Intelligent roundness detection control equipment and method for efficient generator connecting copper pipe

Abstract

The invention relates to intelligent roundness detection control equipment for a high-efficiency generator connecting copper pipe and a detection method of the intelligent roundness detection control equipment. The vertical section limiting sets and the arc section limiting sets are arranged on the base, the number of the vertical section limiting sets and the number of the arc section limiting sets are consistent with the number of the connecting copper pipes, and the vertical section limiting sets and the arc section limiting sets are alternately arranged at equal intervals along the circumference; the plurality of connecting copper pipes are arranged at equal intervals in the height direction, so that preliminary roundness detection is realized; the arc section limiting group rotates along the tangential direction of the circumference where the arc section limiting group is located and is provided with a roundness detection needle head, and the needle head rotates along with the arc section limiting group and is in contact with the unclosed arc section, so that the roundness of each connecting copper pipe is detected again; and the intelligent detection unit comprises a data acquisition module, a signal processing module, a central control module and a result output module. The device has the following advantages that mechanical limiting, precise driving and intelligent measurement and control are integrated through modular and integrated design, the structure is compact, the automation degree is high, and the detection efficiency and consistency are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of motor manufacturing and precision detection of new energy power generation equipment, and particularly relates to an intelligent roundness detection and control device and method for high-efficiency generator connecting copper pipes. BACKGROUND

[0002] The high-efficiency energy-saving generator is a key component of new energy power generation equipment. The outer circumference of the generator parallel ring needs to be installed with multiple connecting copper pipes in the shape of an arc. The connecting copper pipe has excellent electrical conductivity, efficiently transmits current, and reduces energy loss at the connection. The tubular structure of the connecting copper pipe has a larger surface area, which can enhance heat dissipation through natural convection or forced air cooling. The pipe body of the multiple connecting copper pipes on the outside of the parallel ring is in the shape of an open arc, which needs to be installed in a circular structure on the outer circumference of the parallel ring.

[0003] The connecting copper pipe has a special structure, with the pipe body being an open arc segment, which is an under-constrained structure. The end lacks the continuity of a closed ring, the bending moment cannot be transmitted through the ring, and the arc is easily changed. Moreover, the two ends of the open arc segment have a transition section and a vertical section. The open arc segment itself is prone to deformation during placement. After the pressure from the end to the transition section and the vertical section, the bending moment distribution and local curvature of the arc are changed, which affects the overall arc of the connecting copper pipe, causing buckling or deformation of the processed connecting copper pipe. After installation on the outside of the parallel ring, the roundness of the multiple connecting copper pipes cannot be guaranteed. Fatigue cracks are easily generated during the operation of the motor. Uneven roundness leads to uneven current distribution and reduced heat dissipation capacity of the motor.

[0004] Currently, before the multiple connecting copper pipes are installed on the parallel ring (multiple connecting copper pipes are needed on each parallel ring to form a circular structure), the processed connecting copper pipes are usually placed directly on the arc-shaped positioning frame. The connecting copper pipes are prone to deformation to some extent under asymmetric stress distribution. During installation, it is easy to have inconsistent installation gaps between the multiple connecting copper pipes and the parallel ring (in order to ensure good performance of the motor, the parallel ring and the connecting copper pipe must be installed without gaps). At this time, different installation gap pads need to be matched with corresponding conformal materials, which brings great inconvenience to the installation of the parallel ring and the connecting copper pipe. Even if some connecting copper pipes are deformed greatly, the roundness of the connecting copper pipe is greatly different from that of the remaining connecting copper pipes on the outside of the parallel ring, which requires replacement of the connecting copper pipe, increasing the processing cost and wasting materials.

[0005] Therefore, the roundness control and inspection of multiple connecting copper tubes before installation onto the parallel ring is extremely important, directly affecting the motor's current transmission, installation efficiency, cost control, and overall performance. With the development of industries such as new energy vehicles and high-end equipment manufacturing, the requirements for the efficiency, reliability, and manufacturing precision of large motors are becoming increasingly stringent. Traditional roundness inspection methods cannot meet the demands of intelligent, high-precision, and traceable modern manufacturing, necessitating the introduction of intelligent inspection methods that integrate sensing, data judgment, and feedback control. Summary of the Invention

[0006] The purpose of this invention is to overcome the above-mentioned shortcomings and provide an efficient intelligent roundness detection and control device and method for generator connection copper tubes. Through modular and integrated design, mechanical limit, precision drive and intelligent measurement and control are integrated into one, with a compact structure and high degree of automation, which significantly improves detection efficiency and consistency.

[0007] The objective of this invention is achieved through the following technical solution: a high-efficiency intelligent roundness detection and control device for generator connecting copper pipes, wherein the connecting copper pipe has an unclosed arc segment, both ends of which extend horizontally inward through a transition segment and further extend vertically upward through a vertical segment, and the lengths of the vertical segments of multiple connecting copper pipes increase sequentially; characterized in that it includes: Base; Multiple vertical segment limit groups and multiple arc segment limit groups are all set on the base, with the number of each being consistent with the number of connecting copper pipes, and are arranged alternately at equal intervals along the circumference; In this configuration, the two vertical segments of each connecting copper tube are respectively positioned on two corresponding vertical segment limit groups, and the non-closed arc segment is positioned on the corresponding arc segment limit group. The distance between adjacent arc segment limit groups and vertical segment limit groups is consistent with the length of the transition segment. Multiple connecting copper tubes are arranged at equal intervals along the height direction to achieve preliminary roundness detection. The arc segment limiting group rotates along the tangent direction of the circumference and is equipped with a roundness detection needle. The needle contacts the unclosed arc segment as the arc segment limiting group rotates, thereby realizing the roundness detection of each connecting copper tube again. The intelligent detection unit includes a data acquisition module, a signal processing module, a central control module, and a result output module. The data acquisition module acquires displacement analog signals from the roundness detection probe. After filtering, amplification, and analog-to-digital conversion by the signal processing module, the digital signals are transmitted to the central control module. This module uses a roundness evaluation algorithm to calculate roundness error, performs tolerance comparison and intelligent decision-making, and finally, the result output module completes the result display, warning prompts, and data reporting to the higher-level manufacturing execution system, thereby realizing an automated and intelligent closed loop from data acquisition to quality control.

[0008] A further improvement of the present invention is that: the arc segment limiting assembly includes a rotating seat vertically arranged on the base, the rotating seat having an arc-shaped limiting groove for embedding multiple unclosed arc segments, the multiple arc-shaped limiting grooves being evenly distributed from top to bottom, and the arc surface of the arc-shaped limiting grooves engaging with the outer end face of the unclosed arc segment; the outer side of the rotating seat has a vertical cover plate for embedding multiple unclosed arc segments in the arc-shaped limiting grooves, the vertical cover plate having a roundness detection needle near each unclosed arc segment, the roundness detection needle engaging with the outer end of the unclosed arc segment; and the bottom of the base has a rotating drive component for driving the multiple rotating seats to rotate circumferentially.

[0009] A further improvement of the present invention is that: the rotary drive component includes an annular hole on the base for multiple rotating seats to be embedded and rotated; the lower end of the base is located at the position of the annular hole and has a ring beam; the ring beam, the annular hole, and multiple connecting copper tubes are arranged concentrically around the circle formed by them; a connecting piece is provided between the upper end face of the ring beam and the bottom of the rotating seat; the connecting piece passes through the annular hole; the inner wall of the ring beam has a gear ring; the lower end face of the base has multiple reduction motors; the drive end of the reduction motor is fitted with a gear that meshes with the gear ring; when the reduction motor is started, the gear meshes with the gear ring, driving the ring beam to reciprocate in a circular motion, thereby driving the corresponding arc segment limit group to reciprocate between two adjacent vertical segment limit groups, and simultaneously driving multiple roundness detection probes to detect the roundness of the unclosed arc segment.

[0010] A further improvement of the present invention is that: the lower end face of the base has a plurality of C-shaped frames that are circumferentially distributed at equal intervals along the ring beam, the ring beam is embedded in the plurality of C-shaped frames and the openings of the C-shaped frames are oriented toward the ring beam.

[0011] A further improvement of the present invention is that multiple vertical segment limiting groups and multiple C-shaped frames are sequentially and correspondingly arranged vertically.

[0012] A further improvement of the present invention is that: the vertical segment limiting group includes a fixed support seat disposed on the upper end of the base, the fixed support seat has a limiting slot for vertically embedding the vertical segment, the outer side of the fixed support seat has a clamping block for clamping and positioning the vertical segment, and a buffer layer is provided on the inner wall of the vertical segment that contacts the clamping block and the limiting slot.

[0013] A further improvement of the present invention is that the inner wall of the C-shaped frame is embedded with a plurality of ball bearings that respectively contact the upper and lower end faces of the ring beam.

[0014] A further improvement of the present invention is that a self-lubricating material layer is provided on the contact surface between the rotating seat and the C-shaped frame.

[0015] A method for detecting the roundness of an external copper tube in a parallel ring, comprising the following steps: S1. Multiple connecting copper tubes are sequentially staggered and positioned on the vertical segment limiting group and the arc segment limiting group, so that the multiple connecting copper tubes surround to form a ring structure. During the positioning process, if a certain connecting copper tube cannot be positioned in the limiting slot of the vertical segment limiting group or the arc-shaped limiting slot of the arc segment limiting group, the result output module of the intelligent detection unit will immediately prompt that the positioning of the connecting copper tube has failed and does not meet the detection requirements, thereby realizing the preliminary roundness control detection of multiple connecting copper tubes. S2. After the multiple connecting copper tubes are positioned, the central control module commands the geared motor of the rotary drive component to start, driving the ring beam to reciprocate in a circular motion, thereby driving multiple roundness detection probes to scan and detect the roundness of the unclosed arc segments of the multiple connecting copper tubes. S3. The data acquisition module collects the displacement signal of the roundness detection needle in real time, and sends it to the central control module after being converted by the signal processing module. S4. The central control module processes data based on the roundness evaluation algorithm, generates the roundness error value of each connecting copper tube and the overall roundness evaluation result, and displays, alarms and uploads the data through the result output module, so as to realize intelligent online roundness detection and quality control of multiple connecting copper tubes simultaneously.

[0016] A further improvement of the present invention is that the specific steps of the roundness evaluation algorithm include: S41. The central control module receives multiple displacement digital signals from the signal processing module, corresponding to the different angular positions of each roundness probe. S42. For each connecting copper pipe, using the ideal arc center of its unclosed arc segment as a reference, calculate the radial deviation between each actual measurement point and the reference circle. S43. Calculate the range of all radial deviations as the roundness error value of the connecting copper pipe; S44. Compare the roundness error value of each connecting copper tube with the preset tolerance threshold. If the roundness error value of any connecting copper tube exceeds the tolerance, the part is deemed unqualified, and a quality control instruction containing the specific out-of-tolerance part identifier is generated.

[0017] Compared with the prior art, the present invention has the following advantages: 1. This invention pre-positions multiple processed connecting copper tubes on a roundness control and detection device. Multiple circumferentially distributed arc segment limiting groups provide positioning support for multiple non-closed arc segments that are staggered vertically to form a circular structure, ensuring balanced force at each position of the multiple non-closed arc segments. Multiple circumferentially distributed vertical segment limiting groups provide positioning support for multiple vertical segments that are staggered circumferentially, effectively balancing the tensile stress on the ends of the non-closed arc segments by the transition section and the vertical segment, preventing the processed connecting copper tubes from buckling or deforming during placement. At the same time, the multiple vertical segment limiting groups and arc segment limiting groups perform preliminary roundness screening for multiple connecting copper tubes that are staggered vertically to form a circular structure. If a connecting copper tube cannot be positioned within the corresponding vertical segment limiting group and arc segment limiting group, the intelligent detection unit will immediately alarm, achieving rapid initial screening and error prevention. Therefore, this device has three functions: positioning support, initial screening and detection, and deformation prevention and control. The invention drives multiple arc segment limit groups to rotate synchronously and reciprocally through a rotating drive component, so that the roundness detection needles set on them can perform full circumferential scanning of the non-closed arc segments, realize fine re-inspection of the roundness, greatly expand the detection coverage area, and improve the reliability and comprehensiveness of the detection results.

[0018] 2. This invention integrates an intelligent detection unit. A data acquisition module acquires high-precision displacement signals in real time. After filtering, amplification, and analog-to-digital conversion by the signal processing module, the central control module calculates roundness error and compares tolerances based on a roundness evaluation algorithm. This achieves objective, quantitative, and traceable quality evaluation. The result output module not only provides local display and audible / visual alarms but also reports the detection data to the higher-level manufacturing execution system, providing data support for process optimization, quality traceability, and production scheduling. This truly realizes a technological leap from manual judgment to intelligent decision-making, and from offline sampling to online full inspection. Through modular and integrated design, this invention integrates mechanical limiters, precision drives, and intelligent measurement and control into a compact structure with a high degree of automation, significantly improving detection efficiency and consistency. It is suitable for the intelligent upgrade and digital workshop construction needs in the manufacturing process of large generators. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the intelligent roundness detection and control system in this invention.

[0020] Figure 2 This is a schematic diagram of the structure of a single connecting copper tube in this invention.

[0021] Figure 3 This is a schematic diagram of the structure of an intelligent roundness detection and control device for connecting copper pipes of a high-efficiency generator according to the present invention.

[0022] Figure 4 for Figure 3 A schematic diagram of the structure of the middle circular arc segment limiting assembly.

[0023] Figure 5 for Figure 3 A schematic diagram of the bottom structure.

[0024] Figure 6 for Figure 5 A schematic diagram of the contact between the C-shaped frame and the gear ring.

[0025] Numbering on the map: 1-Connecting copper pipe, 2-Base, 3-Vertical segment limit group, 4-Circular arc segment limit group, 5-Rotation drive component; 11-Unclosed circular arc segment, 12-Transition segment, 13-Vertical segment; 31-Fixed support base, 32-Limiting slot, 33-Clamping block; 41-Rotating seat, 42-Arc-shaped limiting groove, 43-Vertical cover plate, 44-Roundness detection needle; 51-ring hole, 52-ring beam, 53-connecting piece, 54-gear ring, 55-gear motor, 56-gear, 57-C-shaped frame, 58-ball bearing. Detailed Implementation

[0026] To enhance understanding of the present invention, the present invention will be further described in detail below with reference to embodiments and accompanying drawings. These embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0027] In the description of this invention, it should be understood that the terms indicating orientation or positional relationship, such as those based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the structure or unit referred to must have a specific orientation, and therefore should not be construed as a limitation of this invention.

[0028] In this invention, unless otherwise explicitly specified and limited, terms such as “connection,” “provided with,” and “have” should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. They can be described as a mechanical connection, a direct connection, or a connection through an intermediate medium. Those skilled in the art can understand the basic meaning of the above terms in this invention according to the specific circumstances.

[0029] A high-efficiency intelligent roundness detection and control device for generator connecting copper pipes, referring to Figure 1 , Figure 2 The connecting copper pipe 1 has an open arc segment 11, the two ends of which extend horizontally inward through a transition segment 12 and further extend vertically upward through a vertical segment 13. The lengths of the vertical segments 13 of the multiple connecting copper pipes 2 increase sequentially; including: Base 2; Multiple vertical segment limit groups 3 and multiple arc segment limit groups 4 are all set on the base 2, and the number of each is the same as the number of connecting copper pipes 1, and they are arranged alternately at equal intervals along the circumference; Among them, the two vertical segments 13 of each connecting copper tube 1 are respectively positioned on two corresponding vertical segment limit groups 3, and the non-closed arc segment 11 is positioned on the corresponding arc segment limit group 4. The distance between the adjacent arc segment limit group 4 and the vertical segment limit group 3 is consistent with the length of the transition segment 12. Multiple connecting copper tubes 1 are arranged at equal intervals along the height direction to achieve preliminary roundness detection. The arc segment limiting group 4 rotates along the tangent direction of the circumference and is equipped with a roundness detection needle 44. The needle contacts the unclosed arc segment 11 as the arc segment limiting group 4 rotates, thereby realizing the roundness detection of each connecting copper tube 1 again. The intelligent detection unit includes a data acquisition module, a signal processing module, a central control module, and a result output module. The data acquisition module acquires displacement analog signals from the roundness detection probe. After filtering, amplification, and analog-to-digital conversion by the signal processing module, the digital signals are transmitted to the central control module. This module uses a roundness evaluation algorithm to calculate roundness error, performs tolerance comparison and intelligent decision-making, and finally, the result output module completes the result display, warning prompts, and data reporting to the higher-level manufacturing execution system, thereby realizing an automated and intelligent closed loop from data acquisition to quality control.

[0030] This invention pre-positions multiple processed connecting copper tubes on a roundness control and detection device. Multiple circumferentially distributed arc segment limiting groups provide positioning support for multiple non-closed arc segments that are staggered vertically to form a circular structure, ensuring balanced force at each position of the multiple non-closed arc segments. Multiple circumferentially distributed vertical segment limiting groups provide positioning support for multiple vertical segments that are staggered circumferentially, effectively balancing the tensile stress on the ends of the non-closed arc segments by the transition section and the vertical segment, preventing the processed connecting copper tubes from buckling or deforming during placement. At the same time, the multiple vertical segment limiting groups and arc segment limiting groups perform preliminary roundness screening for multiple connecting copper tubes that are staggered vertically to form a circular structure. If a connecting copper tube cannot be positioned within the corresponding vertical segment limiting group or arc segment limiting group, the intelligent detection unit will immediately alarm, achieving rapid initial screening and error prevention. Therefore, this device has three functions: positioning support, initial screening and detection, and deformation prevention and control. The invention drives multiple arc segment limit groups to rotate synchronously and reciprocally through a rotating drive component, so that the roundness detection needles set on them can perform full circumferential scanning of the non-closed arc segments, realize fine re-inspection of the roundness, greatly expand the detection coverage area, and improve the reliability and comprehensiveness of the detection results.

[0031] Based on this embodiment, refer to Figure 4The arc segment limiting group 4 includes a rotating seat 41 vertically mounted on the base 2. The rotating seat 41 has an arc-shaped limiting groove 42 for embedding multiple unclosed arc segments 11. The multiple arc-shaped limiting grooves 42 are evenly distributed from top to bottom, and the arc surface of the arc-shaped limiting groove 42 is in contact with the outer end face of the unclosed arc segment 11. The outer side of the rotating seat 41 has a vertical cover plate 43 for embedding multiple unclosed arc segments 11 in the arc-shaped limiting grooves 42. The vertical cover plate 43 has a roundness detection needle 44 near each unclosed arc segment 11. The roundness detection needle 44 is in contact with the outer end of the unclosed arc segment 11. The bottom of the base 2 has a rotating drive 5 for driving the multiple rotating seats 41 to rotate circumferentially.

[0032] During installation, the vertical cover plate 43 and the rotating seat 41 are detachably installed and fixed by bolts. In order to ensure the smooth reciprocating rotation of the arc segment limit group 4 on the unclosed arc segment 11, the arc-shaped limit groove 42 and the unclosed arc segment 11 are in clearance fit. The certain clearance space also avoids wear between the unclosed arc segment 11 and the rotating seat 41.

[0033] Based on this embodiment, refer to Figure 5 The rotary drive component 5 includes an annular hole 51 set on the base 2 for multiple rotating seats 41 to be embedded and rotated. The lower end of the base 2 is located at the position of the annular hole 51 and has a ring beam 52. The ring beam 52, the annular hole 51 and multiple connecting copper tubes 1 are arranged concentrically around the circle formed by them. There is a connecting piece 53 between the upper end face of the ring beam 52 and the bottom of the rotating seat 41. The connecting piece 53 passes through the annular hole 51. The inner wall of the ring beam 52 has a gear ring 54. The lower end face of the base 2 has multiple reduction motors 55. The drive end of the reduction motor 55 is fitted with a gear 56 that meshes with the gear ring 54. When the reduction motor 55 is started, the gear 56 meshes with the gear ring 54, driving the ring beam 52 to reciprocate in a circular motion. This drives the corresponding arc segment limit group 4 to reciprocate between two adjacent vertical segment limit groups 3, and simultaneously drives multiple roundness detection needles 44 to detect the roundness of the unclosed arc segment 11.

[0034] Furthermore, the lower end face of the base 2 has a plurality of C-shaped frames 57 that are circumferentially distributed at equal intervals along the ring beam 52. The ring beam 52 is embedded in the plurality of C-shaped frames 57 and the openings of the C-shaped frames 57 are set facing the ring beam 52.

[0035] The C-shaped frames 57, which are evenly spaced and circumferentially distributed, provide good support for the base 2. At the same time, the C-shaped frames 57 also limit the ring beam 52 to a certain extent, ensuring that the ring beam 52 is always concentrically set with the circular structure formed by the multiple connecting copper tubes 1 during the rotation process. This ensures that the multiple arc segment limit groups 4 connected to the ring beam 52 remain concentric with the multiple non-closed arc segments 11 during the rotation process, thereby achieving the accuracy of the roundness detection of the connecting copper tubes 1 by the multiple roundness detection needles 44.

[0036] Based on this embodiment, multiple vertical segment limit groups 3 and multiple C-shaped frames 57 are sequentially arranged vertically and vertically.

[0037] It should be noted that multiple vertical segment limit groups 3 are fixedly installed at the upper end of the base 2, while multiple C-shaped frames 57 are fixedly installed at the bottom of the base 2. Since each arc segment limit group 4 reciprocates within two adjacent vertical segment limit groups 3 to detect the roundness of the unclosed arc segment 11, in order to maximize the movement distance of the arc segment limit group 4 between two adjacent vertical segment limit groups 3 and improve the detection range of the unclosed arc segment 11, multiple vertical segment limit groups 3 and multiple C-shaped frames 57 in this application are sequentially and correspondingly arranged vertically and vertically. This not only effectively supports multiple connecting copper pipes 1 and ring beams 52, but also maximizes the clearance space for the movement of the vertical segment limit groups 3.

[0038] Based on this embodiment, the vertical segment limiting group 3 includes a fixed support 31 disposed on the upper end of the base 2. The fixed support 31 has a limiting slot 32 for vertically embedding the vertical segment 13. The outer side of the fixed support 31 has a clamping block 33 for clamping and positioning the vertical segment 13. A buffer layer is provided on the inner wall of the vertical segment 13 that contacts the clamping block 33 and the limiting slot 32.

[0039] Due to the special structure of the connecting steel pipe 1 in this application, the unclosed arc segment 11 is prone to buckling or deformation under the pressure of the transition segment 12 and the vertical segment 13. The setting of the vertical segment limit group 3 restricts the degree of freedom of the unclosed arc segment 11, preventing the end from deforming freely. At the same time, after the end is clamped, it provides rigid constraint to the end, increases the critical buckling load, significantly improves the overall stiffness, and prevents the connecting steel pipe 1 from undergoing arc changes or deformation.

[0040] The unclosed arc segment 11 of the connecting copper pipe 1 is embedded in the arc-shaped limiting groove 42 of the rotating seat 41, and the vertical segment 13 of the connecting copper pipe 1 is embedded in the limiting slot 32 of the fixed support seat 31. The multiple connecting copper pipes 1 are supported in a balanced and stable manner in the vertical direction of the horizontal direction machine, which further ensures the balanced force of the connecting copper pipe 1 during the support process.

[0041] The fixed support 31 and the clamping block 33 can be detachably fixed by bolts. The reason why the inner wall of the vertical section 13 in contact with the clamping block 33 and the limiting groove 32 is provided with a buffer layer is as follows: Since the vertical section 13 and the fixed support 31 are both made of metal, the workpiece is prone to slippage under clamping force or vibration due to direct metal-to-metal contact. The buffer layer provides additional gripping force to the vertical section 13, which can effectively clamp the surface of the vertical section 13. Secondly, as a soft medium, the buffer layer can evenly distribute the clamping pressure, greatly reducing or avoiding physical damage to the vertical section 13. Moreover, the buffer layer has a certain compressive deformation capacity, which can adaptively fill the small gap between the vertical section 13 and the clamping surface, providing a more uniform and reliable clamping force.

[0042] Based on this embodiment, refer to Figure 6 The inner wall of the C-shaped frame 57 is embedded with multiple balls 58 that are in contact with the upper and lower end faces of the ring beam 52 respectively. The arrangement of the balls 58 greatly reduces the force required to drive the load, evenly distributes the load, and avoids thermal deformation caused by excessive heat from sliding friction (without balls, the contact area increases and the frictional heat is greater during sliding), thereby ensuring the stable and long-lasting rotation of the ring beam 52.

[0043] Based on this embodiment, the contact surfaces of the rotating seat 41 and the C-shaped frame 57 are provided with a self-lubricating material layer to reduce wear between the relatively sliding contact surfaces.

[0044] A method for detecting the roundness of an external copper tube in a parallel ring, comprising the following steps: S1. Multiple connecting copper tubes 1 are sequentially staggered and positioned on the vertical section limiting group 3 and the arc section limiting group 4, so that the multiple connecting copper tubes 1 surround to form a circular structure. During the positioning process, if a certain connecting copper tube 1 cannot be positioned in the limiting slot 32 of the vertical section limiting group 3 or the arc-shaped limiting slot 42 of the arc section limiting group 4, the result output module of the intelligent detection unit will immediately prompt that the positioning of the connecting copper tube has failed and does not meet the detection requirements, thereby realizing the preliminary roundness control detection of multiple connecting copper tubes 1. S2. After the multiple connecting copper tubes 1 are positioned, the central control module commands the reduction motor 55 of the rotation drive component to start, driving the ring beam 52 to reciprocate in a circular motion, thereby driving multiple roundness detection needles 44 to scan and detect the roundness of the unclosed arc segment 11 of the multiple connecting copper tubes 1. S3. The data acquisition module acquires the displacement signal of the roundness detection needle 44 in real time, and sends it to the central control module after being converted by the signal processing module. S4. The central control module processes data based on the roundness evaluation algorithm, generates the roundness error value of each connecting copper tube 1 and the overall roundness evaluation result, and displays, alarms and uploads the data through the result output module, so as to realize intelligent online roundness detection and quality control of multiple connecting copper tubes 1.

[0045] The specific steps of the roundness evaluation algorithm include: S41, The central control module receives multiple displacement digital signals from the signal processing module, corresponding to each roundness detection probe 44 at different angular positions; S42. For each connecting copper pipe 1, take the ideal arc center of its unclosed arc segment 11 as the reference and calculate the radial deviation between each actual measurement point and the reference circle. S43. Calculate the range of all radial deviations as the roundness error value of the connecting copper pipe 1; S44. Compare the roundness error value of each connecting copper tube 1 with the preset tolerance threshold. If the roundness error value of any connecting copper tube 1 exceeds the tolerance, the part is determined to be unqualified, and a quality control instruction containing the specific out-of-tolerance part identifier is generated.

[0046] This invention integrates an intelligent detection unit. A data acquisition module acquires high-precision displacement signals in real time. After filtering, amplification, and analog-to-digital conversion by the signal processing module, the central control module calculates roundness error and compares tolerances based on a roundness evaluation algorithm. This achieves objective, quantitative, and traceable quality evaluation. The result output module not only provides local display and audible / visual alarms but also reports the detection data to the higher-level manufacturing execution system, providing data support for process optimization, quality traceability, and production scheduling. This truly realizes a technological leap from manual judgment to intelligent decision-making, and from offline sampling to online full inspection. Through modular and integrated design, this invention combines mechanical limiters, precision drives, and intelligent measurement and control into a compact structure with a high degree of automation, significantly improving detection efficiency and consistency. It is suitable for the intelligent upgrade and digital workshop construction needs in large generator manufacturing processes.

[0047] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A high-efficiency intelligent roundness detection and control device for generator connecting copper pipes, wherein the connecting copper pipe has an open arc segment, both ends of which extend horizontally inward through a transition segment and further extend vertically upward through a vertical segment, and the lengths of the vertical segments of multiple connecting copper pipes increase sequentially; characterized in that, include: Base; Multiple vertical segment limit groups and multiple arc segment limit groups are all set on the base, with the number of each being consistent with the number of connecting copper pipes, and are arranged alternately at equal intervals along the circumference; In this configuration, the two vertical segments of each connecting copper tube are respectively positioned on two corresponding vertical segment limit groups, and the non-closed arc segment is positioned on the corresponding arc segment limit group. The distance between adjacent arc segment limit groups and vertical segment limit groups is consistent with the length of the transition segment. Multiple connecting copper tubes are arranged at equal intervals along the height direction to achieve preliminary roundness detection. The arc segment limiting group rotates along the tangent direction of the circumference and is equipped with a roundness detection needle. The needle contacts the unclosed arc segment as the arc segment limiting group rotates, thereby realizing the roundness detection of each connecting copper tube again. The intelligent detection unit includes a data acquisition module, a signal processing module, a central control module, and a result output module. The data acquisition module acquires displacement analog signals from the roundness detection probe, and after filtering, amplification, and analog-to-digital conversion by the signal processing module, the digital signals are transmitted to the central control module. This module uses a roundness evaluation algorithm to calculate roundness error, performs tolerance comparison and intelligent decision-making, and finally, the result output module completes the result display, warning prompts, and data reporting to the higher-level manufacturing execution system, thereby realizing an automated and intelligent closed loop from data acquisition to quality control.

2. The intelligent roundness detection and control device for high-efficiency generator connecting copper pipes according to claim 1, characterized in that: The arc segment limiting assembly includes a rotating seat vertically mounted on a base. The rotating seat has arc-shaped limiting grooves for embedding multiple unclosed arc segments. The multiple arc-shaped limiting grooves are evenly spaced from top to bottom, and the arc surface of the arc-shaped limiting grooves is in contact with the outer end face of the unclosed arc segment. The outer side of the rotating seat has a vertical cover plate for embedding multiple unclosed arc segments in the arc-shaped limiting grooves. The vertical cover plate has a roundness detection needle near each unclosed arc segment. The roundness detection needle is in contact with the outer end of the unclosed arc segment. The bottom of the base has a rotary drive component that drives the multiple rotating seats to rotate circumferentially.

3. The intelligent roundness detection and control device for high-efficiency generator connecting copper pipes according to claim 2, characterized in that: The rotary drive component includes an annular hole on the base for multiple rotating seats to be embedded and rotate. A ring beam is located at the lower end of the base, positioned within the annular hole. The ring beam, the annular hole, and multiple connecting copper pipes are arranged concentrically around a circle. A connecting piece is located between the upper end face of the ring beam and the bottom of the rotating seat, passing through the annular hole. A gear ring is located on the inner wall of the ring beam. Multiple reduction motors are located on the lower end face of the base. A gear meshing with the gear ring is fitted onto the drive end of each reduction motor. When the reduction motor starts, the gear meshes with the gear ring, driving the ring beam to reciprocate in a circular motion. This causes the corresponding arc segment limit group to reciprocate between two adjacent vertical segment limit groups, simultaneously driving multiple roundness detection probes to detect the roundness of the unclosed arc segment. The central control module is connected to the reduction motor for controlling its start / stop, speed, and reciprocating rotation angle.

4. The intelligent roundness detection and control device for high-efficiency generator connecting copper pipes according to claim 3, characterized in that: The lower end face of the base has multiple C-shaped frames that are evenly spaced circumferentially distributed along the ring beam. The ring beam is embedded in the multiple C-shaped frames and the openings of the C-shaped frames face the ring beam.

5. The intelligent roundness detection and control device for high-efficiency generator connecting copper pipes according to claim 4, characterized in that: The multiple vertical segment limit groups and multiple C-shaped frames are sequentially and correspondingly arranged vertically.

6. The intelligent roundness detection and control device for high-efficiency generator connecting copper pipes according to claim 5, characterized in that: The vertical segment limiting assembly includes a fixed support seat set at the upper end of the base. The fixed support seat has a limiting slot for vertically embedding the vertical segment. The outer side of the fixed support seat has a clamping block for clamping and positioning the vertical segment. A buffer layer is provided on the inner wall of the vertical segment that contacts the clamping block and the limiting slot.

7. The intelligent roundness detection and control device for high-efficiency generator connecting copper pipes according to claim 6, characterized in that: The inner wall of the C-shaped frame is embedded with multiple ball bearings that contact the upper and lower end faces of the ring beam respectively.

8. The intelligent roundness detection and control device for high-efficiency generator connecting copper pipes according to claim 7, characterized in that: The contact surface between the rotating base and the C-shaped frame is provided with a self-lubricating material layer.

9. A method for intelligent roundness detection and control of large generator connecting copper pipes according to any one of claims 6 to 8, characterized in that: The specific steps include, S1. Multiple connecting copper tubes are sequentially staggered and positioned on the vertical segment limiting group and the arc segment limiting group, so that the multiple connecting copper tubes surround to form a ring structure. During the positioning process, if a certain connecting copper tube cannot be positioned in the limiting slot of the vertical segment limiting group or the arc-shaped limiting slot of the arc segment limiting group, the result output module of the intelligent detection unit will immediately prompt that the positioning of the connecting copper tube has failed and does not meet the detection requirements, thereby realizing the preliminary roundness control detection of multiple connecting copper tubes. S2. After the multiple connecting copper tubes are positioned, the central control module commands the geared motor of the rotary drive component to start, driving the ring beam to reciprocate in a circular motion, thereby driving multiple roundness detection probes to scan and detect the roundness of the unclosed arc segments of the multiple connecting copper tubes. S3. The data acquisition module collects the displacement signal of the roundness detection needle in real time, and sends it to the central control module after being converted by the signal processing module. S4. The central control module processes data based on the roundness evaluation algorithm, generates the roundness error value of each connecting copper tube and the overall roundness evaluation result, and displays, alarms and uploads the data through the result output module, so as to realize intelligent online roundness detection and quality control of multiple connecting copper tubes simultaneously.

10. The intelligent roundness detection and control method for large generator connecting copper pipes according to claim 9, characterized in that: The specific steps of the roundness evaluation algorithm include: S41. The central control module receives multiple displacement digital signals from the signal processing module, corresponding to the different angular positions of each roundness probe. S42. For each connecting copper pipe, using the ideal arc center of its unclosed arc segment as a reference, calculate the radial deviation between each actual measurement point and the reference circle. S43. Calculate the range of all radial deviations as the roundness error value of the connecting copper pipe; S44. Compare the roundness error value of each connecting copper tube with the preset tolerance threshold. If the roundness error value of any connecting copper tube exceeds the tolerance, the part is deemed unqualified, and a quality control instruction containing the specific out-of-tolerance part identifier is generated.

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