Brushless motor stator preparation device and method for multi-station synchronous winding detection

Abstract

The invention discloses a brushless motor stator preparation device and method for multi-station synchronous winding detection, and the device comprises the steps: carrying out the isolation amplification and analog-to-digital conversion of an electric signal of a local detection loop of each station through a signal isolation collection unit through multi-station synchronous winding and an independently-arranged insulation online detection module of each station; and then the signals are transmitted to the central processing unit for centralized analysis, multi-station interference is avoided through signal isolation, and rapid identification and accurate positioning of insulation abnormity during multi-station synchronous winding are realized in combination with a visual prompt element of the station state indication device. Through fusion of trend monitoring of insulation performance along with sequence evolution and a threshold value judgment principle of multi-station synchronous data, the system can automatically associate to a corresponding process link according to a specific sequence of abnormal signals, so that a process root is quickly positioned while abrasion is judged, targeted optimization is driven, and the reliability of the system is improved. And the detection accuracy and the process diagnosis intelligence are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mechanical manufacturing, in particular to a multi-station synchronous winding detection brushless motor stator preparation device and method. BACKGROUND

[0002] In the production process of brushless motor stator, winding is the core process. In order to improve production efficiency, modern winding equipment generally adopts multi-station (such as 4-station, 6-station) synchronous winding mode. In the process of high-speed winding, the enameled wire passes through the tensioner, the guide wheel in turn, and finally passes through the winding nozzle to bend at high speed and embed into the stator slot. This process challenges the integrity of the enameled wire insulation, especially in the outlet area of the winding nozzle, due to the concentration of force and small bending radius, which is easy to cause invisible pinhole level damage to the enamel film. Such hidden defects may cause breakdown in subsequent voltage resistance test, resulting in the rejection of the whole stator.

[0003] Current online insulation detection is arranged at the guide wheel position in front of the winding nozzle, mainly reflecting the state of the wire before entering the winding nozzle, which is difficult to cover the scratches caused by the structure or movement of the winding nozzle itself; another type of scheme is to test the whole after winding is completed, which can identify failed products, but has consumed all winding materials and working hours. In addition, in a multi-station system, several stations share the same detection circuit. When insulation abnormalities occur, the system can only indicate that there is a fault, and cannot be directly located to a specific station, increasing troubleshooting time and maintenance cost. SUMMARY

[0004] The present application overcomes the shortcomings of the prior art and provides a multi-station synchronous winding detection brushless motor stator preparation device and method.

[0005] To achieve the above purpose, the technical scheme adopted by the present application is as follows: a multi-station synchronous winding detection brushless motor stator preparation device, comprising: a winding main frame for supporting and fixing a plurality of winding stations; a plurality of independent winding units respectively arranged on the winding main frame; an insulation online detection module corresponding to each independent winding unit, for carrying out insulation detection on the enameled wire on each winding slot worked by the independent winding unit; a signal isolation acquisition unit connected one by one with each insulation online detection module, for isolating and amplifying and analog-digital converting the electrical signal output by the insulation online detection module, including the insulation signals detected in the order of winding in the same winding group; The central processing unit is in communication connection with the signal isolation acquisition unit, is used for receiving and analyzing insulation signals of each channel, judging whether insulation abnormity exists, and outputting fault identification information of a corresponding station; the fault identification information includes a station position and an associated specific process optimization suggestion instruction; And a station state indication device connected with the central processing unit is used for lighting a visual prompt element of a corresponding station according to the fault identification information.

[0006] In a preferred embodiment of the present application, each of the independent winding units comprises a winding nozzle, a tension adjusting mechanism, an overline guide wheel assembly, and a stator clamping mechanism, and the winding nozzle is configured to embed the enameled wire into the stator slot in a predetermined bending path.

[0007] In a preferred embodiment of the present application, the insulation online detection module comprises a first electrode and a second electrode, the first electrode is arranged in the vicinity of the outlet end of the winding nozzle, and the second electrode is electrically connected with the stator core or the stator clamping mechanism, thereby forming a local detection loop for the insulation state of the enameled wire at the outlet of the winding nozzle.

[0008] In a preferred embodiment of the present application, the outlet end of the winding nozzle is provided with an insulation bushing made of high wear-resistant insulation material, the inner hole profile of the insulation bushing matches the outer diameter of the enameled wire, the first electrode is embedded in the sidewall of the insulation bushing, and the electrode surface is in non-contact electric field coupling with the outer surface of the enameled wire. The first electrode is a ring electrode structure arranged around the enameled wire running path for one turn, and the ring electrode is isolated from the enameled wire through an insulation medium layer; the second electrode directly contacts the outer circumferential surface of the stator core through a conductive clamp jaw, the conductive clamp jaw is installed on the rotating base of the stator clamping mechanism and rotates synchronously with the stator.

[0009] In a preferred embodiment of the present application, the stator clamping mechanism comprises a stator positioning mandrel, a clamping cylinder, and a rotating servo motor, the stator positioning mandrel is coaxially installed on the output shaft of the rotating servo motor, the piston rod of the clamping cylinder is connected with a pressing head, and the pressing head moves axially under the drive of the clamping cylinder.

[0010] In a preferred embodiment of the present application, the signal isolation acquisition unit comprises a plurality of isolation amplifiers, filter circuits, and analog-to-digital converters, the input end of each isolation amplifier is connected with the output end of the corresponding insulation online detection module, and the output end is connected with the multi-channel input interface of the central processing unit in sequence through the filter circuit and the analog-to-digital converter.

[0011] In a preferred embodiment of the present application, the central processing unit is provided with a threshold comparison algorithm module, which compares the digital signals of each channel with a preset threshold in real time, and when the signal amplitude of any channel exceeds the preset threshold, it is determined that the winding station corresponding to the channel has insulation damage, and a fault data packet containing the station number is generated.

[0012] In a preferred embodiment of the present application, the station state indication device comprises a plurality of light emitting diodes, each of which is connected to the output pin of the central processing unit through a driving circuit, and the positions of the light emitting diodes correspond one-to-one to the physical stations on the winding main rack.

[0013] To achieve the above-mentioned purpose, the technical scheme adopted by the present application is as follows: a use method of a multi-station synchronous winding detection brushless motor stator preparation device, comprising the following steps: S1: controlling a plurality of independent winding units arranged on a winding main rack to perform synchronous winding operation on a plurality of slots on the stator; S2: performing real-time insulation characteristic signal collection on the winding of each independent winding unit; S3: processing the collected insulation characteristic signals through a signal isolation collection unit, and identifying the winding state based on a preset rule by a central processing unit, the winding state including a normal state and an abnormal state, and the insulation characteristic signals exceeding an insulation threshold being determined as the abnormal state; S4: when the identification result is the abnormal state, identifying the associated specific process according to the sequence of winding in the same winding group, and outputting an optimization suggestion instruction pointing to the associated specific process.

[0014] In a preferred embodiment of the present application, the sequence of winding in the same winding group includes a first group, an intermediate group and a last group; when the abnormal state comes from the first group, the associated specific process is an enameled wire transmission process; when the abnormal state comes from the intermediate group, the associated specific process is a winding process; and when the abnormal state comes from the last group, the associated specific process is a post-winding treatment process.

[0015] The present application solves the defects in the background art, and has the following beneficial effects: The application provides a multi-station synchronous winding detection brushless motor stator preparation device, multi-station synchronous winding and an independent insulation online detection module arranged at each station, the electrical signals of the local detection loop of each station are isolated, amplified and analog-digital converted by a signal isolation acquisition unit, and then transmitted to a central processing unit for centralized analysis, signal isolation is used to avoid multi-station interference, the visual prompt element of the station state indication device is combined to realize rapid identification and accurate positioning of insulation abnormalities during multi-station synchronous winding, compared with the motor stator preparation device in the prior art, the insulation state of the enameled wire during the winding process can be monitored in real time at each station, so that the problem station can be found in time in the continuous production process, the downtime is reduced, and the production efficiency and the stator preparation quality are improved.

[0016] In the application, the insulation online detection module adopts a non-contact electric field coupling ring electrode as a first electrode, the ring electrode is isolated from the enameled wire through an insulation medium layer, a second electrode is combined to form a local detection loop in electrical connection with the stator core, the electric field is stable when the insulation layer of the enameled wire is intact, the electric field distribution changes when the insulation layer is damaged or defective, which leads to a change in the detection loop signal, compared with the prior art, direct contact with the enameled wire can be avoided, and the insulation layer is prevented from being scratched, after amplification and conversion by the signal isolation acquisition unit, the central processing unit can identify abnormalities in real time through threshold comparison, realize high-sensitivity insulation detection, ensure the integrity of the enameled wire during the winding process, and improve the winding quality and product reliability.

[0017] In the application, by fusing the trend monitoring of the insulation performance with the sequence evolution and the threshold identification principle of multi-station synchronous data, the system can automatically associate to the corresponding process link according to the specific sequence of abnormal signals, so as to quickly locate the process root while judging the wear, drive targeted optimization, compared with the prior art, the characteristics of the insulation performance of different winding sequences in the same phase winding are analyzed, the accurate evaluation of the enameled wire wear degree is realized, and the accuracy of detection and the intelligence of process diagnosis are improved. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments described in the application, and other drawings can be obtained by those skilled in the art without creating laborious work; Figure 1 It is a perspective structural view of the preferred embodiment of the application; Figure 2 It is a system structural view of the preferred embodiment of the application; Figure 3 It is a schematic diagram of an independent winding unit of the preferred embodiment of the application; Fig. 1, winding main frame; 2, independent winding unit; 21, winding nozzle; 22, tension adjusting mechanism; 23, guide roller assembly; 24, stator clamping mechanism; 3, insulation online detection module; 4, signal isolation acquisition unit; 41, isolation amplifier; 42, filter circuit; 43, analog-to-digital converter; 5, central processing unit; 6, workstation state indication device. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0020] In the following description, many specific details are set forth in order to provide a thorough understanding of the present application, but the present application can also be practiced without some of the details described herein, and therefore, the scope of the present application is not limited to the specific embodiments disclosed herein.

[0021] SUMMARY The enamel wire is abraded during the winding process. In the high-speed and precise automatic winding process, the enamel wire needs to pass through the pay-off guide roller, the guide nozzle (the guide nozzle), and other guide components repeatedly. The abrasion, burr, or poor cleaning on the surface of these components will directly scratch the insulating paint film. At the same time, the enamel wire experiences bending, stretching, and radial pressure applied by the tensioner during winding, and is more prone to extrusion and shearing at the sharp corners of the stator core slot. Especially when winding the intermediate group coil with complex winding path and sharp turning, the mechanical fatigue accumulation effect is significant, which easily leads to microcracks or weak points in the insulating layer, thereby causing the insulating performance to decrease.

[0022] It is accidentally found that because the influence degree of each process on abrasion is inconsistent in the winding sequence of different orders in the same phase, the enamel wires of different orders have different degrees of abrasion risk. Inspecting the insulating performance of the winding of different orders in the same phase can detect the abrasion degree and quickly respond to the process that causes the abrasion. This principle realizes the accurate positioning of the insulating abrasion point and the intelligent association of the process link by monitoring the trend of the insulating performance with the evolution of the group sequence and combining the dynamic threshold established by comparing the multi-station data.

[0023] As shown in Figure 1 and Figure 2 , a brushless motor stator preparation device for multi-station synchronous winding detection includes: a winding main frame for supporting and fixing a plurality of winding stations; Multiple independent winding units are respectively set on the winding main frame. Each independent winding unit includes a winding nozzle, a tension adjustment mechanism, a wire guide wheel assembly, and a stator clamping mechanism. The winding nozzle is configured to embed the enameled wire into the stator slot in a predetermined bending path. It is used to perform insulation testing on the enameled wire in each winding slot of the independent winding unit. An online insulation detection module is set up separately for each independent winding unit. The online insulation detection module includes a first electrode and a second electrode. The first electrode is set in the vicinity of the winding nozzle exit end, and the second electrode is electrically connected to the stator core or stator clamping mechanism to form a local detection circuit for the insulation status of the enameled wire at the winding nozzle exit, including the insulation signals detected in the same winding according to the winding sequence. The signal isolation acquisition unit is connected to each insulation online detection module in a corresponding manner, and is used to isolate, amplify and convert the electrical signal output by each local detection circuit. The central processing unit, which communicates with the signal isolation and acquisition unit, is used to receive and analyze the digital signals from each channel, determine whether there is an insulation abnormality, and output the corresponding fault identification information for the workstation. The fault identification information includes the workstation location and associated specific process optimization suggestions. In addition, a workstation status indicator device, connected to the central processing unit, is used to illuminate the visual prompt element of the corresponding workstation according to the fault identification information.

[0024] Furthermore, an insulating bushing is provided at the outlet end of the winding nozzle. The insulating bushing is made of a highly wear-resistant insulating material, and its inner hole profile matches the outer diameter of the enameled wire. The first electrode is embedded in the side wall of the insulating bushing, and the electrode surface maintains non-contact electric field coupling with the outer surface of the enameled wire.

[0025] More specifically, the first electrode is a ring-shaped electrode structure arranged around the travel path of the enameled wire, and the ring-shaped electrode is isolated from the enameled wire by an insulating dielectric layer. The second electrode is in direct contact with the outer circumferential surface of the stator core through conductive grippers, which are mounted on the rotating base of the stator clamping mechanism and rotate synchronously with the stator.

[0026] The online insulation detection module uses a non-contact electric field coupling ring electrode as the first electrode. The ring electrode is isolated from the enameled wire through an insulating dielectric layer. Combined with the second electrode, it is electrically connected to the stator core to form a local detection circuit. When the enameled wire insulation layer is intact, the electric field is stable. When the insulation layer is damaged or defective, the electric field distribution changes, causing the detection circuit signal to change. This avoids direct contact with the enameled wire and prevents scratching the insulation layer. After amplification and conversion by the signal isolation acquisition unit, the central processing unit identifies anomalies in real time through threshold comparison, achieving high-sensitivity insulation detection. At the same time, it ensures the integrity of the enameled wire during the winding process, improving winding quality and product reliability.

[0027] For example, the signal isolation acquisition unit includes a plurality of isolation amplifiers, filter circuits and analog-to-digital converters, the input end of each isolation amplifier is connected to the output end of the corresponding insulation online detection module, and the output end is sequentially connected to the multi-channel input interface of the central processing unit through the filter circuit and the analog-to-digital converter.

[0028] Preferably, the central processing unit is built-in with a threshold comparison algorithm module, which compares the digital signal of each channel with a preset threshold in real time, and when the signal amplitude of any channel exceeds the preset threshold, it is determined that the winding station corresponding to the channel has insulation damage, and a fault data packet containing the station number is generated.

[0029] In one implementation, the station state indication device includes a plurality of light-emitting diodes, each connected to an output pin of the central processing unit through a driving circuit, and the positions of the light-emitting diodes correspond one-to-one to the physical stations on the winding mainframe.

[0030] As shown in Figure 3 The stator clamping mechanism includes a stator positioning mandrel, a clamping cylinder and a rotary servo motor, the stator positioning mandrel is coaxially installed on the output shaft of the rotary servo motor, the piston rod of the clamping cylinder is connected to the pressing head, and the pressing head moves axially under the drive of the clamping cylinder.

[0031] A method for using a multi-station synchronous winding detection brushless motor stator preparation device, comprising the following steps: S1: controlling a plurality of independent winding units arranged on a winding mainframe to perform synchronous winding operation on a plurality of slots on the stator; S2: performing real-time insulation characteristic signal acquisition on the winding formed by each independent winding unit; S3: processing the collected insulation characteristic signals through a signal isolation acquisition unit, and identifying the winding state based on a preset rule by a central processing unit, the winding state including a normal state and an abnormal state, and the insulation characteristic signals exceeding an insulation threshold being determined as an abnormal state; S4: when the identification result is an abnormal state, identifying the associated specific process according to the sequence of winding in the same winding group, and outputting an optimization suggestion instruction pointing to the associated specific process.

[0032] The sequence of winding in the same winding group includes a first group, an intermediate group and a last group; when the abnormal state comes from the first group, the associated specific process is the enameled wire transmission process; when the abnormal state comes from the intermediate group, the associated specific process is the winding process; and when the abnormal state comes from the last group, the associated specific process is the post-winding processing process.

[0033] The first group is a group of the first winding of the slots in the same phase, the last group is a group of the last winding of the slots in the same phase, and the intermediate group is a number of winding groups between the first group and the last group.

[0034] In the parallel winding process, the detection of abnormal states is a dynamic intelligent judgment process based on real-time data comparison. The system collects insulation signals immediately after each winding unit is completed, and binds the station, phase sequence and group sequence identification for each data point. The core of the detection is to use the characteristics of multi-station synchronous production to build a real-time updated dynamic reference benchmark.

[0035] The system continuously synchronizes the insulation measurement values of all stations at the same winding stage and calculates their statistical distribution. Through statistical process control methods, an adaptive dynamic threshold is generated for each specific production node. If the real-time measurement value of any station deviates significantly from the dynamic range based on the group data, it is determined to be abnormal. At the same time, the system also monitors the insulation performance change trend from the first group to the last group within the same winding. Any sudden drop or mutation that violates the normal process rules will also be identified as a potential abnormality, thereby achieving early, sensitive and anti-interference fault detection.

[0036] Once the abnormal state is confirmed, the system will automatically associate it to the specific process link that is most likely to have a problem according to the precise "group sequence" information attached to the abnormal signal. If the abnormality occurs in the "first group" of a phase, it indicates that the coil has been damaged in the initial stage of winding completion. Since the first group of coils will go through all subsequent winding and assembly processes, but the initial detection of abnormalities will lock the problem source in the winding start stage. Therefore, the system will associate it to the "enamel wire transmission process" and suggest checking the wear and cleanliness of the wire guide roller and the wire guide nozzle, as well as the setting value and stability of the tensioner at the start of winding, to investigate insulation defects caused by initial damage to the wire supply system.

[0037] If the abnormality occurs in the "intermediate group", it directly points to the dynamic process of the core of the winding process. The intermediate group of coils has the most complex path during winding, and the mechanical fatigue of the wire is obvious. Its insulation state directly reflects the quality of the winding action itself. The system will associate this abnormality to the "winding process" and guide the investigation of whether the winding path program of the specific group sequence has interference, check the action accuracy and jitter of the winding head running to this position, and analyze whether there are harmful fluctuations in the instantaneous tension and speed curve when winding this group, so as to accurately optimize the winding dynamic process.

[0038] If the abnormality only occurs in the last group, the problem is likely to be caused by the end-of-line action at the end of the winding of the phase. The post-processing operations such as wire cutting, wire clamping, and wire end processing after the winding of the last group are the main suspects. The system associates the abnormality to the "winding post-processing process" accordingly, and specifically prompts to check the blade condition of the wire cutting pliers and whether the cutting action causes pulling, to verify the clamping force and alignment of the wire clamping mechanism, and to review whether the homing action of the winding mechanism collides with the coil, so as to perfect the final link of the winding cycle and ensure the reliability of the process closed loop.

[0039] Embodiment 1: A multi-station synchronous winding detection brushless motor stator preparation device includes six independent winding units 2 arranged along a circular array on a winding mainframe 1, each of which contains a complete winding execution mechanism and an independent insulation detection circuit. Among them, the winding nozzle 21 is made of high-hardness ceramic material, and an insulation bushing is embedded at the outlet end of the winding nozzle 21, the insulation bushing is made of polyether ether ketone (PEEK) material, and the inner hole diameter is matched with the outer diameter of the enameled wire; the tension adjusting mechanism 22 is arranged between the wire reel and the wire guide roller assembly 23, which is used to dynamically maintain the constant tension of the enameled wire; the wire guide roller assembly 23 is composed of three guide wheels arranged in sequence, and the last guide wheel is adjacent to the inlet of the winding nozzle 21, and the wheel surface is provided with a micro-arc groove to guide the enameled wire to enter smoothly; the stator clamping mechanism 24 is installed on the rotating platform of the winding mainframe 1, which is used to clamp and drive the stator to rotate synchronously.

[0040] In the actual winding process, the enameled wire passes through the tension adjusting mechanism 22, then passes through the wire guide roller assembly 23 into the winding nozzle 21, and completes high-speed bending at the outlet end and embeds into the stator slot. This area is prone to pinhole-level damage to the paint film due to small bending radius and high wire speed. If the front detection method is used, only the state of the wire before entering the winding nozzle can be reflected, and the scratches caused by the winding nozzle structure or movement cannot be covered; if the shared detection circuit is used, when any station has insulation failure, the system can only issue a global alarm, and cannot distinguish the specific fault source.

[0041] To solve the above problems from the structure, the embodiment is provided with an independent insulation online detection module 3 at the outlet end of each winding nozzle 21. The insulation bushing is fixed to the outlet end of the winding nozzle 21 by a threaded connection, and an annular first electrode is embedded in the side wall. The electrode is made of a copper alloy sheet and is arranged around the enameled wire path. The electrode surface is isolated from the enameled wire surface by the body material of the insulation bushing, forming a non-contact capacitive coupling structure. The second electrode is a conductive clamp jaw installed on the rotating base of the stator clamping mechanism 24. The front end is elastically pressed against the outer circumferential surface of the stator core and rotates synchronously with the stator, ensuring stable electrical connection throughout the winding period. Thus, the first electrode, the enameled wire insulation layer, the second electrode and the stator core together form a closed local detection loop that only reflects the insulation state at the outlet of the winding nozzle.

[0042] The signal isolation acquisition unit 4 includes six electrically isolated acquisition channels. Each channel includes an isolation amplifier 41, a low-pass filter circuit 42, and an analog-to-digital converter 43. The input end of the isolation amplifier 41 is connected to the first electrode of the corresponding insulation online detection module 3 through a flexible lead wire. The flexible lead wire is arranged in a special wire slot inside the winding nozzle 21 to avoid breakage due to high-frequency vibration. The output end of the isolation amplifier 41 is connected to the low-pass filter circuit 42 and the analog-to-digital converter 43 in turn, and finally connected to the multi-channel analog input interface of the central processing unit 5.

[0043] The central processing unit 5 has a threshold comparison algorithm module. It receives digital signals from each channel in real time and compares them with the preset threshold. If the signal amplitude of a channel continuously exceeds the threshold for a set time window (e.g. 5ms), it is determined that the winding station corresponding to that channel has insulation damage, and a fault data packet containing the station number is generated. At the same time, the central processing unit 5 sends a pause command to the winding control system of the station, immediately stops the winding action of the unit, and drives the light-emitting diode at the corresponding position in the station status indication device 6 to light up, achieving visual positioning of the fault station.

[0044] For example, the single-sided gap between the inner hole diameter of the insulation bushing and the outer diameter of the enameled wire is controlled to be 10-30μm to ensure smooth passage of the enameled wire while maintaining a stable electric field coupling distance.

[0045] For example, the working frequency of the insulation online detection module 3 is set to 80kHz, which avoids the main frequency band of electromagnetic interference of the servo drive (usually working below 20kHz) and the frequency converter (usually working below 10kHz) in the winding mainframe 1, effectively reducing the false alarm rate.

[0046] For example, the center distance between adjacent independent winding units 2 is not less than 150mm to avoid electric field cross talk between the first electrodes and ensure the independence of each detection loop.

[0047] Example 2: This embodiment further optimizes the electrode structure and signal processing logic of the insulation online detection module 3 based on the multi-station synchronous winding detection device provided in Example 1, to improve the detection sensitivity of weak insulation defects.

[0048] The first electrode adopts a segmented ring structure composed of four 90° arc-shaped electrode pieces evenly distributed along the circumference, each electrode piece being insulated from each other and connected to four independent signal acquisition sub-channels. The central processing unit 5 performs vector synthesis on the four sub-channel signals and calculates their amplitude consistency. When there is a local pinhole in the enameled wire, it will cause a sudden change in the electric field strength in the corresponding direction, making the amplitude of the sub-channel signal in that direction significantly deviate from the other three. By introducing an amplitude dispersion criterion (such as a standard deviation exceeding 15% of the mean value), uniform aging and local breakdown can be effectively distinguished, improving the detection specificity.

[0049] The conductive jaws of the second electrode are made of silver-plated copper alloy, and the contact pressure with the stator core is pre-tightened by a micro-spring, ensuring that the contact resistance is less than 10 mΩ. The rotary servo motor of the stator clamping mechanism 24 is equipped with a high-resolution encoder, and its feedback signal is input to the central processing unit 5 for synchronization of the insulation detection signal and the stator rotation phase. The central processing unit 5 maps the insulation abnormality event to a specific stator slot based on the encoder signal, achieving "station-slot" two-level positioning. For example, when an insulation abnormality is detected at the 3rd station at a rotation angle of 120°, it can be determined that the defect is located in the 8th slot of that stator (assuming 24 slots per pole).

[0050] The low-pass filter circuit 42 in the signal isolation acquisition unit 4 adopts a second-order Butterworth filter with a cutoff frequency set to 120 kHz to filter out high-frequency switching noise while preserving the rising edge characteristics of the insulation breakdown transient signal. The sampling rate of the analog-to-digital converter 43 is not less than 1 MHz, ensuring that microsecond-level discharge pulses can be captured.

[0051] Example 3: This embodiment integrates human-computer interaction and data traceability functions based on Example 1, improving the maintainability and process analysis capability of the system.

[0052] The device also includes a human-computer interaction terminal connected in communication with the central processing unit 5 through an industrial Ethernet. The human-computer interaction terminal is provided with a touch display screen for real-time display of the insulation detection signal waveform, current state (normal / alarm / pause), cumulative winding turns, and historical alarm records of each station. The system supports querying the complete insulation detection data curve within a single winding period by time stamp or station number, and can export it in CSV format for subsequent analysis.

[0053] The human-computer interaction terminal is provided with a permission hierarchical login mechanism: the operator account can only view the running interface and alarm information; the engineer account can modify preset threshold values, detection sensitivity parameters and working frequencies. All parameter modification operations are recorded in an audit log.

[0054] In addition, the winding main rack 1 is provided with a transparent protective cover covering all independent winding units 2 and insulation online detection modules 3. The inside of the protective cover is coated with a 20-micron-thick nickel-copper composite electromagnetic shielding layer with a surface resistivity of less than 0.1 Ω / sq, which can effectively suppress the influence of external variable frequency devices, welding equipment and other strong electromagnetic interference sources on weak insulation detection signals.

[0055] Embodiment 4: This embodiment is based on embodiment 3, and the rapid replacement and maintenance convenience of the insulation bushing is strengthened.

[0056] The insulation bushing is screwed into the outlet end of the winding nozzle 21 through an M8x0.5 fine thread, and the tail portion is provided with a hexagonal flange to facilitate disassembly with a standard wrench. When replacing, the entire winding nozzle 21 does not need to be disassembled or the optical path alignment needs to be adjusted, and only the old bushing can be removed by loosening the fixing nut, and the new one is installed and tightened to the specified torque (such as 0.8 N·m). The first electrode is connected to the flexible lead through a plug-in micro connector to realize plug-and-play of the electrode module.

[0057] The central processing unit 5 is also connected with a data storage module, which adopts a non-volatile flash memory with a capacity of not less than 8 GB, and can store detection data of not less than 10,000 winding cycles. Each time the winding is started, the system automatically allocates a unique task ID, and archives the detection data of all stations in this cycle according to the ID, supporting quality traceability and process optimization in the later stage.

[0058] The above is based on the ideal embodiment of the application, through the above description, relevant personnel can make various changes and modifications without deviating from the technical idea of the application. The technical scope of the application is not limited to the contents in the specification, and the technical scope must be determined according to the scope of claims.

[0059] In order to better enable relevant personnel in the technical field to fully understand and implement the application, the specific implementation principle of the application is further supplemented below in combination with a specific application scenario.

[0060] On the batch production line of brushless motor stator, six independent winding units 2 are arranged in a ring on the winding mainframe, each of which is used for synchronous winding of the same type of stator. Taking No. 3 station as an example, before winding starts, the stator is clamped in the stator clamping mechanism, the end face of the stator is axially pressed by the pressing head driven by the clamping cylinder, the stator positioning mandrel is coaxially connected with the rotating servo motor to ensure accurate rotation of the stator with the motor; after the enameled wire is drawn from the reel, it passes through the tension adjusting mechanism to maintain constant tension, and then is smoothly guided into the winding nozzle through the three guide wheels in the wire guide roller assembly.

[0061] When the enameled wire travels to the outlet end of the winding nozzle, it needs to complete a high-speed bending of more than 90° in a very short time and embed into the stator slot. During this process, the outer surface of the enameled wire is instantaneously rubbed and extruded with the inner wall of the winding nozzle. In order to monitor the insulation integrity of this key area in real time, an insulation bushing is installed at the outlet end of the winding nozzle, which is made of PEEK material and has a ring-shaped first electrode embedded in the side wall. The electrode is isolated from the enameled wire by the bushing body, forming a stable non-contact capacitive coupling structure. At the same time, the second electrode is elastically pressed on the outer circumferential surface of the stator core by the conductive clamp jaw and rotates synchronously with the stator, thereby forming a closed detection loop with the first electrode, the enameled wire insulation layer and the stator core, which only covers the local area of the outlet of the winding nozzle.

[0062] The detection loop applies a high-frequency excitation signal of 80 kHz. When the enameled wire insulation layer is complete, the loop presents a high impedance state and the coupling current is minimal. Once the paint film is damaged due to mechanical stress at the outlet, the enameled wire copper core will form a weak conductive path with the stator core through the damaged point, causing the loop impedance to drop sharply, and the signal amplitude sensed by the first electrode to rise significantly. The analog signal is led out through a flexible lead and is inserted into a special wire slot in the winding nozzle, and is connected to the signal isolation acquisition unit 4 in the corresponding channel.

[0063] The isolation amplifier in the channel first electrically isolates the signal to prevent common ground interference between multiple stations; then the low-pass filter circuit filters out high-frequency switching noise above 120 kHz, retaining the breakdown transient characteristics; the analog-to-digital converter converts the analog signal to digital at a sampling rate of not less than 1 MHz and transmits it to the central processing unit 5. The threshold comparison algorithm module in the central processing unit 5 compares the data in this channel with the preset threshold (for example, the equivalent voltage value corresponding to an insulation resistance of less than 10 MΩ), and if the signal exceeds the limit for 5 ms continuously, it is determined that there is insulation damage at the No. 3 station.

[0064] At this time, the central processing unit 5 immediately sends a pause instruction to the motion controller of the No. 3 independent winding unit 2, stops the rotating servo motor and the wire feeding mechanism, and drives the light-emitting diode corresponding to the No. 3 station in the station state indication device 6 to light, so that the operator can quickly identify the fault position. In addition, since the rotating servo motor is equipped with a high-resolution encoder, the central processing unit 5 synchronously obtains the current rotating angle of the stator (such as 120°), and calculates the defect occurring in the No. 8 slot area by combining the number of stator slots (such as 24 slots), to realize two-level positioning of "station-slot".

[0065] During the whole process, the remaining five stations are not affected by the abnormality of the No. 3 station, continue to normally wind, and maintain the overall production efficiency while ensuring the detection accuracy, because each of the remaining five stations is provided with an independent insulation online detection module 3, an isolated acquisition channel and a control logic.

[0066] According to the ideal embodiments of the application, the above description can be changed and modified in various ways without deviating from the technical idea of the application. The technical scope of the application is not limited to the content of the specification, and must be determined according to the scope of the claims.

Claims

1. A brushless motor stator fabrication device for multi-station synchronous winding detection, characterized in that, include: The winding machine frame is used to support and fix multiple winding stations; Multiple independent winding units are respectively mounted on the winding main frame; An online insulation detection module is provided for each of the independent winding units and is used to perform insulation detection on the enameled wire in each winding slot of the independent winding unit. The signal isolation acquisition unit is connected to each of the above-mentioned online insulation detection modules in a one-to-one manner. It is used to isolate, amplify and convert the electrical signals output by the online insulation detection modules into analog and digital signals, including insulation signals detected in the same winding according to the winding order. The central processing unit is communicatively connected to the signal isolation and acquisition unit. It is used to receive and analyze the insulation signals of each channel, determine whether there is an insulation abnormality, and output the fault identification information of the corresponding workstation. The fault identification information includes the workstation location and associated specific process optimization suggestion instructions. In addition, a workstation status indicator device, connected to the central processing unit, is used to illuminate the visual prompt element of the corresponding workstation according to the fault identification information.

2. The brushless motor stator preparation device for multi-station synchronous winding detection according to claim 1, characterized in that: Each of the independent winding units includes a winding nozzle, a tension adjustment mechanism, a wire guide wheel assembly, and a stator clamping mechanism, wherein the winding nozzle is configured to insert the enameled wire into a stator slot along a predetermined bending path.

3. The brushless motor stator preparation device for multi-station synchronous winding detection according to claim 2, characterized in that: The online insulation detection module includes a first electrode and a second electrode. The first electrode is disposed in the vicinity of the winding nozzle outlet end, and the second electrode is electrically connected to the stator core or the stator clamping mechanism, forming a local detection circuit for the insulation status of the enameled wire at the winding nozzle outlet.

4. The brushless motor stator preparation device for multi-station synchronous winding detection according to claim 3, characterized in that: The winding nozzle outlet end is provided with an insulating bushing, which is made of a high wear-resistant insulating material. Its inner hole profile matches the outer diameter of the enameled wire. The first electrode is embedded in the side wall of the insulating bushing, and the electrode surface maintains non-contact electric field coupling with the outer surface of the enameled wire. The first electrode is a ring electrode structure arranged around the travel path of the enameled wire. The ring electrode is isolated from the enameled wire by an insulating dielectric layer. The second electrode is in direct contact with the outer circumferential surface of the stator core through conductive claws. The conductive claws are mounted on the rotating base of the stator clamping mechanism and rotate synchronously with the stator.

5. The brushless motor stator preparation device for multi-station synchronous winding detection according to claim 2, characterized in that: The stator clamping mechanism includes a stator positioning mandrel, a clamping cylinder, and a rotary servo motor. The stator positioning mandrel is coaxially mounted on the output shaft of the rotary servo motor. The piston rod of the clamping cylinder is connected to a pressing head, and the pressing head moves axially under the drive of the clamping cylinder.

6. The brushless motor stator preparation device for multi-station synchronous winding detection according to claim 1, characterized in that: The signal isolation acquisition unit includes multiple isolation amplifiers, filter circuits, and analog-to-digital converters. The input terminal of each isolation amplifier is connected to the output terminal of the corresponding online insulation detection module, and the output terminal is connected to the multi-channel input interface of the central processing unit after passing through the filter circuit and the analog-to-digital converter in sequence.

7. The brushless motor stator preparation device for multi-station synchronous winding detection according to claim 1, characterized in that: The central processing unit has a built-in threshold comparison algorithm module. This module compares the digital signal of each channel with a preset threshold in real time. When the amplitude of any channel signal exceeds the preset threshold, it is determined that there is insulation damage at the winding station corresponding to that channel, and a fault data packet containing the station number is generated.

8. The brushless motor stator preparation device for multi-station synchronous winding detection according to claim 1, characterized in that: The workstation status indicator includes multiple light-emitting diodes (LEDs). Each LED is connected to the output pin of the central processing unit via a driving circuit. The position of each LED corresponds one-to-one with a physical workstation on the winding main frame.

9. A method of using a multi-station synchronous winding detection brushless motor stator preparation device, as described in any one of claims 1-8, characterized in that... Includes the following steps: S1: Controls multiple independent winding units set on the winding main frame to perform synchronous winding operations on multiple slots on the stator; S2: Real-time insulation characteristic signal acquisition is performed on the windings wound in each independent winding unit; S3: The acquired insulation characteristic signal is processed by the signal isolation acquisition unit, and the central processing unit identifies the winding state based on preset rules. The winding state includes normal state and abnormal state. When the insulation characteristic signal exceeds the insulation threshold, it is determined to be the abnormal state. S4: When the identification result is an abnormal state, based on the winding order within the same winding in the abnormal state, identify the associated specific process and output an optimization suggestion instruction pointing to the associated specific process.

10. The method of using the brushless motor stator preparation device for multi-station synchronous winding detection according to claim 9, characterized in that: The winding order within the same winding includes the first group, the middle group, and the last group; when the abnormal state originates from the first group, the associated specific process is the enameled wire transmission process; when the abnormal state originates from the middle group, the associated specific process is the winding process; when the abnormal state originates from the last group, the associated specific process is the post-winding processing process.

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