A method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors

Abstract

This invention relates to the field of electrical material performance evaluation technology, and particularly to a method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors. The method includes: extracting wiring space topology parameters from a robot's three-dimensional design model to determine installation complexity and test cycle; calculating the assembly matching degree based on the enameled flat wire production specifications and motor electrical specifications; determining the electrical test stress coefficient and applied voltage based on the assembly matching degree; determining the anti-aging requirement parameters and the bending radius and frequency of the bending test by combining the installation complexity, assembly matching degree, and cycle; determining the evaluation endpoint based on the slope of the deviation curve; and outputting the evaluation result based on the final deviation. This invention, by comprehensively quantifying the actual installation conditions and electrical matching status of the robot, dynamically customizes aging test parameters, realizing a shift from fixed-condition testing to adaptive-condition testing, significantly improving the accuracy of the evaluation results and their engineering guidance value.

Description

Technical Field

[0001] This invention relates to the field of electrical material performance evaluation technology, and in particular to a method for evaluating the aging performance of corona-resistant enameled flat wires for robot motors. Background Technology

[0002] In the fields of industrial robots and high-end equipment, the corona-resistant enameled flat wires used in motor windings operate under complex coupling environments of electrical and mechanical stresses. Especially in multi-joint robots, the cables connecting the motors need to bend frequently with the joints, and their insulation materials simultaneously endure the combined effects of pulse voltage, partial discharge, and bending fatigue, resulting in complex aging failure modes. Currently, the aging performance evaluation of such special enameled flat wires mostly employs standardized single-stress accelerated aging tests, such as constant high-voltage corona aging or fixed bending cycle tests.

[0003] Chinese invention patent publication number CN112180191A discloses a method for assessing the aging state of wires and cables. The method involves selecting cable samples of the same model as the cable to be assessed, measuring the characteristic parameters of each cable in the sample, and performing a preliminary state rating based on these parameters. Each cable in the sample is then electromagnetically shielded and polarized. During polarization, the leakage current in the cable insulation layer is measured. The polarized cable is then short-circuited to remove surface free charges, followed by depolarization. During depolarization, the isothermal relaxation current is measured. A neural network model is constructed, and the aging state is rated based on the preliminary state rating and the leakage current and isothermal relaxation current of each cable in the sample. The neural network model is then trained. While this invention effectively overcomes the shortcomings of existing technologies in accurately and effectively assessing the aging state of cables, the following deficiencies remain:

[0004] 1. Failed to consider the differences in mechanical stress caused by different robot wiring space topologies (such as wire length, wiring density, and number of joints);

[0005] 2. The insulation performance of the cable itself (such as breakdown voltage and dielectric loss) was not dynamically matched with the actual electrical conditions of the target motor (such as operating voltage and peak voltage).

[0006] Therefore, there is an urgent need for an aging performance evaluation method that can comprehensively reflect the specific installation environment and electrical operating parameters of a robot, so as to achieve accurate prediction and scientific selection of the suitability of corona-resistant enameled flat wires. Summary of the Invention

[0007] To address this issue, the present invention provides a method for evaluating the aging performance of corona-resistant enameled flat wires for robot motors. This method overcomes the problem that existing standardized aging evaluation methods are severely out of sync with the actual complex working conditions of robots, resulting in evaluation results that cannot accurately predict the service life and reliability of cables in specific motors.

[0008] To achieve the above objectives, the present invention provides a method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors, comprising:

[0009] Spatial topology parameters of the motor wiring are extracted from the robot's 3D design model. The installation complexity is determined based on the spatial topology parameters to apply corresponding anti-electrical aging performance tests during the aging performance evaluation process. The alternation cycle of applying anti-winding bending aging performance tests is also determined. The spatial topology parameters include connection length, path wiring density, and the number of path joints.

[0010] Based on the production specifications of the enameled flat wire and the electrical specifications of the compatible motor, the assembly matching degree is determined. The production specifications include the average breakdown voltage and the standard dielectric loss factor, and the electrical specifications include the rated operating voltage, the peak voltage, and the maximum dielectric loss factor.

[0011] The matching electrical stress coefficient is determined based on the assembly matching degree, and the applied voltage for the electrical anti-aging test strength parameter is determined based on the electrical stress coefficient and the peak voltage.

[0012] Based on the installation complexity, the assembly matching degree, and the alternation cycle, the anti-aging requirement parameters are determined, and combined with the number of path joints, the actual bending radius of the bending aging test parameters is determined.

[0013] The bending frequency of the bending aging test parameters is determined based on the installation complexity, wherein the bending frequency is directly proportional to the installation complexity.

[0014] Based on the test index parameters obtained in real time during the aging performance evaluation process, the deviation of the test index is determined to fit the deviation curve. The test index parameters include partial discharge quantity and dielectric loss factor.

[0015] The aging performance evaluation is performed based on the slope of the deviation curve, and the output aging performance evaluation result is determined based on the final deviation of the aging performance evaluation.

[0016] Furthermore, the connection length, path wiring density, and number of path joints are normalized respectively, and then weighted summation is performed to determine the installation complexity.

[0017] Furthermore, the process of determining the alternating cycles for applying the anti-winding bending aging performance test includes:

[0018] The installation complexity is compared and analyzed with a preset complexity threshold;

[0019] Based on the result that the installation complexity is less than the preset complexity threshold, it is determined to adjust and shorten the alternation cycle;

[0020] The alternation cycle of the anti-winding bending aging performance test is inversely proportional to the installation complexity.

[0021] Furthermore, the process of determining the assembly matching degree includes:

[0022] The ratio of the average breakdown voltage to the rated operating voltage is determined as the first ratio.

[0023] The ratio of the average breakdown voltage to the peak voltage is determined as the second ratio.

[0024] The ratio of the standard dielectric loss factor to the maximum dielectric loss factor is determined as the third ratio.

[0025] The weighted sum of the first ratio, the second ratio, and the third ratio is determined as the assembly matching degree.

[0026] Furthermore, the process of determining the electrical anti-aging test strength parameters includes:

[0027] The assembly matching degree is compared and analyzed with a preset assembly matching degree threshold;

[0028] Based on the result that the assembly matching degree is greater than or equal to the first preset assembly matching degree threshold, or the assembly matching degree is less than or equal to the second preset assembly matching degree, the first adaptive electrical stress coefficient is determined to be adopted.

[0029] Based on the result that the assembly matching degree is less than the first preset assembly matching degree threshold, the second adaptive electrical stress coefficient is determined to be used.

[0030] The product of the adaptive electrical stress coefficient and the peak voltage is determined as the applied voltage;

[0031] Wherein, the adaptive electrical stress coefficient is directly proportional to the assembly matching degree, the first preset assembly matching degree threshold is less than the second preset assembly matching degree threshold, and the first adaptive electrical stress coefficient is less than the second adaptive electrical stress coefficient.

[0032] Furthermore, a comprehensive requirement value is determined based on the installation complexity and the assembly matching degree, and the comprehensive requirement value and the stress duration corresponding to the alternating cycle are correlated and calculated to obtain the anti-aging requirement parameter.

[0033] Furthermore, the process of determining the bending aging test parameters includes:

[0034] The anti-aging requirement parameters are determined based on the installation complexity and assembly compatibility.

[0035] The anti-aging requirement parameter is compared and analyzed with the preset anti-aging requirement parameter threshold to determine the base bending radius, wherein the base bending radius is directly proportional to the anti-aging requirement parameter.

[0036] The basic bending radius is corrected based on the number of path joints to obtain the bending radius of the bending aging test parameters, wherein the bending radius is inversely proportional to the joint density.

[0037] Furthermore, the process of determining the deviation of the test metric includes:

[0038] The relative rate of change of the real-time acquired partial discharge quantity relative to its initial test value is calculated and used as the first deviation component;

[0039] The absolute change of the real-time acquired dielectric loss factor relative to its initial test value is calculated as the second deviation component.

[0040] The first deviation component and the second deviation component are weighted and summed to determine the real-time test index deviation.

[0041] Furthermore, the process of performing the aging performance evaluation based on the slope of the deviation curve includes:

[0042] During the aging performance evaluation process, the instantaneous slope of the deviation curve within a preset time window is continuously calculated;

[0043] Determine whether the absolute value of the instantaneous slope is less than the preset slope stabilization threshold multiple times consecutively to determine that the material aging state has entered a stable stage, end the aging performance evaluation, and record the deviation of the test index at this time as the final deviation.

[0044] Furthermore, the process of determining the output aging performance evaluation result based on the final deviation of the aging performance evaluation includes:

[0045] The final deviation is matched and compared with the pre-stored performance threshold ranges for different motor specifications, wherein the performance threshold ranges are related to the power level of the motor and the allowable installation complexity.

[0046] Based on the result that the final deviation belongs to the threshold range corresponding to the original target motor, it is determined that the aging performance evaluation is qualified, and the specifications of the corona-resistant enameled flat wire matching motor remain unchanged.

[0047] Alternatively, based on the result that the final deviation does not belong to the threshold range corresponding to the original target motor, if the final deviation is greater than the lower limit of the threshold range corresponding to the higher power motor, it is determined that the specifications of the corona-resistant enameled flat wire matching motor should be adjusted upward; if the final deviation is greater than the lower limit of the threshold range corresponding to the lower power motor, it is determined that the specifications of the corona-resistant enameled flat wire matching motor should be adjusted downward; otherwise, it is determined that the aging performance evaluation is unqualified.

[0048] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0049] By automatically extracting spatial topology parameters such as connection length, path wiring density, and number of path joints from the robot's 3D design model, and then normalizing and weighting them, the complex physical wiring structure is quantified into a comprehensive installation complexity index.

[0050] Furthermore, by comparing the installation complexity with a preset threshold, the alternation cycle of the electrical aging and mechanical bending aging tests is dynamically determined, thereby transforming the abstract robot wiring environment into quantifiable and comparable test parameters. This allows the aging test rhythm to simulate the frequency of alternating electrical and mechanical stresses in real robot operation, significantly improving the simulation realism of the test conditions.

[0051] Furthermore, by establishing a quantitative model of the assembly matching degree M, the average breakdown voltage and standard dielectric loss factor of the enameled flat wire are correlated with the rated voltage, peak voltage, and maximum permissible dielectric loss factor of the motor. This model, through weighted fusion of the first, second, and third ratios, comprehensively evaluates the matching degree between the cable insulation system and the electrical requirements of the motor. This allows for the pre-identification of potential risks or redundancies in electrical insulation matching before testing, providing a scientific basis for subsequent customized testing intensity and avoiding inaccurate evaluations caused by blindly adopting fixed test conditions.

[0052] Furthermore, the alternation period T is dynamically adjusted based on the installation complexity C. When the cabling environment is complex (high C value), the alternation period is shortened and the frequency of bending tests is increased. The principle is that complex cabling (especially high joint density) means that the cable is subjected to more frequent bending stress in actual operation, thereby achieving the effect of matching the stress application mode of the accelerated aging test in the laboratory with the actual workload spectrum of the robot. This allows the cable used in complex cabling environments to withstand more stringent intermittent mechanical fatigue tests, and the evaluation conclusions are more targeted.

[0053] Furthermore, by dynamically adjusting the electrical stress coefficient based on the assembly matching degree M, the effect of targeted aging performance testing is achieved. More stringent electrical tests are applied to cables with poor matching degree, while over-testing is avoided for cables with good matching degree. This improves testing efficiency and rationality while ensuring the effectiveness of the test.

[0054] Furthermore, by integrating the reciprocals of installation complexity C and assembly matching degree M, the comprehensive requirement value N is calculated, and then combined with the stress duration to obtain the anti-aging requirement parameter. This parameter comprehensively reflects the overall requirements for cable aging performance under specific working conditions. Based on this, the bending test radius is determined and corrected in reverse by the number of joints J, thereby achieving strict grading of bending tests tailored to different robot application scenarios. For scenarios with complex installation, tight electrical matching, and many joints, bending test conditions with smaller bending radii are automatically generated to accurately reproduce the most severe mechanical stress points.

[0055] Furthermore, the partial discharge quantity PD and dielectric loss factor tanδ are collected and processed in real time. By calculating their relative change rate with respect to the initial value and performing weighted synthesis, a unified test index deviation D(t) is obtained, thereby achieving the purpose of multi-dimensional, quantitative, and online tracking of the aging state of insulating materials.

[0056] Furthermore, by continuously calculating the instantaneous slope s(t) of the deviation curve D(t) and determining whether it continuously enters a stable plateau period, based on this, since the aging process of materials in accelerated testing usually goes through a rapid development period and a relatively stable period, the appearance of the plateau period means that the main aging mechanism under the current stress conditions has been fully manifested, thereby achieving the effect of intelligently and objectively determining the test endpoint, avoiding the undertesting or excessive waste that may be caused by artificially setting a fixed test duration, and ensuring the economy and reliability of the evaluation results.

[0057] Furthermore, a performance threshold range database based on motor power level and allowable installation complexity is pre-established. The final deviation is matched with the range corresponding to the current target motor, and a decision is made on whether it is qualified / unqualified or requires specification adjustment based on the matching result. This achieves the goal of directly converting the quantitative results of aging tests into engineering selection recommendations. Attached Figure Description

[0058] Figure 1 This is a flowchart illustrating the steps of the method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to an embodiment of the present invention.

[0059] Figure 2 This is a flowchart illustrating the steps for determining assembly compatibility, as described in an embodiment of the present invention.

[0060] Figure 3 A flowchart illustrating the steps for determining the deviation of test indicators in an embodiment of the present invention;

[0061] Figure 4 This is a flowchart illustrating the steps for determining the end of the aging performance evaluation based on the slope of the deviation curve, as described in an embodiment of the present invention. Detailed Implementation

[0062] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0063] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0064] Please see Figure 1 As shown, Figure 1 This is a flowchart illustrating the steps of the method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to an embodiment of the present invention.

[0065] The present invention provides a method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors, comprising the following steps:

[0066] Step S1: Extract the spatial topology parameters of the motor wiring through the robot's three-dimensional design model, and determine the installation complexity based on the spatial topology parameters. In order to determine the alternation cycle of applying anti-twisting bending aging performance test on the basis of applying anti-electrical aging performance test during the aging performance evaluation process, the spatial topology parameters include the connection length, path wiring density, and the number of path joints.

[0067] Step S2: Based on the production specifications of the enameled flat wire and the electrical specifications of the compatible motor, determine the assembly matching degree. The production specifications include the average breakdown voltage and the standard dielectric loss factor, and the electrical specifications include the rated operating voltage, the peak voltage, and the maximum dielectric loss factor.

[0068] Step S3: Determine the matching electrical stress coefficient based on the assembly matching degree, and determine the applied voltage of the electrical anti-aging test strength parameter based on the electrical stress coefficient and the peak voltage;

[0069] Step S4: Based on installation complexity, assembly matching degree, and alternation cycle, determine the anti-aging requirement parameters, and based on the anti-aging requirement parameters and the number of path joints, determine the actual bending radius of the bending aging test parameters.

[0070] Step S5: Determine the bending frequency of the bending aging test parameters based on the installation complexity, wherein the bending frequency is directly proportional to the installation complexity.

[0071] Step S6: Based on the test index parameters obtained in real time during the aging performance evaluation process, determine the test index deviation to fit the deviation curve. The test index parameters include partial discharge quantity and dielectric loss factor.

[0072] Step S7: Based on the slope of the deviation curve, determine the end of the aging performance evaluation, and determine the output aging performance evaluation result according to the final deviation when the aging performance evaluation is completed. The aging performance evaluation result includes: aging performance evaluation is qualified, the specifications of the corona-resistant enameled flat wire matching motor remain unchanged, the specifications of the corona-resistant enameled flat wire matching motor are adjusted upward or downward, and aging performance evaluation is unqualified.

[0073] Specifically, in step S1, the connection length, path wiring density, and number of path joints are normalized and then weighted and summed to determine the installation complexity.

[0074] In this embodiment of the invention, the installation complexity C is calculated using the following formula:

[0075]

[0076] in, To normalize the connection length, , where is the maximum wiring length;

[0077] To normalize the path routing density, , Maximum path routing density;

[0078] To normalize the number of path joints, , This represents the maximum number of path joints.

[0079] The influence weight of the connection length, Weighting the impact of path wiring density The weighting coefficient for the number of path joints is given, and + + =1;

[0080] In this embodiment, considering the stress set of joint treatment, the following settings are made: Maximum, specifically:

[0081] , wJ=0.5.

[0082] In this embodiment of the invention, the maximum value upon which the normalization parameter depends is determined as follows:

[0083] Maximum wiring length In this embodiment, the theoretical maximum unfolded length of the internal wiring channel of the target robot's robotic arm is used as the reference. For example, all potential wiring paths can be extracted from a 3D design model, and the maximum length can be taken.

[0084] Maximum path wiring density In this embodiment, Defined as the maximum number of equivalent standard enameled flat wires that can be accommodated at the minimum cross-section of the main cable conduit inside the robot arm, calculated according to industry standards (such as a cable fill factor not exceeding 35%).

[0085] Maximum number of path joints In this embodiment, The total number of joints the robot traverses from its base to the target motor mounting position is directly taken. For a six-joint robot, the J_max of the cable connected to the end joint motor is 5.

[0086] Understandably, by normalizing specific physical parameters (length, density, quantity) relative to their theoretically maximum allowable values, topological features of different scales and dimensions are successfully transformed into dimensionless scale values ​​between 0 and 1. This makes parameters from different robot models and wiring schemes comparable and contributes fairly to the final installation complexity assessment.

[0087] Specifically, the installation complexity is compared with a preset complexity threshold to determine the alternation period for applying the anti-winding bending aging performance test. The alternation period for applying the anti-winding bending aging performance test is inversely proportional to the installation complexity.

[0088] In this real-time scenario, a preset complexity threshold is set. ,when At that time, the alternation cycle is adjusted and shortened, specifically as follows:

[0089] The alternation period T is calculated using the following formula:

[0090] ,

[0091] in, The basic cycle is set to 24 hours in this embodiment, and k is a proportional coefficient, which is set to 10 hours per unit of installation complexity in this embodiment.

[0092] Please see Figure 2 As shown, Figure 2 This is a flowchart illustrating the steps for determining assembly compatibility in an embodiment of the present invention.

[0093] Specifically, in step S2, the process of determining the assembly fit includes:

[0094] Step S21: Determine the ratio of the average breakdown voltage to the rated operating voltage as the first ratio.

[0095] Step S22: Determine the ratio of average breakdown voltage to peak voltage as the second ratio.

[0096] Step S23: Determine the ratio of the standard dielectric loss factor to the maximum dielectric loss factor as the third ratio.

[0097] Step S24: The weighted sum of the first ratio, the second ratio, and the third ratio is determined as the assembly matching degree.

[0098] In this embodiment of the invention, the weighted summation formula for the assembly matching degree M is:

[0099] ,

[0100] in, The first ratio, The second ratio, The third ratio, The influence weight of the first ratio, The influence weight of the second ratio, As the influence weight of the third ratio, in this embodiment, considering that the peak voltage impact force has the greatest impact on anti-aging performance, it is set to... The maximum values ​​are α=0.3, β=0.5, and γ=0.2.

[0101] It is understandable that M>1 indicates that there is a margin in insulation performance, while M<1 indicates that there is a risk.

[0102] Specifically, in step S3, the process of determining the electrical anti-aging test strength parameters includes:

[0103] Step S31: Compare and analyze the assembly matching degree with the preset assembly matching degree threshold to determine the adaptation electrical stress coefficient, wherein the adaptation electrical stress coefficient is directly proportional to the assembly matching degree.

[0104] Step S32: The product of the adaptive electrical stress coefficient and the peak voltage is determined as the applied voltage for the electrical anti-aging test strength parameter.

[0105] In this embodiment, the electrical stress coefficient is adapted. The relationship with the assembly matching degree M is as follows:

[0106] ,

[0107] In this embodiment, =1.5, indicating excellent matching and the ability to apply lower stress;

[0108] Characterizing critical matching requires the application of high stress;

[0109] .

[0110] Specifically, in step S4, the comprehensive requirement value is determined based on the installation complexity and assembly matching degree, and the comprehensive requirement value and the stress duration corresponding to the alternating cycle are correlated and calculated to obtain the anti-aging requirement parameter.

[0111] Specifically, in step S4, the process of determining the bending aging test parameters includes:

[0112] Step S41: Compare and analyze the anti-aging requirement parameter with the preset anti-aging requirement parameter threshold to determine the base bending radius, wherein the base bending radius is directly proportional to the anti-aging requirement parameter.

[0113] Step S42: Correct the basic bending radius based on the number of path joints to obtain the bending radius of the bending aging test parameters, wherein the bending radius is inversely proportional to the joint density.

[0114] In this embodiment of the invention, the anti-aging requirement parameter N is calculated using the following formula:

[0115] ,

[0116] in, Weighting the impact of installation complexity. The influence weight of assembly matching degree reflects the relative importance of installation complexity and assembly matching degree. In this embodiment, =0.6, =0.4.

[0117] Associated alternating periodic duration :

[0118] ,

[0119] in, The duration of a single full-area test is 1 hour in this example.

[0120] Basic bending radius Calculated using the following formula:

[0121] ,

[0122] in, The minimum allowable bending radius is determined according to the gauge.

[0123] In this embodiment, the scaling factor is used. =0.5mm / unit anti-aging requirement parameter.

[0124] The bending radius is obtained by correcting the joint density of the base. The formula is:

[0125] ,

[0126] in, As a joint density influencing factor, in this embodiment, it is set as follows: The higher the joint density, the smaller the bending radius, simulating more demanding bending scenarios.

[0127] Calculate the bending frequency using the following formula. :

[0128] ,

[0129] in, Based on the base frequency, in this embodiment, it is set =0.5Hz;

[0130] As a proportionality coefficient, in this embodiment, it is set to... =0.2Hz / unit installation complexity.

[0131] Understandably, this section uses multi-level formulaic calculations to gradually map abstract design parameters such as installation complexity C, assembly matching degree M, and number of joints J into specific, executable core parameters for bending aging tests—bending radius. N and It realizes the transformation from static parameters to dynamic stress requirements;

[0132] The formula introduces an adjustable proportional coefficient m, which enables linear control of the test severity; the final modified formula accurately captures the amplification effect of the robot joint distribution on local bending stress.

[0133] Please see Figure 3 As shown, Figure 3 A flowchart illustrating the steps for determining the deviation of test indicators in an embodiment of the present invention.

[0134] Specifically, in step S6, the process of determining the deviation of the test index includes:

[0135] Step S61: Calculate the relative rate of change of the real-time acquired partial discharge quantity relative to its initial test value, and use it as the first deviation component;

[0136] Step S62: Calculate the absolute change of the real-time acquired dielectric loss factor relative to its initial test value, as the second deviation component;

[0137] Step S63: Perform a weighted summation of the first deviation component and the second deviation component to determine the real-time deviation of the test index.

[0138] In this embodiment of the invention, the first deviation component Δq is calculated using the following formula:

[0139] ,

[0140] in, This represents the initial partial discharge quantity;

[0141] The partial discharge quantity measured at the current moment is expressed in picocoulombs.

[0142] The initial partial discharge quantity at the start of the test, in picocoulombs;

[0143] This component reflects the relative rate of change of partial discharge activity over aging time; the larger the value, the more significant the development of air gaps or defects inside the insulation.

[0144] Second deviation component Δtanδ:

[0145] ,

[0146] Deviation of test metric D(t):

[0147] ,

[0148] In this embodiment, It is 0.6. It is 0.4;

[0149] The dielectric loss factor measured at the current time t;

[0150] The initial dielectric loss factor at the start of the test;

[0151] This component reflects the absolute change in the overall dielectric loss of the insulating material. An increase in its value means that the overall heating trend of the insulation intensifies and the insulation performance decreases.

[0152] It is understandable that the weighting coefficients are set based on:

[0153] During the aging process of corona-resistant enameled flat wire, partial discharge is an early and sensitive indicator of the development of local insulation defects. Its rate of change can more directly and quickly reflect the corona aging and electrical treeing, and therefore it is given a higher weight. =0.6;

[0154] The dielectric loss factor reflects the combined changes in overall insulation polarization and conductivity loss. Its changes are relatively slow, but it can reflect the overall trend of insulation performance deterioration. Therefore, it is given an appropriate weight wδ=0.4.

[0155] This weighting is based on statistical analysis of a large amount of previous aging test data, and can comprehensively characterize the aging state of the insulation system while taking into account both sensitivity and stability.

[0156] Please see Figure 4 As shown, Figure 4 This is a flowchart illustrating the steps for determining the end of the aging performance evaluation based on the slope of the deviation curve, as described in an embodiment of the present invention.

[0157] Specifically, in step S7, determining the end of the aging performance evaluation process based on the slope of the deviation curve includes:

[0158] Step S711: During the aging performance evaluation process, continuously calculate the instantaneous slope of the deviation curve within a preset time window;

[0159] Step S712: Determine whether the absolute value of the instantaneous slope is less than the preset slope stabilization threshold multiple times consecutively.

[0160] In step S713, if the conditions of step S72 are met, the material aging state is determined to have entered a stable stage, the aging performance evaluation ends, and the deviation of the test index at this time is recorded as the final deviation.

[0161] In this embodiment of the invention, the instantaneous slope s(t) is calculated using the following formula:

[0162] ,

[0163] The constraint condition is that the number of consecutive n iterations, in this embodiment n=5, satisfies the condition. That is, satisfying the condition 5 times consecutively. The aging curve is judged to be normal and sustainable; however, it fails to meet the requirements for five consecutive times. The aging performance evaluation is now complete.

[0164] Slope stability threshold In this embodiment, we take Based on the typical slope of the aging curve as it enters the plateau phase.

[0165] Specifically, in step S7, the process of determining the output aging performance evaluation result based on the final deviation when the aging performance evaluation is completed includes:

[0166] Step S721: The final deviation is matched and compared with the pre-stored performance threshold ranges for different motor specifications, wherein the performance threshold ranges are related to the power level of the motor and the allowable installation complexity.

[0167] Step S722: Based on the result that the final deviation belongs to the threshold range corresponding to the original target motor, it is determined that the aging performance evaluation is qualified and the specifications of the corona-resistant enameled flat wire matching motor remain unchanged.

[0168] Step S723, or, based on the result that the final deviation does not belong to the threshold range corresponding to the original target motor, if the final deviation is greater than the lower limit of the threshold range corresponding to the higher power motor, determine to adjust the specifications of the corona-resistant enameled flat wire matching motor upwards; if the final deviation is greater than the lower limit of the threshold range corresponding to the lower power motor, determine to adjust the specifications of the corona-resistant enameled flat wire matching motor downwards; otherwise, determine that the aging performance evaluation is unqualified.

[0169] In this embodiment of the invention, the final deviation matching and specification adjustment are shown in Table 1. Table 1 is a preset table of threshold ranges for the final deviation matching and specification adjustment.

[0170] Table 1

[0171] Example

[0172] Test objects and basic conditions

[0173] Test wire: F-grade corona resistant enameled flat wire produced in the same batch, with nominal conductor size of 2.0mm × 4.0mm and insulation thickness of 0.2mm.

[0174] Target motors: Two servo motors for industrial robots.

[0175] Motor A (High Operating Condition): Used for the end joint of a six-joint robot, rated voltage 480V, peak voltage 720V, maximum permissible dielectric loss factor 0.01.

[0176] Motor B (Low Operating Condition): Used for the waist rotary joint of a four-joint robot, rated voltage 400V, peak voltage 600V, maximum permissible dielectric loss factor 0.012.

[0177] Wiring topology (extracted from 3D model):

[0178] Option X (High Complexity): Used for motor A, the path needs to pass through 5 joints, the connection length is 3.5 meters, and the path has a high proportion of dense sections with multiple parallel cables.

[0179] Option Y (low complexity): Used for motor B, the path passes through 2 joints, the connection length is 1.8 meters, and the wiring is relatively loose.

[0180] Example 1: Using the method of the present invention to evaluate the compatibility between the wire and motor A (Scheme X).

[0181] 1. Parameter determination (according to the method of this invention):

[0182] Installation complexity C: Calculated C = 0.82 (above the threshold) ).

[0183] Alternation period T: T = 24 - 10 × (0.82 - 0.6) = 21.8 hours.

[0184] Assembly matching degree M: Calculated as M=1.15.

[0185] Electrical stress coefficient k_E: Since M=1.15 is within the threshold range, the calculated value is... =1.1.

[0186] Apply voltage .

[0187] Anti-aging requirements parameters .

[0188] Final bending radius Calculated (Much smaller than the standard minimum bending radius of 15mm for wire).

[0189] Bending frequency f: calculated as f = 0.5 + 0.2 × 0.82 = 0.66 Hz.

[0190] 2. Testing Process and Termination:

[0191] Accelerated aging tests were conducted under alternating cycles of 792V AC voltage and reciprocating bending stress at a radius of 8.2mm and a frequency of 0.66Hz for 21.8 hours. The deviation D(t) was monitored and calculated in real time. After 312 hours of testing, the instantaneous slope of the deviation curve was less than the stable threshold for five consecutive calculated values. =1e-4), indicating the test has entered the aging stability phase, and the test is terminated. Record the final deviation. =0.18.

[0192] 3. Evaluation Results:

[0193] Query the pre-stored threshold range (the threshold range for high-power / high-complexity motors is D≤0.20).

[0194] because =0.18 falls within this range, the evaluation conclusion is qualified, and the wire specifications match motor A, so no adjustment is required.

[0195] III. Example 2: Evaluating the compatibility between the wire and motor B (Scheme Y) using the method of the present invention.

[0196] 1. Parameter determination (according to the method of this invention):

[0197] Installation complexity C: Calculated C = 0.35 (below the threshold) ).

[0198] Alternation period T: The basic period T = 24 hours is adopted.

[0199] Assembly matching degree M: Calculated as M=1.40.

[0200] Electrical stress coefficient Because M=1.40 is relatively high, the calculated value is... =0.9.

[0201] Apply voltage .

[0202] Anti-aging requirements parameters Calculated .

[0203] Final bending radius Calculated =13.5mm (close to the standard minimum bending radius).

[0204] Bending frequency f: calculated to be f=0.57Hz.

[0205] 2. Testing Process and Termination:

[0206] Accelerated aging tests were conducted under alternating 540V AC voltage and reciprocating bending stress at a radius of 13.5mm and a frequency of 0.57Hz, with a 24-hour cycle. After 480 hours of testing, the deviation curve entered a stable phase. The final deviation was recorded as D_final = 0.09.

[0207] 3. Evaluation Results:

[0208] Query the pre-stored threshold range (the threshold range for medium power / medium-low complexity motors is D≤0.15). Because... =0.09 is far below the upper limit, so the evaluation conclusion is not only qualified, but also suggests that it can be adjusted upwards to adapt to a motor with a higher motor power level.

[0209] Comparative example: using traditional fixed-condition testing methods

[0210] Test conditions: Tests are conducted under unified stringent conditions in accordance with current common industry test specifications.

[0211] Electrical aging: Apply a constant AC voltage of 800V (taking the common high value).

[0212] Mechanical bending: Adopt a fixed bending radius of 8mm and a fixed frequency of 0.5Hz.

[0213] Alternating cycle: Fixed at 24 hours.

[0214] Termination condition: Fixed test duration of 400 hours.

[0215] Test results:

[0216] For wire A (used in motor A): D(400h) = 0.22 at the end of the test. Since it exceeds the common qualified line (usually set as D = 0.20), it is judged as unqualified. This may lead to over-conservative design, replacement of higher-specification wires, and cost waste.

[0217] For wire B (used in motor B): D(400h) = 0.14 at the end of the test. It is judged as qualified. However, this test fails to identify its large performance margin under low working conditions, missing the opportunity for cost optimization.

[0218] V. Comparative Analysis and Conclusion

[0219]

[0220] Summary: Through the comparative analysis of the examples and comparative examples, it is fully demonstrated that the method for evaluating the corona-resistant enameled rectangular wire aging performance of the motor for robots provided by the present invention can dynamically customize test conditions by introducing spatial topology parameters and electrical matching degrees, and can intelligently judge the test end point, significantly overcoming the inherent defects of the traditional fixed-condition test method such as disconnection from working conditions, one-sided evaluation, and low efficiency. The present invention ensures that the evaluation result is highly correlated with the expected life of the cable under the actual service conditions of a specific robot motor, providing a powerful technical tool for achieving precise matching, ensuring reliability, and optimizing costs.

[0221] So far, the technical solution of the present invention has been described in combination with the preferred embodiments shown in the drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or replacements to the relevant technical features, and the technical solutions after these changes or replacements will fall within the protection scope of the present invention.

[0222] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors, characterized in that, include: Spatial topology parameters of the motor wiring are extracted from the robot's 3D design model. The installation complexity is determined based on the spatial topology parameters to apply corresponding anti-electrical aging performance tests during the aging performance evaluation process. The alternation cycle of applying anti-winding bending aging performance tests is also determined. The spatial topology parameters include connection length, path wiring density, and the number of path joints. Based on the production specifications of the enameled flat wire and the electrical specifications of the compatible motor, the assembly matching degree is determined. The production specifications include the average breakdown voltage and the standard dielectric loss factor, and the electrical specifications include the rated operating voltage, the peak voltage, and the maximum dielectric loss factor. The matching electrical stress coefficient is determined based on the assembly matching degree, and the applied voltage for the electrical anti-aging test strength parameter is determined based on the electrical stress coefficient and the peak voltage. Based on the installation complexity, the assembly matching degree and the alternation cycle, the anti-aging requirement parameters are determined, and the actual bending radius of the bending aging test parameters is determined in combination with the number of path joints. The bending frequency of the bending aging test parameters is determined based on the installation complexity, wherein the bending frequency is directly proportional to the installation complexity. Based on the test index parameters obtained in real time during the aging performance evaluation process, the deviation of the test index is determined to fit the deviation curve. The test index parameters include partial discharge quantity and dielectric loss factor. Based on the slope of the deviation curve, the aging performance evaluation is performed, and based on the final deviation of the aging performance evaluation, the output aging performance evaluation result is determined. The aging performance evaluation based on the slope of the deviation curve includes: During the aging performance evaluation process, the instantaneous slope of the deviation curve within a preset time window is continuously calculated; Determine whether the absolute value of the instantaneous slope is less than the preset slope stabilization threshold multiple times consecutively to determine that the material aging state has entered a stable stage, end the aging performance evaluation, and record the deviation of the test index at this time as the final deviation.

2. The method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to claim 1, characterized in that, The installation complexity is determined by a weighted sum of the normalized connection length, path wiring density, and number of path joints.

3. The method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to claim 2, characterized in that, The process of determining the alternating cycle for applying the anti-winding bending aging performance test includes: The installation complexity is compared and analyzed with a preset complexity threshold; Based on the result that the installation complexity is less than the preset complexity threshold, it is determined to adjust and shorten the alternation cycle; The alternation cycle of the anti-winding bending aging performance test is inversely proportional to the installation complexity.

4. The method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to claim 3, characterized in that, The process of determining the assembly matching degree includes: The ratio of the average breakdown voltage to the rated operating voltage is determined as the first ratio. The ratio of the average breakdown voltage to the peak voltage is determined as the second ratio. The ratio of the standard dielectric loss factor to the maximum dielectric loss factor is determined as the third ratio. The weighted sum of the first ratio, the second ratio, and the third ratio is determined as the assembly matching degree.

5. The method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to claim 4, characterized in that, The process of determining the applied voltage includes: The assembly matching degree is compared and analyzed with a preset assembly matching degree threshold; Based on the result that the assembly matching degree is greater than or equal to the first preset assembly matching degree threshold, or the assembly matching degree is less than or equal to the second preset assembly matching degree threshold, the first adaptive electrical stress coefficient is determined to be adopted. Based on the result that the assembly matching degree is less than the first preset assembly matching degree threshold, the second adaptive electrical stress coefficient is determined to be used. The product of the adaptive electrical stress coefficient and the peak voltage is determined as the applied voltage; Wherein, the adaptive electrical stress coefficient is directly proportional to the assembly matching degree, the first preset assembly matching degree threshold is less than the second preset assembly matching degree threshold, and the first adaptive electrical stress coefficient is less than the second adaptive electrical stress coefficient.

6. The method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to claim 5, characterized in that, The comprehensive requirement value is determined based on the installation complexity and the assembly matching degree, and the comprehensive requirement value is correlated with the stress duration corresponding to the alternation cycle to obtain the anti-aging requirement parameter.

7. The method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to claim 6, characterized in that, The process of determining the bending aging test parameters includes: The anti-aging requirement parameters are determined based on the installation complexity and assembly compatibility. The anti-aging requirement parameter is compared and analyzed with the preset anti-aging requirement parameter threshold to determine the base bending radius, wherein the base bending radius is directly proportional to the anti-aging requirement parameter. The basic bending radius is corrected based on the number of path joints to obtain the bending radius of the bending aging test parameters, wherein the bending radius is inversely proportional to the joint density.

8. The method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to claim 7, characterized in that, The process of determining the deviation of the test metric includes: The relative rate of change of the real-time acquired partial discharge quantity relative to its initial test value is calculated and used as the first deviation component; The absolute change of the real-time acquired dielectric loss factor relative to its initial test value is calculated as the second deviation component. The first deviation component and the second deviation component are weighted and summed to determine the real-time test index deviation.

9. The method for evaluating the aging performance of corona-resistant enameled flat wire for robot motors according to claim 8, characterized in that, The process of determining the output aging performance evaluation result based on the final deviation of the aging performance evaluation includes: The final deviation is matched and compared with the pre-stored performance threshold ranges for different motor specifications, wherein the performance threshold ranges are related to the power level of the motor and the allowable installation complexity. Based on the result that the final deviation belongs to the threshold range of the final deviation of the original target motor, it is determined that the aging performance evaluation is qualified, and the specifications of the corona-resistant enameled flat wire matching motor remain unchanged. Alternatively, based on the result that the final deviation does not belong to the threshold range corresponding to the original target motor, If the final deviation is greater than the lower limit of the threshold range corresponding to the higher power motor, then the specifications of the corona-resistant enameled flat wire matching motor will be adjusted upwards. If the final deviation is greater than the lower limit of the threshold range corresponding to the lower power motor, the specifications of the corona-resistant enameled flat wire matching motor will be adjusted downwards; otherwise, the aging performance evaluation will be deemed unqualified.

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