Flywheel welding heightening tool and flywheel welding workbench

Abstract

The invention relates to the technical field of flywheel assembly, in particular to a flywheel welding heightening tool and a flywheel welding workbench. The flywheel welding and heightening tool comprises a cylindrical main body, and the cylindrical main body comprises an embedding space and a positioning end; the embedding space is positioned in the cylindrical main body; the positioning end is connected with the embedding space and provided with a first positioning face and a second positioning face, the first positioning face is located on the end face of the positioning end and used for supporting the flywheel, a counter bore is formed in the first positioning face, the second positioning face is located in the counter bore, the second positioning face is parallel to the first positioning face, and a fixing screw hole is formed in the second positioning face; a pin hole is further formed in the positioning end, and a pin for positioning the flywheel is inserted into the pin hole.

Description

Technical Field

[0001] This invention relates to the field of flywheel assembly technology, and in particular to a flywheel welding elevation fixture and a flywheel welding workbench. Background Technology

[0002] In modern small satellite attitude control systems, momentum wheels are widely used as the main actuators due to their advantages such as high control precision, high reliability, fast response, and low power consumption. Based on the law of conservation of angular momentum, the momentum wheel controls and stabilizes the satellite's attitude through angular momentum exchange. The flywheel body is the source of rotational inertia and the main source of mass, providing effective rotational inertia and is a key structure of the entire momentum wheel system.

[0003] Currently, flywheel welding primarily employs manual methods. This manual approach suffers from drawbacks such as low efficiency, low automation, high skill requirements for welders, inconsistent welding quality, and low precision. Consequently, errors are unavoidable, compromising the positional accuracy of welded parts and product quality, and failing to meet the demands of mass production and the overall performance requirements of the momentum wheel. Furthermore, it can lead to imbalances in the flywheel assembly during manufacturing due to processing and assembly factors. Particularly during the welding and assembly of the flywheel to the integrated motor spindle, misalignment or tilting of the inertial and rotational spindles can create additional resistance torque and mechanical vibration, significantly reducing the high precision, high reliability, and long lifespan requirements of the spatial actuator.

[0004] The purpose of this invention is to provide a tooling to improve the positional accuracy between the flywheel body and the motor spindle, and to ensure welding quality. Summary of the Invention

[0005] Based on the above analysis, embodiments of the present invention aim to provide a flywheel welding shim tooling, comprising:

[0006] A cylindrical body, the cylindrical body including an embedding space and a positioning end; The embedded space is located inside the cylindrical body; The positioning end is connected to the embedded space. The positioning end has a first positioning surface and a second positioning surface. The first positioning surface is located on the end face of the positioning end and is used to support the flywheel. A countersunk hole is formed on the first positioning surface. The second positioning surface is located in the countersunk hole. The second positioning surface is parallel to the first positioning surface. A fixing screw hole is formed on the second positioning surface. The positioning end is also provided with a pin hole, which is used to insert a pin for positioning the flywheel.

[0007] In some embodiments, the embedded space is cylindrical and is used to accommodate a motor welded to the flywheel. A positioning flange is provided at one end of the motor near the main shaft. The end face of the positioning flange is in contact with the second positioning surface. A through hole corresponding to the fixing screw hole is provided on the positioning flange. A screw passes through the through hole and is threadedly connected to the fixing screw hole so that the motor is positioned relative to the shim tooling.

[0008] In some embodiments, the flywheel is provided with at least two positioning holes, and the relative positional relationship between the two positioning holes matches the positional relationship between the two pin holes.

[0009] In some embodiments, the flywheel is further provided with an exit hole corresponding to the through hole. When the flywheel is positioned on the first positioning surface by a pin, the exit hole and the through hole coincide when viewed along the normal direction of the first positioning surface.

[0010] In some embodiments, the cylindrical body has a lead wire channel on the side away from the positioning end, the lead wire channel connecting the outer wall of the cylindrical body and the side wall of the embedding space.

[0011] In some embodiments, the embedded space and the end of the cylindrical body away from the positioning end also have an ejection channel, and the embedded space is connected to the outside through the ejection channel.

[0012] In some embodiments, a magnet embedding slot is provided at one end of the cylindrical body away from the positioning end, and a magnet is provided in the magnet embedding slot.

[0013] In some embodiments, the pin holes are formed on the second positioning surface, and the second positioning surface has 6 pin holes evenly distributed circumferentially.

[0014] The present invention also provides a flywheel welding workbench, including the flywheel welding elevation fixture as described in any of the above embodiments, and further including: The base plate, the flywheel welding shim fixture is fixed on the base plate, and the positioning end of the flywheel welding shim fixture faces upward; A visual positioning sensor is fixed above the flywheel welding shim fixture by a sensor bracket. The visual positioning sensor is used to detect the positioning accuracy of the flywheel. An ejector screw is threadedly connected to the base plate and is capable of spiral movement relative to the base plate, so that the ejector screw extends into the embedded space of the flywheel welding shim tool.

[0015] In some embodiments, the base plate includes a magnetically adsorbed positioning disk with a positioning groove. The contour of the positioning groove matches the bottom of the flywheel welding shim fixture. The flywheel welding shim fixture is embedded in the positioning groove, and the ejector screw is threadedly connected to the magnetically adsorbed positioning disk.

[0016] This invention, through the design of embedding space in the cylindrical body, uses the first positioning surface and the second positioning surface to position the motor and flywheel before welding. Compared with the traditional manual welding method, this invention effectively improves the positional accuracy requirements of the welding process assembly between the flywheel and the integrated motor rotating spindle, ensures welding quality, improves the requirements of mass production, and avoids the introduction of additional resistance torque to the momentum wheel during welding assembly, which may even lead to adverse mechanical vibration. Attached Figure Description

[0017] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0018] Figure 1 This is a three-dimensional schematic diagram of the flywheel welding shim tooling provided in an embodiment of the present invention; Figure 2 This is a side cross-sectional view of the flywheel welding shim tooling provided in an embodiment of the present invention; Figure 3 This is a schematic diagram showing the usage state of the flywheel welding shim tooling provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of a flywheel welding workbench structure provided in an embodiment of the present invention.

[0019] Figure Labels 1. Columnar body; 2. Embedded space; 3. Positioning end; 31. First positioning surface; 32. Second positioning surface; 33. Fixing screw hole; 34. Pin hole; 4. Motor; 41. Positioning flange; 42. Flange fixing screw; 5. Flywheel; 51. Exit hole; 6. Lead wire channel; 7. Ejection channel; 8. Magnet embedding slot; 9. Pin; 10. Base plate; 11. Visual positioning sensor; 12. Ejection screw; 13. Magnetic adsorption positioning plate; 14. Sensor bracket; 15. Embedded magnetic magnet; 16. Laser sensor bracket; 17. Laser position sensor; 18. Surface mount stress-strain sensor; 19. Surface mount temperature sensor. Detailed Implementation

[0020] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which constitute a part of the present invention and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0021] In the description of the embodiments of the present invention, it should be noted that, unless otherwise explicitly specified and limited, the term "connected" should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral connection; it can refer to a mechanical connection or an electrical connection; it can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0022] Throughout the text, the terms “top,” “bottom,” “above,” “below,” and “on top” refer to the relative positions of components of the device, such as the relative positions of the top and bottom substrates within the device. It is understood that the device is multifunctional and independent of its spatial orientation.

[0023] The working surface of this invention can typically be a plane or a curved surface, and can be inclined or horizontal. For ease of explanation, the embodiments of this invention are placed on a horizontal surface and used on a horizontal surface, thereby defining "height" and "vertical".

[0024] This invention aims to provide a flywheel welding elevation fixture, such as... Figure 1 and Figure 2 As shown, it includes: A cylindrical body 1, the cylindrical body 1 including an embedding space 2 and a positioning end 3; The embedded space 2 is located inside the cylindrical body 1; The positioning end 3 is connected to the embedded space 2. The positioning end 3 has a first positioning surface 31 and a second positioning surface 32. The first positioning surface 31 is located on the end face of the positioning end 3 and is used to support the flywheel 5. A countersunk hole is formed on the first positioning surface 31, and the second positioning surface 32 is located in the countersunk hole. The second positioning surface 32 is parallel to the first positioning surface 31, and a fixing screw hole 33 is formed on the second positioning surface 32. The positioning end 3 is also provided with a pin hole 34, which is used to insert the pin 9 for positioning the flywheel 5.

[0025] It is understood that this embodiment is a raised fixture, with the axis of the cylindrical body 1 placed vertically and the bottom of the cylindrical body 1 connected to the welding platform. The top of the cylindrical body 1 is the positioning end 3. The embedded space 2 is the hollow accommodating space inside the cylindrical body 1. The cross-sectional shape of the cylindrical body 1 is not limited in this invention. Generally, the cylindrical body 1 is machined from a bar. In some embodiments, the cross-sectional shape of the cylindrical body 1 can be circular. The pin hole 34 can be set on the first positioning surface 31 or the second positioning surface 32. In some embodiments, the pin hole 34 is opened on the second positioning surface 32, and the second positioning surface 32 has 6 pin holes 34 evenly distributed circumferentially.

[0026] When in use, the shim device is placed on the platform, such as Figure 3 As shown, the end face of the positioning end 3 is kept horizontal. The integrated motor 4, which is welded to the flywheel 5, is placed within the embedded space 2. The integrated motor 4 is connected to a positioning flange 41. The positioning flange 41 is fixed to the fixing screw hole 33 on the second positioning surface 32 by flange fixing screws 42, so that the integrated motor 4 is positioned, and its motor 4 shaft is exposed on the positioning end 3. Then, the flywheel 5 is placed on the first positioning surface 31 and fixed on the first positioning surface 31 by pins 9 and pin holes 34, so that the motor 4 shaft is coaxial with the shaft hole of the flywheel 5, that is, the positioning of the welding position of the motor 4 and the flywheel 5 is completed by the gap between the motor 4 shaft and the shaft hole. The positioning flange 41 and the motor 4 are connected by flange machining tolerance to ensure the positional accuracy between them. The two are strongly bonded by filling with adhesive. The first positioning surface 31 of the tooling is in close contact with the end face of the flywheel 5. Its main function is to position the flywheel 5 itself for welding and to ensure the geometric positional relationship between the flywheel 5 and the main shaft of the motor 4, so as to ensure the welding shape and position accuracy.

[0027] In actual assembly operations, the welding platform surface must first be ensured to be clean and flat. The shim fixture is then securely fixed in the predetermined position using its bottom magnetic attachment or other clamps. The operator uses a level to calibrate the first positioning surface 31, ensuring it is level (e.g., levelness error ≤ 0.02°), which is the basis for all subsequent coaxiality assurances.

[0028] When installing the motor, handle it gently and slowly insert the integrated motor 4 vertically into the embedded space 2. The lower surface of the motor positioning flange 41 must be completely flush with the second positioning surface 32, without any visible gaps or foreign objects. Then, select flange fixing screws 42 of appropriate size and length (usually high-strength hexagon socket head cap screws) and screw them into the fixing screw holes 33 in a diagonal sequence until the specified torque value is reached. This process, by applying a uniform preload, rigidly connects the motor housing, positioning flange 41, and the second positioning surface 32 of the tooling into a whole, thereby completely locking the spatial position of the motor spindle, and aligning its axis with the axis of the tooling (i.e., the theoretical axis of the embedded space 2).

[0029] Specifically, the cylindrical body 1, as the core load-bearing structure of the entire tooling, requires precise design of its axial dimension (height) based on the actual height difference between the welding platform and the flywheel welding line. This ensures that the operator can perform welding operations in a comfortable and stable posture, while also guaranteeing that the relative position of the flywheel and the motor shaft is in the optimal welding posture during the welding process. The cylindrical body 1 is typically made of a metal material with good rigidity, stability, and deformation resistance, such as medium carbon steel (e.g., 45# steel) or low-alloy structural steel, and undergoes heat treatment to improve its comprehensive mechanical properties. Its outer surface can be treated with rust prevention, such as blackening, galvanizing, or spraying with high-temperature resistant paint, to adapt to the complex environment of the welding site. The bottom end face of the cylindrical body 1 must ensure high flatness, typically requiring a flatness error of no more than 0.05mm, to ensure stable and full contact with the welding platform, preventing wobbling or tilting due to uneven force during welding, which would affect positioning accuracy.

[0030] The embedded space 2, serving as a crucial cavity for accommodating the motor, must have a shape and size that closely match the external contour of the integrated motor 4 to be welded. Preferably, the embedded space 2 is designed as a cylinder, primarily because the housing of most integrated motors is cylindrical. A cylindrical space not only facilitates machining (e.g., one-time forming through turning or boring) but also provides good circumferential containment with the motor housing, offering some radial auxiliary support and limiting unintended horizontal movement of the motor. The inner diameter of the embedded space 2 should be slightly larger than the maximum outer diameter of the motor housing, forming a small clearance fit (e.g., a single-sided clearance of 0.1-0.3 mm). This clearance facilitates smooth insertion and removal of the motor and can be eliminated by tightening the positioning flange, thereby ensuring precise alignment of the motor axis. The depth of the embedded space 2 needs to be precisely calculated to fully accommodate the portion of the motor that needs to be covered, while ensuring that the positioning flange 41 of the motor is fully exposed and in contact with the second positioning surface 32.

[0031] The positioning end 3 is a key area for the tooling to achieve multi-functional integration. The first positioning surface 31, as the direct support reference surface for the flywheel 5, requires extremely high surface roughness, typically reaching Ra 0.8 μm or higher. It also requires quenching or surface hardening treatment to enhance wear resistance and prevent scratches or wear caused by frequent flywheel placement, which could affect long-term positioning accuracy. The countersunk hole on it is typically 3-8 mm deep, with its diameter determined by the size of the positioning flange 41. The countersunk hole not only provides space for the second positioning surface 32 but, more importantly, forms a stepped structure that can accommodate the thickness of the positioning flange 41 and prevent excessive protrusion of the flange during tightening. This ensures that the bottom surface (wheel body end face) of the flywheel 5 can achieve complete and stable surface contact with the first positioning surface 31.

[0032] The second positioning surface 32 is located at the bottom of the countersunk hole. Its parallelism with the first positioning surface 31 is one of the keys to ensuring the coaxiality of the motor shaft and flywheel shaft hole. Typically, the parallelism error between the two is required to be less than 0.02 mm. The fixing screw holes 33 on the second positioning surface 32 are used for connection with the motor positioning flange 41. The number, specifications, and distribution of the fixing screw holes 33 must be completely consistent with the through holes on the positioning flange 41. Typically, at least three threaded holes evenly distributed around the circumference are used to provide a stable and uniform locking force. The thread accuracy grade of the threaded holes is typically 6H, and wire thread inserts can be used to enhance thread strength and service life to accommodate frequent assembly and disassembly.

[0033] In some embodiments, the flywheel 5 is provided with at least two positioning holes, and the relative positional relationship between the two positioning holes matches the positional relationship of the two pin holes 34. Preferably, the shim fixture and the flywheel 5 body are positioned using a one-plane, two-pin method, utilizing a plane and two pins 9 to precisely position the workpiece. During assembly, diagonal pins 9 are used for positioning without differentiation, and the pins 9 pass through the positioning holes and are inserted into the pin holes 34. In some embodiments, the positioning holes include cylindrical holes and diagonally positioned diamond-shaped holes to prevent over-positioning and compensate for errors.

[0034] In some embodiments, the embedded space 2 is cylindrical and is used to accommodate the motor 4 welded to the flywheel 5. The motor 4 has a positioning flange 41 at one end near the main shaft. The end face of the positioning flange 41 contacts the second positioning surface 32. The positioning flange 41 has a through hole corresponding to the fixing screw hole 33. The screw passes through the through hole and is threaded to the fixing screw hole 33 so that the motor 4 is positioned relative to the shim tooling.

[0035] As a key interface between the motor and the tooling, the design and manufacturing precision of the positioning flange 41 directly determines the final spatial orientation of the motor spindle. This flange is typically machined integrally with the motor housing or formed as a single component through a high-precision connection (such as an interference fit combined with adhesive bonding). The end face that contacts the second positioning surface 32 must possess extremely high flatness and low surface roughness to ensure uniform contact and prevent any gaps. The through holes on the flange are usually smooth holes with a diameter slightly larger than the diameter of the flange fixing screws 42 to provide a small adjustment margin for centering. However, this adjustment margin is eliminated after the screws are tightened, and rigid positioning is achieved entirely by the clamping force of the screws.

[0036] The pin hole 34 is the core element for achieving precise flywheel positioning. When the pin hole 34 is formed on the second positioning surface 32, its axis is perpendicular to the second positioning surface 32. The design of six circumferentially distributed pin holes 34 provides great flexibility, adapting to variations in the distribution of positioning holes on different flywheel models. For example, for a flywheel with two positioning holes, any two of these six pin holes can be selected to match the flywheel's positioning holes, allowing the insertion of the pin 9. The diameter of the pin hole 34 and the pin 9 are precisely clearance-fitted, for example, H7 / g6, ensuring smooth insertion and removal of the pin while effectively limiting the radial movement of the flywheel. The machining of the pin hole 34 must ensure the perpendicularity of its axis to the second positioning surface 32, as well as the positional accuracy between it and the distribution circle of the fixing screw holes 33.

[0037] In some embodiments, such as Figure 3 As shown, the flywheel 5 is also provided with an exit hole 51 corresponding to the through hole. When the flywheel 5 is positioned on the first positioning surface 31 by the pin 9, the exit hole 51 coincides with the position of the through hole when viewed along the normal of the first positioning surface 31.

[0038] After welding is completed, the welded flywheel 5 and motor 4 need to be ejected from the fixture. At this time, the rigid connection between motor 4 and fixture via positioning flange 41 needs to be released. The flange fixing screw 42 in fixing screw hole 33 can be removed through ejection hole 51, and then motor 4 can be ejected from embedded space 2.

[0039] The ejection hole 51 is a specially designed process hole on the flywheel 5. Its diameter must be larger than the head of the flange fixing screw 42 or the size of the disassembly tool used (such as an Allen wrench), and it must have sufficient depth to ensure that the operator can easily reach the tool and operate the screw after the flywheel 5 is installed in place. The positional accuracy of the ejection hole 51 is crucial. It must be ensured that when it is machined simultaneously with the flywheel positioning hole, it maintains a precise positional relationship with the positioning hole system on the bottom surface of the flywheel. This ensures that after the flywheel is positioned by the pin 9, the ejection hole 51 can automatically and accurately align with the fixing screw hole 33 below.

[0040] The disassembly process is as follows: After welding, allow the workpiece to cool to room temperature. First, remove the two pins 9 of the positioning flywheel. Then, using an extended-rod disassembly tool, loosen and remove all flange fixing screws 42 one by one through the ejection hole 51 on the flywheel. At this point, only a small gap remains between the welded assembly (flywheel + motor) and the fixture, where the motor housing and the inner wall of the embedded space 2 are engaged. Finally, using the ejection channel 7 at the bottom of the fixture, apply an ejection force smoothly and evenly through the ejection rod or pneumatic ejector pin device to eject the entire welded assembly from the embedded space 2. The entire disassembly process does not require flipping or forcefully striking the workpiece, effectively protecting the welded parts and the appearance of the workpiece, and improving operational safety and efficiency.

[0041] In some embodiments, such as Figures 1-3 As shown, the cylindrical body 1 also has a lead wire channel 6 on the side away from the positioning end 3. The lead wire channel 6 connects the outer wall of the cylindrical body 1 and the side wall of the embedding space 2. Specifically, the lead wire channel 6 can be a through hole opened at the lower end of the side wall of the cylindrical body 1, leading into the embedding space 2. The lead wire channel 6 serves as a lead wire outlet channel for the motor 4.

[0042] In some embodiments, the embedded space 2 and the end of the cylindrical body 1 away from the positioning end 3 also have an ejection channel 7, through which the embedded space 2 communicates with the outside. Preferably, in some embodiments, the interior of the cylindrical body 1 has a through hole, which serves as the embedded space 2, and the bottom end of the through hole serves as the ejection channel 7 for ejecting the motor 4. Alternatively, in some embodiments, the embedded space 2 can be a blind hole, with a small hole at the bottom of the blind hole serving as the ejection channel 7. If the embedded space 2 is in the form of a blind hole due to structural strength or manufacturing reasons, a smaller ejection channel 7 (such as a threaded hole or a smooth hole) needs to be machined at the center of the bottom of the blind hole. During disassembly, a special pull screw can be screwed in or an ejector rod with a threaded head can be used to provide a smooth pulling force through the threaded connection to remove the component. At this time, it is important to note that the thickness of the bottom of the blind hole needs to be checked for strength to ensure that it can withstand the ejection force without deformation. Regardless of the form, the design of ejection channel 7 embodies the human-centered tooling design philosophy, greatly reducing the labor intensity of operators and avoiding product damage or loss of precision caused by violent disassembly.

[0043] In some embodiments, such as Figure 2 As shown, the cylindrical body 1 is further provided with a magnet embedding slot 8 at one end away from the positioning end 3, and an embedded magnetic magnet 15 is provided in the magnet embedding slot 8. In this way, the welding fixture can be fixed to the welding platform by magnetic attraction, which is convenient for assembly and disassembly.

[0044] The fixture is secured using embedded magnetic magnets 15, offering unparalleled speed and flexibility compared to traditional bolt clamps or vises. The magnet embedding slots 8 are typically annular slots or multiple evenly distributed blind holes located on the bottom surface of the cylindrical body 1. High-performance permanent magnets (such as neodymium iron boron) are embedded within the slots, and a steel cover plate is usually placed above the magnets to press them firmly and prevent them from falling out. Magnetic lines of force form a closed loop through the steel substrate of the cylindrical body 1, generating a strong attraction force on the bottom surface, firmly fixing the fixture to a steel welding platform or a table with a magnetic guide plate.

[0045] This fixing method allows tooling to be installed or moved within seconds without any tools, making it particularly suitable for flexible production scenarios involving multiple product types, small batches, or frequent workstation adjustments. However, magnetic fixing requires a high degree of flatness on the platform surface, ensuring it is clean and free of iron filings to guarantee stable and reliable adhesion. To enhance safety, a manual or pneumatic magnetic switch / demagnetizer can be designed on the side of the tooling, temporarily cutting off or significantly weakening the magnetic force when the tooling needs to be moved, facilitating easy removal.

[0046] The present invention also provides a flywheel welding workbench, such as Figure 4 As shown, the welding elevation fixture for the flywheel 5, as described in any of the above embodiments, also includes: The base plate 10, the flywheel 5 welding shim fixture is fixed on the base plate 10, and the positioning end 3 of the flywheel 5 welding shim fixture is upward; A visual positioning sensor 11 is fixed above the welding shim of the flywheel 5 by a sensor bracket 14. The visual positioning sensor 11 is used to detect the positioning accuracy of the flywheel 5. Ejector screw 12 is threadedly connected to the base plate 10. The ejector screw 12 can move spirally relative to the base plate 10 so that the ejector screw 12 extends into the embedded space 2 of the welding pad tool of the flywheel 5.

[0047] The flywheel welding workbench provided by this invention is a comprehensive welding process equipment platform that integrates high-precision mechanical positioning, non-contact optical inspection, semi-automatic assisted disassembly, and intelligent process status monitoring. Its core design concept is to embed a highly optimized dedicated elevation tooling into a functionally expanded base system, thereby upgrading the simple positioning and support function into a solution covering the entire process of "clamping-verification-monitoring-unloading".

[0048] The base plate 10 serves as the mounting base for the entire worktable. It is typically milled from a thick steel plate (such as Q235 or higher strength alloy steel plate) to ensure overall rigidity and the flatness of its upper surface. The base plate not only has mounting positions for elevation fixtures but also pre-drilled threaded holes or positioning holes for mounting accessories such as the sensor bracket 14 and ejector screws 12. Vibration-damping pads can be installed under the base plate 10, or it can be bolted to a larger worktable surface to ensure the stability of the entire system during welding operations and resist vibrations generated by the welding equipment (such as welding robots) or the welding process itself.

[0049] The visual positioning sensor 11 is typically an industrial CCD or CMOS camera, paired with a lens of appropriate focal length and a ring light source to form a machine vision system. The sensor bracket 14 is designed to ensure that the camera can be vertically aligned with the flywheel 5 already installed on the tooling positioning end 3. The detection principle is as follows: after the flywheel 5 is positioned on the first positioning surface 31 by the pin 9, the vision system captures the features on the upper surface of the flywheel 5 (such as pre-processed positioning marks, shaft hole edges, or specific contours). Through image processing algorithms, the deviation between the actual position and the theoretically designed position of these features is calculated, including translational deviations in the X and Y directions and rotational angle deviations around the Z-axis. This deviation data can be displayed in real time on the operating interface for the operator to judge whether the positioning is qualified (typically, the deviation is required to be less than 0.05mm). In more advanced automated integration schemes, this deviation data can be directly fed back to the welding robot for minute dynamic compensation of the welding torch path, thereby achieving true adaptive precision welding.

[0050] The ejector screw 12 is a key improvement in enabling mechanized workpiece disassembly. Compared to manually tapping or prying from the bottom with an ejector rod, the screw ejection provides a controllable, smooth, and coaxial ejection force. The threads of the ejector screw 12 are typically trapezoidal or rectangular to provide greater load-bearing capacity and self-locking. The screw tip can be designed with a nylon or copper protective cap to prevent damage from direct contact with the motor shaft end face. During operation, after removing the flange fixing screw 42 and the locating pin 9, simply rotate the ejector screw 12 with a wrench or power tool to smoothly screw it in (raise it). Its tip abuts against the motor shaft end or the bottom of the housing, thereby uniformly and vertically ejecting the entire welded assembly into the embedded space 2, greatly reducing labor intensity and the potential risk of damage to workpiece precision.

[0051] In some embodiments, the base plate 10 includes a magnetic adsorption positioning disk 13, the magnetic adsorption positioning disk 13 having a positioning groove, the outline of the positioning groove matching the bottom of the flywheel 5 welding shim fixture, the flywheel 5 welding shim fixture being embedded in the positioning groove, and the ejector screw 12 being threadedly connected to the magnetic adsorption positioning disk 13.

[0052] The magnetic positioning disc 13 is a sophisticated modular interface design. It is a separate steel disc-shaped part, fixed to a specific position on the base plate 10 by screws or its own magnetism. The shape of its positioning groove precisely matches the bottom outer contour (e.g., circular, square, or circular with keyways) of the raised tooling cylindrical body 1, typically using a small clearance fit (approximately 0.02-0.05 mm). When the bottom of the raised tooling is inserted into this groove, rapid and precise radial positioning is achieved, ensuring repeatable height positioning of the tooling each time. Secondly, the magnetic positioning disc 13 contains a powerful permanent magnet (or the entire disc is made of magnetic material, working in conjunction with the magnet 15 at the bottom of the tooling), which firmly attracts and fixes the tooling, preventing it from sliding or rotating under welding stress.

[0053] This design offers significant flexibility: multiple magnetically attached positioning plates 13 of different models can be configured on a single workbench base plate 10 to correspond to different specifications of flywheel welding shims. When it is necessary to switch product models, simply replace the corresponding shim and its matching magnetically attached positioning plate 13 (or just replace the shim if the positioning plate is universal) to quickly complete the production line changeover, making it ideal for flexible production modes with multiple varieties and small batches.

[0054] In some embodiments, such as Figure 4 As shown, a laser sensor bracket 16 is also provided on the base plate 10, and a laser position sensor 17 is provided on the laser sensor bracket 16. The laser head of the laser position sensor 17 faces the position of the tooling. The laser position sensor 17 is used to detect the axial and radial position changes of the flywheel 5 body in real time during welding, and is used to monitor the welding position during the welding process. Preferably, a patch-type stress-strain sensor 18 is designed on the side of the welding tooling to detect the welding pressure conditions in real time. Overheating input may lead to a decrease in the microstructure properties of the weld zone and thermal deformation of the parts; a patch-type temperature sensor 19 is designed on the upper surface of the flywheel 5 body to detect the welding temperature in real time and control the welding temperature conditions.

[0055] During welding, first, the motor 4 and motor 4 flange assembly, which are bonded with adhesive, are placed into the embedded channel of motor 4. Then, the motor 4 lead wire is led out from the lead wire channel 6. Next, the through hole of the positioning flange 41 and the reserved six screw holes of the shim fixture are rigidly connected by screws. The welding shim block is magnetically adsorbed onto the positioning plate, and then the positioning pin is installed. Next, the flywheel 5 to be welded is positioned by the positioning pin and placed flat on the positioning end 3 of the welding fixture. Then, visual positioning inspection and laser position inspection are performed at the welding station. When the welding accuracy is met, temperature and stress strain sensors are attached to detect the working conditions of the welding process.

[0056] This invention utilizes a space embedded within a cylindrical body, employing a first and second positioning surface for pre-welding positioning of the motor and flywheel. Compared to traditional manual welding methods, this invention effectively improves the positional accuracy requirements of the welding process assembly between the flywheel and the integrated motor's rotating spindle, ensuring welding quality, meeting the requirements of mass production, and avoiding the introduction of additional resistance torque or potential adverse mechanical vibrations into the momentum wheel during welding assembly. The welding equipment physically fills the flux between the motor spindle and the flywheel body, completing the welding assembly between the flywheel body and the motor shaft. After static cooling, the welded flywheel body and motor are finally ejected using an ejector screw.

[0057] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A flywheel welding elevation fixture, characterized in that, include: A cylindrical body, the cylindrical body including an embedding space and a positioning end; The embedded space is located inside the cylindrical body; The positioning end is connected to the embedded space. The positioning end has a first positioning surface and a second positioning surface. The first positioning surface is located on the end face of the positioning end and is used to support the flywheel. A countersunk hole is formed on the first positioning surface. The second positioning surface is located in the countersunk hole. The second positioning surface is parallel to the first positioning surface. A fixing screw hole is formed on the second positioning surface. The positioning end is also provided with a pin hole, which is used to insert a pin for positioning the flywheel.

2. The flywheel welding elevation fixture according to claim 1, characterized in that: The embedded space is cylindrical and is used to accommodate a motor welded to the flywheel. A positioning flange is provided at one end of the motor near the main shaft. The end face of the positioning flange is in contact with the second positioning surface. A through hole corresponding to the fixing screw hole is provided on the positioning flange. A screw passes through the through hole and is threadedly connected to the fixing screw hole so that the motor is positioned relative to the shim fixture.

3. The flywheel welding elevation fixture according to claim 1, characterized in that: The flywheel is provided with at least two positioning holes, and the relative positional relationship between the two positioning holes matches the positional relationship between the two pin holes.

4. The flywheel welding elevation fixture according to claim 2, characterized in that: The flywheel is also provided with an exit hole corresponding to the through hole. When the flywheel is positioned on the first positioning surface by a pin, the exit hole and the through hole are aligned when viewed along the normal direction of the first positioning surface.

5. The flywheel welding elevation fixture according to claim 1, characterized in that: The cylindrical body also has a lead wire channel on the side away from the positioning end, and the lead wire channel connects the outer wall of the cylindrical body and the side wall of the embedding space.

6. The flywheel welding elevation fixture according to claim 1, characterized in that: The embedded space and the end of the cylindrical body away from the positioning end also have an ejection channel, and the embedded space is connected to the outside through the ejection channel.

7. The flywheel welding elevation fixture according to claim 1, characterized in that: The cylindrical body is also provided with a magnet embedding slot at one end away from the positioning end, and a magnet is provided in the magnet embedding slot.

8. The flywheel welding elevation fixture according to claim 1, characterized in that: The pin holes are formed on the second positioning surface, and the second positioning surface has 6 pin holes evenly distributed circumferentially.

9. A flywheel welding workbench, characterized in that, The flywheel welding elevation fixture as described in any one of claims 1-6 further includes: The base plate, the flywheel welding shim fixture is fixed on the base plate, and the positioning end of the flywheel welding shim fixture faces upward; A visual positioning sensor is fixed above the flywheel welding shim fixture by a sensor bracket. The visual positioning sensor is used to detect the positioning accuracy of the flywheel. An ejector screw is threadedly connected to the base plate. The ejector screw can move spirally relative to the base plate so that it extends into the embedded space of the flywheel welding shim fixture.

10. The flywheel welding workbench according to claim 9, characterized in that: The base plate includes a magnetic adsorption positioning disk with a positioning groove. The outline of the positioning groove matches the bottom of the flywheel welding shim fixture. The flywheel welding shim fixture is embedded in the positioning groove. The ejector screw is threadedly connected to the magnetic adsorption positioning disk.

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