Permanent magnet semi-direct drive wind power motor rotor assembling and manufacturing system

Abstract

The invention discloses a permanent magnet semi-direct drive wind power motor rotor assembling and manufacturing system, and relates to the technical field of generator rotor assembling. The system comprises a logistics conveying mechanism, a magnetizing device, a magnetizing lower pressing head device, a rotor rotating platform, an assembling robot, a magnetic pole clamp, a visual positioning subsystem and an installable bolt mounting robot. The core point of the invention is assembly line type single magnetic pole integral magnetizing detection and robot grabbing assembly, accurate grabbing is realized through cooperation of a round nut and a conical clamp, double-vision positioning and alignment of magnetic poles and rotor support binding holes are realized, and the robot replaces manpower to overcome magnetic attraction force for operation. According to the invention, the problems of high safety risk, low efficiency, poor precision and high cost of traditional assembly of strong magnets can be solved, safe assembly of the rotor is realized, the assembly period of a single rotor is shortened by more than 50%, the magnetic flux deviation is reduced to be within 2%, the packaging and labor cost is reduced, and the method is suitable for flexible production of rotors of multiple specifications.

Description

Technical Field

[0001] This invention relates to the field of wind turbine rotor assembly technology, and more specifically to a permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system. Background Technology

[0002] The rotor of a permanent magnet semi-direct drive wind turbine is a core power component. Its structure mainly consists of key components such as a rotor support (yoke), pole boxes, tension screws, pole plates, bolts, and nuts. The rotor support has pre-set pole mounting holes for precise assembly of the poles to the support. The pole boxes encapsulate permanent magnets, and multiple pole boxes are stacked axially to form a complete row of poles. The rotor requires multiple rows of these poles to form the motor's magnetomotive force source, and the quality of this assembly directly determines the motor's output performance and operational stability.

[0003] Currently, the mainstream assembly process for permanent magnet semi-direct drive rotors is mainly "pre-magnetization of pole box components + manual assisted installation". This technical solution is typically represented by the content disclosed in patent number CN114498993B. The specific process is as follows: First, the independent pole box components are pre-magnetized to give the pole box a preset magnetic field strength. Then, the pre-magnetized pole box components are installed one by one into the corresponding mounting holes of the rotor bracket by manual assistance with simple tools (such as lifting clamps, positioning rods, etc.). Finally, the overall assembly is completed by tightening the tensioning screws and fixing the pole plate.

[0004] However, this traditional assembly method has significant drawbacks in actual industrial production, mainly in the following aspects: 1. Significant personnel safety risks: After pre-magnetization, the magnetic pole box assembly generates a strong magnetic field. The magnetic field strength on the surface of a single magnetized magnetic pole box can reach thousands of Gauss, and it has strong adsorption properties. During manual installation, operators need to be in close contact with the strong magnetic components. If the magnetic pole box accidentally shifts or collides due to magnetic field adsorption, it may cause physical injuries such as squeezing and scratches to the human body. In fact, the strong magnetic field interference may even pose a life-threatening threat to personnel carrying medical devices such as pacemakers, making safety protection extremely difficult. 2. Low assembly efficiency: The rotor typically has dozens of rows of magnetic poles (generally 16-32 rows depending on the motor power). Each row of magnetic poles is composed of multiple stacked pole boxes, and each magnetized pole box has the characteristic of attracting each other or attracting metal tools. During manual installation, extra time is required to avoid magnetic interference between the poles and adjust the alignment of the pole boxes. The assembly cycle for a single rotor can be as long as 8-12 hours, which is difficult to meet the needs of mass production. 3. Difficulty in controlling assembly precision: Strong magnetic attraction can cause problems such as "offset" and "tilt" of the pole box during installation. It is difficult to accurately control the coaxiality of the pole box and the rotor bracket mounting holes manually, which can easily lead to uneven air gaps between the poles. At the same time, the mutual attraction of pole boxes may cause magnetic circuit disorder inside the permanent magnet, affecting the consistency of the magnetic field of the poles, ultimately reducing the motor's operating efficiency and increasing energy consumption and noise. 4. High overall production costs: On the one hand, the pre-magnetized magnetic pole boxes need to be transported and stored using anti-magnetic packaging (such as aluminum shielding boxes, magnetic rubber pads, etc.) to avoid magnetic field attenuation or adsorption of impurities. The packaging cost is more than 30% higher than that of unmagnetized parts. On the other hand, manual installation requires professional anti-magnetic tools and safety protection equipment. In addition, the operation pace needs to be reduced due to safety risk control, which leads to an increase in unit labor cost and low overall production efficiency.

[0005] In addition, another non-mainstream assembly solution exists in the industry – “rotor assembly followed by pole-by-pole magnetization.” This involves first installing all the unmagnetized pole box assemblies onto the rotor bracket, completing the overall rotor assembly, and then magnetizing each pole on the rotor one by one using a magnetization device. However, this solution also has significant drawbacks: First, during the magnetization process, the magnetized poles can cause magnetic field interference to adjacent poles to be magnetized, resulting in inconsistent magnetic flux density among the poles, with deviations reaching 5%-8%, affecting the stability of the motor's output torque. Second, the rotor is large in size (outer diameter typically 1400-3000mm, weight 3-15t), requiring precise positioning of each pole during magnetization, making the operation complex and time-consuming, with a single rotor magnetization cycle exceeding 4 hours, making it difficult to adapt to efficient production lines. Third, the rotor will experience axial or radial displacement due to magnetic force during magnetization, requiring additional heavy-duty fixing mechanisms, increasing equipment investment costs.

[0006] In summary, existing assembly technologies, whether "manual installation after pre-magnetization" or "polar-by-polar magnetization after overall assembly," suffer from high safety risks, low efficiency, poor precision, and high costs. They are insufficient to meet the production requirements of large-scale, high-precision, and high-safety permanent magnet semi-direct drive wind turbine rotors. A disruptive assembly technology solution is urgently needed to break through the industry bottleneck. Summary of the Invention

[0007] To address the deficiencies and shortcomings of the existing technologies, this invention provides a permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system. The purpose of this invention is to solve the safety risks and low efficiency of "manual installation after pre-magnetizing the magnetic pole box assembly", as well as the large magnetic flux measurement deviation and complex operation of "magnetizing the rotor pole by pole after overall assembly", and to achieve safe, efficient and high-precision batch assembly of rotors.

[0008] The rotor assembly and manufacturing system of this invention includes: unmagnetized magnetic poles (with round nuts at both ends for easy positioning), a flexible and adaptable material conveying mechanism, a magnetizing device with automatic magnetic flux detection and a magnetizing pressure head device, a high-precision rotor rotation platform (or support frame), a heavy-duty assembly robot, a conical open magnetic pole clamp (adapted to the round nuts), and a dual-station visual recognition and positioning system. It can also be equipped with a bolt installation robot. The core invention points are: streamlined, single-pole overall magnetization detection, robot gripping and assembly; precise gripping achieved through the cooperation of the round nuts and conical clamps; visual recognition aligning the magnetic poles with the rotor support mating holes; and robot installation replacing manual labor to overcome magnetic attraction.

[0009] The assembly and manufacturing system of this invention achieves the following: avoiding the risk of injury from strong magnetic fields and ensuring personnel safety; reducing the assembly cycle of a single rotor by more than 50% and adapting to mass production; reducing magnetic field interference by magnetizing individual magnetic poles and making magnetic flux measurement more accurate; improving assembly accuracy through visual positioning and fixture coordination and ensuring stable motor operation; eliminating the need for pre-magnetized anti-magnetic packaging and reducing costs; and adapting the system to rotors of different specifications, providing flexible production capabilities.

[0010] To address the problems existing in the prior art, the present invention is achieved through the following technical solution.

[0011] This invention provides a permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system, which includes a material conveying mechanism, a magnetizing device, a magnetizing pressing head device, a rotor rotating platform, an assembly robot, a magnetic pole clamp, and a vision positioning subsystem. The material conveying mechanism is used to position and convey unmagnetized magnetic poles; The magnetizing device is located above the logistics conveying mechanism and is used to magnetize the unmagnetized magnetic poles that are positioned and conveyed by the logistics conveying mechanism. The magnetizing pressure head device is located below the magnetizing device and is used to cooperate with the magnetizing device to magnetize the unmagnetized magnetic poles that are positioned and conveyed by the material conveying mechanism. The rotor rotation platform is used to fix the rotor support to which the magnetic poles are to be installed; The assembly robot is located between the logistics conveying mechanism and the rotor rotating platform, and is used to assemble the magnetized magnetic poles onto the rotor support on the rotor rotating platform. The magnetic pole clamp is mounted on the execution end of the assembly robot and is used to hold the magnetic poles after the overall magnetization is completed. The visual positioning subsystem includes a first visual acquisition component and a second visual acquisition component. The first visual acquisition component is mounted on the logistics conveying mechanism and is located below the picking station where the assembly robot picks up the magnetized magnetic poles. The first visual acquisition component is used to acquire the positioning features of the outer circle contour of the magnetized magnetic poles and the positioning features of the magnetic pole box mating hole. The second vision acquisition component is mounted on the execution end of the assembly robot and is used to acquire the positioning features of the outer circle contour of the magnetic poles after the overall magnetization is completed, the positioning features of the magnetic pole engagement holes, and the positioning features of the engagement holes on the rotor support. With the assistance of the vision positioning subsystem, the assembly robot uses the magnetic pole gripper at its execution end to pick up the magnetized magnetic poles transported by the logistics conveying mechanism and aligns the magnetic pole engagement holes on the picked-up magnetic poles with the engagement holes on the rotor bracket.

[0012] Further preferably, the assembly also includes a bolt installation robot, which is located on the rotor rotating platform side. The bolt installation robot is configured to tighten the engagement bolts on the rotor support after the assembly robot aligns the magnetic pole engagement hole on the picked-up magnetic pole with the engagement hole on the rotor support, so as to fix the magnetic pole and the rotor support together.

[0013] Further preferably, the magnetic pole includes several non-magnetized magnetic pole box assemblies, pressure plates, tension screws, and nuts; the magnetic pole box assembly includes a magnetic pole box and several magnets, the magnetic pole box is provided with a receiving cavity for accommodating magnets, several magnets are placed into the receiving cavity and fixed with glue to form the magnetic pole box assembly; several magnetic pole box assemblies are stacked together and connected in series by pressure plates at both ends and tension screws and nuts to form the magnetic pole.

[0014] More preferably, the magnetic pole box is composed of several magnetic pole pieces joined together by bonding or fastening.

[0015] More preferably, the magnetic pole includes several magnetic pole pieces, magnets, tension screws, pressure plates and nuts. The magnetic pole pieces are provided with magnet slots. Several magnetic pole pieces are stacked together, and magnets are inserted into the magnet slots of the stacked magnetic pole pieces. The magnetic pole is formed by the pressure plates at both ends, the tension screws and nuts.

[0016] More preferably, the magnetizing device includes a mounting bracket, a coil support base, and an upper hydraulic mechanism. The upper hydraulic mechanism is mounted on the upper end of the mounting bracket, and the coil support base is mounted on the upper hydraulic mechanism. The upper hydraulic mechanism drives the coil support base to move up and down reciprocally. The coil support base is provided with a receiving groove for accommodating unmagnetized magnetic poles, and a magnetizing coil is embedded in the side wall of the receiving groove.

[0017] More preferably, the magnetizing lower pressure head device includes a lower hydraulic mechanism and a tooling fixture. The tooling fixture is mounted on the lower hydraulic mechanism, which is mounted on a mounting bracket. The lower hydraulic mechanism drives the tooling fixture to move up and down reciprocally. The tooling fixture is provided with grooves for accommodating the two ends of the unmagnetized magnetic poles. A support platform is provided between the two grooves. The upper surface of the support platform is an arc surface adapted to the lower surface of the magnetic pole.

[0018] More preferably, the magnetic pole clamp includes a support frame and a conical opening limiting block. The support frame is provided with a first picking arm, a second picking arm, and a clamping drive for controlling the relative movement of the first picking arm and the second picking arm. The conical opening limiting block is respectively disposed on the first picking arm and the second picking arm. The conical opening limiting block matches the specification of the nut on the magnetic pole, and the distance from the end face of the conical opening limiting block to the mating surface of the tensioning screw on the magnetic pole is greater than 0.

[0019] More preferably, the clamp drive component is a cylinder.

[0020] Compared with the prior art, the beneficial technical effects of the present invention are as follows: 1. This invention abandons the traditional "pre-magnetization of magnetic pole boxes" process. Unmagnetized magnetic poles have no strong magnetic characteristics during logistics transportation and pre-installation stages. Operators do not need to come into contact with components with surface magnetic field strength of thousands of gauss. This eliminates physical damage such as squeezing and scratches caused by magnetic pole adsorption from the source, as well as the life threat of strong magnetic fields to carriers of medical devices such as pacemakers. The difficulty of safety protection is reduced from "high-intensity control" to the level of "conventional industrial protection".

[0021] 2. This invention uses a robot to replace manual labor and isolate magnetic interference. The heavy-duty assembly robot (with repeatability within 1mm and path accuracy within 1mm) uses a special magnetic pole clamp to grasp and assemble the magnetized magnetic poles throughout the process. It can stably overcome the magnetic attraction between magnetic poles and the attraction force on metal parts, avoid the loss of control of operation caused by sudden magnetic displacement during manual operation, and realize "unmanned assembly" in a strong magnetic environment.

[0022] 3. The magnetization process of this invention is stable. The magnetization pressing head device drives the tooling fixture through the lower hydraulic mechanism. It utilizes the arc support platform and the grooves at both ends that are adapted to the lower surface of the magnetic pole to achieve reliable fixation of the magnetic pole at the moment of magnetization, avoiding axial / radial displacement of the magnetic pole caused by the magnetic field force during magnetization, and eliminating the risk of component collision during the magnetization stage.

[0023] 4. The assembly manufacturing system provided by this invention has high assembly efficiency, realizing the leap from "inefficient manual labor" to "automated assembly line". It adopts the "single magnetic pole assembly line magnetization-inspection-assembly" mode, integrating the flexible conveying of the logistics conveyor mechanism, the automatic magnetization and magnetic flux detection of the magnetization device, and the high-speed grasping of the robot (operating speed of more than 1m / s). The assembly cycle of a single rotor is shortened by more than 50% compared with the traditional 8-12 hours, breaking through the efficiency bottleneck of mass production.

[0024] 5. The magnetization device incorporates a magnetic flux measurement coil, enabling simultaneous magnetic flux detection upon completion of magnetization, eliminating the need for additional steps to verify magnetic field strength. The visual positioning subsystem uses dual visual acquisition components (collecting magnetic pole features at the logistics end and collecting features of the magnetic pole and rotor support at the robot end) for simultaneous comparative analysis, saving the time-consuming manual adjustment of magnetic pole alignment and improving process efficiency by over 40%. The "independent magnetization of individual magnetic poles" scheme avoids the magnetic field interference of already magnetized poles on adjacent unmagnetized poles in the traditional "magnetization pole by pole after overall assembly" method. Magnetic flux density deviation is reduced from 5%-8% to within 2%, ensuring the stability of the magnetic circuit of each pole, improving the uniformity of motor output torque, and reducing operating noise and energy consumption.

[0025] 6. The rotor rotation platform (or support frame) has a load-bearing capacity of up to 20t, with end face runout ≤0.2mm and radial runout ≤0.1mm. It is equipped with an automatic alignment and positioning fixture and an angle locking device, which can realize rotor inching / continuous arbitrary rotation and precise angle locking. There is no need for manual pushing or calibration of the rotor position. The attitude adjustment time for single-row magnetic pole installation is shortened from the traditional 15-20 minutes to 3-5 minutes.

[0026] 7. The magnetic pole clamp of the present invention precisely matches the conical opening limiting block with the round nuts at both ends of the magnetic pole. Combined with the first vision acquisition component to acquire the features of the outer circle contour of the magnetic pole and the clamping hole, and the second vision acquisition component to position the clamping hole of the rotor support, the coaxiality error between the clamping hole of the magnetic pole and the clamping hole of the rotor support is ≤0.1mm. This solves the problems of "offset" and "tilt" in traditional manual installation and ensures the uniformity of the air gap between the magnetic poles.

[0027] 8. The magnetic pole adopts a pre-assembled structure of "multi-pole box assembly (or lamination) + tension screw + nut". The magnet is fixed with glue and the bolt and nut are connected in series for positioning, avoiding the cumulative error when the magnetic pole box is installed separately in the traditional way. The assembly accuracy of the magnetic pole itself is improved by 30%, laying the foundation for the subsequent assembly accuracy.

[0028] 9. This invention eliminates the need for antimagnetic packaging (such as aluminum shielding boxes and magnetic rubber pads) for pre-magnetized pole boxes, reducing packaging costs by over 30% compared to traditional solutions. Unmagnetized poles do not require special magnetic shielding storage environments, increasing storage space utilization by 50% and reducing storage costs by 25%. Robots replace manual installation, eliminating the need for specialized antimagnetic tools (such as antimagnetic wrenches and gloves) and personnel safety equipment. A bolt installation robot (optional) replaces manual tightening of bolts, reducing labor costs per rotor by over 60% and avoiding the risk of torque deviation during manual tightening. The logistics conveying mechanism can adjust conveying parameters according to different specifications of unmagnetized poles. The rotor rotation platform (or support frame) is compatible with various rotors with outer diameters of 1400-3000mm and weights of 3-15t, eliminating the need for separate equipment for different rotor models and reducing repeated equipment investment costs by over 50%.

[0029] 10. This invention is adaptable to various magnetic pole structures (one being several magnetic pole box components + pressure plate + tension screw + nut, the magnetic pole box being composed of laminations bonded / fastened; the other being several magnetic pole laminations + magnets + tension screw + pressure plate + nut). By adjusting the conical opening specifications of the magnetic pole clamp and the conveying distance of the logistics conveying mechanism, it meets the magnetic pole assembly requirements of motors with different power ratings. The positioning clamp of the rotor rotating platform (or support frame) can be mechanically adjusted to adapt to rotor supports with different outer diameters and weights. Combined with the feature recognition algorithm of the mature visual positioning subsystem, it adapts to rotor supports with different hole distributions, achieving full coverage assembly of 1.5MW-6MW permanent magnet semi-direct drive rotors without replacing core equipment. The system supports modular integration of bolt installation robots, and can select "manual tightening" or "automatic robot tightening" modes according to production needs; at the same time, it can expand multiple sets of magnetization devices and robot workstations to achieve a step-by-step increase in production line capacity, adapting to different scenarios from small and medium batches to large-scale mass production. Attached Figure Description

[0030] Figure 1 This is a structural diagram of the rotor assembly and manufacturing system of the present invention; Figure 2 This is a schematic diagram of the rotor support structure of the present invention; Figure 3 This is a schematic diagram of the magnetic pole lamination structure. Figure 4 This is a schematic diagram of the magnetic pole box structure; Figure 5 This is a schematic diagram of the magnetic pole box assembly structure; Figure 6 This is a schematic diagram of the tension screw structure; Figure 7 This is a schematic diagram of the structure of a magnetic pole; Figure 8 This is a schematic diagram of the rotor magnetic pole assembly structure; Figure 9 A schematic diagram of the magnetization device and the magnetization pressure head device; Figure 10 A schematic diagram of the structure for magnetization in conjunction with the magnetization lower pressure head device; Figure 11 This is a schematic diagram of the rotor rotation platform. Figure 12 This is a schematic diagram of the magnetic pole clamp. Figure 13 A schematic diagram of the structure for assembling magnetic poles in cooperation with an assembly robot and a bolt installation robot; Figure 14 for Figure 13 A schematic diagram of direction B; Reference numerals: 1. Logistics conveying mechanism; 2. Magnetizing device; 3. Magnetizing lower pressure head device; 4. Rotor rotating platform; 5. Assembly robot; 6. Magnetic pole clamp; 7. Magnetic pole; 8. Rotor support; 9. Bolt installation robot; 10. Magnetic pole box assembly; 11. Pressure plate; 12. Tensioning screw; 13. Nut; 14. Magnet; 15. Receiving cavity; 16. Magnetic pole lamination; 17. Magnet slot; 18. Mounting bracket; 19. Coil support seat; 20. Upper hydraulic mechanism; 21. Magnetizing coil; 22. Receiving groove; 23. Lower hydraulic mechanism; 24. Tooling fixture; 25. Groove; 26. Support platform; 27. Arc surface; 28. Support frame; 29. ​​Conical opening limiting block; 30. First picking arm; 31. Second picking arm. Detailed Implementation

[0031] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] As a preferred embodiment of the present invention, please refer to the appendix to the specification. Figure 1 As shown, this embodiment discloses a permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system. The system includes a logistics conveying mechanism 1, a magnetizing device 2, a magnetizing pressing head device 3, a rotor rotating platform 4, an assembly robot 5, a magnetic pole clamp 6, and a vision positioning subsystem. The material conveying mechanism is used to position and convey the unmagnetized magnetic pole 7; The magnetizing device 2 is located above the logistics conveying mechanism 1 and is used to magnetize the unmagnetized magnetic poles 7 that are positioned and conveyed by the logistics conveying mechanism 1. The magnetizing pressure head device 3 is located below the magnetizing device 2 and is used to cooperate with the magnetizing device 2 to magnetize the unmagnetized magnetic poles 7 that are positioned and conveyed by the material conveying mechanism. The rotor rotation platform 4 is used to fix the rotor support 8 to which the magnetic pole 7 is to be installed; The assembly robot 5 is located between the logistics conveying mechanism 1 and the rotor rotating platform 4, and is used to assemble the magnetized magnetic poles 7 onto the rotor bracket 8 on the rotor rotating platform 4. The magnetic pole clamp 6 is mounted on the execution end of the assembly robot 5 and is used to clamp the magnetic pole 7 after the overall magnetization is completed. The visual positioning subsystem includes a first visual acquisition component and a second visual acquisition component. The first visual acquisition component is mounted on the logistics conveying mechanism 1 and is located below the picking station where the assembly robot 5 picks up the magnetized magnetic pole 7. The first visual acquisition component is used to acquire the positioning features of the outer circle contour of the magnetized magnetic pole 7 and the positioning features of the magnetic pole box mating hole. The second vision acquisition component is mounted on the execution end of the assembly robot 5 and is used to acquire the positioning features of the outer circle contour of the magnetic pole 7 after the overall magnetization is completed, the positioning features of the magnetic pole engagement hole, and the positioning features of the engagement hole on the rotor support 8. With the assistance of the vision positioning subsystem, the assembly robot 5 uses the magnetic pole gripper 6 at its execution end to pick up the magnetic pole 7 that has been fully magnetized and transported by the logistics conveying mechanism 1, and aligns the magnetic pole engagement hole on the picked-up magnetic pole 7 with the engagement hole on the rotor bracket 8.

[0033] As a specific implementation method of this embodiment, for the unmagnetized magnetic pole 7, there are at least two structural specifications. Structural specification one includes several magnetic pole box assemblies 10, pressure plates 11, tensioning screws 12 and nuts 13, as shown in the attached instruction manual. Figure 4 Appendix Figure 5 Appendix Figure 6 and attached Figure 7 As shown, the magnetic pole box assembly 10 includes a magnetic pole box and several magnets 14. The magnetic pole box has a receiving cavity 15 for accommodating the magnetizable magnets 14. Several magnetizable magnets 14 are placed into the receiving cavity 15 and fixed with glue to form the magnetic pole box assembly 10. Several magnetic pole box assemblies 10 are stacked together and connected in series by pressure plates 11 at both ends, tension screws 12, and nuts 13 to form the magnetic pole 7. Further details can be found in the appendix to the specification. Figure 3 As shown, the magnetic pole box is composed of several magnetic pole pieces 16 joined together by adhesive or snap-fit.

[0034] As an example of this embodiment, the magnetic pole box is formed by bonding or snap-fitting 3-5 silicon steel laminations with epoxy resin. The inside is provided with a cavity 15 for receiving magnets 14. 5-8 neodymium iron boron magnets 14 are placed into the cavity and fixed with anaerobic adhesive to form a single-pole magnetic pole box assembly 10. After 3-4 magnetic pole box assemblies 10 are stacked along the axial direction, they are connected and fixed in series by Q235 steel plate pressure plates 11 at both ends, M16-M20 grade tension screws 12 and round nuts 13 (the specifications are adapted to the subsequent conical clamps, and the outer diameter is 8-12mm larger than the bolt diameter) to form a complete magnetic pole 7.

[0035] Structural specification two includes several magnetic pole pieces 16, magnets 14, tension screws 12, pressure plates 11, and nuts 13, as shown in the attached instruction manual. Figure 3 and attached Figure 7As shown, the magnetic pole piece 16 is provided with a magnet slot 17. Several magnetic pole pieces 16 are stacked together, and magnets 14 are inserted into the magnet slots 17 of the stacked magnetic pole pieces 16. The magnetic pole 7 is formed by the pressure plates 11 at both ends, the tension screws 12 and the nuts 13. As an example, several magnetic pole pieces 16 (silicon steel sheets with a thickness of 0.35-0.5mm, and 2-4 magnet slots 17 are pre-set on the pieces) are stacked together. After stacking, the magnets 14 are inserted into the slots and spot-welded to fix them. The magnetic pole 7 is then formed by the pressure plates 11 at both ends, the tension screws 12 and the round nuts 13.

[0036] As another example of this embodiment, the logistics conveying mechanism 1 uses a chain pusher conveyor, which pushes the magnetic pole 7 for conveying. The width of the conveyor is adjusted according to the length of the magnetic pole 7 (500-1200mm), and the conveying speed is set to 0.5-1m / min. Guide baffles are installed on both sides of the conveying track (the spacing can be changed by adjusting bolts to adapt to magnetic poles 7 of different diameters). An installation slot is reserved at the pickup station below the track for fixing the first vision acquisition component. Openings are provided at the positions corresponding to the magnetization device 2 and the magnetization pressing head device 3 for the magnetization pressing head device 3 to pass through, so as to adapt to overall magnetization. After magnetization is completed, the magnetization pressing head device 3 is reset, and the magnetized magnetic pole 7 is placed on the track and continues to be pushed by the pusher.

[0037] As a preferred embodiment of the present invention, please refer to the appendix to the specification. Figure 9 and attached Figure 10 As shown, the magnetizing device 2 includes a mounting bracket 18, a coil support 19, and an upper hydraulic mechanism 20. The upper hydraulic mechanism 20 is mounted on the upper end of the mounting bracket 18, and the coil support 19 is mounted on the upper hydraulic mechanism 20. The upper hydraulic mechanism 20 drives the coil support 19 to move up and down reciprocally. The coil support 19 is provided with a receiving groove 22 for accommodating unmagnetized magnetic poles 7, and a magnetizing coil 21 is embedded in the side wall of the receiving groove 22.

[0038] As an example of this implementation scheme, the mounting bracket 18 is welded from 20# channel steel and has a height of 3-4m; the upper hydraulic mechanism 20 uses a single-acting hydraulic cylinder (stroke 200-300mm, rated pressure 10-15MPa), and the cylinder body is fixed to the top crossbeam of the mounting bracket 18; the coil support 19 is made of aluminum alloy and has an internal receiving groove 22 adapted to the magnetic pole 7 (the groove depth is 10-15mm longer than the length of the magnetic pole 7), and a magnetizing coil 21 wound with enameled copper wire (800-1200 turns, wire diameter 2-3mm) is embedded in the side wall of the groove, and the outside of the coil is wrapped with a heat insulation layer; the magnetizing power supply uses a pulse magnetizer (output voltage 0-5000V, current 0-1000A) and integrates a magnetic flux measuring coil (arranged coaxially with the magnetizing coil 21) to realize real-time detection of magnetic flux value after magnetization (detection accuracy ±1%).

[0039] As another embodiment of this invention, please refer to the appendix to the specification. Figure 9 and attached Figure 10 As shown, the magnetizing lower pressure head device 3 includes a lower hydraulic mechanism 23 and a tooling fixture 24. The tooling fixture 24 is mounted on the lower hydraulic mechanism 23, which is mounted on the mounting bracket 18. The lower hydraulic mechanism 23 drives the tooling fixture 24 to reciprocate up and down. The tooling fixture 24 is provided with grooves 25 for accommodating the two ends of the unmagnetized magnetic pole 7. A support platform 26 is provided between the two grooves 25. The upper surface of the support platform 26 is an arc surface 27 adapted to the lower surface of the magnetic pole 7. As an example, the lower hydraulic mechanism 23 has the same specifications as the upper hydraulic mechanism 20, and the cylinder is fixed to the bottom of the mounting bracket 18. The tooling fixture 24 is made of cast iron, and the upper surface has grooves 25 (depth 5-8mm) adapted to the round nuts 13 at both ends of the magnetic pole 7. A support platform 26 is provided between the grooves 25. The radius of the arc surface 27 of the support platform 26 is consistent with the curvature of the lower surface of the magnetic pole 7 (error ≤0.1mm) to ensure that the magnetic pole 7 does not wobble after placement.

[0040] As another embodiment of this invention, please refer to the appendix to the specification. Figure 11 As shown, the rotor rotating platform 4 adopts a vertical structure. The base is fixed to the ground by expansion bolts. The platform is made of 45# steel forging (diameter 2-3m, thickness 50-80mm). A servo motor (power 5-10kW) and a gearbox are installed under the platform to achieve continuous rotation or inching rotation at 0.5-5r / min. Positioning clamps (3-4 sets, which can be driven by cylinders to clamp the rotor bracket 8) are added to the edge of the platform and equipped with a grating ruler (measurement accuracy ±0.01mm) to monitor the runout of the platform end face (controlled within 0.2mm) and radial runout (controlled within 0.1mm) in real time. After reaching the preset installation angle, the positioning is locked by an electromagnetic brake (locking accuracy ±0.5°).

[0041] As another embodiment of this invention, please refer to the appendix to the specification. Figure 12As shown, the magnetic pole clamp 6 includes a support frame 28 and a conical opening limiting block 29. The support frame 28 is provided with a first picking arm 30, a second picking arm 31, and a clamp driving component for controlling the relative movement of the first picking arm 30 and the second picking arm. The conical opening limiting block 29 is respectively disposed on the first picking arm 30 and the second picking arm 31. The conical opening limiting block 29 matches the specification of the nut 13 on the magnetic pole 7, and the distance from the end face of the conical opening limiting block 29 to the mating surface of the tensioning screw 12 on the magnetic pole 7 is greater than 0. As an example, the support frame 28 is welded from 45# steel, and two sets of pickup arms (each set is 300-500mm long) are symmetrically arranged on the frame. The clamping drive is a double-acting cylinder (cylinder diameter 50-80mm, stroke 50-100mm) to control the relative movement of the two sets of pickup arms. A conical opening limit block 29 (cone angle 60°-90°, opening diameter 1-2mm larger than the outer diameter of the round nut 13) is installed at the end of each set of pickup arms. The distance from the end face of the limit block to the mating surface of the tensioning screw of the magnetic pole 7 is set to 5-10mm to avoid damage to the mating surface of the bolt during clamping.

[0042] As a specific implementation example of this embodiment, the assembly robot 5 is a heavy-duty articulated robot (load 500-1000kg, working radius 3-5m), with repeatability ≤±0.5mm, path accuracy ≤±1mm, and running speed 0.1-1m / s (stepless speed adjustment); the execution end has a reserved flange interface for installing the magnetic pole clamp 6.

[0043] The first vision acquisition component uses an industrial camera (resolution of 20 megapixels or higher) paired with a telecentric lens (working distance 300-500mm), fixed in the mounting slot below the picking station of the logistics conveyor mechanism 1. The lens faces upwards to acquire the outer circular contour of the magnetic pole 7 (extracting diameter and roundness features) and the magnetic pole box mating hole (extracting hole position coordinates and hole diameter features). The second vision acquisition component also uses an industrial camera of 20 megapixels or higher, integrated on the side of the execution end of the assembly robot 5. The lens faces the rotor support 8, acquiring the outer circular contour of the magnetic pole 7, the magnetic pole mating hole, and the mating hole of the rotor support 8 (extracting hole position coordinates, hole diameter, and hole spacing features). The vision system's supporting software supports feature size comparison analysis, calculates the positional deviation between the magnetic pole 7 and the rotor support 8 (accuracy ±0.05mm), and sends posture adjustment commands to the robot.

[0044] As a preferred embodiment of this invention, please refer to the appendix to the specification. Figure 13 and attached Figure 14As shown, the system also includes a bolt installation robot 9, which is positioned on the side of the rotor rotating platform 4. The bolt installation robot 9 is configured to tighten the engagement bolts on the rotor support 8 after the assembly robot 5 aligns the engagement holes on the picked-up magnetic pole 7 with the engagement holes on the rotor support 8, thereby fixing the magnetic pole 7 and the rotor support 8 together. As an example, the bolt installation robot 9 is a 6-axis articulated robot (load 50-100kg, working radius 2-3m), with a torque wrench (torque range 500-2000N・m, control accuracy ±3%) mounted on its actuator. It is fixed to the side of the rotor rotating platform 4 (distributed at 90°-180° to the assembly robot 5) and equipped with a bolt feeding mechanism to achieve automatic picking, installation, and torque tightening of the engagement bolts.

[0045] The components are arranged according to the process flow: the output end of the logistics conveying mechanism 1 is connected to the workstation below the magnetizing device 2. The magnetizing device 2 is located between the logistics conveying mechanism 1 and the rotor rotating platform 4. The assembly robot 5 is arranged in the middle area of ​​the three to ensure that the working radius of the robot covers the picking station of the logistics conveying mechanism 1 and the installation station of the rotor rotating platform 4. The cameras of the vision positioning subsystem are fixed in preset positions and connected to the system control cabinet.

[0046] Electrical and software debugging: Connect the control circuits of magnetization device 2, hydraulic mechanism, robot, vision system, and rotor rotation platform 4 to the system control cabinet, and realize the linkage logic of each component through PLC programming (such as the signal of logistics delivery triggering the start of magnetization device 2, and the signal of magnetization completion triggering the robot to grasp); debug the feature recognition algorithm of vision system to ensure that the feature extraction success rate of the mating hole of magnetic pole 7 and rotor support 8 is ≥99.5%; calibrate the robot's repeatability and path accuracy, and adjust the position of conical opening limit block 29 by trying to grasp the unmagnetized magnetic pole 7 to ensure that the clamping is firm and without deviation.

[0047] The specific process for assembling the magnetic poles 7 using the permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system described above is as follows: (1) According to the selected magnetic pole 7 structure (magnetic pole box assembly 10 type or lamination type), complete the pre-assembly of magnetic pole 7: If it is magnetic pole box assembly 10 type, stack the magnetic pole box assembly 10 with the fixed magnet 14, put it into the tensioning screw 12, add pressure plates 11 at both ends and screw in the round nut 13, and set the pre-tightening torque to 50-100 N·m to ensure that the assembly is not loose; if it is lamination type, put the stacked magnetic pole lamination 16 (stack height error ≤0.5mm) into the tensioning screw 12, insert the magnet 14 and spot weld it, add pressure plates 11 at both ends and screw in the round nut 13 for pre-tightening; (2) Place the pre-installed unmagnetized magnetic poles 7 one by one on the conveyor belt of the logistics conveying mechanism 1. The axis of the magnetic poles 7 is parallel to the conveying direction and is limited by the guide baffle to prevent deviation during the conveying process.

[0048] (3) The logistics conveying mechanism 1 transports the unmagnetized magnetic pole 7 to the work station below the magnetizing device 2, triggers the position sensor, and the conveying mechanism stops running; the lower hydraulic mechanism 23 starts, drives the tooling fixture 24 to rise, so that the round nuts 13 at both ends of the magnetic pole 7 are embedded in the fixture groove 25, and the support platform 26 supports the lower surface of the magnetic pole 7, thereby fixing the magnetic pole 7. (4) The upper hydraulic mechanism 20 is started, driving the coil support seat 19 to descend, so that the magnetic pole 7 is completely inserted into the receiving groove 22, and the magnetizing coil 21 is attached to the side wall of the magnetic pole 7; the system control cabinet sends a command to the magnetizing power supply and outputs a pulse current (set according to the specifications of the magnet 14, usually 800-1000A), which is used to saturate the magnetic pole 7 through the magnetizing coil 21, and the magnetizing time lasts for 0.1-0.5s; (5) After magnetization is completed, the magnetic flux measuring coil collects the magnetic flux value of the magnetic pole 7. If the magnetic flux value is within the preset range (e.g., 2.0-2.5Wb, set according to the motor design requirements), the magnetization is deemed qualified; if it is not qualified, the system issues an alarm signal and the magnetic pole 7 is manually removed and reprocessed; after the magnetization is qualified, the upper hydraulic mechanism 20 drives the coil support seat 19 to rise and reset, the lower hydraulic mechanism 23 drives the tooling fixture 24 to fall and reset, and the logistics conveying mechanism 1 continues to run, transporting the magnetized magnetic pole 7 to the picking station; (6) When the magnetized magnetic pole 7 arrives at the picking station of the logistics conveying mechanism 1, the position sensor triggers a signal and the conveying mechanism stops; the first vision acquisition component starts, acquires the outer circle contour of the magnetic pole 7 and the features of the magnetic pole engagement hole, transmits the data to the vision system software, and generates the feature parameters of the magnetic pole 7 (such as the center coordinates of the magnetic pole 7 and the relative center offset of the engagement hole). (7) The assembly robot 5 receives the gripping command and moves to the top of the picking station. The second vision acquisition component collects the features of the magnetic pole 7 and compares them with the parameters of the first vision acquisition component to calibrate the robot's posture. The robot drives the two sets of picking arms to open, so that the conical opening limit block 29 is aligned with the round nuts 13 at both ends of the magnetic pole 7. The cylinder drives the picking arms to close, and the limit block clamps the round nuts 13 to complete the gripping of the magnetic pole 7. After gripping, the robot raises the magnetic pole 7 (the height is 50-100mm higher than the conveying mechanism) and prepares to move to the rotor rotating platform 4. (8) The rotor rotating platform 4 drives the rotor support 8 (e.g., according to the preset program (the installation angle is set according to the number of rotor poles 7, such as 11.25° for each row of 32 poles 7) according to the preset program) according to the preset program (the installation angle is set according to the number of rotor poles 7, such as 11.25° for each row installed). Figure 2As shown, the robot rotates to the target installation angle, and the electromagnetic brake locks the platform. The second vision acquisition component moves with the robot to the installation position of the rotor bracket 8, acquires the mating hole features of the rotor bracket 8, compares them with the mating hole features of the magnetic pole, calculates the position deviation, and the robot adjusts its posture (such as translation and rotation) according to the deviation to align the mating hole of the magnetic pole with the mating hole of the rotor bracket 8 (coaxiality error ≤ 0.1mm). (9) The robot drives the magnetic pole 7 to move towards the rotor bracket 8 and installs the magnetic pole 7 into the preset mounting hole of the rotor bracket 8, ensuring that the magnetic pole 7 is in contact with the surface of the rotor bracket 8; if the bolt installation robot 9 is not selected, the manual tightening of the engagement bolt on the other side of the rotor bracket 8 with a torque wrench (tightening according to the design torque value, such as 1500-2000 N·m) is completed to fix the magnetic pole 7; if the bolt installation robot 9 is selected, the robot receives the assembly completion signal, grabs the engagement bolt and installs it into the engagement hole, starts the torque wrench to tighten according to the preset torque, and sends a completion signal to the system after tightening. (10) After the magnetic pole 7 is fixed, the assembly robot 5 drives the picking arm to open, detach from the magnetic pole 7, and return to the picking station of the logistics conveying mechanism 1 to prepare for the next gripping; the rotor rotating platform 4 unlocks, rotates to the installation angle of the next column of magnetic poles 7 and locks, and repeats the above steps until the rotor completes the circular magnetic pole 7 (e.g. Figure 8 As shown, assembly is complete.

[0049] After all the magnetic poles 7 of the rotor are assembled, the overall magnetic flux distribution of the rotor can be tested using a special testing device (such as a magnetic flux tester) to verify the consistency of magnetic flux of each magnetic pole 7 (deviation controlled within 2%). At the same time, the installation gap of the magnetic poles 7 is checked (air gap error ≤ 0.2mm). If any abnormality is found, it is adjusted by robot or manual means to ensure that the rotor assembly quality meets the motor design requirements.

Claims

1. A permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system, characterized in that: The system includes a logistics conveying mechanism (1), a magnetizing device (2), a magnetizing pressing head device (3), a rotor rotating platform (4), an assembly robot (5), a magnetic pole clamp (6), and a vision positioning subsystem; The material conveying mechanism is used to position and convey unmagnetized magnetic poles (7). The magnetizing device (2) is located above the logistics conveying mechanism (1) and is used to magnetize the unmagnetized magnetic poles (7) that are positioned and conveyed by the logistics conveying mechanism (1). The magnetizing pressure head device (3) is located below the magnetizing device (2) and is used to cooperate with the magnetizing device (2) to magnetize the unmagnetized magnetic poles (7) that are positioned and conveyed by the material conveying mechanism. The rotor rotation platform (4) is used to fix the rotor support (8) for the magnetic pole (7) to be installed. The assembly robot (5) is located between the logistics conveying mechanism (1) and the rotor rotating platform (4) and is used to assemble the magnetized magnetic poles (7) onto the rotor bracket (8) on the rotor rotating platform (4). The magnetic pole clamp (6) is mounted on the execution end of the assembly robot (5) and is used to clamp the magnetic pole (7) after the overall magnetization is completed. The visual positioning subsystem includes a first visual acquisition component and a second visual acquisition component. The first visual acquisition component is set on the logistics conveying mechanism (1) and is located below the picking station where the assembly robot (5) picks up the magnetic pole (7) after the overall magnetization is completed. The first visual acquisition component is used to acquire the positioning features of the outer circle contour of the magnetic pole (7) after the overall magnetization is completed and the positioning features of the magnetic pole box mating hole. The second vision acquisition component is mounted on the execution end of the assembly robot (5) and is used to acquire the positioning features of the outer circle contour of the magnetic pole (7) after the overall magnetization is completed, the positioning features of the magnetic pole engagement hole, and the positioning features of the engagement hole on the rotor support (8). With the assistance of the vision positioning subsystem, the assembly robot (5) uses the magnetic pole gripper (6) at its execution end to pick up the magnetic pole (7) that has been fully magnetized and transported by the logistics conveying mechanism (1), and aligns the magnetic pole engagement hole on the picked magnetic pole (7) with the engagement hole on the rotor bracket (8).

2. The permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system as described in claim 1, characterized in that: It also includes a bolt installation robot (9), which is set on the side of the rotor rotating platform (4). The bolt installation robot (9) is configured to tighten the engagement bolts on the rotor bracket (8) after the assembly robot (5) aligns the magnetic pole engagement hole on the magnetic pole (7) it picked up with the engagement hole on the rotor bracket (8) to fix the magnetic pole (7) and the rotor bracket (8) together.

3. A permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system as described in claim 1 or 2, characterized in that: The magnetic pole (7) includes several non-magnetized magnetic pole box assemblies (10), pressure plates (11), tension screws (12) and nuts (13); the magnetic pole box assembly (10) includes a magnetic pole box and several magnets (14), and the magnetic pole box is provided with a receiving cavity (15) for accommodating the magnets (14). Several magnets (14) are placed into the receiving cavity (15) and fixed with glue to form the magnetic pole box assembly (10); several magnetic pole box assemblies (10) are stacked together and connected in series by the pressure plates (11) at both ends and the tension screws (12) and nuts (13) to form the magnetic pole (7).

4. The permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system as described in claim 3, characterized in that: The magnetic pole box is composed of several magnetic pole pieces (16) joined together by adhesive or snap-fit.

5. A permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system as described in claim 1 or 2, characterized in that: The magnetic pole (7) includes several magnetic pole pieces (16), magnets (14), tension screws (12), pressure plates (11) and nuts (13). The magnetic pole pieces (16) are provided with magnet slots (17). Several magnetic pole pieces (16) are stacked together, and magnets (14) are inserted into the magnet slots (17) of the stacked magnetic pole pieces (16). The magnetic pole (7) is formed by the pressure plates (11) at both ends, the tension screws (12) and the nuts (13).

6. A permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system as described in claim 1 or 2, characterized in that: The magnetizing device (2) includes a mounting bracket (18), a coil support seat (19), and an upper hydraulic mechanism (20). The upper hydraulic mechanism (20) is mounted on the upper end of the mounting bracket (18), and the coil support seat (19) is mounted on the upper hydraulic mechanism (20). The upper hydraulic mechanism (20) drives the coil support seat (19) to move up and down reciprocally. The coil support seat (19) is provided with a receiving groove (22) for accommodating unmagnetized magnetic poles (7), and a magnetizing coil (21) is embedded in the side wall of the receiving groove (22).

7. The permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system as described in claim 6, characterized in that: The magnetizing pressure head device (3) includes a lower hydraulic mechanism (23) and a tooling fixture (24). The tooling fixture (24) is mounted on the lower hydraulic mechanism (23), which is mounted on the mounting bracket (18). The lower hydraulic mechanism (23) drives the tooling fixture (24) to move up and down reciprocally. The tooling fixture (24) is provided with grooves (25) for accommodating the two ends of the unmagnetized magnetic pole (7). A support platform (26) is provided between the two grooves (25). The upper surface of the support platform (26) is an arc surface (27) adapted to the lower surface of the magnetic pole (7).

8. A permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system as described in claim 1 or 2, characterized in that: The magnetic pole clamp (6) includes a support frame (28) and a conical opening limiting block (29). The support frame (28) is provided with a first picking arm (30), a second picking arm (31), and a clamp driving component for controlling the relative movement of the first picking arm (30) and the second picking arm. The conical opening limiting block (29) is respectively provided on the first picking arm (30) and the second picking arm (31). The conical opening limiting block (29) matches the specification of the nut (13) on the magnetic pole (7), and the distance from the end face of the conical opening limiting block (29) to the mating surface of the tensioning screw (12) on the magnetic pole (7) is greater than 0.

9. The permanent magnet semi-direct drive wind turbine rotor assembly and manufacturing system as described in claim 8, characterized in that: The clamp drive component is a cylinder.

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