Automatic press fitting device for motor commutator

Abstract

The invention relates to the technical field of machine manufacturing, and provides a motor commutator automatic press fitting device which comprises a rotary workbench, a plurality of station clamps, a hydraulic cylinder and an ultrasonic transducer. The plurality of station clamps are arranged on the rotary workbench, and the station clamps are used for placing commutators and rotors. The hydraulic cylinder is arranged on the rotary workbench and used for pressing the commutator and the rotor in the station clamp. And the ultrasonic transducer is arranged at the telescopic end of the hydraulic cylinder, and the ultrasonic transducer is used for applying ultrasonic vibration to the rotor in the station clamp. The press-fitting device has the effect of reducing friction force and generated internal stress in the press-fitting process.

Description

Technical Field

[0001] This application relates to the field of mechanical manufacturing technology, and proposes an automatic pressing device for motor commutators. Background Technology

[0002] As an indispensable power device in industrial production and daily life, the performance and quality of electric motors directly affect the operating efficiency and stability of various mechanical equipment. The commutator, as one of the key components of a motor, plays a crucial role in the performance of the motor due to the quality of its assembly with the rotor. With the development of industrial automation, the requirements for the efficiency and quality of motor production are becoming increasingly stringent, and the press-fitting process for motor commutators is constantly being improved and perfected. Efficient and precise press-fitting processes can improve motor production efficiency, reduce production costs, and simultaneously enhance motor performance and reliability, which is of great significance for promoting the development of the motor industry. In the field of motor commutator press-fitting, some semi-automatic press-fitting equipment achieves a certain degree of automation through mechanical structures. These devices typically use simple hydraulic or pneumatic drive devices to press the commutator and rotor together. However, during the press-fitting process, friction and extrusion forces cause deformation and internal stress in the commutator, thus affecting its service life. The aforementioned technologies suffer from the defect of causing deformation and internal stress in the commutator during the press-fitting process. Summary of the Invention

[0003] In order to reduce the deformation and internal stress of the commutator during the pressing process, this application provides an automatic pressing device for motor commutators.

[0004] The automatic pressing device for motor commutators provided in this application adopts the following technical solution: An automatic pressing device for motor commutators includes: Rotary worktable; Multiple station fixtures are set on the rotary worktable, and the station fixtures are used to place the commutator and the rotor; A hydraulic cylinder is disposed above the rotary table, and the hydraulic cylinder is used to press the commutator and the rotor in the workstation fixture. An ultrasonic transducer is disposed on the telescopic end of the hydraulic cylinder. The ultrasonic transducer is used to apply ultrasonic vibration to the rotor inside the workstation fixture. Specifically, during the process of the hydraulic cylinder pressing the rotor into the commutator, the ultrasonic transducer applies ultrasonic vibration to the rotor.

[0005] By adopting the above technical solution, the ultrasonic transducer applies ultrasonic vibrations to the pressure head via an amplitude transformer. During the pressing process between the rotor and the commutator, the pressure head transmits the ultrasonic vibrations to the rotor. This reduces the friction between the pressing surfaces of the rotor and the commutator, allowing the rotor to be smoothly and accurately pressed into the commutator with a smaller hydraulic thrust, effectively reducing pressing stress and the risk of workpiece damage. Furthermore, during the pressing process, the connection between the commutator and the rotor will deform due to pressing, generating internal stress. Applying ultrasonic vibrations to the rotor can effectively reduce the internal stress of the commutator, extending its service life.

[0006] Optionally, a pressure sensor is provided between the rotary table and the workstation fixture. The pressure sensor is connected to the ultrasonic transducer. The pressure sensor is used to detect the pressure information of the workstation fixture and feed the pressure information back to the ultrasonic transducer. When the pressure information meets the preset parameters, the ultrasonic transducer applies ultrasonic vibration to the rotor.

[0007] By adopting the above technical solution, the pressure sensor can measure the pressure information of the workstation fixture in real time and feed the pressure information back to the ultrasonic transducer. The ultrasonic transducer only starts ultrasonic vibration on the rotor when the pressure information received by the workstation fixture meets the preset parameters. This ensures that the rotor and transducer are subjected to ultrasonic vibration only after they are combined, avoiding the situation where the rotor and transducer are misaligned due to the premature application of ultrasonic vibration, thus ensuring the normal progress of the pressing process.

[0008] Optionally, the ultrasonic transducer is provided with an amplitude transformer, the amplitude transformer is provided with a pressure head, and the hydraulic cylinder is used to drive the pressure head to move so as to press the commutator and the rotor.

[0009] By adopting the above technical solution, the amplitude transformer ensures that ultrasonic energy can be efficiently amplified and concentratedly transmitted to the pressure head, thereby acting stably and effectively on the rotor and guaranteeing the effect of reducing friction. The pressure head serves as both a component for transmitting hydraulic cylinder pressure and a component for transmitting ultrasonic vibration, making the device structure more compact and reliable. It avoids the complex design requiring two independent mechanisms to apply force and vibration separately, simplifying the equipment structure and reducing manufacturing costs and failure rates.

[0010] Optionally, the automatic pressing device for the motor commutator further includes a platform, with a rotary worktable disposed on the platform and multiple station fixtures disposed on the rotary worktable. The platform has a loading station and a pressing station. The rotary worktable is used to drive the station fixtures to rotate, so as to sequentially cycle through the loading station and the pressing station. When the station fixture is located at the loading station, the user places the commutator and the rotor in the station fixture. When the station fixture is located at the pressing station, the hydraulic cylinder presses the commutator and the rotor in the station fixture.

[0011] By adopting the above technical solutions, the rotary table significantly shortens the production cycle of a single product. The hydraulic cylinders no longer need to wait for manual loading before starting work, enabling continuous production and significantly accelerating the overall production cycle of the unit, greatly increasing capacity. Operators only need to operate from a fixed loading station away from the danger zone of pressing, without needing to put their hands under the pressing head, greatly improving the safety and convenience of operation.

[0012] Optionally, the rotary worktable is provided with a slide rail, the platform is provided with a slide groove, and the slide rail is located in the slide groove.

[0013] By adopting the above technical solutions, the slide rails and chutes ensure that the rotary table runs smoothly during rotation, without shaking or wobbling. Furthermore, the slide rails and chutes guarantee that after each rotation stops, the fixtures at the workstations can be precisely aligned with the pressing or loading stations below, thus increasing the automation level of the device.

[0014] Optionally, the automatic pressing device for motor commutator further includes a drive motor, which is mounted on the platform. The rotary table is provided with a rotating shaft, and the output shaft of the drive motor is connected to the rotating shaft. The drive motor is used to drive the rotating shaft to rotate, thereby driving the rotary table to rotate.

[0015] By adopting the above technical solution, compared to manual rotation or simple pneumatic / hydraulic drive, using a drive motor (usually a stepper motor or servo motor) allows for precise control of the rotary table's start / stop, speed, and rotation angle. This enables precise program control of the workstation switching process, achieving true automation and improving the reliability and repeatability of workstation switching.

[0016] Optionally, the platform is provided with a cylinder, the telescopic end of the cylinder is provided with a locking block, and the rotary worktable is provided with multiple notches, which are used to engage with the locking block.

[0017] By adopting the above technical solution, the cylinder pushes the locking block to engage with the notch, allowing the rotary table to rotate precisely to the preset position, providing accurate positioning for subsequent pressing processes. The locking block and notch engagement provide a rigid mechanical lock between the rotary table and the platform, resisting pressing reaction forces during the pressing process and ensuring the stability of the pressing process.

[0018] Optionally, the automatic pressing device for the motor commutator further includes a position sensor, which is mounted on the platform and connected to the cylinder. The position sensor is used to detect the notch, wherein when the position sensor detects the notch, the cylinder pushes the locking block to lock into the notch.

[0019] By adopting the above technical solution, the position sensor detects the position of the notch, enabling the cylinder to accurately push the locking block into the notch, thus ensuring the accuracy of the locking.

[0020] Optionally, the platform is also provided with multiple buttons, which are connected to the hydraulic cylinder. When the user presses the button, the hydraulic cylinder presses the commutator and the rotor into place.

[0021] By adopting the above technical solution, dangerous actions such as rotation and pressing can only be started when the user presses the button with both hands at the same time (two-hand start button). This can ensure that the user's hands are in a safe position when pressing is started, preventing personal injury caused by accidental start.

[0022] Optionally, the automatic pressing device for motor commutator further includes a frame, which is mounted on the platform, and the hydraulic cylinder is mounted on the frame; a limiting post is provided between the frame and the platform, and a limiting plate is sleeved on the limiting post, and the limiting plate is connected to the telescopic end of the hydraulic cylinder.

[0023] By adopting the above technical solution, the limiting post and limiting plate provide precise guidance for the vertical movement of the press head, preventing the piston rod from deflecting or wobbling under force, and ensuring that the press head can always move vertically and stably downwards. The limiting post and limiting plate allow the lateral force or torsional load generated during pressing to be borne by the more robust frame and limiting post, rather than acting directly on the piston rod and seals of the hydraulic cylinder, thereby protecting the hydraulic cylinder and extending its service life.

[0024] In summary, this application includes at least one of the following beneficial technical effects: 1. The ultrasonic transducer applies ultrasonic vibrations to the pressure head via an amplitude transformer. During the pressing process between the rotor and the commutator, the pressure head transmits the ultrasonic vibrations to the rotor. This reduces the friction between the rotor and the pressing surfaces of the commutator, allowing the rotor to be smoothly and accurately pressed into the commutator with less hydraulic thrust, effectively reducing pressing stress and the risk of workpiece damage. Furthermore, during the pressing process, the connection between the commutator and the rotor will deform due to pressing, generating internal stress. Applying ultrasonic vibrations to the rotor can effectively reduce the internal stress of the commutator, extending its service life. 2. The pressure sensor can measure the pressure information of the workstation fixture in real time and feed the pressure information back to the ultrasonic transducer. The ultrasonic transducer will start ultrasonic vibration on the rotor only when the pressure information received by the workstation fixture meets the preset parameters. This ensures that the rotor and the transducer are subjected to ultrasonic vibration only after they are combined, avoiding the situation where the rotor and the transducer are misaligned due to the premature application of ultrasonic vibration, thus ensuring the normal progress of the pressing process. 3. The amplitude transformer ensures that ultrasonic energy is efficiently amplified and concentratedly transmitted to the pressure head, thereby acting stably and effectively on the rotor and guaranteeing the reduction of friction. The pressure head serves as both the component transmitting hydraulic cylinder pressure and the component transmitting ultrasonic vibration, making the device structure more compact and reliable. This avoids the complex design requiring two independent mechanisms to apply force and vibration separately, simplifying the equipment structure and reducing manufacturing costs and failure rates. 4. The limiting posts and plates provide precise guidance for the vertical movement of the press head, preventing the piston rod from deflecting or wobbling under force, ensuring that the press head always moves vertically and stably downwards. The limiting posts and plates also allow the lateral forces or torsional loads generated during pressing to be borne by the robust frame and limiting posts, rather than directly acting on the piston rod and seals of the hydraulic cylinder, thus protecting the hydraulic cylinder and extending its service life. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of an automatic pressing device for a motor commutator according to an embodiment of this application; Figure 2 yes Figure 1 Enlarged view of area A in the middle; Figure 3 This is an exploded schematic diagram of an automatic pressing device for a motor commutator according to an embodiment of this application; Figure 4 This is an exploded view of another perspective of an automatic pressing device for a motor commutator according to an embodiment of this application.

[0026] Explanation of reference numerals in the attached drawings: 10, platform; 11, slide rail; 13, cylinder; 14, snap-fit ​​block; 15, button; 20, frame; 30, rotary table; 31, slide rail; 32, notch; 33, shaft; 40, workstation fixture; 50, hydraulic cylinder; 51, pressure head; 52, limit plate; 53, limit post; 60, ultrasonic transducer; 61, amplitude transformer; 70, drive motor; 80, position sensor; 91, commutator; 92, rotor. Detailed Implementation

[0027] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0028] This application discloses an automatic pressing device for motor commutators.

[0029] Figure 1 This is a schematic diagram of the structure of an automatic pressing device for a motor commutator according to an embodiment of this application. Figure 2 yes Figure 1 Enlarged diagram of area A in the middle, Figure 3 This is an exploded schematic diagram of an automatic pressing device for a motor commutator according to an embodiment of this application. Figure 4 This is an exploded view of another perspective of an automatic pressing device for a motor commutator according to an embodiment of this application. (Refer to...) Figure 1 , Figure 2 , Figure 3 and Figure 4The automatic pressing device for the motor commutator includes a platform 10, a frame 20, a rotary table 30, multiple station fixtures 40, a hydraulic cylinder 50, an ultrasonic transducer 60, and a drive motor 70. The frame 20 and the rotary table 30 are both mounted on the platform 10, and the multiple station fixtures 40 are also mounted on the rotary table 30. The platform 10 is divided into a loading station and a pressing station. The rotary table 30 is used to drive the station fixtures 40 sequentially through the loading station and the pressing station. The platform 10 is the basic supporting component of the entire device; it can be made of metal, such as welded steel plates, and has good strength and stability. The shape of the platform 10 can be designed according to actual needs, generally rectangular, to facilitate the arrangement of various components. The rotary table 30 can have a disc-shaped structure and be made of metal. The station fixtures 40 are used to place the commutator and rotor. The station fixture 40 can be made of materials such as plastic or metal. The internal shape of the station fixture 40 is adapted to the external shape of the commutator 91 and the rotor 92, and can accurately position and fix the commutator 91 and the rotor 92. For example, station fixtures 40 of different sizes and shapes can be designed for commutators 91 and rotors 92 of different specifications. Multiple station fixtures 40 are distributed on the rotary table 30 and pass through the loading station and the pressing station in sequence as the rotary table 30 rotates.

[0030] The hydraulic cylinder 50 is mounted on the frame 20 and connected to the ultrasonic transducer 60. The hydraulic cylinder 50 is used to press-fit the commutator 91 and rotor 92 within the workstation fixture 40. The ultrasonic transducer 60 applies ultrasonic vibrations to the rotor 92 to reduce pressing friction and stress. The hydraulic cylinder 50 can be powered by a hydraulic pump, providing stable and powerful pressure during the pressing process to ensure pressing quality. The drive motor 70 is mounted on the platform 10, and its output shaft is connected to the rotary table 30. The drive motor 70 drives the rotary table 30 to rotate. The drive motor 70 can be a servo motor, possessing precise speed and position control capabilities. By controlling the speed and rotation angle of the drive motor 70, the movement of the rotary table 30 can be accurately controlled.

[0031] The platform 10 is provided with a slide groove 11, and the rotary worktable 30 is provided with a slide rail 31, which is located within the slide groove 11. The platform 10 is provided with a cylinder 13, and the telescopic end of the cylinder 13 is provided with a locking block 14. The rotary worktable 30 is provided with multiple notches 32, and the locking block 14 is used to engage with the notches 32.

[0032] The platform 10 is also equipped with a position sensor 80, which is also connected to the cylinder 13. The position sensor 80 is used to detect the notch 32. The position sensor 80 can be a photoelectric sensor. When the position sensor 80 detects that the notch 32 has rotated to a preset position, the cylinder 13 pushes the locking block 14 to lock with the notch 32.

[0033] The telescopic end of the hydraulic cylinder 50 is connected to the ultrasonic transducer 60. The ultrasonic transducer 60 is equipped with an amplitude transformer 61, and a pressure head 51 is mounted on the amplitude transformer 61. The hydraulic cylinder 50 drives the pressure head 51 to move, thereby pressing the commutator 91 and the rotor 92 within the workstation fixture 40. The ultrasonic transducer 60 applies ultrasonic vibrations to the pressure head 51 via the amplitude transformer 61, which in turn applies ultrasonic vibrations to the rotor 92 via the pressure head 51. The ultrasonic transducer 60 converts electrical energy into ultrasonic vibrations. The amplitude transformer 61 adjusts the amplitude of the ultrasonic vibrations to meet different pressing requirements. The shape and size of the pressure head 51 match the top of the rotor 92, enabling accurate application of pressure and transmission of ultrasonic vibrations.

[0034] The platform 10 is provided with a plurality of limiting posts 53, and a limiting plate 52 is fitted on each limiting post 53. The end of the limiting post 53 away from the platform 10 is connected to the frame 20. The limiting plate 52 is connected to the telescopic end of the hydraulic cylinder 50, and the limiting plate 52 can slide relative to the limiting post 53.

[0035] The platform 10 is also equipped with multiple buttons 15, which are connected to the hydraulic cylinder 50. When the user presses multiple buttons 15 at the same time, the hydraulic cylinder 50 pushes the pressure head 51 to press the commutator 91 and the rotor 92.

[0036] The rotary worktable 30 is provided with a rotating shaft 33, and the output end of the drive motor 70 is connected to the rotating shaft 33. The drive motor 70 is used to drive the rotating shaft 33 to rotate, so as to drive the rotary worktable 30 to rotate.

[0037] A pressure sensor is also provided between the workstation fixture 40 and the rotary table 30. The pressure sensor is connected to the ultrasonic transducer 60 and is used to detect the pressure information received by the workstation fixture 40 and feed the pressure information back to the ultrasonic transducer 60. When the pressure information reaches a preset parameter, the ultrasonic transducer 60 begins to apply ultrasonic vibration to the rotor 92. The pressure sensor can be a strain gauge pressure sensor. By monitoring the parameters of the pressure sensor, it is also possible to determine whether the pressing process is normal. For example, if the pressure is too high, it may indicate over-pressing; if the pressure is too low, it may indicate incomplete pressing. Based on the feedback information from the pressure sensor, the pressing parameters can be adjusted in a timely manner to ensure the pressing quality.

[0038] The platform 10 is also equipped with multiple buttons 15, which are connected to the hydraulic cylinder 50. When the user presses all of the buttons 15, the hydraulic cylinder 50 initiates the pressing action. The buttons 15 can be mechanical buttons or touch buttons for convenient user operation.

[0039] The relevant technology generally uses a hydraulic device to press the commutator 91 and the rotor 92 together. During the pressing process, both the commutator 91 and the rotor 92 will deform and generate internal stress, which will affect the service life of the components.

[0040] In this embodiment of the application, when the hydraulic cylinder 50 presses the commutator 91 and the rotor 92 together, the ultrasonic transducer 60 mounted on the telescopic end of the hydraulic cylinder 50 converts electrical energy into high-frequency (typically above 20kHz) mechanical vibration. This vibration is amplified and focused by the amplitude transformer 61 and ultimately transmitted to the pressure head 51 connected to the amplitude transformer 61. Therefore, when the pressure head 51 contacts the top of the rotor 92, it simultaneously applies two forces to the rotor 92: a static pressing force with a stable direction and a large value, and a high-frequency reciprocating micro-vibration force in the pressing direction.

[0041] When the pressure head 51 transmits the composite force to the rotor 92, the high-frequency vibration causes the rotor 92 and the inner bore contact surface of the commutator 91 to periodically separate and re-engage. This microscopic "knocking" effect greatly disrupts the static friction between the two, transforming it into a dynamic friction process much smaller than the static friction. This allows the rotor 92 to smoothly slide into the commutator 91 with less hydraulic thrust, reducing deformation caused by excessive friction.

[0042] During the press-fit process with an interference fit, both the inner bore of the commutator 91 and the journal of the rotor 92 undergo plastic or elastic deformation, generating internal stress. The high-frequency energy introduced by ultrasonic vibration activates dislocation movement within the material, promoting stress relaxation. This is equivalent to "mechanical annealing" the material at a microscale, effectively releasing and redistributing the stress remaining inside the workpiece after press-fitting, thereby significantly improving the fatigue resistance and service life of the commutator 91.

[0043] The implementation principle of the automatic pressing device for a motor commutator according to an embodiment of this application is as follows: The ultrasonic transducer 60 applies ultrasonic vibration to the pressing head 51 through the amplitude transformer 61. During the pressing process of the rotor 92 and the commutator 91, the pressing head 51 transmits ultrasonic vibration to the rotor 92, which reduces the friction between the pressing surfaces of the rotor 92 and the commutator 91. This allows the rotor 92 to be smoothly and accurately pressed into the commutator 91 with a smaller hydraulic thrust, effectively reducing pressing stress and the risk of workpiece damage. Furthermore, during the pressing process, the connection between the commutator 91 and the rotor 92 will deform due to pressing, generating internal stress. Applying ultrasonic vibration to the rotor 92 can effectively reduce the internal stress of the commutator 91 and extend the service life of the commutator 91.

[0044] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An automatic pressing device for motor commutators, characterized in that, include: Rotary worktable (30); Multiple station fixtures (40) are set on the rotary table (30), and the station fixtures (40) are used to place the commutator (91) and the rotor (92). A hydraulic cylinder (50) is disposed above the rotary table (30). The hydraulic cylinder (50) is used to press the commutator (91) and the rotor (92) in the workstation fixture (40). An ultrasonic transducer (60) is disposed on the telescopic end of the hydraulic cylinder (50). The ultrasonic transducer (60) is used to apply ultrasonic vibration to the rotor (92) inside the workstation fixture (40). During the process of the hydraulic cylinder (50) pressing the rotor (92) into the commutator (91), the ultrasonic transducer (60) applies ultrasonic vibration to the rotor (92).

2. The automatic pressing device for motor commutators according to claim 1, characterized in that, A pressure sensor is provided between the rotary table (30) and the workstation fixture (40). The pressure sensor is connected to the ultrasonic transducer (60). The pressure sensor is used to detect the pressure information received by the workstation fixture (40) and feed the pressure information back to the ultrasonic transducer (60). When the pressure information meets the preset parameters, the ultrasonic transducer (60) applies ultrasonic vibration to the rotor (92).

3. The automatic pressing device for motor commutators according to claim 1, characterized in that, The ultrasonic transducer (60) is provided with an amplitude transformer (61), the amplitude transformer (61) is provided with a pressure head (51), and the hydraulic cylinder (50) is used to drive the pressure head (51) to move so as to press the commutator (91) and the rotor (92).

4. The automatic pressing device for motor commutators according to claim 1, characterized in that, It also includes a platform (10), the rotary worktable (30) is set on the platform (10), and multiple workstation fixtures (40) are set on the rotary worktable (30). The platform (10) is provided with a loading station and a pressing station. The rotary worktable (30) is used to drive the workstation fixtures (40) to rotate so as to pass through the loading station and the pressing station in sequence. When the workstation fixture (40) is located at the loading station, the user places the commutator (91) and the rotor (92) in the workstation fixture (40). When the workstation fixture (40) is located at the pressing station, the hydraulic cylinder (50) presses the commutator (91) and the rotor (92) in the workstation fixture (40).

5. The automatic pressing device for motor commutators according to claim 4, characterized in that, The rotary worktable (30) is provided with a slide rail (31), and the platform (10) is provided with a slide groove (11). The slide rail (31) is located in the slide groove (11).

6. The automatic pressing device for motor commutators according to claim 4, characterized in that, It also includes a drive motor (70), which is mounted on the platform (10). The rotary table (30) is provided with a rotating shaft (33). The output shaft of the drive motor (70) is connected to the rotating shaft (33). The drive motor (70) is used to drive the rotating shaft (33) to rotate, so as to drive the rotary table (30) to rotate.

7. The automatic pressing device for motor commutators according to claim 4, characterized in that, The platform (10) is provided with a cylinder (13), and the telescopic end of the cylinder (13) is provided with a snap-fit ​​block (14). The rotary worktable (30) is provided with multiple notches (32), and the notches (32) are used to snap-fit ​​with the snap-fit ​​block (14).

8. The automatic pressing device for motor commutators according to claim 7, characterized in that, It also includes a position sensor (80) disposed on the platform (10), the position sensor (80) being connected to the cylinder (13), the position sensor (80) being used to detect the notch (32), wherein when the position sensor (80) detects the notch (32), the cylinder (13) pushes the latching block (14) to latch with the notch (32).

9. The automatic pressing device for motor commutators according to claim 7, characterized in that, The platform (10) is also provided with a number of buttons (15), which are connected to the hydraulic cylinder (50). When the user presses the button (15), the hydraulic cylinder (50) presses the commutator (91) and the rotor (92) together.

10. The automatic pressing device for motor commutators according to claim 7, characterized in that, It also includes a frame (20), which is mounted on the platform (10), and the hydraulic cylinder (50) is mounted on the frame (20); a limiting post (53) is provided between the frame (20) and the platform (10), and a limiting plate (52) is sleeved on the limiting post (53), and the limiting plate (52) is connected to the telescopic end of the hydraulic cylinder (50).

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