Defect detection method and system based on motor production

Abstract

The invention relates to a defect detection method and system based on motor production, and relates to the technical field of motor detection, and the method comprises the steps: obtaining an internal original image; single rotating gears and a motor rotating shaft are determined in the internal original image, and different single rotating gears are defined as original gears and follow-up gears; marking a follow-up initial angle according to the follow-up gear, and controlling a motor rotating shaft to rotate by an original rotating angle to obtain an internal change image; determining a variable angle set in the internal change image according to the follow-up gear and the follow-up initial angle; randomly selecting a use change angle from each variable angle set, determining a gear transmission ratio according to the original rotation angle and each use change angle, and constructing a simulation transmission ratio combination according to all the gear transmission ratios; an installation defect signal is output when there is no analog transmission ratio combination consistent with the effective transmission ratio combination. The motor detection device has the function of improving the overall detection effect in the motor production process.

Description

Technical Field

[0001] This application relates to the field of motor testing technology, and in particular to a defect detection method and system based on motor production. Background Technology

[0002] During the motor manufacturing process, the installation quality of internal gears directly affects the motor's transmission performance and service life. Gears are typically mounted on the drive shaft and mesh with adjacent gears. If the installation is improper or the meshing is poor, it can lead to abnormal vibration and noise during motor operation, and even serious malfunctions such as gear wear or breakage.

[0003] Currently, the inspection of gear meshing during motor production mainly relies on manual observation or simple tool measurement, which has drawbacks such as low inspection efficiency and high false detection rate, resulting in poor overall inspection effect in motor production and room for improvement. Summary of the Invention

[0004] To improve the overall inspection effect in the motor production process, this application provides a defect detection method and system based on motor production.

[0005] Firstly, this application provides a defect detection method based on motor manufacturing, employing the following technical solution: A defect detection method based on motor manufacturing includes: Obtain the original internal image; Feature recognition is performed on the internal raw image to determine the single rotating gear and the motor rotating shaft; The single rotating gear located on the motor's rotating shaft is defined as the original gear, and the remaining single rotating gears are defined as follower gears. The follower gear is marked with the initial follower angle, and the motor shaft is controlled to rotate at the preset original rotation angle. An image of the internal change is obtained after the motor shaft rotates. The set of variable angles is determined from the internal variation image based on the follower gear and the initial follower angle. An element is randomly selected from each set of variable angles to be defined as the used variable angle. The gear ratio is determined by calculation based on the original rotation angle and each used variable angle. A simulated gear ratio combination is constructed based on all gear ratios. Determine whether there exists a simulated transmission ratio combination that matches the preset effective transmission ratio combination; If an analog transmission ratio combination that matches the effective transmission ratio combination exists, an installation qualified signal will be output. If no analog transmission ratio combination matches the effective transmission ratio combination, an installation defect signal will be output.

[0006] Optionally, the step of performing feature recognition in the internal raw image to determine the single rotating gear includes: The external contour of the gear is determined from the original internal image based on a preset contour extraction algorithm; Feature recognition is performed on the outer contour of the gear to determine the contour tooth block features, and the center point of the protruding end of the contour tooth block feature is defined as the outer boundary point. Three external boundary points are randomly selected to construct a fitted circular arc, and the external boundary points on the fitted circular arc are defined as fitting points. The number of fit points is determined by counting them on a single fitted arc, and the fitted arc with a number of fits greater than the preset baseline number is defined as a gear arc. The contoured tooth block features on the gear arc are combined to construct a single tooth block assembly, and the single rotating gear is determined based on the single tooth block assembly in the internal original image.

[0007] Optionally, after the individual rotating gear is determined, the defect detection method based on motor production also includes: Determine the center point of the gear based on the circular arc of the gear; The adjacent interval angle is determined based on the external boundary points of the adjacent contour tooth block features on the gear arc and the gear center point. The number of teeth on a single gear is determined by calculation based on the preset circumferential angle and the adjacent interval angle. The fixed transmission ratio is determined by calculating the number of teeth of each individual gear, and the gear block transmission ratio combination is constructed based on all the fixed transmission ratios; Determine whether the gear block transmission ratio combination is consistent with the effective transmission ratio combination; If the gear block transmission ratio combination is consistent with the effective transmission ratio combination, the output gear accurate signal is used and the original gear and follower gear are defined. If the gear block transmission ratio combination is inconsistent with the effective transmission ratio combination, a gear error signal will be output.

[0008] Optionally, after the gear error signal is output, the defect detection method based on motor production also includes: The comparison is performed based on the elements corresponding to the fixed transmission ratio and the effective transmission ratio combination to determine the similarities and differences. When the comparison of the similarity and difference states matches the preset dissimilar state, an anomaly marker is added to the single rotating gear corresponding to the fixed transmission ratio. The number of abnormal indicators is determined by counting them on a single rotating gear, and the corresponding single rotating gear is defined as an erroneous gear when the number of indicators matches the preset arrival number.

[0009] Optionally, if a simulated transmission ratio combination consistent with the effective transmission ratio combination exists, the defect detection method based on motor production also includes: The system increments the number of valid attempts (initially zero) by one and checks if the number of valid attempts is less than the preset required number of attempts. If the number of valid attempts is not less than the required number of attempts, then output an installation qualified signal; If the number of valid attempts is less than the number of attempts required, the current internal variation image is determined as the new internal original image, and the motor shaft is controlled to rotate again to perform simulated transmission ratio combination analysis again until an installation qualified signal or an installation defect signal is output.

[0010] Optionally, the steps to re-control the rotation of the motor shaft include: The follower gear that contains a preset stationary angle in the variable angle set is defined as the key gear; Randomly select a virtual rotation angle from the preset feasible rotation range, and determine the set of virtual angles based on the virtual rotation angle; The virtual rotation angle corresponding to the absence of any fixed angle in the set of virtual angles of all key gears is defined as the reasonable rotation angle; The number of key points is determined by counting the key gears according to the defined key gears across all reasonable rotation angles; The reasonable rotation angle corresponding to the minimum number of key points is defined as the efficient rotation angle, and the working rotation angle is determined from the efficient rotation angle to control the corresponding rotation of the motor shaft.

[0011] Optionally, the steps for determining the working rotation angle from the efficient rotation angle include: The initial rotation angle of each gear is determined by calculation based on the original rotation angle and the effective transmission ratio combination. The follow-up rotation angle of each gear is determined by calculation based on the combination of efficient rotation angle and effective transmission ratio. The remaining number of rotations is determined by calculating the difference between the valid number of rotations and the required number of rotations. The rotation angle threshold corresponding to the remaining number of rotations is determined based on the preset rotation matching relationship; The overall rotation angle is determined by summing the initial rotation angle and the rotation angles of each follower gear under the same gear. The efficient rotation angle corresponding to when all overall rotation angles are greater than the corresponding rotation angle threshold is defined as the circumferential coincidence angle, and the smallest circumferential coincidence angle is determined as the working rotation angle.

[0012] Secondly, this application provides a defect detection system based on motor manufacturing, which adopts the following technical solution: A defect detection system based on motor manufacturing includes: The acquisition module is used to acquire the original internal image; The processing module, connected to the acquisition and judgment modules, is used for information storage and processing; The judgment module, connected to the acquisition and processing modules, is used for judging information. The processing module performs feature recognition on the internal raw image to determine the single rotating gear and the motor rotating shaft; The processing module defines the single rotating gear on the motor shaft as the original gear and the remaining single rotating gears as follower gears. The processing module marks the initial angle of the follower gear and controls the motor shaft to rotate at a preset original rotation angle. After the motor shaft rotates, the acquisition module obtains an image of the internal changes. The processing module determines the set of variable angles in the internally changing image based on the follower gear and the initial follower angle. The processing module randomly selects an element from each set of variable angles to define it as the used variable angle, and calculates the gear ratio based on the original rotation angle and each used variable angle, and constructs a simulated gear ratio combination based on all gear ratios; The judgment module determines whether there is a simulated transmission ratio combination that matches the preset effective transmission ratio combination; If the judgment module determines that there is an analog transmission ratio combination that matches the effective transmission ratio combination, the processing module outputs an installation qualified signal. If the judgment module determines that there is no analog transmission ratio combination that matches the effective transmission ratio combination, the processing module outputs an installation defect signal.

[0013] In summary, this application includes at least one of the following beneficial technical effects: When inspecting for defects in the gear installation of an electric motor, the transmission between the gears can be analyzed by rotating the motor shaft. This analysis can then be used to infer whether there are any defects in the gears, thereby improving the overall inspection effect during the motor production process. During gear installation and inspection, gears with abnormalities can be marked directly, making it easier for staff to handle them subsequently. During gear installation and testing, the rotation angle of the motor shaft is controlled to ensure that each gear rotates at least one revolution, in order to eliminate abnormalities such as missing teeth on the gears. Attached Figure Description

[0014] Figure 1 This is a flowchart of a defect detection method based on motor manufacturing.

[0015] Figure 2This is a schematic diagram of gear rotation.

[0016] Figure 3 This is a flowchart of a module based on a defect detection method for motor manufacturing. Detailed Implementation

[0017] To make the purpose, technical solution, and advantages of this application clearer, the following is combined with Figures 1-3 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0018] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0019] This application discloses a defect detection method based on motor manufacturing, referring to... Figure 1 The method flow for defect detection based on motor production includes the following steps: Step S100: Obtain the original internal image.

[0020] The original internal image is an image of the transmission system inside the motor, obtained by an image capturing device installed directly above the motor testing station and facing downwards.

[0021] Step S101: Perform feature recognition in the internal original image to determine the single rotating gear and the motor rotating shaft.

[0022] The single rotating gear is the gear in the image, and the motor rotating shaft is the drive shaft that rotates when the motor starts. The motor rotating shaft is located at the center of the motor, so the motor rotating shaft can be determined by recognizing the center position. The feature recognition of the gear can be achieved by training and learning multiple types of gears in advance to build a corresponding recognition database, or it can be achieved by the method in steps S200-S204.

[0023] Step S102: Define the single rotating gear on the motor shaft as the original gear, and define the remaining single rotating gears as follower gears.

[0024] Define the original gear and the follower gear to distinguish between different individual rotating gears, which will facilitate subsequent analysis.

[0025] Step S103: Mark the initial angle of the follower according to the follower gear, and control the motor shaft to rotate at the preset original rotation angle, and obtain the internal change image after the motor shaft rotates.

[0026] The initial follow-up angle is the current rotation angle of the follow-up gear. A point can be marked on the follow-up gear to define the corresponding initial follow-up angle as 0. The original rotation angle is the fixed angle set by the operator to rotate the motor shaft. The rotation of the motor shaft can be driven by connecting an external rotating component to the motor shaft. The internal change image is the image of the motor with gears inside after the motor shaft rotates.

[0027] Step S104: Determine the set of variable angles in the internal variation image based on the follower gear and the initial follower angle.

[0028] The variable angle set represents the possible rotation angle values ​​of the follower gear when it switches from a state in the original internal image to a state in the variable internal image, as referenced. Figure 2 The angle of possible rotation can be determined by comparing the relative positions of the tooth blocks. Figure 2 For example, if the interval angle between each tooth block is 18°, then the corresponding variable angle set is {9° + 18°n}, where n can be any natural number. To restrict the data, n is generally less than 100.

[0029] Step S105: Randomly select an element from each set of variable angles to define it as the used variable angle, and calculate the gear transmission ratio based on the original rotation angle and each used variable angle, and construct a simulated transmission ratio combination based on all gear transmission ratios.

[0030] The definition uses varying angles to simulate the actual rotation angle. The gear ratio is the transmission ratio between each gear based on the actual rotation angle. The simulated transmission ratio combination is the combination of gear ratios obtained based on the transmission relationship between each gear.

[0031] Step S106: Determine whether there is a simulated transmission ratio combination that matches the preset effective transmission ratio combination.

[0032] The effective transmission ratio combination is the combination of transmission ratios that need to be achieved between the gears when the currently installed gears are of the correct specifications and are effectively meshed. The purpose of the judgment is to know whether the transmission of each gear meets the requirements under the current rotation test, that is, to judge whether the gear installation is correct.

[0033] Step S1061: If there is an analog transmission ratio combination that matches the effective transmission ratio combination, then output an installation qualified signal.

[0034] When a simulated transmission ratio combination that matches the effective transmission ratio combination exists, it indicates that the current gear transmission meets the requirements, meaning the gears are installed correctly. Therefore, an installation qualification signal is output to confirm the test results.

[0035] Step S1062: If there is no analog transmission ratio combination that matches the effective transmission ratio combination, then output an installation defect signal.

[0036] When there is no simulated transmission ratio combination that matches the effective transmission ratio combination, it indicates that there is no transmission ratio that meets the gear transmission requirements, meaning that there is a defect in the current gear installation. Therefore, an installation defect signal is output to confirm the detection result.

[0037] The steps for identifying individual rotating gears by performing feature recognition on the internal raw image include: Step S200: Determine the outer contour of the gear in the original internal image according to the preset contour extraction algorithm.

[0038] The contour extraction algorithm is a rule-based algorithm that can effectively extract data from the external contour of gears. It first converts the image into a grayscale image, then performs filtering and noise reduction, and finally uses Canny edge detection to determine the gear boundary. The external contour of the gear is the determined external contour line of each gear. At this time, due to the meshing of each gear, some tooth blocks of some gears will be covered, and further analysis is needed to effectively distinguish each gear.

[0039] Step S201: Perform feature recognition on the outer contour of the gear to determine the contour tooth block features, and define the center point of the protruding end of the contour tooth block features as the outer boundary point.

[0040] The profile tooth block feature is the profile feature on the outer profile of the gear that meets the requirements of the tooth block. The feature recognition method can be determined by training the profile of the tooth block in advance; external boundary points are defined to mark a position point on the tooth block, which is convenient for subsequent analysis.

[0041] Step S202: Randomly select three external boundary points to construct a fitted circular arc, and define the external boundary points on the fitted circular arc as fitting points.

[0042] The fitted circular arc is a circular arc constructed through three external boundary points, determined by the principle of constructing a circle through three non-collinear points; fitting points are defined to identify the external boundary points on the fitted circular arc for subsequent analysis.

[0043] Step S203: Count the number of fitting points on a single fitted arc to determine the number of fitting points, and define the fitted arc with a number of fitting points greater than the preset reference number as a gear arc.

[0044] The number of fit points is the total number of fit points on a single fitted arc. The reference number is the minimum number of fit points set by the staff to determine that the fitted arc is the outer contour of the gear. When the number of fit points is greater than the reference number, it means that the fitted arc is more likely to be the outer contour of the actual gear, so it can be defined as the gear arc.

[0045] Step S204: Combine the contour tooth block features on the gear arc to construct a single tooth block combination, and determine the single rotating gear in the internal original image based on the single tooth block combination.

[0046] A single gear block combination is a combination of contoured gear blocks located on the same gear arc. In this case, it can be assumed that it is a combination of gear blocks on the same gear. Therefore, the position of the gear blocks in the single gear block combination can be used to determine the single rotating gear, effectively distinguishing different gears.

[0047] After the individual rotating gear is determined, the defect detection method based on motor production also includes: Step S300: Determine the center point of the gear based on the gear arc.

[0048] The center point of the gear is the theoretical center point of the gear, which is also the center of the gear's circular arc.

[0049] Step S301: Determine the adjacent interval angle based on the outer boundary points of the adjacent contour tooth block features on the gear arc and the gear center point.

[0050] The adjacent interval angle is the angle between the line segments formed by connecting the outer boundary points of adjacent contour tooth blocks on the gear arc with the center point of the gear, which is also the interval angle between adjacent gears on the gear.

[0051] Step S302: Calculate the number of teeth on a single gear based on the preset circumferential angle and the adjacent interval angle.

[0052] The circumferential angle is 360°. The number of teeth on a single gear is the number of tooth blocks on the gear, which is determined by dividing the circumferential angle by the adjacent interval angle.

[0053] Step S303: Calculate the fixed transmission ratio based on the number of teeth of each individual gear, and construct the gear block transmission ratio combination based on all fixed transmission ratios.

[0054] The fixed transmission ratio is the transmission ratio between each gear calculated based on the number of teeth of the individual gear. The gear block transmission ratio combination is a transmission ratio combination formed by combining the fixed transmission ratios.

[0055] Step S304: Determine whether the gear block transmission ratio combination is consistent with the effective transmission ratio combination.

[0056] The purpose of the judgment is to determine whether the type of gear selected meets the requirements of meshing transmission.

[0057] Step S3041: If the gear block transmission ratio combination is consistent with the effective transmission ratio combination, output the gear accurate signal and define the original gear and the follower gear.

[0058] When the gear block transmission ratio combination matches the effective transmission ratio combination, it indicates that the currently selected gear type meets the meshing transmission requirements. At this time, the output gear accuracy signal is used to identify this situation, so that subsequent analysis can be performed to determine whether the gear installation is normal.

[0059] Step S3042: If the gear block transmission ratio combination is inconsistent with the effective transmission ratio combination, then output a gear error signal.

[0060] When the gear block transmission ratio combination is inconsistent with the effective transmission ratio combination, it indicates that the currently selected gear type does not meet the meshing transmission requirements, that is, there is a gear placement error. Therefore, a gear error signal is output to identify the situation so that staff can intervene and check in a timely manner.

[0061] Following the output of a gear error signal, defect detection methods based on motor manufacturing also include: Step S400: Compare the elements corresponding to the fixed transmission ratio and the effective transmission ratio combination to determine the similarities and differences.

[0062] The comparison of similarities and differences refers to the state obtained after comparing the specific transmission ratios between two gears. It includes the same state and the different state. The same state means that the two transmission ratios are consistent, which meets the transmission ratio requirements. The different state means that the two transmission ratios are inconsistent, which does not meet the transmission ratio requirements.

[0063] Step S401: When the comparison of the similarity and difference states is consistent with the preset dissimilar states, add an abnormality mark to the single rotating gear corresponding to the fixed transmission ratio.

[0064] When the comparison of the similar and dissimilar states is consistent with the dissimilar states, it indicates that the transmission ratio between the two corresponding gears cannot meet the requirements, that is, at least one of the two gears has a defect; therefore, an anomaly marker is added to distinguish different individual rotating gears for easier subsequent analysis.

[0065] Step S402: Count the number of abnormal indicators on a single rotating gear to determine the number of indicators, and define the corresponding single rotating gear as an erroneous gear when the number of indicators matches the preset arrival number.

[0066] The marking quantity refers to the number of abnormal markings on a single rotating gear. The arrival quantity is the number of markings required for the staff to determine if a gear has a defect. The arrival quantity is determined based on the transmission relationship between the single rotating gear and the other gears. If the single rotating gear has a transmission connection with only one gear, the arrival quantity is one. If the single rotating gear has a transmission connection with two gears, the arrival quantity is two. When the marking quantity and the arrival quantity are the same, it indicates that the corresponding gear has a defect. At this time, an erroneous gear is defined to mark the defective gear, so that the staff can directly check the defective gear during inspection and improve the efficiency of defect investigation.

[0067] If a simulated transmission ratio combination that matches the effective transmission ratio combination exists, defect detection methods based on motor production also include: Step S500: Increment the number of valid counts (initially zero) and determine whether the number of valid counts is less than the preset required number of counts.

[0068] The effective number of tests refers to the number of times the rotating shaft of the motor is tested. The required number of tests is the minimum number of effective tests required to obtain a relatively reliable test result when the motor is inspected for defects. The purpose of the judgment is to determine whether the current test result is reliable.

[0069] Step S5001: If the number of valid attempts is not less than the required number of attempts, then output an installation qualified signal.

[0070] When the number of valid tests is not less than the required number of tests, it indicates that the test results are relatively reliable after multiple tests, so an installation qualified signal can be output.

[0071] Step S5002: If the effective number of times is less than the required number of times, the current internal change image is determined as the new internal original image, and the motor shaft is controlled to rotate again to perform simulated transmission ratio combination analysis again until the installation qualified signal or installation defect signal is output.

[0072] When the number of valid tests is less than the required number, it indicates that the current test results are unreliable and testing needs to continue. At this time, the internal original image is redefined, that is, the motor shaft is rotated to realize the transmission test between the motor gears, so as to realize the effective detection of motor defects.

[0073] The steps to regain control of the motor shaft rotation include: Step S600: Define the follower gears that contain the preset unmoved angle in the variable angle set as the key gears.

[0074] The unmoved angle is 0°, which means it is impossible to know whether the gear has rotated. We define the key gear to mark the gears that may not have rotated, so as to facilitate subsequent analysis.

[0075] Step S601: Randomly select a virtual rotation angle from the preset feasible rotation range, and determine the set of virtual angles based on the virtual rotation angle.

[0076] The feasible rotation range is the range of rotation angles that can be performed when the motor shaft rotates, as set by the operator. The virtual rotation angle is the selected angle for simulated rotation. The virtual angle set is the set of variable angles of each gear that will be obtained when the motor shaft rotates at the virtual rotation angle, provided that the transmission ratio requirements are met.

[0077] Step S602: Define the virtual rotation angle corresponding to the absence of any fixed angle in the set of virtual angles of all key gears as the reasonable rotation angle.

[0078] When the set of virtual angles for all key gears does not include any unmoved angles, it means that the selected virtual rotation angle can guarantee that the key gear will rotate even without defects. In other words, if a key gear does not rotate when it rotates at this angle, then the corresponding key gear must have a defect. Therefore, we define reasonable rotation angles to distinguish between different virtual rotation angles, which will facilitate subsequent analysis.

[0079] Step S603: Count the number of key points according to the defined key gears in all reasonable rotation angles.

[0080] The number of key gears is the number of key gears that will be obtained under simulated rotation at a reasonable rotation angle.

[0081] Step S604: Define the reasonable rotation angle corresponding to the minimum number of key points as the efficient rotation angle, and determine the working rotation angle from the efficient rotation angle to control the corresponding rotation of the motor shaft.

[0082] The efficient rotation angle is defined to determine the minimum number of gears that may not move. Therefore, determining the working rotation angle from the efficient rotation angle can result in better test results. The working rotation angle can be randomly selected or determined by referring to the methods in steps S700-S705.

[0083] The steps for determining the working rotation angle from the efficient rotation angle include: Step S700: Calculate the initial rotation angle of each gear based on the original rotation angle and the effective transmission ratio combination.

[0084] The initial rotation angle is the angle value at which each gear rotates when the transmission ratio requirement is met after the initial rotation angle of the motor shaft.

[0085] Step S701: Calculate and determine the follow-up rotation angle of each gear based on the combination of efficient rotation angle and effective transmission ratio.

[0086] The follow-up rotation angle is the angle value at which each gear rotates when the transmission ratio requirement is met after the efficient rotation angle of the motor shaft.

[0087] Step S702: Calculate the difference between the valid number of rotations and the required number of rotations to determine the remaining number of rotations.

[0088] The remaining number of rotations is the number of tests that still need to be conducted, determined by subtracting the effective number of rotations from the required number of rotations.

[0089] Step S703: Determine the rotation angle threshold corresponding to the remaining number of rotations based on the preset rotation matching relationship.

[0090] The rotation angle threshold is the minimum rotation angle of the gear that needs to be reached with the current number of remaining rotations. In order to ensure that each gear rotates at least once to check the specific condition of each tooth block, it is necessary to ensure that the rotation angle of the gear reaches the corresponding rotation angle threshold with the remaining number of rotations. The fewer the remaining number of rotations, the fewer the subsequent test times, which means that the rotation angle threshold to be reached needs to be larger. The rotation matching relationship between the two is determined by the staff in advance through multiple tests, which will not be elaborated here.

[0091] Step S704: Under the same gear, calculate the overall rotation angle by summing the initial rotation angle and each follow-up rotation angle.

[0092] The overall rotation angle is the total angle of rotation of each gear under the current number of rotation tests, which is determined by adding the initial rotation angle to the follow-up rotation angle under all test numbers.

[0093] Step S705: Define the efficient rotation angle when all overall rotation angles are greater than the corresponding rotation angle threshold as the circumferential coincidence angle, and determine the smallest circumferential coincidence angle as the working rotation angle.

[0094] When all overall rotation angles are greater than the corresponding rotation angle thresholds, it indicates that the currently determined high-efficiency rotation angle can meet the requirements of gear rotation. Therefore, a circumferential coincidence angle is defined to distinguish different angles. At this time, the smallest circumferential coincidence angle is determined as the working rotation angle to reduce the rotation angle of the motor shaft while meeting the test requirements, thereby improving test efficiency.

[0095] Reference Figure 3 Based on the same inventive concept, embodiments of the present invention provide a defect detection system for motor manufacturing, comprising: The acquisition module is used to acquire the original internal image; The processing module, connected to the acquisition and judgment modules, is used for information storage and processing; The judgment module, connected to the acquisition and processing modules, is used for judging information. The processing module performs feature recognition on the internal raw image to determine the single rotating gear and the motor rotating shaft; The processing module defines the single rotating gear on the motor shaft as the original gear and the remaining single rotating gears as follower gears. The processing module marks the initial angle of the follower gear and controls the motor shaft to rotate at a preset original rotation angle. After the motor shaft rotates, the acquisition module obtains an image of the internal changes. The processing module determines the set of variable angles in the internally changing image based on the follower gear and the initial follower angle. The processing module randomly selects an element from each set of variable angles to define it as the used variable angle, and calculates the gear ratio based on the original rotation angle and each used variable angle, and constructs a simulated gear ratio combination based on all gear ratios; The judgment module determines whether there is a simulated transmission ratio combination that matches the preset effective transmission ratio combination; If the judgment module determines that there is an analog transmission ratio combination that matches the effective transmission ratio combination, the processing module outputs an installation qualified signal. If the judgment module determines that there is no analog transmission ratio combination that matches the effective transmission ratio combination, the processing module outputs an installation defect signal. The individual rotating gear recognition module is used to identify each individual rotating gear from the internal raw image; The gear type analysis module is used to analyze and determine whether the type of installed gears is accurate. Error gear marking module, used to mark gears that are installed incorrectly; The multiple detection control module is used to perform multiple tests on the motor's transmission system to reduce detection errors; The rotating shaft rotation control module is used to control the rotation angle of the motor's rotating shaft; The operation rotation angle determination module is used to determine a unique operation rotation angle from multiple efficient rotation angles that meet the requirements.

[0096] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

Claims

1. A defect detection method based on motor manufacturing, characterized in that, include: Obtain the original internal image; Feature recognition is performed on the internal raw image to determine the single rotating gear and the motor rotating shaft; The single rotating gear located on the motor's rotating shaft is defined as the original gear, and the remaining single rotating gears are defined as follower gears. The follower gear is marked with the initial follower angle, and the motor shaft is controlled to rotate at the preset original rotation angle. An image of the internal change is obtained after the motor shaft rotates. The set of variable angles is determined from the internal variation image based on the follower gear and the initial follower angle. An element is randomly selected from each set of variable angles to be defined as the used variable angle. The gear ratio is determined by calculation based on the original rotation angle and each used variable angle. A simulated gear ratio combination is constructed based on all gear ratios. Determine whether there exists a simulated transmission ratio combination that matches the preset effective transmission ratio combination; If an analog transmission ratio combination that matches the effective transmission ratio combination exists, an installation qualified signal will be output. If no analog transmission ratio combination matches the effective transmission ratio combination, an installation defect signal will be output.

2. The defect detection method based on motor production according to claim 1, characterized in that, The steps for identifying individual rotating gears by performing feature recognition on the internal raw image include: The external contour of the gear is determined from the original internal image based on a preset contour extraction algorithm; Feature recognition is performed on the outer contour of the gear to determine the contour tooth block features, and the center point of the protruding end of the contour tooth block feature is defined as the outer boundary point. Three external boundary points are randomly selected to construct a fitted circular arc, and the external boundary points on the fitted circular arc are defined as fitting points. The number of fit points is determined by counting them on a single fitted arc, and the fitted arc with a number of fits greater than the preset baseline number is defined as a gear arc. The contoured tooth block features on the gear arc are combined to construct a single tooth block assembly, and the single rotating gear is determined based on the single tooth block assembly in the internal original image.

3. The defect detection method based on motor production according to claim 2, characterized in that, After the individual rotating gear is determined, the defect detection method based on motor production also includes: Determine the center point of the gear based on the circular arc of the gear; The adjacent interval angle is determined based on the external boundary points of the adjacent contour tooth block features on the gear arc and the gear center point. The number of teeth on a single gear is determined by calculation based on the preset circumferential angle and the adjacent interval angle. The fixed transmission ratio is determined by calculating the number of teeth of each individual gear, and the gear block transmission ratio combination is constructed based on all the fixed transmission ratios; Determine whether the gear block transmission ratio combination is consistent with the effective transmission ratio combination; If the gear block transmission ratio combination is consistent with the effective transmission ratio combination, the output gear accurate signal is used and the original gear and follower gear are defined. If the gear block transmission ratio combination is inconsistent with the effective transmission ratio combination, a gear error signal will be output.

4. The defect detection method based on motor production according to claim 3, characterized in that, Following the output of a gear error signal, defect detection methods based on motor manufacturing also include: The comparison is performed based on the elements corresponding to the fixed transmission ratio and the effective transmission ratio combination to determine the similarities and differences. When the comparison of the similarity and difference states matches the preset dissimilar state, an anomaly marker is added to the single rotating gear corresponding to the fixed transmission ratio. The number of abnormal indicators is determined by counting them on a single rotating gear, and the corresponding single rotating gear is defined as an erroneous gear when the number of indicators matches the preset arrival number.

5. The defect detection method based on motor production according to claim 1, characterized in that, If a simulated transmission ratio combination that matches the effective transmission ratio combination exists, defect detection methods based on motor production also include: The system increments the number of valid attempts (initially zero) by one and checks if the number of valid attempts is less than the preset required number of attempts. If the number of valid attempts is not less than the required number of attempts, then output an installation qualified signal; If the number of valid attempts is less than the number of attempts required, the current internal variation image is determined as the new internal original image, and the motor shaft is controlled to rotate again to perform simulated transmission ratio combination analysis again until an installation qualified signal or an installation defect signal is output.

6. The defect detection method based on motor production according to claim 5, characterized in that, The steps to regain control of the motor shaft rotation include: The follower gear that contains a preset stationary angle in the variable angle set is defined as the key gear; Randomly select a virtual rotation angle from the preset feasible rotation range, and determine the set of virtual angles based on the virtual rotation angle; The virtual rotation angle corresponding to the absence of any fixed angle in the set of virtual angles of all key gears is defined as the reasonable rotation angle; The number of key points is determined by counting the key gears according to the defined key gears across all reasonable rotation angles; The reasonable rotation angle corresponding to the minimum number of key points is defined as the efficient rotation angle, and the working rotation angle is determined from the efficient rotation angle to control the corresponding rotation of the motor shaft.

7. The defect detection method based on motor production according to claim 6, characterized in that, The steps for determining the working rotation angle from the efficient rotation angle include: The initial rotation angle of each gear is determined by calculation based on the original rotation angle and the effective transmission ratio combination. The follow-up rotation angle of each gear is determined by calculation based on the combination of efficient rotation angle and effective transmission ratio. The remaining number of rotations is determined by calculating the difference between the valid number of rotations and the required number of rotations. The rotation angle threshold corresponding to the remaining number of rotations is determined based on the preset rotation matching relationship; The overall rotation angle is determined by summing the initial rotation angle and the rotation angles of each follower gear under the same gear. The efficient rotation angle corresponding to when all overall rotation angles are greater than the corresponding rotation angle threshold is defined as the circumferential coincidence angle, and the smallest circumferential coincidence angle is determined as the working rotation angle.

8. A defect detection system based on motor manufacturing, characterized in that, include: The acquisition module is used to acquire the original internal image; The processing module, connected to the acquisition and judgment modules, is used for information storage and processing; The judgment module, connected to the acquisition and processing modules, is used for judging information. The processing module performs feature recognition on the internal raw image to determine the single rotating gear and the motor rotating shaft; The processing module defines the single rotating gear on the motor shaft as the original gear and the remaining single rotating gears as follower gears. The processing module marks the initial angle of the follower gear and controls the motor shaft to rotate at a preset original rotation angle. After the motor shaft rotates, the acquisition module obtains an image of the internal changes. The processing module determines the set of variable angles in the internally changing image based on the follower gear and the initial follower angle. The processing module randomly selects an element from each set of variable angles to define it as the used variable angle, and calculates the gear ratio based on the original rotation angle and each used variable angle, and constructs a simulated gear ratio combination based on all gear ratios; The judgment module determines whether there is a simulated transmission ratio combination that matches the preset effective transmission ratio combination; If the judgment module determines that there is an analog transmission ratio combination that matches the effective transmission ratio combination, the processing module outputs an installation qualified signal. If the judgment module determines that there is no analog transmission ratio combination that matches the effective transmission ratio combination, the processing module outputs an installation defect signal.

Images