Rotor segment riveting device and riveting method thereof

Abstract

The application discloses a rotor sectional riveting device and a riveting method thereof, and comprises a riveting mechanism, a pressing mechanism, a bearing platform with a riveting station, a riveting unit, a stroke sleeve which is sleeved on the top end of a riveting head and is internally provided with a rebound mechanism, a measuring unit for detecting the displacement of the stroke sleeve, and a controller internally provided with a PID algorithm, and the controller is connected with each mechanism to realize signal transmission and action control. The application provides three embodiments of single-riveting-head rotary type, multi-riveting-head grouping type and multi-riveting-head adjustable type, can realize real-time detection of rivet position deviation and dynamic calibration of riveting head position, realizes sectional riveting of rivets in sequence or in groups, has high automation degree, can be integrated into a frequency conversion rotor intelligent assembly line, is suitable for different specifications of workpieces, effectively improves the riveting yield and production efficiency, and has high practicability.

Description

Technical Field

[0001] This invention relates to the field of motor technology, specifically to a rotor segment riveting device and its riveting method. Background Technology

[0002] As the core component of a motor, the assembly quality of the rotor directly determines the motor's operational stability and service life. The rotor's magnetic core is formed by stacking multiple sheets. After the magnetic core is assembled with the upper and lower magnetic insulating sheets, the overall thickness of the assembled workpiece is uneven due to factors such as stacking tolerances and component machining accuracy. This problem is particularly prominent in the mass production of rotors.

[0003] In the rotor assembly process, riveting is a key step to achieve the fixed connection of various components. Existing technologies often use a process of riveting multiple rivets at the same time, that is, the riveting mechanism completes the riveting operation on all rivets on the workpiece at one time.

[0004] In existing technologies, during the same batch riveting process, a rotor typically has multiple rivets. To improve riveting efficiency, those skilled in the art usually choose a one-time riveting process, where one pressure head acts on multiple rivets simultaneously, allowing multiple rivets to complete the riveting operation at the same time. Although the above process can improve riveting efficiency, its uniform riveting stroke, when dealing with rotor workpieces of uneven thickness, and the riveting method, due to the height differences of different parts of the workpiece, can cause some rivets to fail to form an effective contact with the riveting joint, resulting in problems such as incomplete riveting, insufficient outward angle of rivets, and some rivets even failing to form an effective riveting area, causing the connections between rotor components to become loose.

[0005] To address these issues, some technologies attempt to improve riveting by increasing riveting pressure, but this method easily causes local deformation of the workpiece, further exacerbating deviations in rotor assembly accuracy. Other technologies use manual adjustment of the riveting joint position to accommodate differences in workpiece thickness, but this is inefficient and cannot meet the mass production needs of intelligent rotor assembly lines. Furthermore, manual operation has significant errors, making it difficult to guarantee consistent riveting quality.

[0006] Meanwhile, existing riveting devices lack real-time detection and dynamic calibration functions for workpiece rivet position deviations, and cannot adjust the working position of each rivet joint according to the actual thickness differences of the workpiece, resulting in poor accuracy and adaptability of the riveting process. Therefore, for those skilled in the art, the challenge lies in how to adapt to uneven rotor thickness while maintaining a constant pressing stroke during the riveting process, ultimately developing a riveting process that can be adaptively adjusted in real time. This would solve the technical problems of incomplete riveting, inconsistent quality, and poor adaptability in existing technologies, thereby meeting the production requirements of intelligent rotor assembly lines and improving rotor assembly quality. Summary of the Invention

[0007] The purpose of this invention is to provide a rotor segment riveting device and riveting method to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] A rotor segment riveting device includes a riveting mechanism, the riveting mechanism being provided with a pressing mechanism, a support platform with a riveting station and a riveting unit, the power output end of the pressing mechanism being provided with a pressing head, and the riveting station coinciding with the axis of the pressing head.

[0010] The riveting unit includes at least one servo drive unit and a riveting head, wherein the power output end of the servo drive unit is connected to the riveting head.

[0011] The riveting mechanism also includes a travel sleeve, a measuring unit, and a controller. The travel sleeve is fitted outside the top of the riveting head. A spring-back mechanism is provided inside the travel sleeve. The spring-back mechanism applies a vertically upward thrust to the travel sleeve. A through hole is provided on the surface of the riveting station for the riveting head and the travel sleeve to pass through.

[0012] The measuring unit is used to detect the vertical displacement of the travel sleeve. The controller has a built-in PID algorithm and servo control system, and is electrically connected to the pressing mechanism, the servo drive unit and the measuring unit respectively.

[0013] Preferably, the maximum height difference between the top of the travel sleeve and the top of the rivet head is greater than the length of the rivet protruding from the bottom of the rotor.

[0014] Preferably, a bushing is provided above the riveting station, and the inner diameter of the bushing is larger than the outer diameter of the pressure head and the rotor;

[0015] The bushing is provided with a positioning post and a bottom support, and the axis of the positioning post coincides with the axis of the riveting station and the bushing.

[0016] The base is sleeved on the outside of the positioning post. The base has a hole corresponding to the position of the rivet on the rotor. The inner diameter of the hole is the same as the inner diameter of the through hole.

[0017] Preferably, the riveting mechanism further includes an ejection unit located between the support platform and the riveting unit;

[0018] The ejection unit is composed of multiple ejector rods. The bottom of the ejection unit is provided with a spring that pushes it to move vertically upward. The riveting station is provided with a through hole for the ejector rods to pass through.

[0019] Preferably, the riveting unit further includes a limiting rod and a linear bearing, wherein the top of the limiting rod is fixedly connected to the bottom end of the riveting head, and the limiting rod is inserted into the linear bearing.

[0020] A rotor segment riveting method, applied to the aforementioned rotor segment riveting device, includes the following steps:

[0021] S1: Transfer the rotor after inserting the rivets to the riveting station. At this time, the top faces of multiple rivet joints are flush, and multiple stroke sleeves are in the maximum ejection state with their top faces flush.

[0022] S2: The controller controls the pressing mechanism to drive the pressing head to move slowly downward, pressing the rotor slowly into the bushing. The bottom of the rotor first contacts the stroke sleeve and drives it to move downward. The measuring unit measures the displacement changes and time points of multiple stroke sleeves in real time and feeds them back to the controller.

[0023] S3: The controller determines the deviation value around the rivet based on the time node of the displacement change of the travel sleeve, records the displacement difference, and compares the output signal parameters of the measuring unit with the corresponding parameters of the standard test piece to calculate the dynamic adjustment value and output the dynamic calibration signal.

[0024] S4: The controller executes the calibration program and outputs a servo drive unit control signal according to the displacement difference, controlling the servo drive unit to output an amount equal to the displacement difference to adjust the riveting joint position.

[0025] S5: After calibration, the controller controls the pressing mechanism to output quickly. The pressure abuts the rotor to make the bottom of the rivet contact the top of the rivet head. The bottom of the rivet expands and curls to form the riveting part.

[0026] S6: After riveting is completed, the pressing mechanism is reset, and the ejection unit pushes out the ejector rod through the spring force, pushing the riveted rotor out of the bushing and transferring it for output.

[0027] Preferably, in step S3, the output signal parameters of the measurement unit include the output signal time, the output signal value, and the output signal stop time.

[0028] Preferably, in step S4, the controller records the moving distance of the travel sleeve within the time difference between the action time difference between the travel sleeve and the standard test piece, thereby controlling the moving distance of the rivet joint.

[0029] Preferably, when the action time of the travel sleeve is earlier than the action time of the standard test piece, the controller controls the rivet joint to move vertically downward by a distance corresponding to the movement distance.

[0030] Preferably, when the action time of the travel sleeve is later than the action time of the standard test piece, the controller controls the rivet joint to move vertically upward by a distance corresponding to the movement distance.

[0031] Compared with the prior art, the beneficial effects of the present invention are:

[0032] 1. This invention can adapt to the needs of small-batch multi-specification, large-batch standardized, and multi-specification universal rotor riveting. It can effectively solve the problem of incomplete riveting caused by uneven workpiece thickness, realize real-time independent detection of rivet position deviation, and complete the dynamic position calibration of the rivet joint by combining the PID algorithm of the controller and the precise control of the servo drive unit, so that the rivet joint and the bottom of the rivet are accurately aligned, fundamentally avoiding incomplete riveting caused by position deviation.

[0033] 2. This invention adopts a segmented riveting process design, which replaces the traditional method of riveting multiple rivets simultaneously by riveting single rivets sequentially or by riveting multiple rivets in groups. This ensures that each rivet receives sufficient riveting pressure, ensures the expansion and curling quality of the rivet bottom, and enables the rotor's magnetic core and magnetic shielding sheet to be firmly connected, thereby improving the product yield and long-term operational reliability. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the overall structure of the riveting mechanism and the rotary mechanism of the present invention;

[0035] Figure 2 This is a schematic diagram of the overall structure of the riveting structure of the present invention;

[0036] Figure 3 This is a schematic diagram of the positional distribution of the support platform and riveting unit of the present invention;

[0037] Figure 4 This is a cross-sectional view of the riveting unit of the present invention;

[0038] Figure 5 This is an exploded view of the riveting unit shaft components of the present invention;

[0039] Figure 6 This is an axial exploded view of the ejection unit and riveting unit of the present invention;

[0040] Figure 7 This is a schematic diagram showing the positional distribution of the travel sleeve and measuring unit of the present invention;

[0041] Figure 8 This is a schematic diagram of the internal cross-sectional structure of the travel sleeve of the present invention.

[0042] In the picture:

[0043] 100. Riveting mechanism;

[0044] 110. Pressing mechanism; 111. Press head;

[0045] 120. Foundation; 121. Riveting station; 122. Bushing; 123. Positioning post; 124. Base support;

[0046] 130. Riveting unit; 131. Servo drive unit; 132. Riveting joint; 133. Limiting rod one; 134. Linear bearing;

[0047] 140. Ejector unit; 141. Ejector rod;

[0048] 150. Stroke sleeve; 151. Springback mechanism; 152. Measuring plate; 153. Limiting rod two;

[0049] 160. Measurement unit;

[0050] 200. Rotary mechanism; 210. Telescopic gripper;

[0051] 300. Transfer equipment. Detailed Implementation

[0052] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0053] Please see Figures 1 to 8 The present invention provides the following three embodiments:

[0054] Example 1:

[0055] A single-rivet joint rotary segmented riveting device, as detailed below:

[0056] This embodiment adopts a structural design with a single rivet joint 132 and workpiece rotation positioning, which is suitable for riveting processing of small batches and multi-specification rotors. The core is to realize the sequential riveting of single rivets, avoid pressure dispersion caused by uneven workpiece thickness, and ensure the riveting quality of individual rivets. The device has strong overall integration, small footprint, and is suitable for the modification and upgrading of small and medium-sized production lines.

[0057] The segmented riveting device in this embodiment includes a riveting mechanism 100, which is fixedly installed at the riveting process station of the rotor assembly line. The whole device consists of a pressing mechanism 110, a support platform 120, a single riveting unit 130, an ejection unit 140, a stroke sleeve 150, a measuring unit 160, a rotary positioning mechanism, and a controller. All components are electrically connected to the controller to realize automated linkage control of the entire process. The controller adopts a Mitsubishi PLC control cabinet with built-in PID algorithm and servo control system. The storage module pre-stores standard riveting parameters for rotors of different specifications, which can adapt to the rapid switching of multiple specifications of workpieces.

[0058] The rotor is transferred from the previous process to the feeding side of the riveting mechanism 100 via the transfer fixture 300. The rotary mechanism 200 clamps, rotates, and places the rotor via the telescopic jaw 210 on one side, transferring the rotor from the transfer fixture 300 to the riveting station 121 above the support platform 120.

[0059] Specifically, the telescopic gripper 210 is initially in an open state. After descending to the outside of the rotor above the transfer fixture 300, the gripper retracts to clamp the outside of the rotor. Subsequently, the telescopic gripper 210 rises and rotates 180° along the rotation axis of the rotary mechanism 200. When it rotates to the riveting station 121, the telescopic gripper 210 releases, placing the rotor inside the bushing 122, thus completing the rotor loading operation.

[0060] The pressing and bearing positioning structure pressing mechanism 110 is set on the top of the riveting mechanism 100. It uses Huichuan servo cylinder as the power source. Its vertically downward power output end is fixedly connected to a hard alloy pressing head 111. The lower end surface of the pressing head 111 is treated with smooth wear resistance to avoid scratching the surface of the rotor workpiece during the pressing process.

[0061] The support platform 120 serves as the foundation for the device and is integrally formed from cast iron. A circular riveting station 121 is provided on its upper surface. The central axis of the riveting station 121 is strictly coincident with the axis of the press head 111, ensuring that the pressure of the pressing mechanism 110 acts perpendicularly on the workpiece and preventing workpiece deformation or rivet misalignment caused by bias pressure.

[0062] A wear-resistant nylon bushing 122 is fixedly installed above the riveting station 121. The inner diameter of the bushing 122 is larger than the outer diameter of the pressure head 111 and also larger than the outer diameter of the rotor, ensuring that the pressure head 111 and the rotor workpiece can smoothly extend into the bushing 122. The inner sidewall of the bushing 122 is polished to reduce the frictional resistance between it and the workpiece.

[0063] The bushing 122 has a positioning post 123 and a movable base 124 coaxially arranged inside. The positioning post 123 is aligned with the axis of the riveting station 121 and the bushing 122, and is used to achieve the center positioning of the rotor workpiece and prevent the workpiece from shifting circumferentially during rotation and riveting.

[0064] The base support 124 is movably sleeved on the outside of the positioning column 123, and its upper end face fits against the bottom of the rotor workpiece. The base support 124 has holes that correspond one-to-one with the positions of the rotor rivets. The inner diameter of the holes is adapted to the outer diameter of the rivets to ensure that the rivets can pass through vertically.

[0065] The core design of this embodiment is that a rotary positioning mechanism is provided at the bottom of the riveting station 121. This mechanism consists of a servo motor, a reducer and a rotary table. The base 124 is fixedly set on the upper surface of the rotary table. The controller can control the rotary positioning mechanism to drive the workpiece to rotate around the positioning column 123 at a fixed angle. The rotation accuracy can reach ±0.1°, realizing the sequential repositioning of rivets at different positions on the workpiece, and completing segmented riveting in conjunction with a single riveting unit 130.

[0066] The riveting and inspection feedback structure single riveting unit 130 is set below the support 120 and aligned with the hole of the riveting station 121. It consists of a servo drive unit 131, a riveting head 132, a limit rod 133 and a linear bearing 134. The servo drive unit 131 adopts a Mitsubishi high-precision servo motor. Its power output end is vertically upward and fixedly connected to the riveting head 132, which can accurately control the vertical displacement of the riveting head 132 with a displacement accuracy of up to 0.01mm.

[0067] The top of the limiting rod 133 is fixedly connected to the bottom of the rivet joint 132, and its lower part is movably inserted into the linear bearing 134. The linear bearing 134 plays a strict guiding and limiting role in the movement of the rivet joint 132, preventing the rivet joint 132 from deflecting during the pushing of the rivet, and ensuring the expansion and curling accuracy of the bottom of the rivet.

[0068] The travel sleeve 150 is movably sleeved on the outside of the top end of the rivet joint 132. Inside it is a spring-loaded mechanism 151. In this embodiment, the spring-loaded mechanism 151 is a compression spring. Under normal conditions, it applies a continuous upward vertical thrust to the travel sleeve 150, so that the travel sleeve 150 is in the maximum ejection state. The maximum height difference between the top end of the travel sleeve 150 and the top end of the rivet joint 132 is greater than the length of the rivet protruding from the bottom of the rotor, ensuring that the bottom of the rotor contacts the travel sleeve 150 first when it moves down, so as to realize the early detection of the rivet position deviation.

[0069] The bottom of the riveting station 121 is provided with a through hole for the riveting head 132 and the travel sleeve 150 to pass through vertically. The inner diameter of the through hole is matched with the outer diameter of the travel sleeve 150 to ensure the smooth vertical movement of the two.

[0070] The measuring unit 160 uses a German SICK laser displacement sensor, with its detection end set vertically upwards to correspond to the bottom of the travel sleeve 150. It can detect the vertical displacement change of the travel sleeve 150 in real time, and record the displacement trigger time, displacement signal output value and stop time. All detection data are fed back to the controller without delay, providing accurate raw data for rivet position deviation judgment.

[0071] Specifically, the bottom edge of the travel sleeve 150 is provided with a horizontal measuring plate 152, and a vertically distributed limiting rod 153 is provided on one side of the travel sleeve 150. The limiting rod 153 is perpendicular to the measuring plate 152, and the measuring plate 152 can slide along the surface of the limiting rod 153. The limiting rod 153 is used to keep the measuring plate 152 in a horizontal state when it moves up and down with the travel sleeve 150, ensuring the measurement progress of the measuring unit 160.

[0072] It is worth noting that the measuring unit 160 can also be replaced by a grating ruler.

[0073] The ejector unit 140 of the ejector feeding structure is located between the support 120 and the riveting unit 130. Three sets of ejector rods 141 are evenly distributed around the positioning post 123. The bottom of the ejector rod 141 is connected to a spring. The spring applies a vertical upward thrust to the ejector unit 140, so that the ejector rod 141 extends out of the upper end face of the riveting station 121 under normal conditions. The riveting station 121 is provided with through holes two corresponding to the ejector rods 141. The ejector rods 141 can move vertically without jamming along the through holes two, so as to realize the automatic ejection and removal of the workpiece from the riveting station 121 after riveting is completed.

[0074] The specific riveting process steps are as follows:

[0075] The single-rivet joint rotary segmented riveting device of this embodiment has the following riveting process for the rotor with 3 rivets. The entire process is controlled by the controller and requires no manual intervention.

[0076] S11: Workpiece loading and initial positioning: The rotary mechanism 200 of the assembly line transfers the rotor after inserting 3 rivets to the riveting station 121. The rotor workpiece is coaxially sleeved outside the positioning post 123, with its bottom fitting against the upper surface of the base 124. The rivets pass vertically through the hole 1 of the base 124. At this time, the controller controls the rotary positioning mechanism to rotate the workpiece to the position where the first rivet and the riveting head 132 are precisely aligned, completing the initial positioning. At the same time, the stroke sleeve 150 is in the maximum ejection state under the action of the spring mechanism 151, and the measuring unit 160 is reset, ready to perform displacement detection.

[0077] S12: Single rivet position deviation detection: The controller sends a control signal, and the pressing mechanism 110 drives the pressing head 111 to move vertically downward at a low speed. The pressing head 111 pushes the rotor workpiece to move slowly downward. The position of the first rivet at the bottom of the rotor contacts the top of the stroke sleeve 150 first, and overcomes the thrust of the compression spring to push the stroke sleeve 150 to move vertically downward.

[0078] The measuring unit 160 detects the displacement change and trigger time of the travel sleeve 150 in real time and feeds the data back to the controller. The controller compares the detection data with the standard test piece parameters in the storage module and calculates the position deviation value of the first rivet and the adjustment amount of the rivet joint 132.

[0079] S13: Rivet joint position calibration and single rivet riveting: The controller outputs a control signal to the servo drive unit 131 according to the calculated adjustment amount. The servo drive unit 131 drives the rivet joint 132 to make precise vertical displacement adjustment so that the top of the rivet joint 132 is precisely aligned with the bottom of the first rivet.

[0080] After calibration, the pressing mechanism 110 quickly outputs pressure, and the pressing head 111 vertically contacts the rotor workpiece. At the same time, the servo drive unit 131 drives the riveting head 132 to push the rivet vertically upward, so that the bottom of the rivet is forced to expand and curl, forming a riveting part that meets the process requirements, thus completing the riveting of the first rivet.

[0081] S14: Workpiece rotation and sequential riveting of multiple rivets: After the first rivet is riveted, the pressing mechanism 110 drives the pressing head 111 to reset upwards, the riveting head 132 moves downwards and resets synchronously, and the stroke sleeve 150 returns to the maximum ejection state under the action of the compression spring.

[0082] The controller controls the rotary positioning mechanism to drive the rotor workpiece to rotate 120° around the positioning column 123, so that the second rivet and the rivet head 132 are precisely aligned. The above steps of deviation detection, position calibration and riveting are repeated to complete the riveting of the second rivet. Then the workpiece is controlled to rotate 120° again to complete the riveting of the third rivet, realizing the sequential segmented riveting of the three rivets.

[0083] S15: Workpiece ejection and unloading: After all rivets are riveted, the controller controls the riveting head 132 to move down to the initial position. The spring at the bottom of the ejection unit 140 releases its elastic force, pushing the three sets of push rods 141 to move vertically upward along the through hole 2. The push rods 141 simultaneously push the bottom of the rotor workpiece, ejecting the workpiece out of the bushing 122 and away from the riveting station 121. The conveying mechanism of the assembly line then grabs the workpiece and transfers it to the subsequent burnishing and runout testing processes to complete the entire riveting process.

[0084] Example 2:

[0085] Multi-joint group-type segmented riveting device, as detailed below:

[0086] This embodiment features a structure design with independent control of multiple riveting joints and no rotational positioning, suitable for riveting processing of large batches of standardized rotors. The core of the design is to achieve synchronous riveting of rivets in groups, which greatly improves riveting efficiency while ensuring riveting quality. It matches the high-speed and continuous production requirements of intelligent assembly lines, and the device has a higher degree of automation, enabling seamless integration with production lines.

[0087] The overall structure of the segmented riveting device in this embodiment is basically the same as that in Embodiment 1. It also includes the pressing mechanism 110, the support platform 120, the riveting unit 130, the ejection unit 140, the stroke sleeve 150, the measuring unit 160, and the controller of the riveting mechanism 100. The core difference is that the riveting unit 130 is set in multiple independent groups, the rotation positioning mechanism is eliminated, and each riveting joint 132 is equipped with an independent stroke sleeve 150 and a measuring unit 160, so as to realize independent detection, independent calibration, and group riveting of multiple rivets. The power source and sensors of each component of the device are of the same specifications and brands as those in Embodiment 1, so as to ensure the consistency of control accuracy.

[0088] The independent configuration of multiple riveting units 130: In this embodiment, three rivets are fixed on a standardized rotor, and three independent riveting units 130 are set accordingly. The three riveting units 130 are evenly distributed along the circumference of the riveting station 121, corresponding one-to-one with the positions of the three rivets on the rotor. Each riveting unit 130 consists of an independent servo drive unit 131, a riveting head 132, a limit rod 133, and a linear bearing 134. Each servo drive unit 131 is electrically connected to a controller. The controller can independently control the displacement and adjust the pressure of each riveting unit 130, so as to realize the individual action or group linkage of each riveting head 132.

[0089] Each riveting unit 130 has a riveting joint 132 with a corresponding configuration of the detection components. Each riveting joint 132 has an independent travel sleeve 150 at its top. Each travel sleeve 150 has an independent spring-back mechanism 151 inside, and each travel sleeve 150 has an independent measuring unit 160 at its bottom. This enables independent real-time detection of the position deviation of each rivet. The detection data from each measuring unit 160 is fed back to the controller separately. The controller can calculate the position deviation value of each rivet and the adjustment amount of the corresponding riveting joint 132, avoiding mutual interference between the deviation detection of multiple rivets and ensuring detection accuracy.

[0090] In this embodiment, the bottom of the riveting station 121 of the support platform 120 is provided with three sets of through holes, which correspond one-to-one with the three sets of riveting units 130 and stroke sleeves 150.

[0091] The holes 1 on the base 124, the push rod 141 of the ejector unit 140, and the through hole 2 are all adjusted to match the corresponding number of parts to ensure precise fit. At the same time, the rotation positioning mechanism is eliminated, and the rotor workpiece does not need to be rotated after loading. The group riveting of multiple rivets is completed directly, reducing the number of process steps and improving work efficiency.

[0092] The specific riveting process steps are as follows:

[0093] The multi-rivet joint group-type segmented riveting device in this embodiment adopts a group riveting method for the riveting process of three rivets on a standardized rotor. That is, the single rivet with the largest deviation is riveted independently first, and then the other two rivets with smaller deviations are riveted simultaneously. The specific steps are as follows:

[0094] S21: Workpiece loading and overall positioning: The rotary mechanism 200 of the assembly line transfers the rotor with 3 rivets inserted to the riveting station 121. The rotor is coaxially sleeved outside the positioning post 123, and its bottom is in contact with the base 124. The 3 rivets pass through the corresponding holes and correspond one-to-one with the stroke sleeves 150 of the three riveting units 130. At this time, the three stroke sleeves 150 are all in the maximum ejection state, and the three measuring units 160 are synchronously reset, ready to perform displacement detection.

[0095] S22: Multi-rivet synchronous deviation detection: The controller controls the pressing mechanism 110 to drive the pressing head 111 to move down at low speed, pushing the rotor workpiece to move down slowly. Due to the uneven thickness of the rotor workpiece, the rotor bottom positions corresponding to the three rivets contact their respective stroke sleeves 150 one after another, pushing the stroke sleeves 150 to move down vertically.

[0096] Three sets of measuring units 160 synchronously and independently detect the displacement change, trigger time, signal value, and other data of their respective travel sleeves 150, and feed the data back to the controller. The controller analyzes and calculates the three sets of data separately to obtain the position deviation values ​​of the three rivets and the independent adjustment amount of the corresponding riveting joints 132. At the same time, based on the magnitude of the deviation value, it automatically determines that the rivet with the largest deviation is a single riveting part, and the other two are synchronous riveting parts.

[0097] S23: Independent and precise calibration of multiple rivet joints: The controller outputs control signals to three sets of servo drive units 131 according to the three independent adjustment values ​​calculated. The three sets of servo drive units 131 independently drive their respective rivet joints 132 to make precise vertical displacement adjustments, so that the top of each rivet joint 132 is precisely aligned with the bottom of the corresponding rivet, realizing independent calibration of multiple rivets. The calibration process is carried out synchronously without any order, which greatly shortens the calibration time.

[0098] S24: Grouping and Segmenting of Rivets: After calibration, the controller first controls the riveting unit 130 corresponding to the rivet with the largest deviation to move. The servo drive unit 131 drives the riveting head 132 to push upward, and at the same time, the pressing mechanism 110 outputs the corresponding pressure to complete the independent riveting of the rivet. After the rivet is riveted, the controller synchronously controls the other two groups of riveting units 130 to move. The two groups of servo drive units 131 synchronously drive the riveting head 132 to push upward, and the pressing mechanism 110 synchronously outputs pressure to complete the synchronous riveting of the other two rivets, realizing the grouping and segmenting of three rivets. If the deviation values ​​of the three rivets on the workpiece are similar, the controller can directly control the three groups of riveting units 130 to move synchronously, realizing the synchronous segmenting of multiple rivets and further improving efficiency.

[0099] S25: Workpiece ejection and continuous feeding: After all rivets are riveted, the three sets of rivet joints 132 move down and reset synchronously, and the three sets of stroke sleeves 150 return to the maximum ejection state under the action of the spring mechanism 151; the ejector rod 141 of the ejection unit 140 moves upward under the action of the spring force, ejecting the riveted rotor workpiece out of the bushing 122, and the conveying mechanism then grabs the workpiece and transfers it to the next process. At the same time, the previous process of the assembly line transfers the next rotor workpiece to the riveting station 121, realizing continuous riveting operation.

[0100] Example 3:

[0101] The multi-rivet joint adjustable segmented riveting device is as follows:

[0102] This embodiment is based on Embodiment 2, with the addition of an adjustable position structure for the riveting unit 130. It is suitable for riveting of uneven workpieces with multiple specifications and multiple rivet numbers. The core is to achieve free adjustment of the position of the riveting unit 130, which can match the riveting requirements of different models of rotors with 2-4 rivets and different rivet spacing. The device has strong versatility and greatly reduces the equipment modification costs caused by product specification switching in the production line.

[0103] The segmented riveting device of this embodiment has the same basic structure as the multi-rivet joint grouped segmented riveting device of Embodiment 2. It includes four independent riveting units 130, four corresponding stroke sleeves 150 and measuring units 160. The core improvement is that an adjustment platform for the riveting units 130 is set below the support platform 120. All four riveting units 130 are movably set on the adjustment platform, which can realize radial movement along the circumferential direction, thereby adjusting the spacing and position of each group of riveting units 130 to adapt to rotors with different numbers of rivets and different rivet spacings.

[0104] The adjustment platform adopts a precision ball screw slide structure, driven by a servo motor, which can realize the independent radial movement of each riveting unit 130 with a movement accuracy of 0.02mm. The controller has built-in rivet position parameters for rotors of different specifications, and can control the riveting unit 130 to move to the designated position with one click according to production needs, thus completing the rapid switching of equipment. At the same time, the through hole 1 of the support 120 and the hole 1 of the base 124 are both replaceable structures. The base 124 of the corresponding specification can be replaced according to the number and position of rivets, and the through hole 1 can be adapted and sealed to ensure the sealing and structural stability of the device.

[0105] The specific riveting process steps are as follows:

[0106] The multi-rivet adjustable segmented riveting device of this embodiment has the same core riveting process as the group riveting in Embodiment 2. The difference is that an adjustment step for the position of the riveting unit 130 is added. Specifically, according to the specifications of the rotor to be processed, such as the number of rivets and the rivet spacing, the controller first controls the servo motor of the adjustment platform to drive each group of riveting units 130 to move radially to a position that precisely corresponds to the rivet position, thus completing the position calibration of the riveting unit 130. Then, the base 124 matching the rotor specifications is replaced, and the through hole of the support 120 is adapted and sealed. After the equipment specification switching is completed, the steps of workpiece loading, synchronous deviation detection, independent calibration, group riveting, and ejection unloading in Embodiment 2 are followed to realize the segmented riveting of rotors of different specifications. The entire specification switching process does not require manual disassembly and reassembly and can be completed with one click, greatly improving production flexibility.

[0107] In summary, the segmented riveting device for uneven workpieces of the present invention, through the structural design of different embodiments, is adapted to the rotor riveting requirements of small batch multi-specification, large batch standardization, and multi-specification universality, and can effectively solve the problem of incomplete riveting caused by uneven workpiece thickness. The core is to realize the real-time independent detection of rivet position deviation through the combination of stroke sleeve 150 and measuring unit 160. Combined with the PID algorithm of the controller and the precise control of servo drive unit 131, the dynamic position calibration of rivet head 132 is completed, so that the rivet head and the bottom of the rivet are accurately aligned, fundamentally avoiding incomplete riveting caused by position deviation.

[0108] Meanwhile, this invention employs a segmented riveting process design, using single rivets sequentially or multiple rivets in groups to replace the traditional simultaneous riveting of multiple rivets. This ensures that each rivet receives sufficient riveting pressure, guaranteeing the expansion and curling quality of the rivet base, and enabling a firm connection between the rotor's magnetic core and the magnetic shielding sheet. This improves product yield and long-term operational reliability. The device boasts a high degree of automation and can be directly integrated into intelligent rotor assembly lines, linking with upstream and downstream processes to achieve continuous riveting operations, effectively improving production efficiency. Furthermore, the device structures in each embodiment are rationally designed, highly versatile, easy to maintain, and adaptable to the needs of production lines of different scales, possessing high practical and promotional value.

[0109] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A rotor segment riveting device, comprising a riveting mechanism (100), characterized in that: The riveting mechanism (100) is provided with a pressing mechanism (110), a support (120) with a riveting station (121) and a riveting unit (130). The power output end of the pressing mechanism (110) is provided with a pressing head (111). The axis of the riveting station (121) coincides with that of the pressing head (111). The riveting unit (130) includes at least one servo drive unit (131) and a riveting head (132), wherein the power output end of the servo drive unit (131) is connected to the riveting head (132). The riveting mechanism (100) also includes a travel sleeve (150), a measuring unit (160), and a controller. The travel sleeve (150) is fitted over the top of the rivet head (132). A spring-back mechanism (151) is provided inside the travel sleeve (150). The spring-back mechanism (151) applies a vertically upward thrust to the travel sleeve (150). A through hole is provided on the surface of the riveting station (121) for the rivet head (132) and the travel sleeve (150) to pass through. The measuring unit (160) is used to detect the vertical displacement of the travel sleeve (150). The controller has a built-in PID algorithm and servo control system, and the controller is electrically connected to the pressing mechanism (110), the servo drive unit (131) and the measuring unit (160) respectively.

2. The rotor segment riveting device according to claim 1, characterized in that: The maximum height difference between the top of the travel sleeve (150) and the top of the rivet (132) is greater than the length of the rivet protruding from the bottom of the rotor.

3. The rotor segment riveting device according to claim 2, characterized in that: A bushing (122) is provided above the riveting station (121), and the inner diameter of the bushing (122) is larger than the outer diameter of the pressure head (111) and the rotor. The bushing (122) is provided with a positioning post (123) and a base (124). The axis of the positioning post (123) coincides with the axis of the riveting station (121) and the bushing (122). The base (124) is sleeved on the outside of the positioning post (123). The base (124) has a hole corresponding to the position of the rivet on the rotor. The inner diameter of the hole is the same as the inner diameter of the through hole.

4. The rotor segment riveting device according to claim 1, characterized in that: The riveting mechanism (100) further includes an ejection unit (140) located between the support platform (120) and the riveting unit (130); The ejection unit (140) is composed of multiple ejector rods (141). The bottom of the ejection unit (140) is provided with a spring that pushes it to move vertically upward. The riveting station (121) is provided with a through hole for the ejector rods (141) to pass through.

5. The rotor segment riveting device according to claim 1, characterized in that: The riveting unit (130) also includes a limiting rod (133) and a linear bearing (134). The top of the limiting rod (133) is fixedly connected to the bottom of the riveting head (132), and the limiting rod (133) is inserted into the linear bearing (134).

6. A rotor segment riveting method, applied to the rotor segment riveting device according to any one of claims 1 to 5, characterized in that: Includes the following steps: S1: The rotor after the rivets are inserted is transferred to the riveting station (121). At this time, the top end faces of multiple rivet joints (132) are flush, and multiple stroke sleeves (150) are in the maximum ejection state and their top end faces are flush. S2: The controller controls the pressing mechanism (110) to drive the pressing head (111) to move slowly downward, and slowly press the rotor into the bushing (122). The bottom of the rotor first contacts the stroke sleeve (150) and drives it to move downward. The measuring unit (160) measures the displacement changes and time nodes of multiple stroke sleeves (150) in real time and feeds them back to the controller. S3: The controller judges the deviation value around the rivet based on the time node of the displacement change of the travel sleeve (150), records the displacement difference, and compares the output signal parameters of the measuring unit (160) with the corresponding parameters of the standard test piece, calculates the dynamic adjustment value and outputs the dynamic calibration signal. S4: The controller executes the calibration procedure and outputs a control signal to the servo drive unit (131) based on the displacement difference, thereby controlling the servo drive unit (131) to output an amount equal to the displacement difference to adjust the position of the rivet head (132). S5: After calibration, the controller controls the pressing mechanism (110) to output quickly, and the pressure abuts the rotor to make the bottom of the rivet contact the top of the rivet joint (132), and the bottom of the rivet expands and curls to form the riveting part; S6: After riveting is completed, the pressing mechanism (110) is reset, and the ejection unit (140) ejects the ejector rod (141) through the spring force, ejecting the riveted rotor out of the bushing (122) and transferring it out.

7. The rotor segment riveting method according to claim 6, characterized in that: in, In step S3, the output signal parameters of the measurement unit (160) include the output signal time, the output signal value, and the output signal stop time.

8. The rotor segment riveting method according to claim 6, characterized in that: in, In step S4, the controller records the moving distance of the travel sleeve (150) within the time difference between the action time difference between the travel sleeve (150) and the standard test piece, thereby controlling the moving distance of the rivet joint (132).

9. The rotor segment riveting method according to claim 8, characterized in that: When the action time of the travel sleeve (150) is earlier than the action time of the standard test piece, the controller controls the rivet joint (132) to move vertically downward by a distance corresponding to the movement distance.

10. The rotor segment riveting method according to claim 8, characterized in that: When the action time of the travel sleeve (150) is later than the action time of the standard test piece, the controller controls the rivet joint (132) to move vertically upward by a distance corresponding to the movement distance.

Images