 800nm ​​to 900nm, and the scattered and reflected light will be transmitted to the penetration detection module (5) via the galvanometer module (3); the received scattered and reflected light and the light emitted by the emission light path are detected by the penetration detection module (5), thereby detecting the welding penetration; Step 6: Generate a curve graph with the test results of step 4 and step 5 in the same chart. The welding quality can be clearly judged through the curve graph.

2. The method for synchronously detecting the laser welding of the stator of an X-pin flat wire motor using the X-pin flat wire motor stator welding quality detection system according to claim 1 is characterized in that: The three lights with different wavelengths generated in step three are infrared light, visible light, and reflected light with a wavelength of 1060nm to 1080nm.

3. An X-pin flat wire motor stator welding quality detection system for implementing the detection method of claim 1, characterized in that: The invention comprises a positioning seat (1) and an X-pin flat wire motor stator (2) placed thereon, a galvanometer module (3) is arranged above the X-pin flat wire motor stator (2) via a bracket, the galvanometer module (3) is connected to a laser via an optical fiber (4), and a melting depth detection module (5) and a photoelectric sensor module (6) are arranged on the side wall of the galvanometer module (3).

4. The X-pin flat wire motor stator welding quality detection system according to claim 3 is characterized in that: The penetration depth detection module (5) can emit near-infrared light, and irradiate the near-infrared light on the laser welding penetration of the copper wire welding end of the X-pin flat wire motor stator (2) through the galvanometer module (3); the near-infrared light reflected and scattered by the welding penetration is fed back to the penetration depth detection module (5) via the galvanometer module (3).

5. The X-pin flat wire motor stator welding quality detection system according to claim 3 is characterized in that: The penetration depth detection module (5) detects the received scattered and reflected light and the light emitted from the emission light path, and obtains a one-dimensional signal in the depth direction by detecting the light interference signal generated in this way, thereby detecting the welding penetration depth.

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