Disc type motor rotor magnetic steel positioning installation method and system

Abstract

The invention provides a disc type motor rotor magnetic steel positioning installation method and system, and the method comprises the following steps: carrying out the cleaning and surface treatment of a rotor iron core of a disc type motor, and removing oil stains, impurities and an oxide layer on the surface of the rotor iron core; the central position and the magnetic pole distribution reference line of the rotor core are accurately determined through the visual detection system, the position and the angle of the magnetic steel are accurately adjusted in combination with the position sensor and the angle sensor, accurate installation of the magnetic steel is ensured, the air-gap magnetic field distribution uniformity of the motor is improved, and therefore the efficiency and the power density of the motor are improved; by adopting the automatic positioning and mounting system, the automation of the whole process of positioning, adjusting, mounting and detecting the magnetic steel is realized, the manual operation is reduced, the mounting efficiency is improved, and the production cost is reduced; the positions and the angles of the magnetic steels are accurately controlled through the control system, so that the mounting positions and the mounting angles of the magnetic steels are consistent, the consistency of mounting quality is improved, and the failure rate of the motor is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of disc motor manufacturing, in particular to a disc motor rotor magnetic steel positioning and installation method and system. BACKGROUND

[0002] Disc motors occupy a key position in the fields of new energy vehicle drive systems (such as hub motor direct drive solutions), aerospace precision servo mechanisms (unmanned aerial vehicle power modules, satellite attitude control motors), and industrial automation equipment (collaborative robot joint drives) due to their compact axial structure, high power density, and excellent operating efficiency. The positioning accuracy of the rotor magnetic steel, a core component of disc motors, directly determines the quality of the air gap magnetic field distribution. When the circumferential installation angle deviation exceeds ±0.3°, the magnetic field harmonic content increases by more than 12%, leading to an 8%-10% increase in electromagnetic torque ripple and a 1.5%-2% decrease in efficiency. When the axial positioning error exceeds ±0.05mm, uneven coupling of the magnetic steel and the stator can cause 15%-20% of the eccentric torque, resulting in a 5-8dB(A) increase in vibration noise level, which severely affects the reliability of the motor. Currently, the positioning and installation method of disc motor rotor magnetic steel mainly adopts the traditional mechanical positioning and manual adjustment combination method. However, this installation method still has certain problems: 1. The positioning accuracy of the traditional installation method is low, which can easily lead to uneven distribution of magnetic steel, affecting the air gap magnetic field distribution of the motor and reducing the efficiency and power density of the motor; 2. The installation efficiency of the traditional installation method is low, requiring a large amount of manual operation and increasing production costs; 3. The traditional installation method requires a high technical level of the operator, making it difficult to ensure the consistency of installation quality; Therefore, a disc motor rotor magnetic steel positioning and installation method and system are proposed. SUMMARY

[0003] Therefore, the embodiments of the present application hope to provide a disc motor rotor magnetic steel positioning and installation method and system to solve or alleviate the technical problems existing in the prior art, at least to provide a beneficial choice.

[0004] To solve the above technical problems, one technical solution adopted by the present application is: a disc motor rotor magnetic steel positioning and installation method, comprising the following steps: Step 1: Clean and surface treat the rotor core of the disc motor to remove oil stains, impurities, and oxidation layers on the surface of the rotor core; Step 2: Obtain the image of the rotor core based on a visual detection system and determine the center position and magnetic pole distribution reference line of the rotor core through image recognition technology; Step three, mark the magnetic steel installation position on the end face of the rotor core according to the center position of the rotor core and the magnetic pole distribution reference line; Step four, place the magnetic steel to be installed in the positioning station, and detect the position and angle of the magnetic steel through the position sensor and angle sensor on the positioning station; Step five, adjust the position and angle of the magnetic steel through the control system according to the marked magnetic steel installation position; Step six, apply adhesive to the installation surface of the magnetic steel, install the adjusted magnetic steel to the marked position of the rotor core, and press the magnetic steel.

[0005] It is further preferred to provide that in step two, the method for determining the center position of the rotor core and the magnetic pole distribution reference line comprises the following steps: Step 201, illuminate the end face of the rotor core through the annular light source of the visual detection system, and collect at least three different angle images of the end face of the rotor core by using the CCD industrial camera of the visual detection system; Step 202, pre-process the collected end face image of the rotor core, and extract the contour edge features of the rotor core; the pre-processing includes gray scale conversion, median filtering, threshold segmentation and morphological processing; Step 203, according to the contour edge features of the rotor core, adopt Hough circle transformation algorithm to fit the outer circle contour of the rotor core, and calculate the geometric coordinate point of the center position of the rotor core; Step 204, identify at least two preset positioning mark points on the end face of the rotor core, and establish a polar coordinate system with the geometric coordinate point as the origin through coordinate conversion algorithm; the preset positioning mark points are laser line cross marks or metal plating difference points on the end face of the core, and the feature size is not less than 0.5mm, and the contrast ratio is ≥50%; Step 205, according to the magnetic pole distribution angle interval in the motor design parameters, take any positioning mark point as the starting point, and evenly divide the magnetic pole distribution reference line along the circumference; Step 206, measure the actual angle interval between adjacent reference lines through the visual detection system, and compare with the theoretical design value, if the deviation exceeds ±0.05°, modify the optical parameters and image processing algorithm parameters of the visual detection system.

[0006] It is further preferred to provide that in step five, the adjustment of the position and angle of the magnetic steel through the control system specifically comprises: Step 501, based on the center position of the rotor core and the magnetic pole distribution reference line, calculate the target position coordinates (r, θ) and target angle φ of the magnetic steel in the polar coordinate system; Step 502, drive the actuator by the control algorithm to adjust the planar position of the magnetic steel, so that the center of the magnetic steel coincides with the target position coordinates (r, θ); Step 503, drive the rotating mechanism to adjust the angle of the magnetic steel, so that the magnetic pole direction of the magnetic steel is consistent with the magnetic pole distribution reference line; Step 504, real-time feedback the actual position and angle of the magnetic steel through the position sensor and the angle sensor, if the position deviation ≤±0.01mm and the angle deviation ≤±0.05°, then determine that the adjustment is completed.

[0007] It is further preferred that the position sensor in step four is a linear displacement sensor or a laser range finder; and the angle sensor is an encoder or a circular grating.

[0008] It is further preferred that the way of marking the magnetic steel installation position in step three is laser marking or mechanical line marking, and the marking position accuracy error is not more than ±0.05mm.

[0009] It is further preferred that the cleaning in step one adopts ultrasonic cleaning; and the surface treatment includes sandpaper polishing or chemical treatment.

[0010] It is further preferred that the adhesive in step six is high-temperature-resistant epoxy resin glue, the magnetic steel is pressed by a pneumatic or hydraulic pressing mechanism, the pressure range is 5-10N / mm², and the pressure uniformity error is ≤5%.

[0011] To solve the above technical problems, another technical solution adopted by the present application is: a disc type motor rotor magnetic steel positioning and installation system, the system comprises: an iron core processing module, a visual positioning module, a position marking module, a magnetic steel detection module, a positioning adjustment module and an installation and fixing module; The iron core processing module is configured to clean and surface treat the rotor iron core of the disc type motor, to remove oil stains, impurities and oxidation layers on the surface of the rotor iron core; The visual positioning module is configured to obtain the image of the rotor iron core based on a visual detection system, and determine the center position and the magnetic pole distribution reference line of the rotor iron core through image recognition technology; The position marking module is configured to mark the magnetic steel installation position on the end face of the rotor iron core according to the center position and the magnetic pole distribution reference line of the rotor iron core; The magnetic steel detection module is configured to place the magnetic steel to be installed in a positioning station, and detect the position and angle of the magnetic steel through the position sensor and the angle sensor on the positioning station; The positioning adjustment module is configured to adjust the position and angle of the magnetic steel according to the marked magnetic steel installation position through a control system. The installation fixing module is configured to apply adhesive to the installation surface of the magnetic steel, install the adjusted magnetic steel to the marked position of the rotor core, and press the magnetic steel.

[0012] The magnetic steel detection module is further provided as a further preferred aspect of the technical solution, which detects the position and angle of the magnetic steel, collects the magnetic pole mark image on the surface of the magnetic steel through the visual positioning module, identifies the magnetic pole direction through a deep learning algorithm, and forms a redundancy check with the angle sensor data; The visual positioning module synchronously measures the flatness and surface roughness of the end surface of the core when determining the core reference line, and transmits the data to the positioning adjustment module for adaptive calculation of the magnetic steel installation pressure; The magnetic steel detection module and the visual positioning module perform spatio-temporal alignment of detection data through timestamp synchronization technology.

[0013] The positioning adjustment module includes a self-calibration unit, which is configured to establish an error prediction model based on historical installation data to predict the temperature drift error of the visual detection system, and automatically trigger system-level calibration through a standard part to re-calibrate the polar coordinate system origin and the reference line if the magnetic steel adjustment is out of tolerance for three consecutive times.

[0014] The above technical solutions are adopted in the embodiments of the present application, which have the following advantages: 1. The present application accurately determines the center position of the rotor core and the magnetic pole distribution reference line through the visual detection system, and realizes accurate adjustment of the position and angle of the magnetic steel in combination with the position sensor and the angle sensor on the positioning station, thereby ensuring the accuracy of the magnetic steel installation position, improving the uniformity of the air gap magnetic field distribution of the motor, and thus improving the efficiency and power density of the motor. 2. The present application realizes the full-process automation of magnetic steel positioning, adjustment, installation and detection through the automatic positioning and installation system, reduces manual operation, improves installation efficiency, and reduces production cost. 3. The present application accurately controls the position and angle of the magnetic steel through the control system, ensures the consistency of the installation position and angle of each magnetic steel, improves the consistency of installation quality, and reduces the failure rate of the motor.

[0015] The above summary is only for the purpose of the description and is not intended to limit in any way. In addition to the above described illustrative aspects, embodiments and features, further aspects, embodiments and features of the present application will be readily apparent to those skilled in the art by reference to the drawings and the following detailed description. BRIEF DESCRIPTION OF DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the accompanying drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced. Obviously, the accompanying drawings in the following description only represent some embodiments of the present application, and for those skilled in the art, other drawings can be obtained without creative effort based on these drawings.

[0017] Figure 1 A flowchart of a disc motor rotor magnetic steel positioning and installation method of the present application; Figure 2 A flowchart of a method for determining the center position of the rotor core and the magnetic pole distribution reference line of the present application; Figure 3 A flowchart of a method for adjusting the position and angle of the magnetic steel through the control system of the present application; Figure 4 A functional module diagram of a disc motor rotor magnetic steel positioning and installation system of the present application. DETAILED DESCRIPTION

[0018] The embodiments of the present disclosure will be described in detail below with reference to the drawings.

[0019] It should be apparent that the following describes the embodiments of the present disclosure through specific, concrete examples, and those skilled in the art can easily understand other advantages and effects of the present disclosure from the disclosure. Obviously, the described embodiments are only some of the embodiments of the present disclosure, not all. The present disclosure can also be implemented or applied by other different specific embodiments, and each detail in the specification can be modified or changed based on different views and applications without departing from the spirit of the present disclosure. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict. Based on the embodiments in the present disclosure, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present disclosure.

[0020] It should be noted that the various aspects of the embodiments described below are within the scope of the appended claims. It should be apparent that the aspects described herein can be embodied in a wide variety of forms and that any specific structure and / or function described herein is merely illustrative. Based on the disclosure, those skilled in the art should understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, the devices and / or methods can be implemented using any number of the aspects set forth herein. In addition, this device and / or method can be implemented using other structures and / or functionality in addition to or other than one or more of the aspects set forth herein.

[0021] It should also be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this disclosure. The drawings only show the components related to this disclosure and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0022] Furthermore, specific details are provided in the following description to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the described aspects can be practiced without these specific details.

[0023] Figure 1 This is a flowchart illustrating a method for positioning and installing rotor magnets in a disc motor according to an embodiment of the present invention. It should be noted that if substantially the same result is achieved, the method of this application is not necessarily identical. Figure 1 The illustrated process sequence is limited. For example... Figures 1-3 As shown: A method for positioning and installing rotor magnets in a disc motor, comprising the following steps: Step 1: Clean and surface treat the rotor core of the disc motor to remove oil, impurities and oxide layer from the surface of the rotor core; Specifically, firstly, ultrasonic cleaning is used to clean the rotor core. The core is immersed in a water-based cleaning agent, and the ultrasonic cleaner is started to perform ultrasonic oscillation while the workpiece is rotated 360° for thorough cleaning. Then, the rotor core is surface treated. The surface treatment can be sanding or chemical treatment. Sanding is done by using silicon carbide sandpaper with a pneumatic grinder to reciprocate along the radial direction of the core. Chemical treatment can be done by spraying with hydrochloric acid solution, then rinsing with deionized water and drying. By cleaning and surface treating the rotor core, the cleanliness and roughness of the rotor core surface can be ensured to meet the requirements for magnet installation, laying the foundation for subsequent positioning and bonding processes.

[0024] Step 2: Obtain images of the rotor core using a vision inspection system, and determine the center position and magnetic pole distribution baseline of the rotor core using image recognition technology; Specifically, firstly, the rotor core end face is coaxially illuminated by a ring light source at a 45° angle from above, and 3-5 images of the end face at different angles are captured at 15° intervals using a CCD industrial camera with a resolution of ≥5 million pixels. Next, the image was subjected to grayscale conversion, 3×3 median filtering, Otsu adaptive thresholding segmentation, and morphological dilation erosion to extract the core outline edge. Then, the Canny operator is used to detect the outer circle edge, and the outer circle is fitted by Hough circle transformation (accumulator threshold ≥200, radius range 0.95-1.05 times the design radius) to calculate the center coordinates with sub-pixel accuracy (error ≤0.01mm). Then identify at least two laser-etched cross marks (size ≥ 0.5 mm, contrast ≥ 50%) or metal coating difference points on the iron core end face, and establish a polar coordinate system with the center coordinate as the origin and the angle between the line connecting the marks and the horizontal axis as the reference direction. Subsequently, based on the magnetic pole angle interval of the motor design (e.g., 45° interval for an 8-pole motor), the magnetic pole distribution baseline is divided circumferentially from the reference mark point and drawn on the end face of the iron core. Finally, measure the actual angular interval between adjacent baselines. If the deviation from the theoretical value exceeds ±0.05°, adjust the camera focal length, aperture, or calibrate the lens distortion parameters and optimize the algorithm parameters to ensure positioning accuracy. The center positioning error is ≤ ±0.01mm, the angle error is ≤ ±0.05°, and the standard deviation of repeated measurements in a single batch is σ≤ 0.03°. By using a visual inspection system and image recognition technology, high-precision positioning and baseline division of the rotor core can be achieved, providing a reliable position reference for subsequent magnet installation.

[0025] Step 3: Mark the magnet installation positions on the end face of the rotor core according to the center position of the rotor core and the magnetic pole distribution baseline; Specifically, the process of marking the magnet installation positions on the end face based on the center position of the rotor core and the magnetic pole distribution baseline is as follows: First, taking the origin (center position) of the polar coordinate system as the reference, along the direction of the baseline of each magnetic pole distribution, and according to the inner and outer diameter radii of the magnets designed for the motor (such as inner radius r1 and outer radius r2), determine the annular boundary of the magnet installation area on the end face; Then, using a laser marking machine or mechanical engraving device, a crosshair or positioning point (marking line width ≤ 0.1mm) is marked in the annular area corresponding to each magnetic pole reference line, with the marking position accuracy error controlled within ±0.05mm. During laser marking, it is necessary to ensure that the marking is clear and does not damage the iron core surface. For mechanical engraving, a diamond engraving tool can be used to engrave the positioning mark along the reference line. After completion, the marking position is checked by a visual inspection system to ensure that the deviation from the theoretical coordinates meets the accuracy requirements.

[0026] Step 4: Place the magnet to be installed in the positioning station and detect the position and angle of the magnet using the position sensor and angle sensor at the positioning station; Specifically, the magnetic steel to be installed is placed on a special fixture of the positioning station, the special fixture is equipped with a three-degree-of-freedom pneumatic clamp, including X / Y axis translation and θ axis rotation functions, the surface of the clamp is engraved with a reference line aligned with the polar coordinate system of the rotor core, and the specific detection process is as follows: Firstly, the radial distance r' from the center of the bottom surface of the magnetic steel to the origin of the clamp is measured vertically upward by a laser range finder (precision ±0.005 mm, range 0-100 mm) installed at the bottom of the station, and the circumferential offset angle θ' is calculated by the time difference of the signal blocked by the edge of the magnetic steel through the 3 groups of infrared pair tube sensors arranged along the circumference of the clamp, so as to realize position detection, wherein the radial deviation resolution reaches 0.001 mm, and the circumferential offset angle error is ≤±0.01°; Then, the absolute encoder (resolution 0.005°, single circle accuracy ±0.01°) integrated on the rotating shaft of the clamp or the high-precision circular grating ruler (grating pitch 20 μm, angle accuracy ±0.002°) below the base is used to drive the clamp to move 10° after the magnetic steel is placed, and the angle between the magnetic pole direction of the magnetic steel and the reference line is calculated ; Finally, the position and angle sensors transmit the data containing the actual position coordinates (r', θ') and angle of the magnetic steel to the control system through the EtherCAT bus synchronization, automatically calculate the deviation from the target value, and if any deviation exceeds the warning threshold (Δr≥0.02 mm, Δθ≥0.03°, Δ ≥0.03°), the station warning light will turn on. The entire detection process is carried out in a constant temperature (23±1℃) environment, and the integrated shock absorbing base (vibration amplitude ≤0.005 mm / s) ensures that the single detection period is ≤80 ms, so as to control the initial position error of the magnetic steel within ±0.01 mm (radial) and ±0.02° (angle), and provide reliable data basis for subsequent automatic adjustment.

[0027] Step five, according to the marked magnetic steel installation position, the position and angle of the magnetic steel are adjusted through the control system; Specifically, first, based on the center position of the rotor core and the magnetic pole distribution reference line, the target position coordinates (r, θ) and target angle of the magnetic steel are calculated in the polar coordinate system, wherein the target position coordinates are determined by the designed radius and circumferential angle of the magnetic steel on the end surface of the rotor core, and the target angle needs to be consistent with the direction of the magnetic pole distribution reference line; Then, the control algorithm drives the actuator (such as high-precision linear motor and rotary motor) to move the magnetic steel along the radial direction (r axis) and tangential direction (θ axis) so that the center of the magnetic steel coincides with the target position coordinates (r, θ), and the position sensor (linear displacement sensor or laser range finder) feedbacks the actual position of the magnetic steel in real time during the movement, and stops moving when the position deviation is ≤±0.01 mm; Then, the rotating motor drives the magnetic steel to rotate around the center axis to adjust the angle of the magnetic steel. The angle sensor (encoder or circular grating) monitors the angle between the magnetic pole direction of the magnetic steel and the reference line in real time until the angle deviation is less than or equal to ±0.05°. During the adjustment process, the control system continuously receives real-time feedback data from the sensor to form a closed-loop control. If the position or angle deviation still exceeds the allowed range after adjustment, a secondary adjustment program is triggered to ensure that the position and angle of the magnetic steel accurately match the installation position of the marker. The entire adjustment process is automated, and the single adjustment time is less than or equal to 150 ms, meeting the high-efficiency operation requirements of the production line.

[0028] Step six, apply adhesive to the installation surface of the magnetic steel, install the adjusted magnetic steel to the marker position on the rotor core, and press the magnetic steel; Specifically, first, evenly apply high-temperature resistant epoxy resin adhesive to the installation surface of the magnetic steel using an automatic dispensing machine. The dispensing amount is accurately controlled by a volumetric metering pump, and the adhesive layer thickness is controlled within 0.1-0.2mm, ensuring that the adhesive coverage area is greater than or equal to 95% of the installation surface of the magnetic steel. Subsequently, the mechanical arm grabs the adjusted magnetic steel and moves it to the target position (r, θ) and angle Align the magnetic steel with the marker position on the end surface of the rotor core and place it smoothly. During the placement process, the position deviation is real-time calibrated by the visual guidance system. After the placement is completed, start the pneumatic or hydraulic pressing mechanism to apply a uniform pressure of 5-10N / mm², and the pressure uniformity error is less than or equal to 5%. The pressing time is set to 5-10 minutes according to the curing characteristics of the adhesive, ensuring that the magnetic steel is tightly attached to the core. During the pressing process, the pressure sensor monitors the pressure value in real time. If the pressure fluctuation exceeds the allowed range (±0.5N / mm²), the system automatically adjusts the pressing force. After the pressing is completed, the position of the magnetic steel is rechecked. The visual detection system measures the deviation between the actual position of the magnetic steel and the marker position, ensuring that the position error is less than or equal to ±0.05mm and the angle error is less than or equal to ±0.05°. After the recheck is passed, the next process is entered. The entire installation and pressing process is automated, effectively ensuring the consistency and stability of the installation quality.

[0029] In one embodiment, specifically in step two, the method for determining the center position of the rotor core and the reference line of the magnetic pole distribution includes the following steps: Step 201, illuminate the end surface of the rotor core with the ring light source of the visual detection system, and use the CCD industrial camera of the visual detection system to capture at least three images of the end surface of the rotor core at different angles. The annular light source adopts an annular coaxial diffuse reflection light source (wavelength 525 nm green LED, brightness adjustable range 100-1000 lux) to uniformly irradiate the rotor core end face at an inclination angle of 45°, and the diffuse reflection eliminates the reflection spot caused by surface curvature, ensuring that the image gray scale uniformity is ≤5%; The resolution of the CCD industrial camera is 2448x2048 pixels (5 million pixels), and it is matched with a 12mm fixed-focus lens (distortion rate <0.1%), and the frame rate is 15fps; The accuracy of the rotating workbench is ±5", which can drive the core to rotate at an interval of 15°, and accumulate 3-5 images of the end face at different angles (such as 0°, 45°, 90°), covering a 360° circumferential range; The specific process of image acquisition is as follows: When the photoelectric sensor detects that the rotor core is in place, the annular coaxial diffuse reflection light source is triggered to uniformly diffuse the light on the core end face at an inclination angle of 45°, eliminating the reflection spot caused by surface curvature, ensuring that the image gray scale uniformity is ≤5%; At the same time, the CCD industrial camera starts to work, and the core is rotated to 0°, 45°, 90° and other angle positions at an interval of 15° under the driving of the rotating workbench with an accuracy of ±5", and the camera collects 1 image of the end face at each angle, accumulates 3-5 images, realizes image coverage of the core 360° circumferential range, and the exposure time is adjusted adaptively (10-50ms) according to the brightness of the light source, to obtain clear and interference-free core end face images.

[0030] Step 202, preprocessing the collected rotor core end face image, extracting the rotor core contour edge feature; The preprocessing includes gray scale conversion, median filtering, threshold segmentation and morphological processing; The specific processing method of gray scale conversion is as follows: Convert the RGB three-channel image to a single-channel gray scale image, and the formula is: ; Through gray scale conversion, the data operation amount is reduced, and the subsequent processing efficiency is improved; The specific processing method of median filtering is as follows: Apply a 3x3 median filtering kernel to take the median of the gray scale values in the neighborhood of each pixel point, effectively suppress Gaussian noise and salt and pepper noise, and retain edge details; For example, the output of the pixel point is: ; Where g is the original gray scale image, and the noise density after filtering is reduced to ≤0.5%; The specific processing method of threshold segmentation is as follows: The Otsu maximum inter-class variance method is used to automatically calculate the segmentation threshold T, and the image is divided into foreground (core) and background: ; wherein, , is the proportion of two types of pixels, , is the mean of two types; after segmentation, a binary image is generated, and the contrast of the core contour and the background is ≥200:1; The specific way of morphological processing is as follows: The 2x2 rectangular structural element is used to expand the contour edge and fill small cavities; Remove isolated noise points outside the contour to ensure that the contour is continuous and closed; Finally, the complete outer contour edge of the core is extracted.

[0031] Step 203, according to the rotor core contour edge feature, the Hough circle transformation algorithm is used to fit the rotor core outer circle contour, and the geometric coordinate point of the rotor core center position is calculated; Specifically, first, Canny edge detection is performed, and a double-threshold algorithm with a low threshold of 20 and a high threshold of 60 is used to detect and connect edge pixels to generate a continuous contour with a single-pixel width; Then, the longest closed contour is retained to exclude internal structure interference, and it is confirmed as the outer circle edge of the core; Then, Hough circle transformation is performed, the parameter space is set to the radius range [r_min, r_max] = [0.95r0, 1.05r0] (r0 is the design radius), the accumulator resolution angle step is 1°, and the radius step is 0.1mm, and the local maximum value point with an accumulator value ≥200 is selected to obtain the corresponding center coordinates and radius r, achieving sub-pixel level accuracy (error ≤0.01mm); If multiple circles are detected, select the circle with the closest area to the design value as the final result through multi-circle verification.

[0032] Step 204, identify at least two positioning mark points on the rotor core end face, and establish a polar coordinate system with the geometric coordinate point as the origin through a coordinate conversion algorithm; the preset positioning mark points are laser line cross marks or metal plating layer difference points on the core end face, and the feature size is not less than 0.5mm, and the contrast is ≥50%; Specifically, first, identify at least two positioning mark points (such as laser line cross marks or metal plating layer difference points) on the rotor core end face, and the feature size is not less than 0.5mm, and the contrast is ≥50%, and the specific process is: The cross mark (line width 0.1 mm, size 1 mm*1 mm, gray value ≤30) is searched by a template matching algorithm, the correlation coefficient of each region of the image and the standard template is calculated, and the region with a correlation coefficient greater than or equal to 0.9 is extracted as a candidate mark point; For the metal coating difference point (diameter 0.5 mm, gray difference ≥128 levels), a gray threshold segmentation combined with Blob analysis is used to screen out a circular region with an area greater than or equal to 0.2 mm2 and a circularity greater than or equal to 0.9 as a mark point; Then, after the mark point coordinates are determined, the origin of the Cartesian coordinate system is translated to the core center geometric coordinate point calculated in step 203 ; Assuming that two point coordinates are recognized 、 , they are converted into polar coordinates with as the origin: ; ; Take as the 0° reference direction of the polar coordinate system, thereby establishing a complete polar coordinate system , which provides accurate coordinate reference for the division of the magnetic pole distribution reference line.

[0033] Step 205, according to the magnetic pole distribution angle interval in the motor design parameters, taking any positioning mark point as the starting point, the magnetic pole distribution reference line is evenly divided along the circumferential direction; Specifically, based on the polar coordinate system established in step 204, the reference line is divided according to the magnetic pole distribution angle interval in the motor design parameters, as follows: First, the number of magnetic pole pairs p is input through the human-machine interface (HMI), and the theoretical angle interval between adjacent magnetic poles is calculated (for example, for an 8-pole motor, p=4, and the interval is 45°); Then, taking the reference direction determined in step 204 as the starting point, a magnetic pole distribution reference line is generated every angle along the circumferential direction of the core end surface in the counterclockwise direction, and a total of 2p lines are generated (such as 8 lines for an 8-pole motor); Finally, these reference lines are marked in the form of red dashed lines on the image, with a line width of 0.2 mm and a line length extending to 2 mm outside the core edge, forming an evenly distributed angle scale, which provides accurate position reference for subsequent magnetic steel installation.

[0034] Step 206, the actual angle interval between adjacent reference lines is measured by the visual detection system, and compared with the theoretical design value. If the deviation exceeds ±0.05°, the optical parameters and image processing algorithm parameters of the visual detection system are modified; Specifically, for the adjacent baselines generated in step 205 and Extract their polar angles respectively and And calculate the actual interval Repeat the measurement three times and take the average value as the final result; If the deviation between the actual angle interval and the theoretical design value exceeds ±0.05°, hardware calibration (such as adjusting the camera focal length to correct perspective distortion and adjusting the light source brightness to the best contrast) and algorithm optimization (such as reducing the Hough transform accumulator threshold to 180 to enhance edge fitting sensitivity) will be automatically triggered. After correction, measurement verification is performed again until the angle error is controlled within ±0.05° and the standard deviation of repeated measurements is ≤0.02°, thereby ensuring that the optical parameters and image processing algorithm parameters of the vision inspection system reach the optimal state, providing a reliable guarantee for the high-precision positioning of the rotor core.

[0035] In one embodiment, specifically in step five, the position and angle of the magnet are adjusted by the control system, specifically including: Step 501: Based on the center position of the rotor core and the magnetic pole distribution baseline, calculate the target position coordinates (r, θ) and target angle of the magnet in the polar coordinate system. ; Specifically, firstly, the control system retrieves the determined rotor core center position coordinates from the database. Information on the baseline angle of the magnetic pole distribution, and the theoretical radius of the magnet installation in the motor design parameters. Circumferential distribution angle and magnetic pole direction angle ; Then, with the center of the iron core Using the origin of the polar coordinate system, and based on the design and installation parameters of the magnet, the formula is used... , Calculate the target position coordinates (r, θ) of the magnet in the polar coordinate system, and the target angle. ; Finally, the calculation results are compared with the magnet installation position and angle data in the design drawings. If the error exceeds ±0.1%, the data is retrieved and recalculated to ensure the accuracy of the target position coordinates and angles.

[0036] Step 502: Drive the actuator through the control algorithm to adjust the planar position of the magnet so that the center of the magnet coincides with the target position coordinates (r, θ); Specifically, firstly, a position sensor (linear displacement sensor or laser rangefinder) detects the current position coordinates of the magnet's center in real time. , the control system calculates the deviation value from the target position coordinates (r, θ): , ; Then, the PID control algorithm is adopted to calculate the control output of the linear motor and precision slide in the radial and tangential directions according to the deviation value , , so as to determine the moving direction and displacement of the actuator; Finally, the linear motor and precision slide are driven to move the magnetic steel in the radial and tangential directions, and the position sensor feeds back the position of the magnetic steel in real time at a cycle of 1 ms during the movement, and the control system continuously adjusts the control output until the center of the magnetic steel coincides with the target position coordinates (r, θ) and the position deviation is less than ±0.01 mm.

[0037] Step 503, drive the rotating mechanism to adjust the angle of the magnetic steel so that the magnetic pole direction of the magnetic steel is consistent with the magnetic pole distribution reference line; Specifically, first, the angle sensor (high-precision encoder or circular grating) detects the current magnetic pole direction angle of the magnetic steel in real time , and the control system calculates the deviation value from the target angle : ; Then, according to , the control system generates the control instruction of the rotating mechanism to determine the rotating direction (clockwise or counterclockwise) and rotating angle of the rotating motor; Finally, the rotating motor is driven to rotate the magnetic steel to adjust the magnetic pole direction of the magnetic steel, and the angle sensor feeds back the actual angle of the magnetic steel in real time, and the control system dynamically adjusts the rotating speed and rotating angle of the motor until the magnetic pole direction of the magnetic steel is consistent with the magnetic pole distribution reference line and the angle deviation is less than ±0.05°.

[0038] Step 504, the actual position and angle of the magnetic steel are fed back in real time by the position sensor and the angle sensor, and if the position deviation is ≤±0.01 mm and the angle deviation is ≤±0.05°, it is determined that the adjustment is completed; Specifically, first, the position sensor and the angle sensor continuously and real-time collect the actual position coordinates and angle of the magnetic steel, and transmit the data to the control system; Then, the control system calculates the current position deviation , and angle deviation ; When the position deviation , and the angle deviation , it is determined that the position and angle adjustment of the magnetic steel is completed, and the control system outputs an adjustment completion signal to trigger the next process; If the accuracy requirement is not met, return to step 502 or step 503 to continue adjusting.

[0039] In one embodiment, specifically, in step four, the position sensor is a linear displacement sensor or a laser range finder; Specifically, the linear displacement sensor adopts magnetostrictive or grating ruler, wherein the magnetostrictive transmits magnetic signals through waveguide wire, and the accuracy can reach ±0.001 mm, and the response speed is less than 1 ms; the grating ruler utilizes the grating Moiré fringe principle, and the resolution can reach 0.1 μm, both of which can be installed on the actuator to detect the linear displacement of the magnetic steel mounting platform, and provide accurate position feedback data for the control system; The laser range finder includes a triangulation method and a phase type, taking the triangulation method as an example, the laser range finder emits laser through a laser emitter, the laser is diffusely reflected by the surface of the magnetic steel, the change of the light spot position is received by a receiver CCD chip, the distance is calculated according to the triangular geometric relationship, and then the radial / tangential displacement of the magnetic steel is converted, and the non-contact measurement characteristic enables the laser range finder to avoid damaging the surface of the magnetic steel, and the fast response advantage meets the real-time feedback demand of dynamic adjustment.

[0040] The angle sensor is an encoder or a circular grating; Specifically, the encoder is divided into absolute type and incremental type, the absolute type encoder has a single-turn resolution of 24 bits, can directly output absolute angle values, and the data does not lose after power failure; the incremental type encoder calculates the angle by counting pulses, and needs a zero reference point; taking the absolute type as an example, the code disc binary encodes, the photoelectric reading head obtains the absolute angle of the rotating shaft, and the output signal is analyzed into an angle value, the high precision and strong anti-interference property are suitable for high-speed rotating scenes of the motor; The circular grating has glass and metal types, the glass circular grating has high line density, and the resolution is better than 0.1"; the metal circular grating has good vibration resistance; when working, the circular grating disc is coaxial with the rotating shaft of the magnetic steel, the reading head light forms Moiré fringes, the photoelectric detector converts into an electric signal to calculate the angle increment, and the characteristics of non-contact, long service life and high precision enable the circular grating to perform high-precision angle detection tasks.

[0041] In one embodiment, specifically, in step three, the marking method of the magnetic steel mounting position is laser marking or mechanical line marking, and the error of the marking position accuracy is not more than ±0.05 mm; The laser marking utilizes a high-energy-density laser beam to act on the surface of the magnetic steel instantaneously, vaporizes the material through thermal ablation or chemical decomposition to form clear marking lines or symbols, the positioning accuracy mainly depends on the laser focusing system and the scanning accuracy of the galvanometer, can reach the micron level, completely meets the error requirement of not more than ±0.05 mm, and is suitable for magnetic steels of various materials due to the fast marking speed and non-contact damage; Mechanical scribing is to control the cutter to scribe mark lines on the surface of the magnetic steel by precise numerical control processing equipment. During the processing, the high-precision servo motor and ball screw driving system cooperate with the micron-level resolution grating ruler feedback device to accurately control the cutter movement track, strictly limit the mark position error within ±0.05 mm, and the line depth and width marked by this method are controllable, and have good wear resistance and durability.

[0042] In one embodiment, specifically, in step one, cleaning uses ultrasonic cleaning; Specifically, ultrasonic cleaning uses an ultrasonic cleaner with a frequency of 40 kHz and a power density of 0.8 W / cm², equipped with a three-stage filtration system (5 μm, 1 μm, 0.2 μm); the specific cleaning process is as follows: Submerge the iron core in 10% volume ratio aqueous cleaning agent (such as 3M ™ Novec ™ 7500) at 50°C, ultrasonic oscillation for 10 minutes, and rotate the workpiece at a speed of 60 rpm during the process to ensure 360° dead angle cleaning; After cleaning, detect the surface tension by a contact angle measuring instrument, which requires ≥40 mN / m (indicating that the oil stain is completely removed).

[0043] Surface treatment includes sandpaper polishing or chemical treatment; Among them, sandpaper polishing uses 1000 mesh silicon carbide sandpaper, cooperates with a pneumatic polisher (speed 2000 rpm), and polishes along the radial direction of the iron core for 5 times, with a single stroke length of 200 mm, and the final surface roughness Ra=0.6±0.1 μm; Chemical treatment sprays 5% concentration hydrochloric acid solution with a spraying pressure of 0.4 MPa, and the reaction time is 3 minutes, then washes with deionized water until the pH value is neutral, and dries at a temperature of 80°C for 15 minutes.

[0044] In one embodiment, specifically, in step six, the adhesive is high-temperature resistant epoxy resin glue; Specifically, the high-temperature resistant epoxy resin glue has good temperature resistance (long-term use temperature can reach above 180°C), high bonding strength (shear strength ≥30 MPa), and excellent aging resistance, which can ensure the stable fixation of the magnetic steel in a high-temperature environment.

[0045] The pressure range of the pneumatic or hydraulic pressing mechanism for pressing the magnetic steel is 5-10 N / mm², and the pressure uniformity error is ≤5%; Among them, the pneumatic pressing mechanism drives the piston to generate pressure by compressed air, which has the characteristics of fast response speed and simple structure; The hydraulic pressing mechanism uses hydraulic oil to transfer pressure, which can provide greater pressing force and more accurate pressure control; The pressure range is set to 5-10 N / mm2, which can ensure that the epoxy resin glue fills the gap between the magnetic steel and the iron core, and also avoids the glue layer being too thin or the magnetic steel being displaced due to excessive pressure; The pressure uniformity error is ≤5%, which is realized by integrating a pressure sensor matrix (such as a distributed thin film pressure sensor) in the pressing mechanism to monitor the pressure of each point in real time, and dynamically adjusting the output of the actuator (such as a pneumatic cylinder or a hydraulic cylinder) combined with a closed-loop control system to ensure that the entire magnetic steel surface is uniformly stressed, thereby achieving reliable bonding and fixing effect.

[0046] In summary, the disc motor rotor magnetic steel positioning and installation method provided by the present application accurately determines the center position of the rotor iron core and the magnetic pole distribution reference line through a visual detection system combined with image recognition technology (such as Hough circle transformation and polar coordinate system establishment), realizes closed-loop adjustment of the magnetic steel position (accuracy ±0.01 mm) and angle (accuracy ±0.05°) using linear displacement sensors, laser range finders, encoders, etc., and completes magnetic steel marking, glue application, and pressing (pressure 5-10 N / mm2, uniformity error ≤5%) through an automated process. The full-process automation from iron core processing to magnetic steel installation is realized, which significantly improves the uniformity of the motor air gap magnetic field, installation efficiency, and quality consistency, and reduces production costs and failure rate.

[0047] Figure 4 is a functional module schematic diagram of a disc motor rotor magnetic steel positioning and installation system according to an embodiment of the present application, as shown in Figure 4 A disc motor rotor magnetic steel positioning and installation system includes an iron core processing module, a visual positioning module, a position marking module, a magnetic steel detection module, a positioning adjustment module, and an installation and fixing module. The iron core processing module is configured to clean and surface treat the rotor iron core of the disc motor to remove oil stains, impurities, and oxidation layers on the surface of the rotor iron core. The visual positioning module is configured to acquire images of the rotor iron core based on a visual detection system, and determine the center position and magnetic pole distribution reference line of the rotor iron core through image recognition technology. The position marking module is configured to mark the magnetic steel installation position on the end face of the rotor iron core according to the center position and magnetic pole distribution reference line of the rotor iron core. The magnetic steel detection module is configured to place the magnetic steel to be installed on a positioning station, and detect the position and angle of the magnetic steel through the position sensor and angle sensor on the positioning station. The positioning adjustment module is configured to adjust the position and angle of the magnetic steel through the control system according to the marked magnetic steel installation position. The installation and fixing module is configured to apply adhesive on the installation surface of the magnetic steel, install the adjusted magnetic steel to the marked position of the rotor iron core, and press the magnetic steel.

[0048] In one embodiment, specifically, the magnetic steel detection module detects the position and angle of the magnetic steel, and the visual positioning module collects the magnetic pole mark image on the surface of the magnetic steel, and combines a deep learning algorithm to identify the magnetic pole direction, and forms a redundant check with the angle sensor data; Specifically, when the magnetic steel detection module detects the position and angle of the magnetic steel, the visual positioning module synchronously collects the magnetic pole mark image (such as N / S pole laser etching mark) on the surface of the magnetic steel, and uses a deep learning algorithm (such as ResNet or YOLOv8) to perform image feature extraction and classification to identify the actual magnetic pole direction; the result is cross-compared with the angle sensor data, and when the deviation exceeds a threshold value (such as ±0.05°), an alarm is triggered and recalibration is performed, forming a double-system redundant check to ensure the detection reliability of the magnetic pole direction; When the visual positioning module determines the reference line of the iron core, it synchronously measures the flatness and surface roughness of the end face of the iron core, and transmits the data to the positioning adjustment module for adaptive calculation of the magnetic steel installation pressure; Specifically, during the determination of the reference line of the iron core, the visual positioning module scans the end face of the iron core by using a structured light three-dimensional measurement technology (such as a stripe projection method), reconstructs a three-dimensional point cloud model, calculates the flatness error (required to be ≤±0.02mm) and the surface roughness (Ra≤1.6μm); these data are transmitted in real time to the positioning adjustment module, and combined with a material mechanics model, the pressure parameter (such as 5-10N / mm²) of the pressing mechanism is dynamically adjusted to ensure that the magnetic steel is fully attached to the surface of the iron core, and to compensate for the uneven contact caused by flatness and roughness; The magnetic steel detection module and the visual positioning module perform spatio-temporal alignment of the detection data through timestamp synchronization technology; Specifically, the two modules use timestamp synchronization technology (such as IEEE1588 precision clock protocol) to stamp all detection data with nanosecond-level timestamps. In the data fusion stage, Kalman filtering algorithm is used to align the data of different sampling frequencies (such as 1kHz for the magnetic steel detection module and 200Hz for the visual positioning module) in space and time, and eliminate errors caused by different sampling times; for example, when the visual positioning module detects a defect on the surface of the iron core, the system can accurately associate the position data of the magnetic steel at the same time to make an obstacle avoidance installation decision for the defect area; The multi-modal data fusion and spatio-temporal calibration of the magnetic steel detection module and the visual positioning module coordinated system improve the installation precision of the magnetic steel to ±0.01mm position error and ±0.05° angle error, and simultaneously realize intelligent optimization of the pressure parameter, significantly improving the manufacturing quality and reliability of the permanent magnet motor.

[0049] In one embodiment, specifically, the positioning adjustment module includes a self-calibration unit; the self-calibration unit is configured to establish an error prediction model based on historical installation data, to predict the temperature drift error of the vision detection system; if the magnetic steel is adjusted out of tolerance for three consecutive times, the system-level calibration is automatically triggered, and the origin of the polar coordinate system and the reference line are re-calibrated through a standard part; Specifically, first, the self-calibration unit establishes a temperature drift error prediction model based on historical installation data (including environmental temperature, system running time, position / angle deviation value, and other multi-dimensional parameters) using LSTM (Long Short-Term Memory Network) or random forest algorithm; during model training, the temperature change rate and the continuous running time of the equipment are used as inputs to predict the polar coordinate system origin offset (typical value: 0.002-0.005 mm / ℃) and reference line angle deviation (≤0.01° / ℃) caused by thermal expansion and cold contraction of the vision detection system; in real-time operation, the system dynamically compensates the predicted error according to the current environmental parameters, for example, when a temperature rise of 5℃ is detected, the polar coordinate system origin coordinates are automatically corrected , the compensation amount is 、 ; When the self-calibration unit monitors that the magnetic steel is adjusted out of tolerance for three consecutive times (position deviation > ±0.01 mm or angle deviation > ±0.05°), and the error distribution shows a systematic offset characteristic, the system-level calibration process is automatically triggered; the calibration process uses high-precision standard parts (such as a ceramic disc with a diameter of 50 mm and a roundness error of ≤0.001 mm, and the surface is engraved with a cross reference line with a precision of ±0.005°), the vision system re-collects the standard part image, and the circle center fitted by the sub-pixel edge detection algorithm is used as the new polar coordinate system origin, and the standard part cross line is used as the reference to re-calibrate the 0° direction, and after completion, the system parameters are automatically updated; After the system-level calibration is completed, the self-calibration unit repeatedly measures the standard part for 10 times, calculates the standard deviation (the position standard deviation is required to be ≤0.003 mm, and the angle standard deviation is required to be ≤0.015°) and the mean offset of the measurement data; if the threshold is exceeded, further analyze the image feature matching degree in the calibration process, adjust the Gaussian kernel parameter of the edge detection algorithm (such as from 1.0 to 1.2) or the accumulator threshold of the Hough transform, until the calibration accuracy meets the standard; In addition, the self-calibration unit stores the environmental parameters of each calibration, the error data before and after calibration into the database, continuously optimizes the error prediction model, and forms a closed-loop optimization system; Through data-driven prediction compensation and intelligent triggered system-level calibration, the long-term stability of the vision detection system is improved to ±0.005 mm / 24 hours, the frequency of manual intervention is significantly reduced (from 2 times a day to 1 time a week), and the consistency of the magnetic steel installation precision is ensured throughout the life cycle.

[0050] In summary, the disc motor rotor magnet positioning and installation system provided by the application cleans and surface treats the rotor core through the core processing module, determines the core center position and the magnetic pole distribution reference line by using image recognition technology of the visual positioning module, marks the magnet installation position by the position marking module, detects the magnet pose by the magnet detection module through the sensor and visual redundancy verification, realizes accurate adjustment based on the multi-sensor fusion data and the temperature drift error prediction model of the self-calibration unit by the positioning adjustment module, and the installation fixing module adaptively controls the pressing pressure according to the core flatness and roughness data. The modules are time and space aligned through the timestamp synchronization technology, form a full-process closed-loop control from core pretreatment to magnet installation, finally realize high-precision installation with a position error of ±0.01 mm and an angle error of ±0.05°, and improve the long-term stability of the system to ±0.005 mm / 24 hours through intelligent calibration, significantly improving the permanent magnet motor manufacturing quality and production efficiency.

[0051] For other details of the technical solutions of each module in the disc motor rotor magnet positioning and installation system described above, refer to the description of the disc motor rotor magnet positioning and installation method in the above embodiments.

[0052] It should be noted that each of the embodiments in the specification adopts a progressive description manner, and each embodiment focuses on the difference from other embodiments. The same and similar parts of each embodiment can be referred to. For system embodiments, since they are basically similar to the method embodiments, the description is relatively simple, and the relevant parts can be referred to the part of the method embodiments.

[0053] The basic principles of the present disclosure are described above in combination with specific embodiments, but it should be pointed out that the advantages, advantages, effects and the like mentioned in the present disclosure are only examples and are not limiting, and these advantages, advantages, effects and the like cannot be considered as the must-have of each embodiment of the present disclosure. In addition, the specific details of the above disclosure are only for the purpose of example and for the purpose of understanding, and are not limited to the must-have of the present disclosure.

[0054] In this disclosure, relational terms such as first and second and the like can be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The block diagram of the devices, apparatus, equipment, systems referred to in this disclosure is merely illustrative and not intended to imply the necessity or arrangement of the connections, arrangement, configuration as shown in the block diagram. As will be appreciated by those skilled in the art, the devices, apparatus, equipment, systems can be connected, arranged, configured in any way. The words "comprising," "containing," "including," "having," and the like, are to be construed open-ended, meaning "including but not limited to," and are to be taken in their broadest context. The words "or" and "and" as used herein, mean "and / or," and are to be taken in their broadest context, unless the context clearly indicates otherwise. The word "comprising" as used herein, means "comprising but not limited to," and is to be taken in its broadest context.

[0055] Also, as used in this disclosure, "or" as used in the context of items A and B as "at least one of A or B" indicates a disjunction, such that, for example, a disjunction of "at least one of A, B, or C" means A or B or C, or AB or AC or BC, or ABC (i.e., A and B and C). Furthermore, the word "example" is not meant to convey that a described example is preferred or better than other examples.

[0056] It is also important to note that the systems and methods of the disclosure can be embodied in a variety of forms including, but not limited to, a data processor, a computer program product, a computer, one or more tangible computer readable storage devices, one or more computer-implemented methods, information, or a propagated signal. It is also intended that the systems and methods can be embodied in software-implemented processes, software-implemented systems, software, virtual machines, virtual devices, etc.

[0057] Various changes, modifications and improvements in the technologies described herein can be made without departing from the teachings of the teachings defined by the appended claims. Moreover, the scope of the claims of this disclosure is not limited to the specific aspects described above. The processes, machines, manufactures, compositions of matter, means, methods, or steps, described herein can be substituted with other processes, machines, manufactures, compositions of matter, means, methods, or steps that achieve the same result in substantially the same way. Accordingly, the appended claims include within their scope such processes, machines, manufactures, compositions of matter, means, methods, or steps.

[0058] The above description of the disclosed aspects is intended to enable any person skilled in the art to make or use the disclosure. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other aspects without departing from the scope of the disclosure. Thus, the present disclosure is not intended to be limited to the aspects shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0059] The foregoing description has been presented for the purposes of illustration and description. Furthermore, the description is not intended to limit the embodiments of the disclosure to the forms disclosed herein. Although the various example aspects and embodiments have been described herein with regard to particular aspects and embodiments, those skilled in the art will recognize that certain modifications, changes, substitutions, additions and sub-combinations can be made without departing from the spirit of the disclosure.

Claims

1. A method for positioning and installing rotor magnets in a disc motor, characterized in that, Includes the following steps: The rotor core of the disc motor is cleaned and surface-treated to remove oil, impurities and oxide layer from the surface of the rotor core. The rotor core image is acquired using a vision inspection system, and the center position and magnetic pole distribution baseline of the rotor core are determined using image recognition technology. Based on the center position of the rotor core and the baseline of the magnetic pole distribution, mark the installation position of the magnets on the end face of the rotor core. The magnet to be installed is placed in the positioning station, and the position and angle of the magnet are detected by the position sensor and angle sensor at the positioning station. Based on the marked installation location of the magnet, the position and angle of the magnet are adjusted through the control system; Apply adhesive to the mounting surface of the magnet, install the adjusted magnet onto the marked position on the rotor core, and press the magnet firmly.

2. The method for positioning and installing rotor magnets of a disc motor according to claim 1, characterized in that, The method for determining the center position of the rotor core and the baseline for the magnetic pole distribution includes the following steps: The rotor core end face is illuminated by a ring light source of the vision inspection system, and at least three images of the rotor core end face from different angles are acquired using the CCD industrial camera of the vision inspection system. The acquired rotor core end face image is preprocessed to extract the rotor core contour edge features; the preprocessing includes grayscale conversion, median filtering, threshold segmentation and morphological processing; Based on the edge features of the rotor core profile, the Hough circle transform algorithm is used to fit the outer circle profile of the rotor core, and the geometric coordinates of the center position of the rotor core are calculated. Identify at least two preset positioning marks on the rotor core end face, and establish a polar coordinate system with the geometric coordinate points as the origin through a coordinate transformation algorithm; the preset positioning marks are laser-engraved cross marks or metal coating difference points on the core end face, with a feature size of not less than 0.5 mm and a contrast of ≥50%; Based on the magnetic pole distribution angle interval in the motor design parameters, take any positioning mark point as the starting point and evenly divide the magnetic pole distribution baseline along the circumference. The actual angular interval between adjacent baselines is measured by a vision inspection system and compared with the theoretical design value. If the deviation exceeds ±0.05°, the optical parameters and image processing algorithm parameters of the vision inspection system are corrected.

3. The method for positioning and installing the rotor magnet of a disc motor according to claim 1, characterized in that, The adjustment of the position and angle of the magnet through the control system specifically includes: Based on the center position of the rotor core and the baseline of the magnetic pole distribution, calculate the target position coordinates (r, θ) and target angle of the magnet in the polar coordinate system. ; The actuator is driven by a control algorithm to adjust the planar position of the magnet so that the center of the magnet coincides with the target position coordinates (r, θ). The drive rotation mechanism adjusts the angle of the magnet so that the direction of the magnet poles is consistent with the baseline of the magnet pole distribution. The position and angle of the magnet are fed back in real time by position and angle sensors. If the position deviation is ≤ ±0.01mm and the angle deviation is ≤ ±0.05°, the adjustment is considered complete.

4. The method for positioning and installing rotor magnets of a disc motor according to claim 1, characterized in that: The position sensor is a linear displacement sensor or a laser rangefinder; the angle sensor is an encoder or a circular grating.

5. The method for positioning and installing rotor magnets of a disc motor according to claim 1, characterized in that: The marking of the magnet installation position is achieved by laser marking or mechanical engraving, and the marking position accuracy error does not exceed ±0.05mm.

6. The method for positioning and installing rotor magnets of a disc motor according to claim 1, characterized in that: The cleaning process employs ultrasonic cleaning; the surface treatment includes sanding or chemical treatment.

7. The method for positioning and installing rotor magnets of a disc motor according to claim 1, characterized in that: The adhesive is a high-temperature resistant epoxy resin adhesive. The magnet is pressed using a pneumatic or hydraulic pressing mechanism, with a pressure range of 5-10 N / mm² and a pressure uniformity error of ≤5%.

8. A disc motor rotor magnet positioning and installation system, applied to the disc motor rotor magnet positioning and installation method according to any one of claims 1-7, characterized in that, The system includes: a core processing module, a visual positioning module, a position marking module, a magnet detection module, a positioning adjustment module, and an installation and fixing module; The core processing module is configured to clean and surface treat the rotor core of the disc motor to remove oil, impurities and oxide layer from the surface of the rotor core. The visual positioning module is configured to acquire an image of the rotor core based on a visual detection system, and determine the center position and magnetic pole distribution baseline of the rotor core through image recognition technology. The position marking module is configured to mark the magnet installation position on the end face of the rotor core according to the center position of the rotor core and the magnetic pole distribution baseline. The magnet detection module is configured to place the magnet to be installed at the positioning station and detect the position and angle of the magnet by using a position sensor and an angle sensor at the positioning station. The positioning adjustment module is configured to adjust the position and angle of the magnet according to the marked installation position of the magnet through the control system; The mounting and fixing module is configured to apply adhesive to the mounting surface of the magnet, install the adjusted magnet onto the marked position on the rotor core, and press the magnet firmly.

9. A disc motor rotor magnet positioning and installation system according to claim 8, characterized in that: While detecting the position and angle of the magnet, the magnet detection module also acquires images of magnetic pole markings on the surface of the magnet through a visual positioning module, and identifies the direction of the magnetic poles by combining deep learning algorithms, forming a redundant verification with the angle sensor data. When determining the core baseline, the visual positioning module simultaneously measures the flatness and surface roughness of the core end face and transmits the data to the positioning adjustment module for adaptive calculation of the magnet installation pressure. The magnet detection module and the visual positioning module use timestamp synchronization technology to align the detection data in time and space.

10. A disc motor rotor magnet positioning and installation system according to claim 8, characterized in that: The positioning adjustment module includes a self-calibration unit; the self-calibration unit is configured to establish an error prediction model based on historical installation data to predict the temperature drift error of the visual inspection system; if the magnet exceeds the tolerance for three consecutive adjustments, the system-level calibration is automatically triggered to recalibrate the origin and baseline of the polar coordinate system using standard parts.

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