A disc type rotary intelligent patching device and intelligent patching method

Abstract

The application provides a disc type rotary intelligent wiring device and an intelligent wiring method, and belongs to the field of intelligent manufacturing of automobiles. The disc type rotary intelligent wiring device comprises a mechanical hand wiring mechanism, a multi-station turntable mechanism, a wiring position jacking rotary mechanism, a material taking jacking mechanism, a mistake-proof visual detection mechanism and a rotary wiring controller. The multi-station turntable mechanism is used for rotating to provide wiring stations of different layers and receiving flat wire connectors provided by the mechanical hand wiring mechanism. The wiring position jacking rotary mechanism and the material taking jacking mechanism are arranged below the multi-station turntable mechanism and are used for rotating to assist wiring and jacking to take materials. The mistake-proof visual detection mechanism monitors the wire type and position of the flat wire connector, realizes real-time judgment and feedback of wrong insertion and missed insertion. The application adopts automatic wiring combined with real-time monitoring, ensures the wiring quality and motor performance, and can be popularized and applied in the manufacturing of drive motors of new energy vehicles or the manufacturing of other motors requiring efficient and accurate wiring.

Description

Technical Field

[0001] This invention belongs to the field of intelligent automotive manufacturing, specifically relating to a disc-type rotating intelligent wiring device and an intelligent wiring method. Background Technology

[0002] With the global energy crisis and growing environmental awareness, the new energy vehicle industry is booming at an unprecedented pace. As one of the core components of new energy vehicles, the performance of the drive motor directly affects the vehicle's power, economy, and driving range.

[0003] In recent years, flat-wire motors have gradually become the preferred choice for drive motors in new energy vehicles due to their high power density, high efficiency, low noise, and good heat dissipation performance. However, the stator wire insertion process is a technical challenge in the manufacturing of flat-wire motors. Traditional manual wire insertion methods suffer from low production efficiency, difficulty in ensuring slot fill factor, and easy scratching of enameled wires, which not only increases manufacturing costs but also affects the performance and reliability of the motor. Therefore, developing an efficient and precise automatic wire insertion device is of great significance for improving the manufacturing quality and production efficiency of flat-wire motors. Summary of the Invention

[0004] In order to overcome the shortcomings of the existing technology, the purpose of this invention is to develop a disc-type rotating intelligent wire insertion device and intelligent wire insertion method for the flat wire stator of electric drive for new energy vehicles, so as to solve the stator wire insertion problem in the manufacturing process of flat wire motors.

[0005] A disc-type rotating intelligent wire insertion device includes a robotic arm wire insertion mechanism, a multi-station turntable mechanism, a wire insertion position lifting and rotating mechanism, a material picking and lifting mechanism, an error-proof visual detection mechanism, and a rotating wire insertion controller. The robotic arm wire insertion mechanism is used to grip flat wire clips of different specifications and transport them to the wire insertion positions of the multi-station turntable mechanism. The multi-station turntable mechanism is used to rotate and provide wire insertion positions of different layers and receive flat wire clips provided by the robotic arm wire insertion mechanism. The wire insertion position lifting and rotating mechanism and the material picking and lifting mechanism are located below the multi-station turntable mechanism and are used to rotate and assist wire insertion at the upper wire insertion positions or to lift them to facilitate full-layer material picking. The error-proof visual detection mechanism is located around the multi-station turntable mechanism and is used to monitor the wire type and position of the flat wire clips to achieve real-time judgment and feedback of incorrect or missing insertions.

[0006] Furthermore, the robotic arm cable insertion mechanism includes a multi-axis robotic arm, a cable insertion lifting rod, and a flat cable clamp, wherein the flat cable clamp is installed at the end of the vertically arranged cable insertion lifting rod.

[0007] Furthermore, the multi-station turntable mechanism includes a turntable rotating base, a multi-station turntable body, multiple hypothetical sub-tools, and a tooling wire taking and positioning component; the multi-station turntable body is fixed to the turntable rotating base at the lower center and is driven to a rotation switching station; the multiple hypothetical sub-tools are arranged on the wire insertion station of the multi-station turntable body and are controllably positioned by the tooling wire taking and positioning component.

[0008] Furthermore, it is assumed that the sub-tooling includes a positioning groove base plate that slides up and down within the wire insertion cage, a push plate with radially distributed slots and positioning fins, and a through groove top plate; the positioning groove base plate and the through groove top plate are supported and connected by an upper support column group, the push plate is slidably arranged between the positioning groove base plate and the through groove top plate along the upper support column group, and multiple wire insertion lifting rods passing through the positioning groove base plate are connected at the bottom of the push plate; two rotating plates are connected from below the wire insertion cage to the bottom surface of the positioning groove base plate above.

[0009] Furthermore, the lower ends of multiple wire-inserting lifting rods are mounted on a wire-inserting lifting plate, which is matched with the material-retrieving lifting mechanism below.

[0010] Furthermore, the cable insertion position lifting and rotating mechanism includes a lifting and rotating gantry frame, a lifting plate, a lifting driver, a rotating driver, a rotating adapter, and a rotating contouring component. The four corners of the bottom surface of the lifting plate are slidably mounted above the crossbeam plate of the lifting and rotating gantry frame via guide column assemblies. The lifting rods of the two lifting drivers pass through the crossbeam plate of the lifting and rotating gantry frame from below and are connected to both ends of the bottom surface of the lifting plate. The housing of the rotating driver is fixed to the lifting plate, and the end of the rotating shaft of the rotating driver is connected to the rotating adapter, thereby driving the rotating adapter and the rotating contouring component to rotate according to the design.

[0011] Furthermore, the material lifting mechanism includes a material lifting gantry, a material lifting driver, and a lifting head, with the lifting head located at the end of the lifting rod of the vertically extending material lifting driver.

[0012] Furthermore, the error-proof visual inspection mechanism includes a light curtain sensing inspection component and an optical camera inspection component. The light curtain sensing inspection component is arranged horizontally toward the insertion position of the multi-station turntable mechanism, and the optical camera inspection component is arranged above the middle of the multi-station turntable mechanism and obliquely downward toward the insertion position.

[0013] This invention also provides an intelligent wire insertion method, which includes: S1, a robotic arm picks up a flat wire clip and moves it above the insertion position, and a turntable rotates to move a hypothetical sub-tool to the insertion position; S2, the robotic arm descends and inserts the flat wire clip into the hypothetical sub-tool; S3, the robotic arm rises and picks up the next flat wire clip; S4, the hypothetical sub-tool rotates itself to the next empty wire slot, and the robotic arm moves the picked-up flat wire clip above the insertion position; S5, S2-S4 are repeated until a full rotation of insertion is completed; S6, the turntable rotates, the station where the hypothetical sub-tool with a full rotation is located moves to the wire taking station, and the other empty hypothetical sub-tool moves to the insertion position for a new round of insertion.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: The disc-type rotating intelligent wire insertion device of this application adopts advanced automation technology to realize the automated grasping, arrangement and insertion of flat wire coils, ensuring the accurate position and tight arrangement of the coils in the stator slots; the system will also monitor and provide feedback on the enameled wire status in real time during the insertion process to avoid scratches and damage, and ensure that the insertion quality and motor performance meet the design requirements. It can be promoted and applied in the manufacturing of drive motors for new energy vehicles or other motor manufacturing fields that require efficient and precise wire insertion. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the disc-type rotating intelligent cable insertion device of the present invention;

[0016] Figure 2 This is a schematic diagram of the robotic arm's wire insertion mechanism;

[0017] Figure 3 This is a schematic diagram of a multi-station rotary table mechanism;

[0018] Figure 4 This is a schematic diagram of a hypothetical sub-tooling.

[0019] Figure 5 This is a schematic diagram of the assumed sub-tooling.

[0020] Figure 6 This is a schematic diagram of a push plate.

[0021] Figure 7 A schematic diagram of the lifting and rotating mechanism for the insertion position;

[0022] Figure 8 This is a schematic diagram of the material lifting mechanism.

[0023] In the picture,

[0024] 10. Robotic arm cable insertion mechanism; 11. Multi-axis robotic arm; 12. Cable insertion lifting rod; 13. Flat cable clamp;

[0025] 20. Multi-station turntable mechanism; 21. Turntable rotating base; 22. Multi-station turntable body; 23. Assumed sub-tooling; 24. Tooling wire picking and positioning assembly;

[0026] 231. Cable insertion cage; 2311. Cage top ring; 2312. Cage bottom ring; 2313. Cage support upright; 2314. Positioning pin; 232. Positioning slot base plate; 233. Push plate; 234. Through slot top plate; 235. Upper support column assembly; 236. Cable insertion lifting rod; 237. Cable insertion lifting plate; 238. Rotating plate; 239. Cable taking positioning block; 2310. Cable insertion side baffle;

[0027] 30. Cable insertion position lifting and rotating mechanism; 31. Lifting and rotating gantry frame; 32. Lifting plate; 33. Lifting driver; 34. Rotation driver; 35. Rotation adapter; 36. Rotation profile component; 37. Guide column assembly;

[0028] 40. Material lifting mechanism; 41. Material lifting gantry; 42. Material lifting drive; 43. Lifting head;

[0029] 51. Light curtain sensing detection component; 52. Optical camera detection component. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] A disc-type rotating intelligent power strip device, see [link / reference] Figures 1-8 The disc-type rotating intelligent wire insertion device includes a robotic arm wire insertion mechanism 10, a multi-station turntable mechanism 20, a wire insertion position lifting and rotating mechanism 30, a material picking and lifting mechanism 40, an error-proof visual inspection mechanism, and a rotating wire insertion controller.

[0032] The robotic arm insertion mechanism 10 is used to grip flat wire clips of different specifications and transport them to the insertion positions above the multi-station turntable mechanism 20. The multi-station turntable mechanism 20 is used to rotate and provide insertion positions at different levels and to receive flat wire clips provided by the robotic arm insertion mechanism 10. The insertion position lifting and rotating mechanism 30 and the material picking lifting mechanism 40 are located below the multi-station turntable mechanism 20 and are used to rotate the upper insertion positions to assist in insertion or lift them to facilitate full-layer material picking. The error-proof visual detection mechanism is located around the multi-station turntable mechanism 20 and is used to monitor the wire type and position of the flat wire clips to achieve real-time judgment and feedback of incorrect or missing insertions.

[0033] Among them, see Figure 2 The robotic arm wire insertion mechanism 10 includes a multi-axis robotic arm 11, a wire insertion lifting rod 12, and a flat wire clamp 13, wherein the flat wire clamp 13 is installed at the end of the vertically arranged wire insertion lifting rod 12.

[0034] The multi-axis robotic arm 11 is a four-axis robotic arm. The wire insertion lifting rod 12 is set on the end shaft of the four-axis robotic arm in the form of a lead screw or threaded rod, and is driven by the four-axis robotic arm to lift and lower, thereby realizing the pressing and lifting of the flat wire clamp 13. The four-axis robotic arm can rotate horizontally. After the flat wire clamp 13 clamps the flat wire, it is lifted and transferred to the wire insertion position above the multi-station turntable mechanism 20 for sequential pressing and insertion of the wire.

[0035] Among them, see Figures 3-6 The multi-station turntable mechanism 20 includes a turntable rotating base 21, a multi-station turntable body 22, multiple hypothetical sub-tools 23, and a tooling wire taking and positioning component 24. The multi-station turntable body 22 is fixed to the turntable rotating base 21 at the lower center and is driven to rotate and switch stations. The multiple hypothetical sub-tools 23 are arranged on the wire insertion stations of the multi-station turntable body 22 and are controllably positioned by the tooling wire taking and positioning component 24.

[0036] Assume that the sub-tool 23 includes a positioning groove base 232 that slides up and down inside the cable cage 231, a push plate 233 with radially distributed slots and positioning fins, and a through groove top plate 234; the positioning groove base 232 and the through groove top plate 234 are supported and connected by an upper support column group 235, the push plate 233 is slidably arranged between the positioning groove base 232 and the through groove top plate 234 along the upper support column group 235, and multiple cable lifting rods 236 passing through the positioning groove base 232 are connected to the bottom of the push plate 233; two rotating plates 238 are connected from below the cable cage 231 to the bottom surface of the positioning groove base 232 above.

[0037] The lower ends of the multiple wire-inserting lifting rods 236 are mounted on a wire-inserting lifting plate 237, which is matched with the material-retrieving lifting mechanism 40 below.

[0038] A wire-taking positioning block 239 is also provided on the outer peripheral surface of the positioning groove base 232, and a positioning pin hole is opened radially in the wire-taking positioning block 239.

[0039] The wire cage 231 includes a top ring 2311, a bottom ring 2312, and a support rod 2313. A positioning pin 2314 is provided on the outer periphery of the bottom ring 2312. The positioning pin 2314 is driven by the tooling wire taking positioning component 24 to insert or disengage the positioning pin into the pin hole of the wire taking positioning block 239.

[0040] Between the positioning groove base plate 232 and the through groove top plate 234, a plurality of radially evenly distributed wire insertion side baffles 2310 are also provided, which pass through the radially evenly distributed slots of the push plate 233 of the positioning fin plate.

[0041] Among them, see Figure 7 The cable insertion position lifting and rotating mechanism 30 includes a lifting and rotating gantry frame 31, a lifting plate 32, a lifting driver 33, a rotating driver 34, a rotating adapter 35, and a rotating contouring component 36. The four corners of the bottom surface of the lifting plate 32 are slidably mounted above the crossbeam plate of the lifting and rotating gantry frame 31 through guide column assemblies 37. The lifting rods of the two lifting drivers 33 pass through the crossbeam plate of the lifting and rotating gantry frame 31 and are connected to both ends of the bottom surface of the lifting plate 32. The housing of the rotating driver 34 is fixed to the lifting plate 32. The end of the rotating shaft of the rotating driver 34 is connected to the rotating adapter 35, thereby driving the rotating adapter 35 and the rotating contouring component 36 to rotate according to the design.

[0042] The bottom of the rotating plate 238 is provided with a drive slot such as an arc-shaped groove or a V-shaped groove. The shape of the rotating contour part 36 is adapted to the drive slot, for example, it is in the form of a shaft or a shaft and bearing roller. The rotating plate 238 with an arc-shaped drive slot is matched with it.

[0043] Of course, the mechanism is also equipped with lifting and rotation limit components, as well as rotation sensors, to facilitate intelligent control of lifting and rotation.

[0044] Among them, see Figure 8 The material lifting mechanism 40 includes a material lifting gantry 41, a material lifting driver 42, and a lifting head 43. The lifting head 43 is located at the end of the lifting rod of the vertically extending material lifting driver 42.

[0045] Among them, see Figure 1 The error-proof visual inspection mechanism includes a light curtain sensing inspection component 51 and an optical camera inspection component 52. The light curtain sensing inspection component 51 is arranged horizontally toward the insertion position of the multi-station turntable mechanism 20, and the optical camera inspection component 52 is arranged above the middle of the multi-station turntable mechanism 20 and obliquely downward toward the insertion position.

[0046] The present invention also provides an intelligent wiring method, which is implemented based on the aforementioned disc-type rotating intelligent wiring device. The intelligent wiring method includes the following steps.

[0047] S1. The robotic arm picks up the flat wire clip and moves it above the insertion position. The turntable rotates to move the assumed sub-tool to the insertion position.

[0048] S2. The robotic arm descends and inserts the flat wire hairpin into the assumed sub-tool.

[0049] S3. The robotic arm rises and picks up the next flat wire hair clip.

[0050] S4. Assuming the sub-tool rotates itself to the next empty wire slot, the robot arm moves the clamped flat wire hairpin to the top of the insertion position.

[0051] S5. Repeat S2-S4 until the entire circle is inserted.

[0052] S6. The turntable rotates, and the station where the assumed sub-tool is filled with wires moves to the wire taking station, while the other empty assumed sub-tool moves to the wire insertion station for a new round of wire insertion.

[0053] This device employs advanced automation technology combined with visual intelligent detection to automate the gripping, arranging, and insertion of flat wire coils, ensuring accurate positioning and tight arrangement of the coils in the stator slots. Simultaneously, the system will monitor and provide real-time feedback on the condition of the enameled wire during the insertion process, preventing scratches and damage, and ensuring that the insertion quality and motor performance meet design requirements. Currently, this device is primarily used in the manufacturing of drive motors for new energy vehicles, but it can also be extended to other motor manufacturing fields requiring efficient and precise insertion.

[0054] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A disc-type rotating intelligent power cord adapter, characterized in that: The disc-type rotating intelligent wire insertion device includes a robotic arm wire insertion mechanism (10), a multi-station turntable mechanism (20), a wire insertion position lifting and rotating mechanism (30), a material picking and lifting mechanism (40), an error-proof visual detection mechanism, and a rotating wire insertion controller. The robotic arm wire insertion mechanism (10) is used to clamp flat wire clips of different specifications and transport them to the wire insertion position above the multi-station turntable mechanism (20). The multi-station turntable mechanism (20) is used to rotate and provide wire insertion positions of different layers and receive flat wire clips provided by the robotic arm wire insertion mechanism (10). The wire insertion position lifting and rotating mechanism (30) and the material picking and lifting mechanism (40) are located below the multi-station turntable mechanism (20) and are used to rotate and assist wire insertion or lift the upper wire insertion positions to facilitate full-layer material picking. The error-proof visual detection mechanism is located around the multi-station turntable mechanism (20) and is used to monitor the wire type and position of the flat wire clips to realize real-time judgment and feedback of incorrect or missing insertion. The multi-station turntable mechanism (20) includes a turntable rotating seat (21), a multi-station turntable body (22), multiple hypothetical sub-tools (23), and a tooling wire taking and positioning assembly (24); the hypothetical sub-tools (23) include a positioning groove base (232) that slides up and down inside the wire insertion cage (231), a push plate (233) with radially distributed slots and positioning fins, and a through groove top plate (234); a wire taking and positioning block (239) is provided on the outer peripheral surface of the positioning groove base (232). The positioning slot base (232) and the through slot top plate (234) are supported and connected by an upper support column group (235). The push plate (233) is slidably arranged between the positioning slot base (232) and the through slot top plate (234) along the upper support column group (235). Multiple wire lifting rods (236) passing through the positioning slot base (232) are connected at the bottom of the push plate (233). Two rotating plates (238) are connected from below the wire cage (231) to the bottom surface of the positioning slot base (232) above. Multiple of the assumed sub-tools (23) are set on the insertion station and are positioned controllably by the tooling wire taking and positioning component (24).

2. The disc-type rotating intelligent wiring device according to claim 1, characterized in that: The robotic arm wire insertion mechanism (10) includes a multi-axis robotic arm (11), a wire insertion lifting rod (12), and a flat wire clamp (13), wherein the flat wire clamp (13) is installed at the end of the vertically arranged wire insertion lifting rod (12).

3. The disc-type rotating intelligent wiring device according to claim 1, characterized in that: The multi-station turntable body (22) is fixed to the turntable rotating seat (21) at the lower middle part and is driven to rotate and switch the station. Multiple of the assumed sub-tools (23) are set on the wire insertion station of the multi-station turntable body (22). The wire taking positioning block (239) cooperates with the tool taking positioning component (24) for positioning.

4. The disc-type rotating intelligent wiring device according to claim 1, characterized in that: The lower ends of multiple wire-inserting lifting rods (236) are mounted on a wire-inserting lifting plate (237) and matched with the material-picking lifting mechanism (40) below.

5. The disc-type rotating intelligent wiring device according to claim 1, characterized in that: The cable insertion position lifting and rotating mechanism (30) includes a lifting and rotating gantry (31), a lifting plate (32), a lifting driver (33), a rotating driver (34), a rotating adapter (35), and a rotating profiler (36). The four corners of the bottom surface of the lifting plate (32) are slidably installed above the crossbeam plate of the lifting and rotating gantry (31) through the guide column assembly (37). The lifting rods of the two lifting drivers (33) pass through the crossbeam plate of the lifting and rotating gantry (31) and are connected to both ends of the bottom surface of the lifting plate (32). The housing of the rotating driver (34) is fixed to the lifting plate (32). The rotating shaft end of the rotating driver (34) is connected to the rotating adapter (35), thereby driving the rotating adapter (35) and the rotating profiler (36) to rotate according to the design.

6. The disc-type rotating intelligent wiring device according to claim 1, characterized in that: The material lifting mechanism (40) includes a material lifting gantry (41), a material lifting driver (42), and a lifting head (43). The lifting head (43) is located at the end of the lifting rod of the vertically extending material lifting driver (42).

7. The disc-type rotating intelligent wiring device according to claim 1, characterized in that: The error-proof visual inspection mechanism includes a light curtain sensing inspection component (51) and an optical camera inspection component (52). The light curtain sensing inspection component (51) is arranged horizontally toward the insertion position of the multi-station turntable mechanism (20), and the optical camera inspection component (52) is arranged above the middle of the multi-station turntable mechanism (20) and obliquely downward toward the insertion position.

8. A smart wiring method based on the disc-type rotating smart wiring device according to any one of claims 1-7, characterized in that, Smart plug-in methods include: S1. The robotic arm picks up the flat wire clip and moves it to the top of the insertion position. The turntable rotates to move the assumed sub-tool to the insertion position. S2. The robotic arm descends and inserts the flat wire clip into the assumed sub-tooling. S3. The robotic arm rises and picks up the next flat wire hair clip; S4. Assuming the sub-tool rotates itself to the next empty wire slot, the robot arm moves the clamped flat wire hairpin to the top of the insertion position; S5. Repeat S2-S4 until the entire circle is inserted; S6. The turntable rotates, and the station where the assumed sub-tool is filled with wires moves to the wire taking station, while the other empty assumed sub-tool moves to the wire insertion station for a new round of wire insertion.

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