Motor stator welding spot appearance detection device

Abstract

The invention relates to the technical field of detection equipment, and particularly discloses a motor stator welding spot appearance detection device which comprises a rack, a transmission line, a carrier, a CCD detection module and a manipulator. The rack is provided with a first stop piece and a second stop piece; the transmission line is fixedly arranged on the rack; the carrier is configured on the transmission line, and the carrier is used for carrying a motor stator module to be detected; the CCD detection module is used for detecting the appearance of a motor stator welding spot; the manipulator is fixedly arranged on the rack, and the manipulator is used for driving the CCD detection module to move; the CCD detection module is positioned above the transmission line; when the carrier is transported to a detection area of the CCD detection module by the transmission line, the first stop piece and the second stop piece are configured to keep the carrier in a static state; the motor stator welding spot appearance detection device can automatically carry out multi-angle quality detection on the stator welding spots of the motor to be detected, and the detection efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of detection equipment, and in particular to a device for detecting appearance of welding points of a motor stator. Background Art

[0002] With the vigorous development of the new energy industry, the use of motors in various fields is increasing. In particular, flat wire motors, which are smaller in size, more compact in structure, and have higher power density, are likely to become an important technical route for future motors. Compared with other motors, flat wire motors have a higher degree of integration and more stringent requirements on the process and quality of components. In order to ensure the quality and production efficiency of the motor, the detection speed, precision and accuracy of the key components of the motor must be improved. In the field of motor manufacturing, the stator weld is the key part of the motor stator coil and other components. Its quality directly affects the performance and reliability of the motor. However, due to the complex process of the flat wire motor stator winding method, the immaturity of the actual process, and the possible errors in manual operation, a series of welding defects are often caused, such as leaking welding, blasting welding, bifurcation or overlap welding, which will cause the current to be unable to pass through the weld continuously and stably. Therefore, effective detection of the quality of the stator weld is a key task in the motor manufacturing process.

[0003] Traditional stator weld spot detection methods usually rely on manual detection or the use of simple mechanical equipment. However, these methods have some limitations, including low detection efficiency, high misjudgment rate, over-reliance on operator experience, and difficulty in meeting the growing demand for large-scale production. With the continuous development of science and technology, automated and intelligent detection devices are becoming increasingly important. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a motor stator weld appearance inspection device that can automatically perform multi-angle quality inspection on the stator welds of the motor to be inspected, solve the current problems of low inspection efficiency and high inspection misjudgment rate, and meet the growing needs of large-scale production.

[0005] To solve the above problems, the present invention adopts the following technical solutions:

[0006] A motor stator welding point appearance detection device comprises a frame, a transmission line, a carrier, a CCD detection module and a manipulator.

[0007] The frame has a first stop and a second stop.

[0008] The transmission line is fixedly arranged on the frame.

[0009] The carrier is arranged on the transmission line, and the carrier is used for carrying the stator module of the motor to be tested.

[0010] The CCD detection module is used to detect the appearance of the motor stator welding points.

[0011] The manipulator is fixedly arranged on the frame, and is used for driving the CCD detection module to move.

[0012] The CCD detection module is located above the transmission line.

[0013] When the carrier is transported by the transmission line to the detection area of ​​the CCD detection module, the first stopper and the second stopper are configured to keep the carrier in a stationary state.

[0014] The motor stator weld appearance inspection device provided in at least one embodiment of the present disclosure further includes: a deep learning module 10 for calculating weld information.

[0015] The deep learning module 10 is configured to be electrically connected to the CCD detection module to obtain the shooting information of the CCD detection module.

[0016] In the motor stator weld appearance inspection device provided in at least one embodiment of the present disclosure, the manipulator is a four-axis manipulator.

[0017] In the motor stator welding point appearance inspection device provided by at least one embodiment of the present disclosure, the CCD inspection module includes: a first camera, a second camera, a third camera, a first light source, a second light source and a retaining frame.

[0018] The second camera is configured on one side of the first camera; and the third camera is configured on the other side of the first camera.

[0019] The first camera is higher than the second camera and the third camera.

[0020] The first camera, the second camera, the third camera, the first light source and the second light source are all fixedly connected to the holding frame.

[0021] In the motor stator welding point appearance inspection device provided by at least one embodiment of the present disclosure, both the first stopper and the second stopper have a buffer component.

[0022] In the motor stator welding point appearance inspection device provided by at least one embodiment of the present disclosure, the first stop member and the second stop member are arranged opposite to each other.

[0023] In the motor stator weld appearance inspection device provided in at least one embodiment of the present disclosure, the transmission line is a double-speed chain transmission line.

[0024] In the motor stator welding spot appearance inspection device provided by at least one embodiment of the present disclosure, a positioning base is provided on the carrier for positioning the motor stator to be inspected.

[0025] The beneficial effects of the present invention are as follows: the use of multiple shooting angles can effectively eliminate blind spots, solve problems such as imaging distortion and missed defect categories, and accurately and efficiently determine defect types through algorithm control. It has strong versatility and can detect a variety of different products by simply replacing fixtures. It uses a four-axis manipulator with rapid response, which is beneficial to improving detection efficiency and the safety of the detection process. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0027] Figure 1 It is a three-dimensional diagram of a stator welding point appearance inspection device in an embodiment of the present invention.

[0028] Figure 2 1 is a top view of a stator welding point appearance inspection device in an embodiment of the present invention.

[0029] Figure 3 It is a front view of the stator welding point appearance inspection device in an embodiment of the present invention.

[0030] Figure 4 FIG. 4 is a schematic diagram of the assembly of a CCD detection module in an embodiment of the present invention.

[0031] Figure 5 Schematic diagram of the structure of the transmission line in the embodiment of the present invention.

[0032] In the figure:

[0033] 1. Rack; 2. Transmission line; 3. Carrier; 4. Stator module to be tested; 5. Speed ​​chain motor; 6. First camera; 7. Second camera; 8. Third camera; 9. Four-axis robot; 10. Deep learning module; 11. First light source; 12. Second light source; 13. Retaining frame; 14. Robot base; 15. First speed chain; 16. Second speed chain; 17. First stop; 18. Second stop; 19. Drive shaft. DETAILED DESCRIPTION

[0034] The technical solutions in the embodiments will be described clearly and completely below in conjunction with the drawings in the embodiments. Obviously, the described embodiments are only a part of the embodiments, rather than all the embodiments.

[0035] Example

[0036] like Figures 1 to 5As shown, this embodiment provides a motor stator welding point appearance inspection device, including a frame 1, a transmission line 2, a carrier 3, a CCD detection module, a four-axis manipulator 9 and a deep learning module 10.

[0037] Specifically, the frame 1 has a first stopper 17 and a second stopper 18 .

[0038] Specifically, the transmission line 2 is fixedly set on the frame 1, and the carrier 3 is configured on the transmission line 2. The transmission line 2 is used to transport the carrier 3 carrying the motor stator module to be tested. There are multiple carriers 3, and the multiple carriers 3 are evenly spaced on the transmission line 2. A stator module 4 to be tested can be placed on each carrier 3.

[0039] Specifically, the CCD detection module is used to detect the appearance of the motor stator welding point. The four-axis manipulator 9 is fixedly set on the frame 1. The four-axis manipulator 9 is used to drive the CCD detection module to move. The CCD detection module is located above the transmission line 2.

[0040] Specifically, when the carrier 3 is transported by the transmission line 2 to the detection area of ​​the CCD detection module, the first stopper 17 and the second stopper 18 are configured to keep the carrier 3 in a stationary state.

[0041] Specifically, the deep learning module 10 is used to calculate the solder joint information. The deep learning module 10 is configured to be electrically connected to the CCD detection module, so as to obtain the shooting information of the CCD detection module.

[0042] During use, when the carrier 3 moves into the detection range of the CCD detection module, the first stop member 17 and the second stop member 18 control the carrier 3 to stop moving, so that the carrier 3 remains stationary, so that the four-axis four-axis manipulator 9 carries three sets of detection cameras to detect the welding points on the motor stator one by one, and take pictures to transmit the data to the deep learning module 10 in real time.

[0043] In this embodiment, the CCD detection module includes a first camera 6 , a second camera 7 , a third camera 8 , a first light source 11 , a second light source 12 and a holder 13 .

[0044] Furthermore, the second camera 7 is configured on one side of the first camera 6, and the third camera 8 is configured on the other side of the first camera 6. The first camera 6 is higher than the second camera 7 and the third camera 8. The first camera 6, the second camera 7, the third camera 8, the first light source 11 and the second light source 12 are all fixedly connected to the retaining frame 13.

[0045] Furthermore, the first camera 6, the second camera 7 and the third camera 8 are all composed of a CCD camera and a lens. During detection, the first light source 11 and the second light source 12 jointly provide light sources. The first camera 6, the second camera 7 and the third camera 8 simultaneously detect the welding points of the motor stator module to be inspected.

[0046] In this embodiment, the transmission line 2 is a double-speed chain transmission line 2. Specifically, the transmission line 2 includes a double-speed chain motor 5, a metal plate side, a driving shaft 19, a first double-speed chain 15 and a second double-speed chain 16.

[0047] Furthermore, the double-speed chain motor 5 is fixed to the outer side of the metal plate, and the output shaft of the double-speed chain motor 5 is connected to the drive shaft 19 through a coupling. The drive shaft 19 passes through the metal plate side, and gears are arranged on the drive shaft 19. The gears are configured to mesh with the first double-speed chain 15 and the second double-speed chain 16.

[0048] After starting, the double-speed chain motor 5 is linked with the first double-speed chain 15 and the second double-speed chain 16 through the driving shaft 19 and the gears, and the double-speed chain motor 5 can be set to different speeds according to actual working conditions.

[0049] Furthermore, the first speed chain 15 and the second speed chain 16 synchronously drive the carrier 3 to move. A positioning base is provided on the carrier 3. Different positioning bases can be selected according to the actual size of the stator module of the motor to be tested. The outer shell of the stator module 4 to be tested is in contact with the inner groove of the positioning base, so as to ensure that the stator of the motor to be tested remains vertically moved to the testing position during the transmission process.

[0050] Exemplarily, the positioning base is connected to the carrier 3 by bolts, and the positioning base has an arc inner groove, which can vertically fix the particle to be measured to avoid sliding or tipping during the transmission and detection process.

[0051] In this embodiment, both the first stopper 17 and the second stopper 18 have a buffer component. The first stopper 17 and the second stopper 18 are disposed opposite to each other.

[0052] Exemplarily, the first stop member 17 and the second stop member 18 both include an electric guide rail (not shown) and an electric telescopic rod (not shown), one end of the electric telescopic rod is configured to be fixedly connected to the slider of the electric guide rail, and the buffer component is fixedly connected to the other end of the electric telescopic rod.

[0053] Exemplarily, the buffer component includes a positioning frame (not shown) and a rubber wheel (not shown), the rubber wheel is configured to be rotatably connected to the positioning frame, and the positioning frame is configured to be fixedly connected to the electric telescopic rod.

[0054] When in use, the first stop member 17 rises and the carrier 3 moves until the front edge of the carrier 3 contacts the first stop member 17; the second stop member 18 moves and rises until the rear edge of the carrier 3 contacts the second stop member 18, and the two stop members simultaneously apply force to the carrier 3 so that the carrier 3 is fixed in a position directly below the detection position.

[0055] In this embodiment, the four-axis manipulator 9 is fixed to the frame 1 through the manipulator base 14. The four axes on the four-axis manipulator 9 can rotate according to the different stator modules of the motor to be inspected. The four-axis manipulator 9 carries a retaining frame 13, and the retaining frame 13 can rotate with the four-axis manipulator 9, so that the defects of the stator welding points of the motor to be inspected can be inspected one by one.

[0056] In this embodiment, the detection module uses a computer with a detection program. The detection algorithm is composed of traditional algorithms + logic algorithms + AI algorithms, including two-dimensional and three-dimensional visual algorithms, deep learning algorithms, image acquisition algorithms, signal management algorithms and motion control algorithms, etc. It can perform online real-time data acquisition, freely set tolerances and automatically judge OK / NG. Through algorithm management and control, the defect type can be accurately and efficiently determined. The platform automatically collects the detection data of the detection equipment, monitors the production process in real time based on SPC analysis, scientifically distinguishes random fluctuations and abnormal fluctuations in product quality during the production process, and gives alarms for abnormal trends, so that managers can take timely measures to eliminate abnormalities, effectively predict and control, and manage the quality of the entire process.

[0057] The detection method of the deep learning module will be disclosed below to further illustrate the working principle of the motor stator weld point appearance detection device in the embodiment.

[0058] When detecting the penetration height of the solder joint through the detection module, the measuring station uses the second and third cameras on the side to collect solder joint data. According to the geometric characteristics of the distance, the AI ​​deep learning algorithm is first used to extract the side solder joint contour and calculate the area of ​​the closed contour of the solder joint. The software fits the minimum circumscribed rectangle of the solder joint contour. Secondly, the edge points of the two copper wires are searched and the midpoint is taken. A center line is made through the midpoint. The length of the intersection with the extracted solder joint contour is the penetration height. When calculating the inclination angle, the angle between the straight line fitting the contour of the lower half of the solder joint and the horizontal line is the solder joint inclination angle. When calculating the mirror area difference, the vertical section line divides the solder joint contour into left and right parts, and the difference in the contour areas of the left and right parts is the mirror area difference. Finally, the software outputs the following: solder joint area, solder joint penetration height, solder joint width, solder joint inclination angle and solder joint mirror area difference.

[0059] When detecting the solder joint coverage through the detection module, the measurement station uses the first camera on the top to collect solder joint data. According to the geometric characteristics of the defect area, the AI ​​deep learning algorithm is first used to extract the positive solder joint contour and calculate the area of ​​the closed contour of the solder joint. The software fits the minimum circumscribed rectangle of the solder joint contour. Secondly, the length and width of the copper wire are manually filled in the algorithm. The software calculates the solder joint coverage. Finally, the software outputs the following: solder joint coverage, solder joint area, solder joint length and solder joint width; to judge and control the quality of solder joints under the overhead angle.

[0060] When detecting the solder joint spacing through the detection module, the measurement station uses the second CCD camera and the third camera on the side to collect solder joint data. According to the geometric characteristics of the distance, the AI ​​deep learning algorithm is first used to extract the side solder joint contour, and the software fits the minimum circumscribed rectangle of the solder joint contour. The distance between the minimum circumscribed rectangles of the fitted solder joint contour is then calculated by the software, which is the solder joint spacing.

[0061] When the detection module is used to detect whether there is a weld leak, the measurement station uses the first camera, the second camera and the third camera to collect solder joint data. Based on the geometric features of whether there are defects, the first camera on the top is first used to determine whether the copper wire has a weld leak through the AI ​​deep learning algorithm. The second and third cameras on the side are then used to extract the solder joint contour through the AI ​​deep learning algorithm. The relative position and size of the solder joint and the copper wire are calculated to determine whether there is a weld leak.

[0062] When the detection module is used to detect whether the solder joint is blown, the measurement station uses the first camera, the second camera and the third camera to collect solder joint data respectively. Based on whether there are defective geometric features, the first camera is first used to determine whether the copper wire is blown through the AI ​​deep learning algorithm and the size of the contour parameters. Then, the second camera and the third camera are used to extract the solder joint contour through the AI ​​deep learning algorithm. The solder joint parameters are calculated to control whether the solder joint is blown.

[0063] When the detection module is used to detect whether there is a solder joint bifurcation, the measurement station uses the first camera, the second camera and the third camera to collect solder joint data respectively. According to the geometric features of whether there are defects, the first camera on the top is first used to extract the solder joint contour through the AI ​​deep learning algorithm to determine the solder joint separation, and then the second camera and the third camera on the side are used to extract the solder joint contour through the AI ​​deep learning algorithm to determine the solder joint separation.

[0064] When the detection module detects whether there is overlap welding, the measuring station uses the second and third cameras on the side to collect the welding point data respectively, and judges whether there is overlap welding through the second and third cameras on the side through the AI ​​deep learning algorithm according to whether there are geometric features of defects. The obtained detection data results can be queried in real time on the computer display.

[0065] Although the embodiments of the present application have been shown and described above, the scope of protection of the present invention is not limited thereto, and any changes or substitutions that are not conceivable through creative work should be included in the scope of protection of the present invention; unless explicitly stated, any elements, actions or instructions used in this document should not be interpreted as critical or necessary.

Claims

1. A motor stator welding point appearance inspection device, characterized in that: include: a frame having a first stop and a second stop; A transmission line is fixedly arranged on the frame; A carrier, arranged on the transmission line, and used for carrying the stator module of the motor to be tested; CCD detection module, used to detect the appearance of motor stator welding points; as well as A manipulator, fixedly arranged on the frame, and used for driving the CCD detection module to move; Wherein, the CCD detection module is located above the transmission line; When the carrier is transported by the transmission line to the detection area of ​​the CCD detection module, the first stopper and the second stopper are configured to keep the carrier in a stationary state.

2. The motor stator welding point appearance inspection device according to claim 1, characterized in that: Also includes: A deep learning module 10, for calculating solder joint information; The deep learning module 10 is configured to be electrically connected to the CCD detection module to obtain the shooting information of the CCD detection module.

3. The motor stator welding point appearance inspection device according to claim 1, characterized in that: The manipulator is a four-axis manipulator.

4. The motor stator welding point appearance inspection device according to claim 1, characterized in that: The CCD detection module includes: First Camera; A second camera, arranged on one side of the first camera; A third camera, arranged on the other side of the first camera; The first light source; Second light source; as well as Cage; Wherein, the first camera is higher than the second camera and the third camera; The first camera, the second camera, the third camera, the first light source and the second light source are all fixedly connected to the holding frame.

5. The motor stator welding spot appearance inspection device according to claim 1, characterized in that: The first stopper and the second stopper both have a buffer component.

6. The motor stator welding point appearance inspection device according to claim 1, characterized in that: The first stop member and the second stop member are arranged opposite to each other.

7. The motor stator welding point appearance inspection device according to claim 1, characterized in that: The transmission line is a double-speed chain transmission line.

8. The motor stator welding point appearance inspection device according to claim 1, characterized in that: The carrier is provided with a positioning base for positioning the stator of the motor to be inspected.

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