Equipment for realizing automatic vibration, hole rolling and shape correction of compressor motor

Abstract

The invention discloses equipment for realizing automatic vibration, hole rolling and shape correction of a compressor motor, which integrates an equipment rack, a conveying assembly line, a manipulator system, a vibration station, a roll finish station, a shape correction station and a control system, and is characterized in that a feeding assembly line and a discharging assembly line are respectively arranged at two ends of the rack, and the stations are sequentially arranged along a stator assembly processing flow; assembly transfer is achieved through the truss type mechanical arm system, and the control system is electrically connected with all the components to guarantee cooperative work. The vibration station drives a vibration generator through a symmetrical air cylinder and is matched with a positioning tool to complete winding vibration treatment; at the tumbling station, a servo motor is adopted to drive a mirror surface rolling cutter, and inner hole tumbling correction is achieved in combination with a limiting device and a positioning tool; the correction station drives an upper die and a lower die to be matched through a servo thrust cylinder, and correction of the perpendicularity of the stator and the straightness of an inner hole is completed. According to the equipment, automatic integrated machining of vibration, hole rolling and shape correcting procedures of the stator assembly is achieved, and the problems that traditional dispersion machining is low in efficiency, insufficient in precision, poor in consistency and the like are solved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of compressor motor manufacturing equipment, in particular to a device for realizing automatic vibration hole rolling and shaping of a compressor motor. BACKGROUND

[0002] With the upgrading of energy efficiency standards in the home appliance industry, the development of small and lightweight compressors, and the expansion of production scale, the quality of the motor stator, as a core component of the compressor, directly determines the overall energy efficiency and reliability of the machine. The traditional sheet stacking process faces problems such as insufficient positioning accuracy and stability, and manual operation or semi-automatic processing equipment has the pain points of low efficiency, large quality fluctuations, and high labor intensity.

[0003] At the same time, under the driving of energy-saving and emission-reducing policies and the trend of intelligent manufacturing "machine replacing man", the domestic industry urgently needs to solve the technical bottlenecks of sheet stator hole rolling, shaping, and vibration processes. In the existing processing mode, each process is carried out separately and requires manual transfer, which not only leads to low production efficiency, but also makes it difficult to ensure the consistency of processing accuracy, resulting in high product failure rate, excessive motor iron loss and vibration noise, and affecting the overall performance of the compressor.

[0004] Therefore, it is an inevitable demand for the development of the industry to develop an integrated and automated processing equipment. SUMMARY

[0005] The purpose of the present application is to provide a device for realizing automatic vibration hole rolling and shaping of a compressor motor, solving the problems of low efficiency, insufficient accuracy, poor product consistency, and high labor cost in the traditional processing mode.

[0006] To solve the above technical problems, the present application is realized by the following technical scheme: The present application is a device for realizing automatic vibration hole rolling and shaping of a compressor motor, comprising a device frame, a conveying assembly line, a mechanical hand system, a vibration station, a rolling station, a shaping station, and a control system. The conveying assembly line includes an inlet assembly line and an outlet assembly line, which are respectively arranged at the inlet end and the outlet end of the device frame. The mechanical hand system, the vibration station, the rolling station, and the shaping station are installed in sequence along the stator component processing flow on the device frame, and the transfer of the stator component between each station is realized through the mechanical hand system. The control system is electrically connected with the mechanical hand system, the vibration station, the rolling station, and the shaping station, and is used for controlling the cooperative work of each component.

[0007] In one embodiment, the mechanical hand system is a truss mechanical hand; the mechanical hand system includes a driving unit, a plurality of core expanding mechanical hands, and a clamping jaw mechanical hand; the driving unit is selected from a servo motor or a stepping motor, and is used for driving the core expanding mechanical hands and the clamping jaw mechanical hand to realize the transfer of the stator component.

[0008] In one embodiment, the vibration station includes cylinders, a vibration generator, and a positioning fixture A arranged symmetrically at the top and bottom; the cylinders are fixedly mounted on the support of the equipment frame, and the output end of the cylinders is fixedly connected to the vibration generator.

[0009] In one embodiment, the positioning fixture A includes a positioning seat A and a linear drive module A for driving the positioning seat A. The positioning seat A is provided with a positioning groove A that is adapted to the shape of the stator assembly. The vibration generator cooperates with the positioning fixture A.

[0010] In one embodiment, the polishing station includes upper and lower limit devices, a servo motor, a power head, a mirror rolling cutter, and a positioning fixture B. The upper and lower limit devices include a limit plate and a limit post. The limit plate is driven by the servo motor to achieve lifting and lowering, and the limit post is fixedly installed on the limit plate. The limit plate and the limit post are adapted to the positioning fixture B. The output shaft of the servo motor is connected to the power head through the upper and lower limit devices. The power head is a drive motor. The mirror rolling cutter is installed at the lower end of the power head, and the power head drives the mirror rolling cutter to achieve up-and-down reciprocating motion.

[0011] In one embodiment, the positioning fixture B includes a positioning seat B and a linear drive module B for driving the positioning seat B. The positioning seat B is provided with a positioning groove B that is adapted to the shape of the stator assembly. The mirror rolling cutter cooperates with the positioning fixture B.

[0012] In one embodiment, the calibration station includes an upper mold, a lower mold, and a servo thrust cylinder; the lower mold includes a calibration mandrel, a mounting base, and a linear drive module C, the calibration mandrel being fixedly mounted on the mounting base, and the outer diameter of the calibration mandrel being adapted to the inner hole of the stator assembly; the linear drive module C is mounted on the surface of the equipment frame, and the output end of the linear drive module C is connected to the mounting base of the lower mold; the upper mold includes an upper calibration mold and a connecting base, the lower surface of the upper calibration mold being adapted to the upper core surface of the stator assembly; the piston rod of the servo thrust cylinder is fixedly connected to the connecting base of the upper mold.

[0013] In one embodiment, the control system includes a main controller, an operation panel, and several sensors. The main controller is a PLC controller or an industrial control computer, used to process the signals collected by each sensor and issue control commands to the robotic arm system, vibration station, tumbling station, and alignment station according to a preset program. The operation panel is electrically connected to the main controller and is used to input operation commands and display the operating status of the equipment. Several sensors are respectively installed at key parts of the robotic arm system, vibration station, tumbling station, and alignment station to monitor the operating parameters of each station in real time and transmit the monitoring signals to the main controller.

[0014] The present invention has the following beneficial effects: The equipment in this invention integrates three core processes: vibration, rolling, and shaping. It achieves automatic transfer of stator components and collaborative operation of each workstation through a robotic arm system. No manual intervention is required for process connection, which greatly reduces transfer time and labor costs. Production efficiency is significantly improved compared to traditional decentralized processing methods, meeting the needs of large-scale production.

[0015] In this invention, each workstation is equipped with positioning fixtures and precision drive mechanisms adapted to the shape of the stator assembly. The vibration workstation achieves precise winding processing through specific frequency amplitude control. The burnishing workstation uses a mirror burnishing tool to non-cut and correct the roundness and smoothness of the inner hole. The alignment workstation uses a servo thrust cylinder to provide stable pressure correction accuracy. Combined with the real-time monitoring and feedback adjustment of the control system, the processing accuracy is effectively guaranteed, the product defect rate is reduced, and the excessive iron loss and vibration noise of the motor are avoided.

[0016] The equipment in this invention operates fully automatically, replacing traditional manual operation and semi-automatic processing modes. This not only reduces the labor intensity of workers but also reduces the safety risks associated with manual operation, which is in line with the development trend of "machine replacing human" in intelligent manufacturing.

[0017] In response to the current situation where domestic high-end compressor core equipment relies on imports, this invention overcomes the technical challenge of multi-process integrated processing of discrete stators, and realizes the automated integration of vibration, rolling, and shaping processes. It provides the domestic compressor motor manufacturing industry with efficient and reliable domestically produced equipment, helps the industry break through technological monopolies, and responds to energy conservation, emission reduction and energy efficiency upgrading policies.

[0018] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 A schematic diagram of the overall structure of a device for automatically vibrating and rolling the bores of a compressor motor; Figure 2 A front view of a device for automatically vibrating and shaping the rolling holes of a compressor motor; Figure 3 A rear view of a device for automatically vibrating and shaping the rolling holes of a compressor motor; Figure 4 This is a top view of a device for automatically vibrating and shaping the rolling holes of a compressor motor.

[0021] The attached diagram lists the components represented by each number as follows: 1. Equipment frame; 2. Feeding assembly line; 3. Discharge assembly line; 4. Robotic arm system; 5. Vibration station; 6. Burnishing station; 7. Shaping station; 8. Stator assembly; 41. Drive unit; 42. Core expansion robot; 43. Gripper robot; 51. Cylinder; 52. Vibration generator; 53. Positioning fixture A; 531. Positioning seat A; 532. Linear drive module A; 533. Positioning groove A; 61. Upper and lower limit devices 62. Servo motor; 63. Power head; 64. Mirror rolling cutter; 65. Positioning fixture B; 611. Limit plate; 612. Limit post; 651. Positioning seat B; 652. Linear drive module B; 653. Positioning groove B; 71. Upper mold; 72. Lower mold; 73. Servo thrust cylinder; 74. Linear drive module C; 711. Upper calibration mold; 712. Connecting seat; 721. Calibration mandrel; 722. Mounting seat. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0023] In the description of this invention, it should be understood that the terms "upper," "middle," "outer," "inner," etc., which indicate orientation or positional relationship, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this invention.

[0024] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Example

[0025] Please see Figures 1-4As shown, this invention is a device for automatically vibrating and rolling the holes of a compressor motor, comprising a machine frame 1, a conveyor line, a robotic arm system 4, a vibration station 5, a rolling station 6, a straightening station 7, and a control system; the conveyor line includes a feeding line 2 and a discharging line 3, respectively located at the feeding end and discharging end of the machine frame 1; the robotic arm system 4, the vibration station 5, the rolling station 6, and the straightening station 7 are sequentially installed on the machine frame 1 along the processing flow of the stator assembly 8, and the stator assembly 8 is transferred between each station via the robotic arm system 4; the control system is electrically connected to the robotic arm system 4, the vibration station 5, the rolling station 6, and the straightening station 7, respectively, for controlling the coordinated operation of each component.

[0026] Furthermore, the robotic arm system 4 is a gantry robotic arm; the robotic arm system 4 includes a drive unit 41, several core-expanding robotic arms 42 and gripper robotic arms 43; the drive unit 41 is selected from servo motors or stepper motors, used to drive the core-expanding robotic arms 42 and gripper robotic arms 43 to realize the transfer of the stator assembly 8.

[0027] Furthermore, the vibration station 5 includes a cylinder 51, a vibration generator 52, and a positioning fixture A53 arranged symmetrically at the top and bottom; the cylinder 51 is fixedly installed on the support of the equipment frame 1, and the output end of the cylinder 51 is fixedly connected to the vibration generator 52.

[0028] Furthermore, the positioning fixture A53 includes a positioning seat A531 and a linear drive module A532 for driving the positioning seat A531. The positioning seat A531 is provided with a positioning groove A533 that is adapted to the shape of the stator assembly 8. The vibration generator 52 cooperates with the positioning fixture A53.

[0029] Furthermore, the burnishing station 6 includes upper and lower limit devices 61, a servo motor 62, a power head 63, a mirror burnishing cutter 64, and a positioning fixture B65; the upper and lower limit devices 61 include a limit plate 611 and a limit post 612. The limit plate 611 is driven by the servo motor 62 to achieve lifting and lowering, and the limit post 612 is fixedly installed on the limit plate 611. The limit plate 611 and the limit post 612 are adapted to the positioning fixture B65; the output shaft of the servo motor 62 is connected to the power head 63 through the upper and lower limit devices 61, and the power head 63 is a drive motor; the mirror burnishing cutter 64 is installed at the lower end of the power head 63, and the power head 63 drives the mirror burnishing cutter 64 to achieve up and down reciprocating motion.

[0030] Furthermore, the positioning fixture B65 includes a positioning seat B651 and a linear drive module B652 for driving the positioning seat B651. The positioning seat B651 is provided with a positioning groove B653 that is adapted to the shape of the stator assembly 8. The mirror rolling cutter 64 cooperates with the positioning fixture B65.

[0031] Furthermore, the calibration station 7 includes an upper mold 71, a lower mold 72, and a servo thrust cylinder 73; the lower mold 72 includes a calibration mandrel 721, a mounting base 722, and a linear drive module C74. The calibration mandrel 721 is fixedly mounted on the mounting base 722, and the outer diameter of the calibration mandrel 721 is adapted to the inner hole of the stator assembly 8; the linear drive module C74 is mounted on the surface of the equipment frame 1, and the output end of the linear drive module C74 is connected to the mounting base 722 of the lower mold 72; the upper mold 71 includes an upper calibration mold 711 and a connecting base 712, and the lower surface of the upper calibration mold 711 is adapted to the upper core surface of the stator assembly 8; the piston rod of the servo thrust cylinder 73 is fixedly connected to the connecting base 712 of the upper mold 71.

[0032] Furthermore, the control system includes a main controller, an operation panel, and several sensors. The main controller is a PLC controller or an industrial control computer, used to process the signals collected by each sensor and send control commands to the robotic arm system 4, vibration station 5, tumbling station 6, and alignment station 7 according to a preset program. The operation panel is electrically connected to the main controller and is used to input operation commands and display the operating status of the equipment. Several sensors are installed at key parts of the robotic arm system 4, vibration station 5, tumbling station 6, and alignment station 7 to monitor the operating parameters of each station in real time and transmit the monitoring signals to the main controller. Example

[0033] Please see Figures 1-4 As shown in the figure, this embodiment describes the workflow of a device for automatically vibrating and rolling the holes of a compressor motor: The stator assembly 8 is conveyed to the feeding end of the equipment frame 1 via the feeding line 2. The core-expanding robot 42 in the robot system 4 grabs the stator assembly 8 according to the preset program and transfers it to the positioning fixture A53 of the vibration station 5, so that the stator assembly 8 falls accurately into the positioning groove A533. The positioning seat A531 moves to the working area of ​​the vibration generator 52 under the drive of the linear drive module A532. At this time, the cylinder 51 pushes the vibration generator 52 to move towards the stator assembly 8, so that it contacts the stator assembly 8 and applies vibration. Through the vibration of a specific frequency and amplitude generated by the vibration generator 52, the winding of the stator assembly 8 is subjected to vibration impact, which forces the damaged and flattened enameled wire in the winding to break, thereby improving the inspection rate of the subsequent process.

[0034] After vibration treatment, the core-expanding robot 42 grabs the stator assembly 8 again and transfers it to the positioning fixture B65 at the burnishing station 6, so that the stator assembly 8 falls precisely into the positioning groove B653. The positioning seat B651 moves under the drive of the linear drive module B652 to directly below the mirror rolling cutter 64. At the same time, the servo motor 62 drives the limit plate 611 to descend. The limit post 612 cooperates with the positioning fixture B65 to limit the stator assembly 8 and prevent it from shifting during the burnishing process. The power head 63 drives the mirror rolling cutter 64 to move downward. The mirror rolling cutter 64 rolls the inner hole of the stator, correcting the roundness of the inner hole of the stator assembly 8 in a non-cutting manner, and improving the surface finish of the inner hole.

[0035] After the burnishing process is completed, the gripper robot 43 picks up the stator assembly 8 and transfers it to the lower mold 72 of the calibration station 7. The calibration mandrel 721 is inserted into the inner hole of the stator assembly 8 for initial positioning. The linear drive module C74 drives the lower mold 72 to move as a whole, so that the stator assembly 8 reaches the preset calibration position. The servo thrust cylinder 73 pushes the upper mold 71 to move downward. The lower surface of the upper calibration mold 711 contacts the upper iron core surface of the stator assembly 8. The upper mold 71 generates a thrust of about 3T to press the upper mold 71 onto the iron core surface of the stator assembly 8. The pressure is used to correct the verticality of the motor and the straightness of the inner hole.

[0036] During the calibration process, sensors at each station monitor operating parameters in real time, such as vibration frequency, rolling pressure, and calibration force, and transmit the monitoring signals to the main controller. The main controller monitors and adjusts the operating status of each station in real time according to a preset program to ensure stable equipment operation and processing quality. After calibration, the gripper robot 43 picks up the stator assembly 8 and transfers it to the discharge line 3, which then transports it to the next process or finished product area. This completes the automatic vibration rolling calibration process for one stator assembly 8.

[0037] In the description of this specification, references to terms such as "an embodiment," "example," and "specific example" indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0038] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A device for implementing automatic vibration hole rolling of a compressor motor, characterized in that, The device rack (1), the conveying line, the mechanical arm system (4), the vibration station (5), the rolling station (6), the type checking station (7) and the control system are included; the conveying line includes the feeding line (2) and the discharging line (3), which are arranged at the feeding end and the discharging end of the device rack (1) respectively; the mechanical arm system (4), the vibration station (5), the rolling station (6) and the type checking station (7) are sequentially arranged on the device rack (1) along the stator assembly (8) processing flow, and the transfer of the stator assembly (8) is realized through the mechanical arm system (4) between the stations; the control system is electrically connected with the mechanical arm system (4), the vibration station (5), the rolling station (6) and the type checking station (7) respectively, and is used for controlling the cooperative work of the components.

2. The device for automatically correcting the shape of the hole by vibration of the compressor motor according to claim 1, wherein The mechanical arm system (4) is a truss mechanical arm; the mechanical arm system (4) includes a driving unit (41), a plurality of core expanding mechanical arms (42) and clamping jaw mechanical arms (43); the driving unit (41) is selected from a servo motor or a stepping motor, and is used for driving the core expanding mechanical arms (42) and the clamping jaw mechanical arms (43) to realize the transfer of the stator assembly (8).

3. The device for automatically correcting the shape of the hole by vibration of the compressor motor according to claim 1, wherein The vibration station (5) includes air cylinders (51) arranged symmetrically upwards and downwards, a vibration generator (52) and a positioning tool A (53); the air cylinders (51) are fixedly installed on the support of the device rack (1), and the output ends of the air cylinders (51) are fixedly connected with the vibration generator (52).

4. The device for automatically correcting the shape of the hole by vibration of the compressor motor according to claim 3, wherein The positioning tool A (53) includes a positioning seat A (531) and a linear driving module A (532) for driving the positioning seat A (531), and the positioning seat A (531) is provided with a positioning groove A (533) matched with the shape of the stator assembly (8); the vibration generator (52) cooperates with the positioning tool A (53).

5. The apparatus for automatically correcting the shape of a hole by vibration of a compressor motor according to claim 1, wherein The rolling station (6) includes an up-down limiting device (61), a servo motor (62), a power head (63), a mirror surface rolling cutter (64) and a positioning tool B (65); the up-down limiting device (61) includes a limiting plate (611) and a limiting column (612), the limiting plate (611) is driven to realize lifting by the servo motor (62), and the limiting column (612) is fixedly installed on the limiting plate (611); the limiting plate (611) and the limiting column (612) are matched with the positioning tool B (65); the output shaft of the servo motor (62) is connected with the power head (63) through the up-down limiting device (61), and the power head (63) is a driving motor; the mirror surface rolling cutter (64) is installed at the lower end of the power head (63), and the power head (63) drives the mirror surface rolling cutter (64) to realize up-down reciprocating movement.

6. The apparatus for automatically correcting the shape of a hole by vibration of a compressor motor according to claim 5, wherein The positioning tool B (65) includes a positioning seat B (651) and a linear driving module B (652) for driving the positioning seat B (651), and the positioning seat B (651) is provided with a positioning groove B (653) matched with the shape of the stator assembly (8); the mirror surface rolling cutter (64) cooperates with the positioning tool B (65).

7. The apparatus for automatically correcting the shape of a hole by vibration of a compressor motor according to claim 1, wherein The sizing station (7) comprises an upper die (71), a lower die (72) and a servo thrust cylinder (73); the lower die (72) comprises a sizing mandrel (721) and a mounting seat (722) and a linear drive module C (74), the sizing mandrel (721) is fixedly installed on the mounting seat (722), and the outer diameter of the sizing mandrel (721) is matched with the inner hole of the stator assembly (8); the linear drive module C (74) is installed on the surface of the equipment rack (1), and the output end of the linear drive module C (74) is connected with the mounting seat (722) of the lower die (72); the upper die (71) comprises an upper sizing die (711) and a connecting seat (712), and the lower surface of the upper sizing die (711) is matched with the upper core surface of the stator assembly (8); the piston rod of the servo thrust cylinder (73) is fixedly connected with the connecting seat (712) of the upper die (71).

8. The apparatus for automatically correcting the shape of a hole by vibration of a compressor motor according to claim 1, wherein The control system comprises a main controller, an operation panel and a plurality of sensors; the main controller is selected from a PLC controller or an industrial control computer, is used for processing signals collected by the sensors, and sends control instructions to the manipulator system (4), the vibration station (5), the tumbling station (6), the sizing station (7) according to a preset program; the operation panel is electrically connected with the main controller, is used for inputting operation instructions and displaying the running state of the equipment; the plurality of sensors are respectively installed at key positions of the manipulator system (4), the vibration station (5), the tumbling station (6) and the sizing station (7), are used for monitoring the running parameters of the stations in real time, and transmit monitoring signals to the main controller.

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