Rotor and stator combined assembly system of range extender

Abstract

The invention discloses a rotor and stator combined mounting system for a range extender, and relates to the technical field of new energy automobile power system manufacturing. The rotor and stator combined mounting system of the range extender comprises a base, an electric control system and a pneumatic control system. The base is divided into a left side platform and a right side platform, the rotor fixing assembly is installed on the left side platform, the combining assembly is installed on the right side platform, and the photographing and coating assembly is arranged on one side of the base; the rotor fixing assembly comprises an engine rotating and swinging assembly, an engine lifting and swinging assembly and an engine mounting assembly, and the assembling assembly comprises an X-direction servo moving assembly, a Y-direction servo lifting assembly, a Z-direction servo switching assembly, a probe servo displacement detection assembly and a stator floating centering assembly. In the assembling process of the stator and the rotor, the assembling assembly drives the stator to move and move for a certain distance or until the combined surfaces of the stator and the rotor are attached, bolts are manually screwed, a corresponding torque wrench is used for tightening, and the stator moving assembly returns to the original position. And the assembling quality and efficiency of the rotor and the stator of the range extender are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle power system manufacturing technology, specifically to a range extender rotor-stator assembly system. Background Technology

[0002] Against the backdrop of the rapid development of the new energy vehicle industry, the range extender, as the core power unit of the series hybrid system, plays a crucial role in power generation and auxiliary drive. Its performance directly determines the vehicle's power response speed, energy utilization efficiency, and driving range. The stator and rotor of the motor are the core moving components of the range extender, and their assembly precision is crucial to ensuring stable operation: misalignment of the assembly center will lead to uneven air gaps, resulting in increased operating noise, electromagnetic torque fluctuations, and reduced power output smoothness; non-parallel end faces will exacerbate component wear, increase energy loss, shorten the range extender's lifespan, and even affect the vehicle's driving range and safety.

[0003] Currently, rotor and stator assembly in the industry is still mainly done manually. However, the strong magnetic attraction between the rotor and stator makes it difficult to accurately control the assembly force and direction during manual assembly. This not only makes it impossible to ensure the precise alignment of the assembly center and the parallel alignment of the end faces, resulting in poor consistency of assembly accuracy, but also causes problems such as low operating efficiency, damage to parts due to collisions, and personnel safety risks. These issues seriously restrict the improvement of quality and capacity in the large-scale production of range extenders. Summary of the Invention

[0004] The purpose of this invention is to address the above-mentioned shortcomings by proposing a range extender rotor-stator assembly system that achieves precise alignment of the rotor and stator assembly centers through a semi-automatic assembly mechanism, ensuring that the end faces of the two components remain strictly parallel throughout the assembly process.

[0005] The present invention specifically adopts the following technical solution:

[0006] A range extender rotor-stator assembly system includes a base, an electronic control system, and a pneumatic control system. The base is divided into a left platform and a right platform. A swing base plate and a rotor fixing assembly are installed on the left platform, and an assembly assembly is installed on the right platform. The assembly assembly includes a slide table. A photography and painting assembly is provided on one side of the base. The rotor fixing assembly includes an engine rotation swing assembly, an engine lifting swing assembly, and an engine mounting assembly. The engine rotation swing assembly is located at the bottom of the swing base plate, the engine lifting swing assembly is located on one side of the swing base plate, and the engine mounting assembly is located on the upper surface of the swing base plate. An X-axis servo movement assembly, a Y-axis servo lifting assembly, and a Z-axis servo switching assembly are connected to the slide table. A probe servo displacement detection assembly and a stator floating alignment assembly are provided on the side of the slide table.

[0007] Preferably, the photography and painting components include a mounting base, on which a collaborative robot is mounted, and at the end of the collaborative robot are a gluing component and a photography component.

[0008] Preferably, the engine rotation and oscillation assembly includes a hollow rotary platform connected to a servo motor. A rotary table is mounted on the hollow rotary platform and connected to an oscillation base plate. An upper base plate is located on the upper right side of the oscillation base plate, and multiple upper support plates are arranged between the oscillation base plate and the upper base plate. The engine is mounted on the upper base plate, and a rotary support shaft is installed between the rotary table and the engine mounting assembly. The rotary support shaft is fixed with two bearing seats, and the servo motor drives the rotary support shaft to adjust the angle of the engine mounting assembly.

[0009] Preferably, the engine lifting and swinging assembly is installed at one end of the swinging base plate, including a servo motor. The servo motor is connected to the swinging base plate and drives the upper base plate to move by driving the movement of the swinging base plate.

[0010] Preferably, a linear guide rail is provided on the right platform of the base along the long side of the base. A slide table is installed on the linear guide rail, and a vertical guide rail is provided on the slide table. The probe servo displacement detection component and the stator floating alignment component are fixed to the left side of the slide table by left and right floating plates. The slide table slides freely in the X direction under the drive of the X-axis servo moving component and slides freely in the Z direction under the drive of the Z-axis servo lifting component. The left and right floating plates drive the probe servo displacement detection component and the stator floating alignment component to achieve free sliding in the Y direction under the drive of the Y-axis servo switching component. The X-axis servo moving component, the Y-axis servo lifting component and the Z-axis servo switching component all include servo motors. The servo motors are connected to reducers and ball screws through couplings.

[0011] Preferably, the cables of the X-axis servo moving component, the Y-axis servo lifting component, and the Z-axis servo switching component are all located inside the cable chain, and the cable chain moves along the cable chain groove, which is located on the cable chain mounting plate.

[0012] Preferably, the probe servo displacement detection component includes a cross-shaped mounting base plate, on which a pitch drive plate and a multi-axis linkage mechanism are provided. The pitch drive plate is located at the center, and the probe component is mounted at the center of the pitch drive plate. The multi-axis linkage mechanism is located on the periphery and is connected to the hinge point on the pitch drive plate through a connecting rod to form a spatial linkage mechanism, thereby realizing the multi-degree-of-freedom movement of the probe component.

[0013] Preferably, the stator floating alignment component includes a stator assembly fixture component at the foremost end, a rotary disk connected to the stator assembly fixture component, a rotating handle provided on the rotary disk, and a stator floating swing alignment component connected to the back of the rotary disk.

[0014] Preferably, the base is equipped with feet.

[0015] Preferably, the specific working process of the system is as follows: the engine is manually lifted, the support frame is installed on the engine, and placed on the left platform;

[0016] The stator fixture is manually installed onto the stator housing, the whole unit is lifted up, then the guide post is installed into the threaded hole on the stator, and then the whole unit is installed onto the rotary disc using the stator fixture.

[0017] The start button is pressed manually;

[0018] The probe assembly moves to the detection position to perform parallelism detection, and then returns to its original position after completion.

[0019] The collaborative robot, equipped with a camera, locates the center line of the rotor;

[0020] After taking the photo, the collaborative robot uses a glue gun to apply glue, and then returns to its original position.

[0021] Move the stator to the center line alignment position;

[0022] During the assembly and transfer of the stator and rotor, manually observe whether the mounting holes are aligned. If they are not aligned, adjust the rotating handle to align the guide post with the corresponding mounting hole.

[0023] When the stop or bearing enters the corresponding chamfer position, the floating pin is unlocked, allowing the stator to float.

[0024] Continue moving until the stator and rotor mating surfaces are in contact, remove the guide column, manually tighten the bolts, and tighten them with the appropriate torque wrench;

[0025] The stator moving component returns to its original position.

[0026] The present invention has the following beneficial effects:

[0027] The design of a semi-automatic assembly mechanism that moves the stator closer to the rotor of the engine by moving the components achieves precise alignment of the stator and rotor assembly centers, ensuring that the end faces of the two remain strictly parallel throughout the assembly process. This fundamentally eliminates potential problems such as uneven air gap and electromagnetic torque fluctuations caused by insufficient assembly precision, thereby ensuring the smoothness of power output during the operation of the range extender.

[0028] This solves the problems of low efficiency and poor precision consistency in manual assembly. By optimizing the semi-automatic assembly process, the automation level of assembly operations can be significantly improved, the interference of human factors on assembly quality can be reduced, the assembly precision of the range extender stator and rotor can be made stable and controllable, the defect rate can be reduced, and technical support can be provided for the mass production of range extenders.

[0029] It is designed to mitigate the safety risks and component wear associated with manual assembly. Through precise control of semi-automatic assembly, it achieves smooth docking and slow assembly of the rotor and stator, effectively preventing damage to components due to magnetic impact, ensuring operator safety, and reducing various losses during production.

[0030] By improving the assembly quality and efficiency of the range extender's rotor and stator, the operational stability, energy utilization efficiency, and service life of the range extender can be further optimized, thereby providing a reliable guarantee for improving the power performance and extending the driving range of new energy vehicles. This will help the new energy vehicle industry upgrade its technology in the field of core power component manufacturing and meet the market's demand for high-quality, high-reliability range extender products. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the overall assembly system of the range extender rotor and stator;

[0032] Figure 2 Top view of the range extender rotor-stator assembly system;

[0033] Figure 3 A schematic diagram of the overall assembly system for the range extender rotor and stator without the assembled components;

[0034] Figure 4 Main view of the range extender rotor-stator assembly system with the assembled components removed;

[0035] Figure 5 This is a schematic diagram of the photographed and painted components;

[0036] Figure 6 This is a schematic diagram of the structure of the assembled components;

[0037] Figure 7 This is a schematic diagram of a probe servo displacement detection component;

[0038] Figure 8 This is the main view of the probe servo displacement detection component;

[0039] Figure 9 This is a side view of the probe servo displacement detection component.

[0040] Among them, 1 is the base, 2 is the left platform, 3 is the right platform, 4 is the assembly component, 5 is the photography and painting component, 6 is the mounting base, 7 is the collaborative robot, 8 is the glue application component, 9 is the photography component, 10 is the hollow rotary platform, 11 is the rotary table, 12 is the swing base plate, 13 is the upper base plate, 14 is the bearing seat, 15 is the rotary support shaft, 16 is the linear guide rail, 17 is the mounting base plate, 18 is the variable pitch drive plate, 19 is the sliding plate, and 20 is the probe. Components: 21 is the connecting rod, 22 is the hinge point, 23 is the mounting hole, 24 is the rotary disk, 25 is the rotating handle, 26 is the X-axis servo movement component, 27 is the Y-axis servo lifting component, 28 is the Z-axis servo switching component, 29 is the upper and lower floating plate, 30 is the track, 31 is the foot, 32 is the support frame, 33 is the cable chain, 34 is the cable chain groove, 35 is the cable chain mounting plate, 36 is the probe servo displacement detection component, and 37 is the stator floating centering component. Detailed Implementation

[0041] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and specific examples:

[0042] Combination Figures 1-9 A range extender stator assembly system is disclosed, controlled by an electronic and pneumatic control system. The system includes a base 1 with height-adjustable feet 31. The base is divided into a left platform 2 and a right platform 3. A swing base plate 12 and a rotor fixing assembly are mounted on the left platform 2, while an assembly assembly 4, including a slide, is mounted on the right platform. A photographing and painting assembly 5 is located on one side of the base. The rotor fixing assembly includes an engine rotation swing assembly, an engine lifting swing assembly, and an engine mounting assembly. The engine rotation swing assembly is located at the bottom of the swing base plate, the engine lifting swing assembly is located on one side of the swing base plate, and the engine mounting assembly is located on the upper surface of the swing base plate. An X-axis servo movement assembly 26, a Y-axis servo lifting assembly 27, and a Z-axis servo switching assembly 28 are connected to the slide. A probe servo displacement detection assembly 36 and a stator floating alignment assembly 37 are located on the side of the slide.

[0043] The photography and painting component 5 includes a mounting base 6, on which a collaborative robot 7 is mounted. At the end of the collaborative robot 7, an adhesive application component 8 and a photography component 9 are mounted.

[0044] The engine rotation and oscillation assembly includes a hollow rotary platform 10, which is connected to a servo motor. A rotary disk 11 is mounted on the hollow rotary platform 10, and the rotary disk 11 is connected to an oscillation base plate 12. An upper base plate 13 is located on the upper right side of the oscillation base plate 12, and multiple upper support plates 13 are arranged between the oscillation base plate 12 and the upper base plate 13. The engine is mounted on the upper base plate, and a rotating support shaft 15 is installed between the rotary disk 11 and the engine mounting assembly. The rotating support shaft is driven by the servo motor through two bearing seats 14 to achieve angle adjustment of the engine mounting assembly.

[0045] The engine lifting and swinging assembly is installed at one end of the swinging base plate and includes a servo motor. The servo motor is connected to the swinging base plate 12 and drives the upper base plate to swing up and down by driving the movement of the swinging base plate.

[0046] A linear guide rail 16 is provided on the right platform 3 of the base 1 along the long side of the base. A slide table is installed on the linear guide rail 16, and a vertical guide rail is provided on the slide table. The probe servo displacement detection component and the stator floating alignment component are fixed to the left side of the slide table through left and right floating plates. The slide table slides freely in the X direction under the drive of the X-axis servo moving component 26 and slides freely in the Z direction under the drive of the Z-axis servo lifting component 27. The left and right floating plates drive the probe servo displacement detection component and the stator floating alignment component to achieve free sliding in the Y direction under the drive of the Y-axis servo switching component 28. The X-axis servo moving component 26, the Y-axis servo lifting component 27 and the Z-axis servo switching component 28 all include servo motors. The servo motors are connected to reducers and ball screws through couplings.

[0047] The cables for the X-axis servo moving component, the Y-axis servo lifting component, and the Z-axis servo switching component are all housed within the cable chain 33. The cable chain is installed within the cable chain groove 34, which is located on the cable chain mounting plate 35.

[0048] The probe servo displacement detection assembly includes a cross-shaped mounting base 17. A pitch-changing drive plate 18 and a multi-axis linkage mechanism are mounted on the mounting base 17. The pitch-changing drive plate 18 is located at the center, and a probe assembly 20 is mounted at the center of the pitch-changing drive plate 18. The multi-axis linkage mechanism is located on the periphery and is connected to the hinge point 22 on the pitch-changing drive plate 18 via a connecting rod 21, forming a spatial linkage mechanism to realize multi-degree-of-freedom movement of the probe assembly. Specifically, an elliptical mounting hole 23 is formed on the outer edge of the mounting base. A groove 24 is provided on the outer edge of the mounting hole 23, and a sliding plate 19 is placed inside the mounting hole. A slider is provided on the outer edge of the sliding plate. The groove and the slider cooperate to realize the movement of the sliding plate within the mounting hole. The probe assembly 20 is mounted on the sliding plate, and each sliding plate is fixedly connected to the mounting base via a connecting rod 21.

[0049] The stator floating alignment assembly includes a stator assembly fixture assembly at the front end, a rotating disk 24 connected to the stator assembly fixture assembly, a rotating handle 25 provided on the rotating disk 24, and a stator floating swing alignment assembly connected to the back of the rotating disk 24.

[0050] The specific working process of the range extender stator assembly system is as follows: the engine is manually lifted, the support frame 32 is installed on the engine, and placed on the left platform 2.

[0051] The stator fixture is manually installed onto the stator housing, the whole unit is lifted up, then the guide post is installed into the threaded hole on the stator, and finally the whole unit is installed onto the rotary disc using the stator fixture.

[0052] The start button is pressed manually.

[0053] The probe assembly 20 moves to the detection position to perform parallelism detection, and then returns to its original position after completion.

[0054] Collaborative robot 7, equipped with camera module 9, locates the rotor's center line.

[0055] After taking the photo, the collaborative robot uses a glue gun to apply glue, and then returns to its original position.

[0056] Move the stator to the center line alignment position.

[0057] During the assembly and movement of the stator and rotor, manually observe whether the mounting holes are aligned. If they are not aligned, adjust the rotating handle to align the guide post with the corresponding mounting hole.

[0058] When the stop or bearing enters the corresponding chamfer position, the floating pin is released, allowing the stator to have a certain amount of floating (no more than 0.5mm on one side).

[0059] Continue moving the stator and rotor until they are in contact, remove the guide column, manually tighten the bolts, and tighten them with the appropriate torque wrench.

[0060] The stator moving component returns to its original position.

[0061] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A range extender rotor-stator assembly system, comprising a base, an electronic control system, and a pneumatic control system, characterized in that, The base is divided into a left platform and a right platform. The left platform is equipped with a swing base plate and a rotor fixing assembly, while the right platform is equipped with an assembly assembly, which includes a slide table. A photography and painting assembly is located on one side of the base. The rotor fixing assembly includes an engine rotation swing assembly, an engine lifting swing assembly, and an engine mounting assembly. The engine rotation swing assembly is located at the bottom of the swing base plate, the engine lifting swing assembly is located on one side of the swing base plate, and the engine mounting assembly is located on the upper surface of the swing base plate. The slide table is connected to an X-axis servo movement assembly, a Y-axis servo lifting assembly, and a Z-axis servo switching assembly. A probe servo displacement detection assembly and a stator floating centering assembly are located on the side of the slide table.

2. The range extender rotor-stator assembly system as described in claim 1, characterized in that, The photography and painting components include a mounting base on which a collaborative robot is mounted. The end effector of the collaborative robot is equipped with an adhesive application component and a photography component.

3. The range extender rotor-stator assembly system as described in claim 2, characterized in that, The engine rotation and oscillation assembly includes a hollow rotary platform connected to a servo motor. A rotary table is mounted on the hollow rotary platform and connected to an oscillation base plate. An upper base plate is located on the upper right side of the oscillation base plate. Multiple upper support plates are arranged between the oscillation base plate and the upper base plate. A rotary support shaft is provided between the rotary table and the engine mounting assembly. The rotary support shaft is fixed by two bearing seats. The servo motor drives the rotary support shaft to adjust the angle of the engine mounting assembly.

4. The range extender rotor-stator assembly system as described in claim 3, characterized in that, The engine lifting and swinging assembly is installed at one end of the swinging base plate and includes a servo motor. The servo motor is connected to the swinging base plate and drives the upper base plate to move by driving the movement of the swinging base plate.

5. The range extender rotor-stator assembly system as described in claim 4, characterized in that, A linear guide rail is provided on the right platform of the base along the long side of the base. A slide table is installed on the linear guide rail, and a vertical guide rail is provided on the slide table. The probe servo displacement detection component and the stator floating alignment component are fixed to the left side of the slide table by left and right floating plates. The slide table slides freely in the X direction under the drive of the X-axis servo moving component and slides freely in the Z direction under the drive of the Z-axis servo lifting component. The left and right floating plates drive the probe servo displacement detection component and the stator floating alignment component to achieve free sliding in the Y direction under the drive of the Y-axis servo switching component. The X-axis servo moving component, the Y-axis servo lifting component and the Z-axis servo switching component all include servo motors. The servo motors are connected to reducers and ball screws through couplings.

6. The range extender rotor-stator assembly system as described in claim 5, characterized in that, The cables for the X-axis servo moving component, the Y-axis servo lifting component, and the Z-axis servo switching component are all housed within the cable chain. The cable chain moves along the cable chain groove, which is located on the cable chain mounting plate.

7. The range extender rotor-stator assembly system as described in claim 5, characterized in that, The probe servo displacement detection component includes a cross-shaped mounting base plate, on which a pitch drive plate and a multi-axis linkage mechanism are mounted. The pitch drive plate is located at the center, and the probe component is mounted at the center of the pitch drive plate. The multi-axis linkage mechanism is located on the periphery and is connected to the hinge point on the pitch drive plate through a connecting rod to form a spatial linkage mechanism, thereby realizing the multi-degree-of-freedom movement of the probe component.

8. The range extender rotor-stator assembly system as described in claim 7, characterized in that, Stator floating centering components include The stator assembly fixture at the very front is connected to a rotary disc, which has a rotating handle. The back of the rotary disc is connected to a stator floating swing centering component.

9. The range extender rotor-stator assembly system as described in claim 8, characterized in that, The base is equipped with feet.

10. The range extender rotor-stator assembly system as described in claim 9, characterized in that, The specific working process of the system is as follows: The engine is manually lifted, the support frame is installed on the engine, and the engine with the support frame installed is placed on the left platform; The stator fixture is manually installed onto the stator housing, the whole unit is lifted up, then the guide post is installed into the threaded hole on the stator, and then the whole unit is installed onto the rotary disc using the stator fixture. The start button is pressed manually; The probe assembly moves to the detection position to perform parallelism detection, and then returns to its original position after completion. The collaborative robot, equipped with a camera, locates the center line of the rotor; After taking the photo, the collaborative robot uses a glue gun to apply glue, and then returns to its original position. Move the stator to the center line alignment position; During the assembly and transfer of the stator and rotor, manually observe whether the mounting holes are aligned. If they are not aligned, adjust the rotating handle to align the guide post with the corresponding mounting hole. When the stop or bearing enters the corresponding chamfer position, the floating pin is unlocked, allowing the stator to float. Continue moving until the stator and rotor mating surfaces are in contact, remove the guide column, manually tighten the bolts, and tighten them with the appropriate torque wrench; The stator moving component returns to its original position.

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