Stator assembly detection method, device and equipment

Abstract

The invention relates to the technical field of stator detection, in particular to a detection method, device and equipment for a stator assembly. Generating optimized load parameters according to the stator manufacturing state and a preset model database; controlling a pin inserting machine to insert a PIN into a pin inserting hole according to the optimized load parameter; analyzing the state of the pin to obtain the outline of the PIN; according to a preset standard axis, carrying out included angle calculation on the outline of the PIN to obtain an axis included angle; when the axis included angle is smaller than or equal to an included angle threshold value, a preliminary qualified detection signal is generated; the pin inserting machine ensures the pin inserting precision, analyzes the pin inserting state to calculate the included angle between the PIN and the standard axis, quantifies the pin bending degree, effectively recognizes the hidden pin bending defect, gives an alarm in time when the included angle exceeds a threshold value, facilitates the quick troubleshooting of the parameters or positioning deviation of the pin inserting machine, improves the production efficiency and the assembly precision of a stator assembly, and guarantees the operation reliability of a shaded pole motor.

Description

Technical Field

[0001] This invention relates to the field of stator testing technology, and specifically to a method, apparatus, and equipment for testing stator components. Background Technology

[0002] As a core refrigeration device for both household and commercial use, the energy efficiency of freezers is directly related to the reliability of their core component, the shaded-pole motor. Shaded-pole motors, due to their simple structure, low cost, and low energy consumption, have become the mainstream drive component in freezer refrigeration systems. The stator assembly, as a core component of the shaded-pole motor, directly affects the motor's operating efficiency, noise level, and lifespan through its pin insertion accuracy, winding parameters, and load performance. In the stator assembly production process, the pin insertion process is a critical step, requiring that the pin insertion position meet design requirements; otherwise, it can easily lead to winding short circuits, poor contact, and other malfunctions. Current technologies for detecting the pin insertion position are limited in scope, relying solely on visual inspection or a single sensor to check the pin status. This method is prone to human error, resulting in a high rate of missed detections for hidden defects such as bent pins and insufficient assembly precision, impacting the reliability of the shaded-pole motor, product quality, and overall production efficiency. Summary of the Invention

[0003] To address the shortcomings of the prior art, this invention proposes a method, apparatus, and device for detecting stator components.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a method for detecting stator components, applied to a device for detecting stator components. The device for detecting stator components includes a stator, pins, a frame, a pin insertion machine, and a shaded-pole motor. The frame is mounted on the shaded-pole motor, the stator is mounted on the frame, and the frame has pin insertion holes. The pins are inserted and pulled into the pin insertion holes, and the pin insertion machine is drivenly connected to the pins. The method for detecting stator components includes the following steps: acquiring the stator manufacturing status and generating optimized load parameters based on the stator manufacturing status and a preset model database; controlling the pin insertion machine to insert the pins into the pin insertion holes according to the optimized load parameters; acquiring the pin insertion status and analyzing the pin insertion status to obtain the pin profile; calculating the included angle of the pin profile according to a preset standard axis to obtain the axis angle; determining whether the axis angle is less than or equal to a preset included angle threshold; and generating a preliminary qualified detection signal when the axis angle is less than or equal to the included angle threshold.

[0005] Furthermore, the step of generating optimized load parameters based on the stator manufacturing status and a preset model database includes: performing a status analysis on the stator manufacturing status; when the stator manufacturing status is completed, obtaining the actual position of the skeleton and performing a deviation analysis on the actual position of the skeleton according to a preset standard position to obtain a first analysis result; when the first analysis result is a position standard, obtaining the stator model; obtaining the load configuration parameters from the model database according to the stator model; and optimizing the load configuration parameters according to a preset PIN diameter to obtain optimized load parameters.

[0006] Furthermore, the step of analyzing the pin state to obtain the pin outline includes: analyzing the pin state; when the pin state is the pin insertion completed state, entering the detection state; in the detection state, acquiring the pin image; and performing feature analysis on the pin image according to a preset image ranging method and a preset Sobel operator to obtain the pin outline.

[0007] Further, the step of performing feature analysis on the PIN image according to a preset image ranging method and a preset Sobel operator to obtain the PIN outline includes: performing feature analysis on the PIN image according to the image ranging method to obtain the exposed height; performing comparative analysis on the exposed height according to a preset standard height to obtain a second analysis result; when the second analysis result indicates that the exposed height is normal, performing feature analysis on the PIN image according to the Sobel operator to obtain the gradient magnitude and gradient direction; and identifying the PIN image according to a preset high threshold, a preset low threshold, gradient magnitude, and gradient direction to obtain the PIN outline.

[0008] Furthermore, the step of calculating the included angle of the PIN pin profile according to the preset standard axis to obtain the included angle of the axis includes: obtaining the coordinates of multiple positioning points from the preset planar coordinate system according to the PIN pin profile; analyzing the PIN pin profile according to the coordinates of the multiple positioning points to obtain the reference coordinates; generating the PIN pin axis according to the reference coordinates; and calculating the included angle of the PIN pin axis according to the standard axis to obtain the included angle of the axis.

[0009] Furthermore, after the step of generating a preliminary qualified detection signal when the included angle of the axis is less than or equal to the included angle threshold, the method further includes: acquiring pin pressure data, and analyzing the pin pressure data according to the preset maximum allowable pressure value and the preset minimum allowable pressure value to obtain pressure detection results; when the pressure detection result indicates that the PIN pin is under normal force, acquiring the actual voltage and actual current of the motor; and generating qualified calibration data based on the optimized load parameters, the actual voltage and actual current of the motor.

[0010] Furthermore, the step of generating qualified calibration data based on optimized load parameters, actual motor voltage, and actual motor current includes: calculating the actual motor voltage and actual motor current to obtain the actual load impedance; calculating the difference between the actual load impedance and a preset impedance threshold to obtain the impedance difference; determining whether the impedance difference is less than or equal to a preset difference threshold; and generating qualified calibration data based on optimized load parameters, PIN pin images, pin pressure data, actual motor voltage, actual motor current, actual load impedance, impedance difference, and the measured impedance difference.

[0011] Furthermore, a stator assembly testing device performs the stator assembly testing method as described in any one of the above descriptions. The stator assembly testing device includes a control unit, a stator assembly, a pin insertion machine electrically connected to the control unit, and a shaded-pole motor. The stator assembly is mounted on the shaded-pole motor, and the pin insertion machine is drively connected to the stator assembly.

[0012] Furthermore, the stator assembly includes a stator, pins, and a frame. The frame is mounted on the shaded-pole motor, the stator is mounted on the frame, and the frame has pin insertion holes. The pins are plugged into and pulled into the pin insertion holes, and the pin insertion mechanism is drivenly connected to the pins.

[0013] Furthermore, a testing device for a stator assembly includes: a memory and at least one processor, wherein the memory stores instructions;

[0014] At least one of the processors invokes the instructions in the memory to cause the stator assembly detection device to perform the steps of the stator assembly detection method as described in any of the preceding descriptions.

[0015] The beneficial effects of the stator assembly detection method of the present invention are as follows:

[0016] By acquiring the stator manufacturing status and combining it with the model database to generate optimized load parameters, invalid operations on incomplete stators are avoided, reducing resource waste. At the same time, it ensures that the parameters are accurately matched with the stator model, laying a reliable foundation for subsequent processes. Based on the optimized load parameters, the pin insertion machine is controlled to accurately insert PIN pins, ensuring pin insertion accuracy and consistency. Subsequently, by analyzing the pin insertion status, the PIN pin profile can be obtained, and its angle with the standard axis can be calculated. The degree of PIN pin bending can be accurately quantified, effectively identifying hidden bending defects. When the angle exceeds the threshold, an alarm is triggered and the machine is stopped in time, facilitating rapid troubleshooting of pin insertion machine parameters or positioning deviations. This improves production efficiency and stator assembly accuracy, ensures the reliability of shaded-pole motor operation, and meets the high-efficiency quality inspection and quality control requirements of automated production. Attached Figure Description

[0017] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0018] Figure 1 This is a first flowchart of a method for detecting a stator assembly according to an embodiment of the present invention;

[0019] Figure 2 This is a second flowchart of a method for detecting a stator assembly provided in an embodiment of the present invention;

[0020] Figure 3 This is a third flowchart of a method for detecting a stator assembly provided in an embodiment of the present invention;

[0021] Figure 4 This is a fourth flowchart of a method for detecting a stator assembly provided in an embodiment of the present invention;

[0022] Figure 5 A fifth flowchart of a method for detecting a stator assembly provided in an embodiment of the present invention;

[0023] Figure 6 A sixth flowchart of a method for detecting a stator assembly provided in an embodiment of the present invention;

[0024] Figure 7 A seventh flowchart of a method for detecting a stator assembly provided in an embodiment of the present invention;

[0025] Figure 8 This is a schematic diagram of the structure of a stator assembly provided in an embodiment of the present invention;

[0026] Figure 9 This is a schematic diagram of the structure of a stator assembly testing device provided in an embodiment of the present invention.

[0027] Figure Labels

[0028] 1-Stator; 2-PIN pin; 3-Frame. Detailed Implementation

[0029] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" or "having" and any variations thereof are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0031] For ease of understanding, the specific process of an embodiment of the present invention is described below. A method for detecting stator assemblies is applied to a detection device for stator assemblies. The detection device for stator assemblies includes a stator, pins, a bobbin, a pin insertion machine, and a shaded-pole motor. The bobbin is mounted on the shaded-pole motor, and the stator is mounted on the bobbin. The pin insertion machine is also equipped with a turntable fixture. The bobbin is mounted on the turntable fixture and is rotatably connected to the turntable fixture. After the bobbin is manually placed into the turntable fixture, the turntable rotates 90° to complete the feeding. The main shaft rises and sends the turntable fixture to the pin insertion position. Subsequently, the pin insertion process of automatic pin crimping, automatic pin insertion, and automatic cutting is performed sequentially. After completion, the turntable moves, and the robot unloads the material, thereby realizing the automated operation process of pin insertion on the stator bobbin. The machine feeds in parallel and discharges via a conveyor belt. It can insert round pins and pins. The bobbin has pin insertion holes, and the pins are inserted and pulled into the pin insertion holes. The pin insertion machine is drivenly connected to the pins. Please refer to [link to relevant documentation]. Figure 1 An embodiment of a method for detecting a stator assembly according to the present invention includes:

[0032] 101. Obtain the stator manufacturing status and generate optimized load parameters based on the stator manufacturing status and the preset model database;

[0033] In this embodiment, by obtaining the stator manufacturing status and generating optimized load parameters in combination with the model database, invalid operations on unfinished stators can be avoided, reducing resource waste; at the same time, it ensures that the load parameters are accurately matched with the stator model, providing a reliable basis for subsequent processes and improving production efficiency and quality consistency.

[0034] 102. Control the pin insertion machine to insert the PIN pins into the pin insertion holes according to the optimized load parameters;

[0035] In this embodiment, the optimized load parameters (digital signals) are converted into analog commands (such as voltage and current) for each actuator of the pin insertion machine by the PLC controller.

[0036] 103. Obtain the pin status and analyze the pin status to obtain the pin outline;

[0037] 104. Calculate the included angle of the PIN pin profile according to the preset standard axis to obtain the included angle of the axis;

[0038] In this embodiment, by calculating the angle between the PIN pin profile and the standard axis, the degree of PIN pin bending can be accurately quantified, effectively identifying hidden bending defects and avoiding motor failures caused by bending pins; providing data support for quality control and process optimization, and improving the quality of stator components and the reliability of motor operation;

[0039] 105. Determine whether the included angle of the axes is less than or equal to the preset included angle threshold;

[0040] 106. When the included angle of the axes is less than or equal to the included angle threshold, a preliminary qualified detection signal is generated;

[0041] In this embodiment, when the included angle of the axis is less than or equal to the included angle threshold, it is determined that a bent pin or no pin is detected, an alarm is activated and the machine is stopped, which facilitates timely investigation of pin insertion machine parameters or positioning deviations, reduces the risk of batch defects, strengthens quality control, ensures the assembly accuracy of stator components, improves the operational reliability of shaded pole motors, and adapts to the high-efficiency quality inspection requirements of automated production.

[0042] In this embodiment, by acquiring the stator manufacturing status and combining it with the model database to generate optimized load parameters, invalid operations on incomplete stators are avoided, reducing resource waste. At the same time, it ensures that the parameters are accurately matched with the stator model, laying a reliable foundation for subsequent processes. Based on the optimized load parameters, the pin insertion machine is controlled to accurately insert PIN pins, ensuring pin insertion accuracy and consistency. Subsequently, by analyzing the pin insertion status, the PIN pin profile can be obtained, and its angle with the standard axis can be calculated. The degree of PIN pin bending can be accurately quantified, effectively identifying hidden bending defects. When the angle exceeds the threshold, an alarm is triggered and the machine is stopped in time, facilitating rapid troubleshooting of pin insertion machine parameters or positioning deviations. This improves production efficiency and stator assembly accuracy, ensures the reliability of shaded-pole motor operation, and meets the high-efficiency quality inspection and quality control requirements of automated production.

[0043] Please see Figure 2 In a second embodiment of a method for detecting a stator assembly according to the present invention, step 101 includes:

[0044] 201. Perform state analysis on the stator manufacturing process;

[0045] In this embodiment, the stator manufacturing progress data (such as whether the winding, skeleton assembly and other processes are completed) is collected in real time by the production management system (MES) or equipment sensors (such as process completion signalers and vision sensors) to determine whether it is in the manufacturing completion state. The subsequent process is only started for stators that have completed all the preceding processes, so as to avoid invalid operations on unfinished products (such as unwound windings and unassembled skeletons) and reduce resource waste.

[0046] 202. When the stator manufacturing status is "manufacturing completed", the actual position of the skeleton is obtained, and the deviation of the actual position of the skeleton is analyzed according to the preset standard position to obtain the first analysis result.

[0047] In this embodiment, after the stator is manufactured, the actual position coordinates of the skeleton on the stator (such as the X-axis and Y-axis coordinates in a plane coordinate system with the stator center as the origin) are obtained by a high-precision visual positioning system (such as a 2D vision camera with a positioning algorithm) or a laser displacement sensor. The actual position of the skeleton is compared with the preset standard position coordinates (calibrated according to the stator design drawings, the allowable deviation range is usually ±0.1mm), and the position deviation (ΔX, ΔY) is calculated to form the first analysis result. If the deviation is within the allowable range, the position is determined to be standard; if it exceeds the range, an adjustment command is triggered (such as fine-tuning the skeleton position using a fixture).

[0048] 203. If the first analysis result is the position standard, then obtain the stator model;

[0049] 204. Obtain the load configuration parameters from the model database based on the stator model;

[0050] 205. Optimize the load configuration parameters according to the preset PIN diameter to obtain optimized load parameters;

[0051] In this embodiment, when the frame position meets the standard, the stator model (such as different stator models that are adapted to the freezer capacity) is obtained by barcode scanning (model barcode affixed to the stator surface) or visual character recognition (OCR). Based on the model, the corresponding load configuration parameters (such as pin pressure range, pin insertion speed adapted to PIN pin diameter, motor load impedance reference value, etc.) are retrieved from the preset model database to ensure that the parameters of the subsequent pin insertion process are accurately matched with the stator model.

[0052] In this embodiment, by analyzing the stator manufacturing status, subsequent processes are initiated only for completed products, avoiding unnecessary operations and reducing resource waste; high-precision vision or laser detection of the skeleton position ensures skeleton positioning accuracy and reduces the risk of pin misalignment; the stator model is identified by barcode or OCR, and matching load parameters are retrieved from the database, combined with PIN pin diameter optimization parameters to ensure that pin insertion pressure, speed, etc. are compatible with the product. The entire process is automated, reducing manual intervention, improving production efficiency and consistency, laying the foundation for accurate execution of subsequent processes, effectively reducing quality risks, and adapting to the production needs of multiple stator models.

[0053] Please see Figure 3 In a third embodiment of a method for detecting a stator assembly according to the present invention, step 103 includes:

[0054] 301. Analyze the status of the insertion pins;

[0055] 302. When the pin insertion status is "pin insertion complete", the system enters the detection state.

[0056] In this embodiment, the stroke sensor or pressure sensor built into the pin insertion machine (linked with the pin insertion pressure detection) determines in real time whether the pin insertion action is completed (such as the pin insertion machine reaching the preset end position or the pressure curve entering the stable stage). The subsequent detection process is triggered only when the pin insertion is determined to be completed, thus avoiding the detection of products in invalid states such as no pin insertion or half-pin insertion.

[0057] 303. In detection mode, acquire the PIN pin image;

[0058] In this embodiment, after entering the detection state, the industrial camera acquires images of the PIN pins. The acquisition parameters (such as focal length and exposure time) are dynamically adjusted according to the PIN pin model (round pin or straight pin) and size (such as using high resolution mode for 0.3mm fine pins) to ensure that the edges of the PIN pins are clear and the grayscale contrast is obvious in the image.

[0059] 304. Perform feature analysis on the PIN image based on the preset image ranging method and the preset Sobel operator to obtain the PIN outline;

[0060] In this embodiment, image ranging and Sobel operator analysis of PIN pin images are combined to accurately extract the contours. Image ranging provides a size reference, while the Sobel operator strengthens the edges and effectively filters out noise, ensuring the integrity and accuracy of the contours, providing reliable data for subsequent testing, and improving the accuracy of stator assembly quality testing.

[0061] In this embodiment, by accurately determining the pin insertion completion status, invalid detection of products with incomplete or partially inserted pins is avoided. After entering the detection state, the industrial camera acquires the PIN pin image, ensuring clear image edges and obvious grayscale contrast. Then, the image ranging method and the Sobel operator are combined to extract the contour. The former provides a size reference, while the latter strengthens the edges, ensuring the integrity and accuracy of the contour, improving detection efficiency and accuracy, providing reliable data for subsequent detection, enhancing the quality control capability of the stator assembly, and helping to ensure the reliability of motor operation.

[0062] Please see Figure 4 In a fourth embodiment of a method for detecting a stator assembly according to the present invention, step 304 includes:

[0063] 401. Perform feature analysis on the PIN pin image using image ranging methods to obtain the exposed height;

[0064] 402. Compare and analyze the exposed height according to the preset standard height to obtain the second analysis result;

[0065] In this embodiment, based on image ranging technology (such as binocular vision or monocular ranging algorithm), the size of the PIN pin image is converted to extract the exposed height of the PIN pin (the vertical distance from the skeleton surface to the tip of the PIN pin). This step uses a preset standard height range (such as 0.3-0.6mm for round pins corresponding to an exposed height of 2-4mm, and 0.8-1.2mm corresponding to 3-5mm) as a benchmark to quickly determine whether the height is abnormal. If it exceeds the range (too short may cause poor contact, too long may cause winding interference), an alarm is directly triggered and the machine is stopped.

[0066] 403. When the second analysis result is that the exposed height is normal, the PIN needle image is subjected to feature analysis according to the Sobel operator to obtain the gradient magnitude and gradient direction.

[0067] In this embodiment, when the exposed height is normal, the Sobel operator is used to perform edge detection on the PIN image. The Sobel operator calculates the gradient of the image in the X and Y directions in the plane coordinate system (corresponding to the horizontal edge and the vertical edge, respectively), and outputs the gradient magnitude (reflecting the edge intensity) and gradient direction (reflecting the edge direction), which can effectively highlight the grayscale difference between the PIN and the background (skeleton, fixture).

[0068] 404. The PIN needle image is identified based on the preset high threshold, preset low threshold, gradient magnitude, and gradient direction to obtain the PIN needle outline.

[0069] In this embodiment, a dual-threshold screening is performed on gradient magnitude and direction by combining a preset high threshold (strong edge determination standard) and a low threshold (weak edge association standard): strong edges with gradient magnitude higher than the high threshold are retained, while weak edges with gradient magnitude lower than the high threshold but higher than the low threshold and connected to the strong edges are included in the outline, and finally a complete PIN needle outline (including continuous edges of the top, side and root) is formed. This step can avoid outline breakage or redundancy caused by a single threshold.

[0070] In this embodiment, the exposed height of the PIN pin is accurately extracted using image ranging. Combined with a standard height, it is quickly determined whether the PIN pin height is normal. If the height is normal, the Sobel operator is used to extract gradient features, and then strong and weak edges are integrated through dual threshold filtering to form a complete PIN pin outline. This improves the accuracy of exposed height detection and the completeness of outline recognition, reducing the missed detection of hidden defects. The automated process speeds up the detection pace, adapts to high-speed production, and reduces human error. At the same time, it provides reliable data for subsequent testing, ensures the quality of the stator assembly, enhances the reliability of motor operation, and meets the performance requirements of the freezer equipment.

[0071] Please see Figure 5 In the fifth embodiment of a method for detecting a stator assembly according to the present invention, step 104 includes:

[0072] 501. Obtain the coordinates of multiple positioning points from the preset planar coordinate system based on the PIN pin outline;

[0073] In this embodiment, a planar coordinate system (e.g., with the center of the skeleton pin hole as the origin, the horizontal direction as X, and the vertical direction as Y) is used as the reference. Multiple positioning point coordinates (preferably 3) are extracted from the PIN pin outline image. The design of selecting 3 points is based on the geometric principle that three points determine a straight line. Usually, the top, middle and root of the PIN pin are selected to ensure that the entire length of the PIN pin is covered and to reduce the interference of local deformation on the overall axis judgment.

[0074] 502. Analyze the PIN pin profile based on the coordinates of multiple positioning points to obtain the reference coordinates;

[0075] In this embodiment, the coordinates of the three acquired positioning points are processed, and the equation of a straight line (such as y = kx + b) is fitted by the least squares method. The midpoint or perpendicular point of the line is calculated as the reference coordinates. The determination of the reference coordinates can offset the measurement error of a single point (such as coordinate offset caused by image noise) and ensure the stability of the subsequent axis generation.

[0076] 503. Generate the PIN needle axis based on the reference coordinates;

[0077] In this embodiment, the actual axis of the PIN needle (i.e., the PIN needle axis) is generated by taking the reference coordinates as the starting point and combining the slope (k) of the fitted straight line. This axis directly reflects the spatial tilt state of the PIN needle (such as tilting 3° to the left, tilting 5° to the right, etc.).

[0078] 504. Calculate the included angle of the PIN pin axis based on the standard axis to obtain the included angle of the axis;

[0079] In this embodiment, the angle between the actual axis of the generated PIN pin and a preset standard axis (such as a plumb line along the normal direction of the pin hole) is calculated using the vector dot product formula. In the formula, a is the axis of the PIN needle and b is the standard axis. The included angle value is calculated to quantify the degree of bending of the PIN needle.

[0080] In this embodiment, multiple positioning points are extracted based on the PIN pin contour. Based on the three-point alignment principle, a straight line is fitted using the least squares method to determine the reference coordinates, generating an actual axis reflecting the PIN pin's tilt state. Then, the angle with the standard axis is calculated using the vector dot product formula to quantify the degree of PIN pin bending, improving the accuracy of bent pin detection and reducing the missed detection of hidden defects. Standardized processes and automated calculations ensure consistent detection, adapt to large-scale production, and improve efficiency. At the same time, they provide data support for process optimization, ensure the quality of stator components, and enhance the reliability of motor operation.

[0081] Please see Figure 6 In a sixth embodiment of a method for detecting a stator assembly according to an embodiment of the present invention, after step 106, the method further includes:

[0082] 601. Obtain the pin pressure data and analyze the pin pressure data according to the preset maximum allowable pressure value and the preset minimum allowable pressure value to obtain the pressure detection result;

[0083] In this embodiment, a high-precision pressure sensor installed at the actuation end of the pin insertion machine is used to collect pressure data in real time during the insertion of the PIN pin into the skeleton (focusing on extracting the average pressure during the stable insertion phase). The collected pin pressure data is compared with the maximum and minimum allowable pressure values. If the data is within the range of the maximum and minimum allowable pressure values ​​(e.g., 2-5N for 0.3-0.6mm round pins, 2-8N for 0.8-1.2mm), the PIN pin force state is determined to be normal; if it exceeds the threshold, it is determined to be abnormal.

[0084] 602. When the pressure detection result shows that the PIN pin is under normal force, obtain the actual voltage and actual current of the motor.

[0085] In this embodiment, if the pressure detection result shows that the PIN pin is under normal force, the stator assembly is deemed qualified; if the pressure detection result shows that the PIN pin is under abnormal force, the stator assembly is deemed unqualified, and the processes such as tinning height, tinning time, flux replacement, and visual inspection of solder joints on the circuit board are automatically changed.

[0086] 603. Generate qualified calibration data based on optimized load parameters, actual motor voltage, and actual motor current;

[0087] In this embodiment, a high-precision pressure sensor is used to collect pin pressure data in real time, accurately determine the stress state, effectively identify hidden defects such as micro-cracks in the skeleton and poor contact of the pins, improve the assembly quality of the stator assembly, and when the pressure is normal, the motor electrical parameters are collected in conjunction to generate qualified calibration data. When there is an abnormality, it is directly judged as unqualified and subsequent processes such as tinning and flux replacement are automatically adjusted. This not only reduces manual intervention and misjudgment and improves detection efficiency, but also improves the quality traceability chain, ensures the stability and energy-saving performance of the freezer shaded pole motor, and adapts to the needs of large-scale production.

[0088] Please see Figure 7 In the seventh embodiment of a method for detecting a stator assembly according to the present invention, step 603 includes:

[0089] 701. Calculate the actual voltage and current of the motor to obtain the actual load impedance;

[0090] In this embodiment, the formula is used. Calculate the actual load impedance, where, This is the actual voltage of the motor. This is the actual current of the motor. The motor power factor (preset by the characteristics of the shaded pole motor) is calculated to directly reflect the equivalent electrical impedance after the stator winding and PIN pins are assembled. It is a core indicator for judging the reliability of electrical connections.

[0091] 702. Calculate the difference between the actual load impedance and the preset impedance threshold to obtain the impedance difference.

[0092] 703. Determine whether the impedance difference is less than or equal to the preset difference threshold;

[0093] 704. When the impedance difference is less than or equal to the difference threshold, then generate qualified calibration data based on optimized load parameters, PIN pin image, pin pressure data, actual motor voltage, actual motor current, actual load impedance, impedance difference, and the data.

[0094] In this embodiment, when the impedance difference is less than or equal to the difference threshold, it is determined to be electrically normal; a preset impedance threshold matching the stator model is used. ), and through formula Calculate the impedance difference. The actual impedance of the load is given, and the magnitude of the impedance difference directly corresponds to the degree of deviation in electrical performance. For example, Exceeding the difference threshold (e.g., 5% ×) When this occurs, it can be determined to be an electrical defect such as poor PIN contact or winding short circuit. By integrating optimized load parameters, PIN images (visual evidence of mechanical assembly), pin pressure data (mechanical parameters of the assembly process), actual motor voltage and current (operating parameters), and actual load impedance and impedance difference (quantified performance deviation value), complete qualified calibration data is formed. The data format is standardized and can be directly used for quality traceability and system optimization.

[0095] In this embodiment, the equivalent electrical impedance is calculated based on the actual voltage, current, and preset power factor of the motor. Combined with impedance threshold and difference threshold judgment, it can accurately identify hidden electrical defects such as poor PIN contact and winding short circuit, improve the detection rate of electrical defects, and effectively avoid the risk of malfunction of the refrigerator shaded pole motor. At the same time, it integrates and optimizes multi-dimensional data such as load parameters, PIN images, and pin pressure to generate standardized qualified calibration data, providing a complete chain support for quality traceability. It can quickly locate the root cause of the problem, and the qualified judgment results can also support the automated optimization of the production system, ensure the stability and energy consumption performance of motor operation, adapt to the needs of large-scale production, and improve product reliability and production control efficiency.

[0096] The above describes a method for detecting a stator assembly according to an embodiment of the present invention. The following describes a device for detecting a stator assembly according to an embodiment of the present invention. Please refer to [link to relevant documentation]. Figure 8 A schematic diagram of a stator assembly in an embodiment of the present invention is shown. A detection device for the stator assembly includes:

[0097] A stator assembly testing device performs a stator assembly testing method as described in any one of the above descriptions. The stator assembly testing device includes a control unit, a stator assembly, a pin insertion machine electrically connected to the control unit, and a shaded-pole motor. The stator assembly is mounted on the shaded-pole motor, and the pin insertion machine is drively connected to the stator assembly.

[0098] The stator assembly includes a stator 1, PIN pins 2, and a frame 3. The frame 3 is mounted on the shaded-pole motor, and the stator 1 is mounted on the frame 3. The pin insertion machine is also equipped with a turntable fixture, on which the frame 3 is mounted. The frame 3 is rotatably connected to the turntable fixture. After the frame 3 is manually placed into the turntable fixture, the turntable rotates 90° to complete the feeding. The main shaft rises and sends the turntable fixture to the pin insertion position. Subsequently, the pin insertion process of automatic PIN wire crimping, automatic pin insertion, and automatic cutting is performed in sequence. After completion, the turntable moves, and the robot unloads the material, thereby realizing the automated operation process of stator frame pin insertion. The machine feeds in parallel and discharges via a conveyor belt. It can insert round pins and straight pins. The frame 3 is provided with pin insertion holes, and the PIN pins 2 are inserted and unplugged into the pin insertion holes. The pin insertion machine is drivenly connected to the PIN pins 2.

[0099] In this embodiment, the stator assembly testing device achieves efficient production through an automated workflow. The operator only needs to place the frame 3 into the turntable fixture, and then feed it through the 90° rotation of the turntable and the spindle to the pin insertion position. The device automatically completes the PIN wire crimping, pin insertion, and cutting processes, and finally the robot unloads the material. The entire process requires minimal human intervention. The device adopts a parallel feeding and conveyor belt discharge design, which is suitable for the insertion requirements of round and straight pins and is compatible with the production of multiple types of PIN pins 2. The automated actions are precise and controllable, reducing human operation errors, improving pin insertion consistency and assembly accuracy, and helping to improve the overall quality and production efficiency of the shaded pole motor.

[0100] Figure 9 This is a schematic diagram of the structure of a stator assembly detection device 900 provided in an embodiment of the present invention. The stator assembly detection device 900 can vary significantly due to different configurations or performance characteristics. It may include one or more central processing units (CPUs) 910 (e.g., one or more processors) and a memory 920, and one or more storage media 930 (e.g., one or more mass storage devices) storing application programs 933 or data 932. The memory 920 and storage media 930 can be temporary or persistent storage. The program stored in the storage media 930 may include one or more modules (not shown in the diagram), each module including a series of instruction operations on the stator assembly detection device 900. Furthermore, the processor 910 may be configured to communicate with the storage media 930 and execute a series of instruction operations in the storage media 930 on the stator assembly detection device 900 to implement the steps of the stator assembly detection method provided in the above-described method embodiments.

[0101] A stator assembly testing device 900 may further include one or more power supplies 940, one or more wired or wireless network interfaces 950, one or more input / output interfaces 960, and / or one or more operating devices 931, such as Windows Server, MacOSX, Unix, Linux, FreeBSD, etc. Those skilled in the art will understand that... Figure 9 The structure of the stator assembly testing device 900 shown does not constitute a limitation on the stator assembly testing device 900, and may include more or fewer components than shown, or combine certain components, or have different component arrangements.

[0102] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the device or unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0103] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0104] The present invention and its embodiments have been described above. This description is not restrictive. The accompanying drawings are only one embodiment of the present invention. The actual content is not limited thereto. In short, if a person skilled in the art is inspired by this description and designs a similar structure and embodiment without departing from the spirit of the present invention, such design should fall within the protection scope of the present invention.

Claims

1. A method for detecting a stator assembly, characterized in that, A testing device for a stator assembly includes a stator, pins, a frame, a pin insertion machine, and a shaded-pole motor. The frame is mounted on the shaded-pole motor, the stator is mounted on the frame, and the frame has pin insertion holes. The pins are inserted and removed into the pin insertion holes, and the pin insertion machine is drivenly connected to the pins. The testing method for the stator assembly includes the following steps: Obtain the stator manufacturing status and generate optimized load parameters based on the stator manufacturing status and the preset model database; The pin insertion machine is controlled to insert the PIN pins into the pin insertion holes based on optimized load parameters; Obtain the pin status and analyze the pin status to obtain the pin outline; The included angle of the PIN pin profile is calculated based on the preset standard axis to obtain the included angle of the axis; Determine whether the included angle of the axes is less than or equal to a preset included angle threshold; When the included angle of the axes is less than or equal to the included angle threshold, a preliminary qualified detection signal is generated.

2. The method for detecting a stator assembly as described in claim 1, characterized in that, The process of generating optimized load parameters based on the stator manufacturing status and a preset model database includes: Perform state analysis on the stator manufacturing process; When the stator manufacturing status is completed, the actual position of the skeleton is obtained, and the deviation analysis of the actual position of the skeleton is performed according to the preset standard position to obtain the first analysis result. If the first analysis result is a position standard, then obtain the stator model; The load configuration parameters are obtained from the model database based on the stator model. The load configuration parameters are optimized based on the preset PIN diameter to obtain optimized load parameters.

3. The method for detecting a stator assembly as described in claim 1, characterized in that, The analysis of the pin state to obtain the pin profile includes: Analyze the status of the insertion pins; When the pin insertion status is "pin insertion complete", the system enters the detection state. In detection mode, acquire the PIN pin image; The PIN needle image is analyzed using a preset image ranging method and a preset Sobel operator to obtain the PIN needle profile.

4. The method for detecting a stator assembly as described in claim 3, characterized in that, The step of performing feature analysis on the PIN image based on a preset image ranging method and a preset Sobel operator to obtain the PIN outline includes: Feature analysis of the PIN pin image is performed using image ranging methods to determine the exposed height; A comparative analysis was conducted on the exposed height based on a preset standard height to obtain the second analysis result; If the second analysis result is that the exposed height is normal, then the PIN needle image is subjected to feature analysis according to the Sobel operator to obtain the gradient magnitude and gradient direction; The PIN needle image is identified based on a preset high threshold, a preset low threshold, gradient magnitude, and gradient direction to obtain the PIN needle outline.

5. The method for detecting a stator assembly as described in claim 1, characterized in that, The step of calculating the included angle of the PIN pin profile based on a preset standard axis to obtain the included angle of the axis includes: The coordinates of multiple positioning points are obtained from the preset planar coordinate system based on the PIN pin outline; The PIN pin profile is analyzed based on the coordinates of multiple positioning points to obtain the reference coordinates; Generate the PIN needle axis based on the reference coordinates; The included angle of the PIN pin axis is calculated based on the standard axis to obtain the included angle of the axis.

6. The method for detecting a stator assembly as described in claim 3, characterized in that, After the step of generating a preliminary qualified detection signal when the included angle of the axes is less than or equal to the included angle threshold, the method further includes: Acquire pin pressure data and analyze the pin pressure data according to the preset maximum allowable pressure value and the preset minimum allowable pressure value to obtain pressure detection results; If the pressure detection result indicates that the PIN pin is under normal force, then the actual voltage and actual current of the motor are obtained. Qualified calibration data is generated based on optimized load parameters, actual motor voltage, and actual motor current.

7. The method for detecting a stator assembly as described in claim 6, characterized in that, The process of generating qualified calibration data based on optimized load parameters, actual motor voltage, and actual motor current includes: The actual voltage and current of the motor are calculated to obtain the actual load impedance; The impedance difference is calculated based on the difference between the actual load impedance and the preset impedance threshold. Determine whether the impedance difference is less than or equal to a preset difference threshold; When the impedance difference is less than or equal to the difference threshold, qualified calibration data is generated based on optimized load parameters, PIN images, pin pressure data, actual motor voltage, actual motor current, actual load impedance, impedance difference, and the data.

8. A testing device for a stator assembly, characterized in that, The method for testing a stator assembly as described in any one of claims 1-7, wherein the testing device for the stator assembly includes a control unit, a stator assembly, a pin insertion machine electrically connected to the control unit, and a shaded-pole motor, wherein the stator assembly is disposed on the shaded-pole motor, and the pin insertion machine is drively connected to the stator assembly.

9. The detection device for a stator assembly as described in claim 8, characterized in that, The stator assembly includes a stator, pins, and a frame. The frame is mounted on the shaded-pole motor, the stator is mounted on the frame, and the frame has pin insertion holes. The pins are plugged into and pulled into the pin insertion holes, and the pin insertion mechanism is drivenly connected to the pins.

10. A testing device for a stator assembly, characterized in that, include: A memory and at least one processor, wherein the memory stores instructions; At least one of the processors invokes the instructions in the memory to cause the stator assembly detection device to perform the steps of the stator assembly detection method as claimed in any one of claims 1-7.

Images