Automatic production process flow of coreless motor

Abstract

The invention belongs to the technical field of motors, and relates to an automatic production process flow of a coreless motor, which comprises the following steps in sequence: S1, shell heating and lamination press fitting: after a motor shell is heated, a stator lamination is press-fitted into the shell; step S2, winding assembly: press-fitting the preformed hollow cup winding into the shell subjected to lamination press-fitting; s3, press fitting of an output end flange is conducted, specifically, the output end flange is pressed to one end of the shell; s4, press fitting of the rotor assembly: the rotor assembly is press-fitted into a bearing of the output end flange; s5, assembling a circuit board bracket: mounting and fixing the circuit board bracket at a specified position of the shell; s6, mounting a PCB (Printed Circuit Board): mounting and electrically connecting the PCB to the circuit board bracket; the method has the advantages that high automation, intelligence and datamation of the whole production process can be achieved, and the consistency, production efficiency and traceability of products are remarkably improved.

Description

Technical Field

[0001] This invention relates to the technical field of electric motors, and more particularly to an automated production process for a coreless motor. Background Technology

[0002] An electric motor (commonly known as a "motor") is an electromagnetic device that converts or transmits electrical energy based on the law of electromagnetic induction. It is divided into electric motors (symbol M) and generators (symbol G).

[0003] In the prior art, a thermoforming manufacturing method for armature windings of a hollow cup electric motor, disclosed in CN120691683A, includes the following steps: S1, coil flattening: placing the winding coil in a heated flattening base, and using the synergistic locking action of the flattening pressure plate and the fixing screw; S2, pre-bending: guiding the flattened coil into an arc-shaped mold groove, and using the progressive pressure of the arc-shaped pressure shaft driven by the hydraulic push rod and the directional heating of the heater to make the coil produce a uniform axial curvature and establish the foundation of the rolled structure.

[0004] Although it is possible to keep the armature winding within a specific temperature range in each thermoforming step, it is difficult to achieve a high degree of automation, intelligence and data-driven operation of the entire production process. Summary of the Invention

[0005] The purpose of this invention is to provide an automated production process for coreless motors, in order to solve the technical problem of achieving a high degree of automation, intelligence and datafication throughout the entire production process, thereby significantly improving product consistency, production efficiency and traceability.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: An automated production process for a hollow cup motor includes the following sequential steps: Step S1: Housing heating and lamination pressing: After heating the motor housing, press the stator laminations into the housing; Step S2: Winding assembly: Press the pre-formed hollow cup winding into the housing that has been laminated and pressed together; Step S3: Output flange press-fit: Press the output flange onto one end of the housing; Step S4: Rotor assembly press-fitting: Press the rotor assembly into the bearing of the output flange; Step S5: Circuit board bracket assembly: Install and fix the circuit board bracket in the designated position on the housing; Step S6: PCB board installation: Install the PCB board and electrically connect it to the board bracket; Step S7: Input flange and seal assembly: Press the oil seal, sealing ring and input flange to the other end of the housing in sequence; Step S8: Comprehensive performance testing: Perform electrical performance and functional testing on the assembled motor; Step S9: Data Recording and Traceability: Link the test results with product information and upload them to the management system; Step S10: Feeding and Packaging: Qualified products are automatically fed, plated, and packaged.

[0007] As a preferred embodiment of the present invention, step S1 specifically includes: S1-1: The loading robot picks up the motor housing and transfers it to the heating station for heating; S1-2: Another loading robot picks up the stator laminations and places them into the upper pressure head fixture of the press machine; S1-3: The heated shell is transferred from the gripper to the pressing station; S1-4: The servo press drives the upper pressure head to precisely press the stacked sheets into the housing; S1-5: After pressing is completed, the pressing depth and flatness of the stacked sheets are inspected using a visual inspection system; S1-6: After passing the inspection, the handling mechanism will transfer the semi-finished product to the conveyor belt and flow into step S2.

[0008] As a preferred embodiment of the present invention, the winding in step S2 is a hollow cup winding that has been pre-formed by winding, shaping, laser welding the ends and UV curing.

[0009] As a preferred embodiment of the present invention, step S7 specifically includes: S7-1: Automatically apply grease to the sealing ring; S7-2: Assemble the oiled sealing ring onto the oil seal; S7-3: Press the assembled oil seal and sealing ring assembly into the designated position of the housing assembly; S7-4: Finally, press the input flange into place.

[0010] As a preferred embodiment of the present invention, in step S7, when the pallet carrying the semi-finished product is transferred to the workstation, the product model is obtained by reading the RFID information on the pallet, and the corresponding assembly parameters are retrieved accordingly.

[0011] As a preferred embodiment of the present invention, the rotor assembly in step S4 needs to undergo dynamic balancing correction before press-fitting.

[0012] As a preferred embodiment of the present invention, the comprehensive performance testing in step S8 includes, but is not limited to: DC resistance testing, insulation withstand voltage testing, no-load speed and current testing, and steering confirmation.

[0013] As a preferred embodiment of the present invention, in step S9, each product has a unique identification identifier, and all process parameters, test data and operation information are bound to this identification identifier and uploaded to the MES system in real time to achieve full-process data traceability.

[0014] As a preferred embodiment of the present invention, the unloading and packaging in step S10 is performed by a collaborative robot or a Delta robot, which places qualified products into a customized tray according to a preset tray arrangement pattern and automatically packages them.

[0015] As a preferred embodiment of the present invention, the material transfer, positioning, pressing and testing processes are all completed by servo motors, robotic arms and vision systems in collaboration throughout the entire process, forming a continuous automated production line.

[0016] The beneficial effects of this invention are: 1. Achieved a high degree of automation and intelligence throughout the entire process: By integrating automated equipment such as SCARA robots, servo presses, and vision systems, the entire production process, from shell loading to final packaging, was fully automated, minimizing human intervention. This not only increased production efficiency by more than 50%, but more importantly, it completely eliminated quality fluctuations caused by manual operation, ensuring high product consistency.

[0017] 2. Significantly improved product quality and stability: Precision control: The servo press is used for pressing key components such as laminations, windings, and flanges. The pressing force and displacement curves can be monitored in real time to ensure that each pressing is completed within the process window and avoid over-pressing or incomplete pressing.

[0018] Online inspection: Introduce a vision inspection system at key work stations (such as after stacking and pressing) to judge the pressing quality in real time, realize instant quality control (IPQC) in the production process, curb defects in the early stage, and reduce waste in subsequent processes.

[0019] Process optimization: Pre-laser welding and UV curing of the windings ensured the rigidity and consistency of the winding structure, laying a solid foundation for subsequent automated pressing.

[0020] 3. A comprehensive data traceability system has been established: End-to-end traceability: Each product (or pallet) is assigned a unique identifier using RFID technology. All key process parameters (such as pressing data) and test results (such as resistance and insulation withstand voltage) are linked to this identifier and uploaded to the MES (Manufacturing Execution System).

[0021] Quality analysis and management: When quality problems occur, all production data of the product can be quickly traced, the problem link can be accurately located, greatly improving the efficiency and accuracy of quality analysis. At the same time, the accumulated big data provides data support for continuous process optimization.

[0022] 4. Enhanced the flexibility and reliability of the production line: Flexible production: By using RFID to identify the product model, the system can automatically call the corresponding processing programs and parameters, enabling the production line to quickly adapt to the production requirements of different types of motors and achieving flexible manufacturing.

[0023] High reliability: The rotor assembly is subjected to dynamic balance correction before press-fitting, ensuring the smooth operation and low noise of the motor from the source and improving the reliability of the final product.

[0024] 5. Reduced the overall cost: Although the investment in automation equipment is relatively high in the early stage, in the long run, it significantly reduces the dependence on skilled technical workers and lowers the labor cost; at the same time, the remarkable improvement in the product qualification rate and the shortening of the production cycle bring considerable economic benefits. Detailed implementation manners

[0025] To make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below. Apparently, the described embodiments are some but not all of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0026] Embodiment: An automated production process flow of a coreless motor includes the following sequential steps: Step S1: Heating of the housing and press-fitting of laminations: After heating the motor housing, press-fit the stator laminations into the housing; Step S1 specifically includes: S1-1: The feeding manipulator picks up the motor housing and transfers it to the heating station for heating; In this embodiment, a SCARA robot can be used, but is not limited to, to pick up the material from the magazine, place the aluminum alloy housing in the induction heating coil, and heat it to a predetermined temperature, such as 150°C ± 5°C, to cause moderate thermal expansion.

[0027] S1-2: Another feeding manipulator picks up the stator laminations and places them on the upper punch fixture of the press; S1-3: The heated housing is transferred to the press-fitting station by the gripper; S1-4: The servo press drives the upper punch to accurately press the laminations into the housing; S1-5: After the press-fitting is completed, the visual inspection system is used to detect the press-fitting depth and flatness of the laminations; S1-6: After passing the inspection, the handling mechanism will transfer the semi-finished product to the conveyor belt and flow into step S2.

[0028] Meanwhile, the inspection in this step includes, but is not limited to: triggering an industrial camera to take pictures of the stacked end faces, and using image processing algorithms to detect whether the pressing is in place and whether there is any skewing. Qualified products are transferred from the linear module to the circular WPC conveyor belt.

[0029] Step S2: Winding Assembly: Press the pre-formed hollow cup winding into the housing that has been laminated and pressed together; wherein, the winding in step S2 is a hollow cup winding that has been pre-formed by winding, shaping, laser welding of the ends, and UV curing. The winding is a purchased pre-formed part that has been wound, shaped, laser welded at the ends, and UV cured using specialized equipment, and has consistent rigidity and dimensions.

[0030] Step S3: Output flange press-fit: Press the output flange onto one end of the housing; Step S4: Rotor assembly press-fitting: Press the rotor assembly into the bearing of the output flange; wherein, the rotor assembly in step S4 needs to undergo dynamic balancing before press-fitting.

[0031] Step S5: Circuit board bracket assembly: Install and fix the circuit board bracket in the designated position on the housing; Step S6: PCB board installation: Install the PCB board and electrically connect it to the board bracket; Step S7: Input flange and seal assembly: Press the oil seal, sealing ring, and input flange sequentially onto the other end of the housing; Step S7 specifically includes: S7-1: Automatically apply grease to the sealing ring; S7-2: Assemble the oiled sealing ring onto the oil seal; S7-3: Press the assembled oil seal and sealing ring assembly into the designated position of the housing assembly; S7-4: Finally, press the input flange into place.

[0032] In step S7, when the pallet carrying the semi-finished product is transferred to the workstation, the product model is obtained by reading the RFID information on the pallet, and the corresponding assembly parameters are retrieved accordingly.

[0033] Step S8: Comprehensive performance testing: Perform electrical performance and functional testing on the assembled motor; wherein, the comprehensive performance testing in step S8 includes, but is not limited to: DC resistance testing, insulation withstand voltage testing, no-load speed and current testing, and rotation direction confirmation.

[0034] Step S9: Data Recording and Traceability: Bind the test results with product information and upload them to the management system; In step S9, each product has a unique identification, and all process parameters, test data and operation information are bound to this identification and uploaded to the MES system in real time to achieve full-process data traceability.

[0035] Step S10: Feeding and Packaging: Qualified products are automatically fed, plated, and packaged.

[0036] The unloading and packaging in step S10 are performed by a collaborative robot or Delta robot. Qualified products are placed into customized trays according to a preset tray arrangement pattern and automatically packaged.

[0037] Meanwhile, throughout the entire process, the material transfer, positioning, pressing, and inspection procedures are all completed collaboratively by servo motors, robotic arms, and vision systems, forming a continuous automated production line.

[0038] In summary, this application achieves the following: 1. High degree of automation and intelligence throughout the entire process: By integrating automated equipment such as SCARA robots, servo presses, and vision systems, the entire production process, from shell loading to final packaging, is fully automated, minimizing human intervention. This not only increases production efficiency by more than 50%, but more importantly, it completely eliminates quality fluctuations caused by manual operation, ensuring high product consistency.

[0039] Significantly improved product quality and stability: Precision control: The servo press is used for pressing key components such as laminations, windings, and flanges. The pressing force and displacement curves can be monitored in real time to ensure that each pressing is completed within the process window and avoid over-pressing or incomplete pressing.

[0040] Online inspection: Introduce a vision inspection system at key work stations (such as after stacking and pressing) to judge the pressing quality in real time, realize instant quality control (IPQC) in the production process, curb defects in the early stage, and reduce waste in subsequent processes.

[0041] Process optimization: Pre-laser welding and UV curing of the windings ensured the rigidity and consistency of the winding structure, laying a solid foundation for subsequent automated pressing.

[0042] 3. A comprehensive data traceability system has been established: End-to-end traceability: Each product (or pallet) is assigned a unique identifier using RFID technology. All key process parameters (such as pressing data) and test results (such as resistance and insulation withstand voltage) are linked to this identifier and uploaded to the MES (Manufacturing Execution System).

[0043] Quality Analysis and Management: When quality problems occur, all production data of the product can be quickly traced, and the problem link can be accurately located, greatly improving the efficiency and accuracy of quality analysis. At the same time, the accumulated big data provides data support for continuous process optimization.

[0044] 4. Enhanced the Flexibility and Reliability of the Production Line: Flexible Production: By using RFID to identify the product model, the system can automatically call the corresponding processing programs and parameters, enabling the production line to quickly adapt to the production requirements of different types of motors and achieving flexible manufacturing.

[0045] High Reliability: The rotor assembly is subjected to dynamic balance correction before press-fitting, ensuring the smooth operation and low noise of the motor from the source and enhancing the reliability of the final product.

[0046] 5. Reduced Comprehensive Costs: Although the initial investment in automated equipment is relatively high, in the long run, it significantly reduces the dependence on skilled technical workers and lowers labor costs. At the same time, the remarkable improvement in the product yield rate and the shortening of the production cycle bring considerable economic benefits.

[0047] All components selected in this application are common standard components or components known to those skilled in the art. Their structures and principles can be learned from technical manuals or obtained through conventional experimental methods by those skilled in the art.

[0048] In the description of the embodiments of the present invention, unless otherwise clearly specified and limited, the terms "installation", "connection", and "coupling" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0049] Taking the above ideal embodiments of the present invention as an inspiration, through the above description, relevant staff can make various changes and modifications without departing from the technical idea of this invention. The technical scope of this invention is not limited to the content in the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. An automated production process for a hollow cup motor, characterized in that, Includes the following sequential steps: Step S1: Housing heating and lamination pressing: After heating the motor housing, press the stator laminations into the housing; Step S2: Winding assembly: Press the pre-formed hollow cup winding into the housing that has been laminated and pressed together; Step S3: Output flange press-fit: Press the output flange onto one end of the housing; Step S4: Rotor assembly press-fitting: Press the rotor assembly into the bearing of the output flange; Step S5: Circuit board bracket assembly: Install and fix the circuit board bracket in the designated position on the housing; Step S6: PCB board installation: Install the PCB board and electrically connect it to the board bracket; Step S7: Input flange and seal assembly: Press the oil seal, sealing ring and input flange to the other end of the housing in sequence; Step S8: Comprehensive performance testing: Perform electrical performance and functional testing on the assembled motor; Step S9: Data Recording and Traceability: Link the test results with product information and upload them to the management system; Step S10: Feeding and Packaging: Qualified products are automatically fed, plated, and packaged.

2. The automated production process of a hollow cup motor as described in claim 1, characterized in that, Step S1 specifically includes: S1-1: The loading robot picks up the motor housing and transfers it to the heating station for heating; S1-2: Another loading robot picks up the stator laminations and places them into the upper pressure head fixture of the press machine; S1-3: The heated shell is transferred from the gripper to the pressing station; S1-4: The servo press drives the upper pressure head to precisely press the stacked sheets into the housing; S1-5: After pressing is completed, the pressing depth and flatness of the stacked sheets are inspected using a visual inspection system; S1-6: After passing the inspection, the handling mechanism will transfer the semi-finished product to the conveyor belt and flow into step S2.

3. The automated production process of a hollow cup motor as described in claim 1, characterized in that, The winding in step S2 is a hollow cup winding that has been pre-formed by winding, shaping, laser welding the ends, and UV curing.

4. The automated production process of a hollow cup motor as described in claim 1, characterized in that, Step S7 specifically includes: S7-1: Automatically apply grease to the sealing ring; S7-2: Assemble the oiled sealing ring onto the oil seal; S7-3: Press the assembled oil seal and sealing ring assembly into the designated position of the housing assembly; S7-4: Finally, press the input flange into place.

5. The automated production process of a hollow cup motor as described in claim 1, characterized in that, In step S7, when the pallet carrying the semi-finished product is transferred to the workstation, the product model is obtained by reading the RFID information on the pallet, and the corresponding assembly parameters are retrieved accordingly.

6. The automated production process of a hollow cup motor as described in claim 1, characterized in that, Before pressing, the rotor assembly in step S4 needs to undergo dynamic balancing.

7. The automated production process of a hollow cup motor as described in claim 1, characterized in that, The comprehensive performance testing in step S8 includes, but is not limited to: DC resistance testing, insulation withstand voltage testing, no-load speed and current testing, and steering confirmation.

8. The automated production process of a hollow cup motor as described in claim 1, characterized in that, In step S9, each product has a unique identification, and all process parameters, test data and operation information are bound to this identification and uploaded to the MES system in real time to achieve full-process data traceability.

9. The automated production process of a hollow cup motor as described in claim 1, characterized in that, The unloading and packaging in step S10 are performed by a collaborative robot or Delta robot. Qualified products are placed into customized trays according to a preset tray arrangement pattern and automatically packaged.

10. The automated production process of a hollow cup motor as described in claim 1, characterized in that, Throughout the entire process, the transfer, positioning, pressing, and inspection of materials are all completed collaboratively by servo motors, robotic arms, and vision systems, forming a continuous automated production line.