Intelligent welding method and device for split cover of speed reducer

Abstract

The present application relates to a kind of gearbox split type box cover intelligent welding method and device, it is related to the field of gearbox connection, it includes: step 100: collection operation vibration;Step 101: extract vibration amplitude from the operation vibration;Step 102: when the vibration amplitude is greater than the wear threshold value, determine the connection quantity according to the vibration amplitude, and collection input image;Step 103: based on the connection quantity from input image identification welding position;Step 104: according to the welding position generates welding stroke;Step 105: response to the welding stroke generates and sends motor welding instruction.The present application has the effect of improving the stability of gearbox use, reduce the situation of vibration leading to transmission efficiency reduction.

Description

Technical Field

[0001] This invention relates to the field of speed reducer connections, and in particular to an intelligent welding method and apparatus for a split-type gear reducer housing cover. Background Technology

[0002] A speed reducer is a power transmission device that reduces the output speed of a prime mover (such as a motor or engine) by using mechanical structures (such as gears, worm gears, planetary gear systems, etc.) to proportionally increase the output torque.

[0003] In the prior art, the motor output end is generally connected to the reducer input shaft via a flange. The motor output end with a key or spline is inserted into the inner hole of the reducer input shaft to drive the reducer and motor to rotate coaxially, thereby reducing the transmission clearance.

[0004] Motors are prone to vibration during operation, which can cause the motor output end to vibrate within the reducer's inner bore. This can lead to wear on both the motor output end and the reducer input shaft, resulting in increased transmission clearance between the motor and the reducer and reduced transmission efficiency. Summary of the Invention

[0005] To improve the stability of speed reducers and reduce the reduction in transmission efficiency caused by vibration, this invention provides a smart welding method and device for split-type gear reducer housing covers.

[0006] In a first aspect, the present invention provides an intelligent welding method for a split-type gearbox cover, employing the following technical solution: A method for intelligent welding of a split-type gearbox cover includes: Step 100: Collect vibration data during operation; Step 101: Extract the vibration amplitude from the operational vibration; Step 102: When the vibration amplitude is greater than a preset wear threshold, determine the number of connections based on the vibration amplitude and acquire the input image; Step 103: Identify the welding positions from the input image based on the number of connections; Step 104: Generate the welding stroke based on the welding position; Step 105: In response to the welding stroke, generate and send a motor welding command.

[0007] By adopting the above technical solution, the vibration of the motor is detected in real time. When the vibration amplitude is too high, an appropriate number of connections can be selected. The welding points of the connection are evenly distributed at the welding positions where the cover and the motor contact each other through visual technology. This reduces the wear of the motor output end and the input shaft of the reducer caused by vibration, thereby improving the transmission efficiency and the stability of the reducer.

[0008] Optional, also includes: Step 106: When the vibration amplitude is greater than the preset wear threshold, extract the vibration direction from the operating vibration; Step 107: Determine the amplitude ratio by combining the vibration direction and vibration amplitude; Step 108: Determine the number of welds based on the number of connections and the amplitude ratio; Step 109: Update the welding position from the input image in response to the number of welds and the vibration direction.

[0009] By adopting the above technical solution, the vibration amplitude in different vibration directions is detected, and different welding quantities are allocated in different directions according to the magnitude of the vibration amplitude. The welding position is updated synchronously according to the welding quantity, thereby reducing the situation where the welding fixation effect is low due to different vibration conditions in different directions, improving the stability of the connection between the motor output end and the reducer input shaft, and thus improving the transmission efficiency and the stability of the reducer.

[0010] Optional, also includes: Step 110: When the vibration amplitude exceeds the preset wear threshold, the motor speed is retrieved; Step 111: Determine the rotational speed frequency based on the motor speed, and extract the vibration frequency from the operating vibration; Step 112: Determine the frequency deviation by combining the rotational speed frequency and the vibration frequency; Step 113: If the frequency deviation is less than a preset error threshold, determine the axial peak value based on the vibration direction; Step 114: Determine the degree of eccentricity based on the axial peak value; Step 115: Generate and display a motor eccentricity prompt in response to the eccentricity level.

[0011] By adopting the above technical solution, the motor speed is retrieved to determine the rotational frequency, and the rotational frequency is compared with the vibration frequency to obtain the frequency deviation. When the frequency deviation is low, it is determined that the vibration is caused by the motor, that is, the motor is eccentric. At this time, the degree of eccentricity is estimated according to the axial peak value of the axial vibration, so as to promptly notify the staff of the motor eccentricity.

[0012] Optionally, it also includes an eccentricity correction method, the eccentricity correction method comprising: Step 200: If the frequency deviation is less than a preset error threshold, determine the single peak value based on the axial peak value; Step 201: Determine the displacement difference based on the single peak value, and identify the end face distance from the input image; Step 202: Determine the eccentricity angle by combining the displacement difference and the end face distance; Step 203: Update the motor eccentricity alert in response to the eccentricity angle.

[0013] By adopting the above technical solution, the single peak value is determined based on the axial peak value, and the eccentric angle is accurately calculated by combining the displacement difference and the end face distance. This achieves a quantitative analysis of the degree of angular eccentricity, solves the problem that the degree of eccentricity can only be qualitatively judged but cannot be accurately quantified, makes the eccentricity indication more valuable, provides accurate data for subsequent targeted correction, and improves the accuracy and reliability of eccentricity diagnosis.

[0014] Optionally, the eccentricity correction method further includes: Step 204: If the frequency deviation is less than a preset error threshold, determine the axial frequency based on the axial peak value; Step 205: Determine the correction force by combining the axial frequency and axial peak value, and identify the correction direction from the input image based on the eccentricity angle; Step 206: Determine the correction stroke based on the correction force, correction direction, and eccentricity angle; Step 207: In response to the generation of the correction stroke, a motor correction command is sent, and in response to the generation of the welding stroke, a motor welding command is sent.

[0015] By adopting the above technical solution, the correction force is determined by combining the axial frequency and axial peak value, the correction direction is locked and the correction stroke is generated, and the correction command and welding command are sent simultaneously. This eliminates the angular eccentricity cause from the root, and then the fixing effect is consolidated by welding. This solves the problem of repeated loosening caused by eccentricity that cannot be completely cured by welding alone, improves the accuracy of the correction operation and the long-term effectiveness of the welding fixation, further ensures the coaxiality of the motor and the reducer, and reduces the damage of vibration to the equipment.

[0016] Optionally, the eccentricity correction method further includes: Step 208: If the frequency deviation is less than the preset error threshold, determine the reinforcement quantity based on the correction force; Step 209: Update the welding quantity based on the reinforcement quantity and the correction direction, and determine the normal direction according to the correction direction; Step 210: Determine the normal amplitude based on the normal direction; Step 211: Update the welding quantity based on the normal amplitude and normal direction.

[0017] By adopting the above technical solution, the welding is strengthened in the correction direction and the welding points are reasonably distributed according to the vibration amplitude in the normal direction. This solves the problems of unreasonable welding layout and insufficient reinforcement after correction, avoids stress concentration caused by excessive welding or fixation failure caused by insufficient welding, improves the scientificity and stability of welding fixation, and effectively prevents the motor from becoming eccentric again.

[0018] Optionally, it also includes a correction guidance method, the correction guidance method comprising: Step 300: When the eccentric angle is greater than the preset correction threshold, determine the loosening distance based on the eccentric angle; Step 301: In response to the release distance generation, a motor release command is sent, and in response to the correction stroke, a motor correction command is generated and sent, and the guide length is determined according to the release distance; Step 302: Generate a guide coil model by combining the guide length, eccentricity angle and correction direction, and determine the wire number according to the guide length; Step 303: Generate the winding stroke by combining the wire number and the guide coil model; Step 304: In response to the winding stroke generation, a motor winding command is sent, and in response to the welding stroke, a motor welding command is generated and sent.

[0019] By adopting the above technical solution, when the eccentric angle is too large, it is difficult to adjust the angle of the motor output end within the inner hole. At this time, a suitable loosening distance is selected according to the eccentric angle to pull the motor output end out of the inner hole, and a suitable guide length is selected according to the loosening distance to generate a guide coil. The guide coil is used to assist in correction and positioning, reducing the situation where the motor output end is easily shaken after being pulled out of the inner hole, which leads to a decrease in correction accuracy and improving the accuracy of eccentric correction.

[0020] Optionally, the corrective guidance method further includes: Step 305: When the eccentricity angle is greater than the preset correction threshold, in response to the correction stroke, a motor correction command is generated and sent, and the input image is updated; Step 306: Identify the output region from the input image; Step 307: Identify the contact location from the input image based on the output region; Step 308: Identify the input position from the input image based on the contact position; Step 309: Update the welding stroke in response to the input position.

[0021] By adopting the above technical solution, when the inner hole is pulled out of the motor output end, the contact area between the motor and the reducer input shaft is reduced, which makes it easy for the motor output end and the reducer input shaft to slip. At this time, the input position on the guide coil that is connected to both the motor output end and the reducer input shaft is found. The guide coil and the motor output end are welded at one end, and the guide coil and the reducer input shaft are welded at the other end, thereby improving the stability of the connection between the motor output end and the reducer input shaft.

[0022] Optionally, the corrective guidance method further includes: Step 310: When the eccentricity angle is greater than the preset correction threshold, the motor volume is identified from the input image; Step 311: Determine the coil load based on the motor size and motor speed; Step 312: Determine the number of overlapping turns based on the coil load and guide length; Step 313: Generate an overlapping coil model in response to the number of overlapping turns and the guide coil model; Step 314: Update the winding stroke based on the wire number and the overlapping coil model.

[0023] By adopting the above technical solution, when the motor is too heavy, the load on the guide coil is too large, which can lead to deformation of the guide coil. At this time, the number of overlapping turns required to prevent deformation of the guide coil is determined according to the motor volume and motor speed. Multiple layers of guide coils are stacked to form overlapping coils. The use of overlapping coils reduces the deformation of the coil and improves the stability of the connection between the motor output end and the reducer input shaft.

[0024] Secondly, this application provides an intelligent welding device for a split-type gearbox cover, which adopts the following technical solution: A smart welding device for a split-type gearbox cover, employing the aforementioned smart welding method for a split-type gearbox cover, includes a gearbox body. The gearbox body is provided with a cover for sealing the gearbox body. An input shaft for connecting to a motor is provided on the side of the gearbox body near the cover. A communication groove is provided on the cover for the output shaft to communicate with the outside. An inner hole for inserting the motor is provided on the input shaft. An output shaft for outputting power is provided on the side of the gearbox body away from the cover.

[0025] By adopting the above technical solution, the vibration of the motor is detected in real time. When the vibration amplitude is too high, an appropriate number of connections can be selected. The welding points of the connection are evenly distributed at the welding positions where the cover and the motor contact each other through visual technology. This reduces the wear of the motor output end and the input shaft of the reducer caused by vibration, thereby improving the transmission efficiency and the stability of the reducer.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. Real-time detection of motor vibration allows for the selection of an appropriate number of connections when vibration amplitude is too high. Visual technology is used to evenly distribute the welding points of the connections at the contact points between the housing cover and the motor, thereby reducing wear on the motor output end and the reducer input shaft caused by vibration, thus improving transmission efficiency and the stability of the reducer. 2. Detect the vibration amplitude in different vibration directions, and then allocate different welding quantities in different directions according to the magnitude of the vibration amplitude. Update the welding position synchronously according to the welding quantity, thereby reducing the situation where the welding fixation effect is low due to different vibration conditions in different directions, improving the stability of the connection between the motor output end and the reducer input shaft, and thus improving the transmission efficiency and the stability of the reducer. 3. Determine the motor speed frequency by adjusting the motor speed, and compare the motor speed frequency with the vibration frequency to obtain the frequency deviation. If the frequency deviation is low, it can be determined that the vibration is caused by the motor, that is, the motor is eccentric. At this time, the degree of eccentricity can be estimated according to the axial peak value of the axial vibration, so as to notify the staff of the motor eccentricity in time. Attached Figure Description

[0027] Figure 1 This is a structural schematic diagram of an intelligent welding device for a split-type gearbox cover. Figure 2 This is a flowchart of an intelligent welding method for a split-type gearbox cover; Figure 3 This is a flowchart of the eccentricity correction method.

[0028] The parts referred to by the numbers in the above attached diagrams are as follows: 1. Housing; 2. Housing cover; 3. Input shaft; 4. Communicating groove; 5. Inner hole; 6. Output shaft. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0030] Reference Figure 1 This application discloses an intelligent welding device for a split-type gearbox cover of a speed reducer, including a housing 1. A cover 2 for sealing the housing 1 is fixed to the housing 1 by bolts. The bolts are located at the four corners of the cover 2. An input shaft 3 connected to a motor is provided on the side of the housing 1 near the cover 2. The input shaft 3 is connected to the sun gear in the speed reducer. A communication groove 4 is provided on the cover 2 for the output shaft 6 to communicate with the outside. An inner hole 5 for inserting the motor is provided on the input shaft 3. The inner hole 5 includes a circular groove for inserting the output end of the motor and a rectangular groove for inserting a positioning pin fixed on the output end of the motor. An output shaft 6 for outputting power is provided on the side of the housing 1 away from the cover 2. The output shaft 6 is connected to the planetary gear in the speed reducer.

[0031] Reference Figure 2 Based on the same inventive concept, embodiments of the present invention provide an intelligent welding method for a split-type gearbox cover, comprising: Step 100: Collect vibration data during operation.

[0032] Operational vibration refers to data describing the vibration of the motor and reducer, such as vibration frequency, vibration amplitude, and vibration direction. Operational vibration can be collected by vibration sensors installed on the circumferential direction of the motor and reducer respectively. The vibration sensors on the motor and reducer are one-to-one and located in the same radial direction. The method of collecting operational vibration is selected by the staff according to the actual situation, and will not be elaborated here.

[0033] Step 101: Extract the vibration amplitude from the running vibration.

[0034] Vibration amplitude refers to the displacement value of the motor in different directions. Vibration amplitude can be extracted from the vibration during operation. The method of vibration amplitude extraction is selected by the staff according to the actual situation, and will not be elaborated here.

[0035] Step 102: When the vibration amplitude is greater than the preset wear threshold, determine the number of connections based on the vibration amplitude and acquire the input image.

[0036] The wear threshold refers to the minimum vibration amplitude that easily leads to wear on the motor output end and the reducer input shaft 3. The wear threshold is selected by the operator based on the actual situation and will not be elaborated here. A vibration amplitude greater than the wear threshold indicates that the motor vibration is relatively severe, requiring welding to reduce the vibration. The number of connections refers to the number of welding points required; the greater the vibration amplitude, the greater the number of connections needed. The number of connections corresponding to the vibration amplitude (maximum value) can be found in the quantity correspondence table, which records different vibration amplitudes and their corresponding connection numbers.

[0037] The input image refers to the picture of the input shaft 3 of the reducer. The input image can be captured by a camera. The method of capturing the input image is selected by the staff according to the actual situation, and will not be described in detail here.

[0038] Step 103: Identify the welding positions from the input image based on the number of connections.

[0039] The welding position refers to the position where the number of welding points is evenly distributed on the cover 2. When the motor output end is inserted into the inner hole 5 of the reducer input shaft 3, the motor enters the connecting groove 4 and contacts the cover 2. The welding position is the position evenly distributed in the circumferential direction of the motor and located on the contact surface between the motor housing and the cover 2 in the connecting groove 4. The welding position can be determined by image recognition technology. The method of identifying the welding position is common knowledge to those in the art and will not be described in detail here.

[0040] Step 104: Generate the welding stroke based on the welding position.

[0041] The welding equipment refers to the equipment used for welding the motor housing and the gearbox cover 2. The welding equipment is selected by the staff according to the actual situation, and will not be described in detail here.

[0042] The welding stroke refers to the process by which the welding device connects the motor housing and the gearbox cover 2 one by one according to the welding position. The method of generating the welding stroke is common knowledge to those skilled in the art and will not be described in detail here.

[0043] Step 105: In response to the welding stroke, generate and send a motor welding command.

[0044] Electric motor welding instructions are instructions that control the welding device to perform welding according to the welding stroke. The method for generating electric motor welding instructions is common knowledge to those skilled in the art and will not be elaborated here.

[0045] The system monitors the motor's vibration in real time, allowing for the selection of an appropriate number of connections when the vibration amplitude is too high. Visual technology is used to evenly distribute the welding points of the connections at the welding positions where the cover 2 and the motor contact each other, thereby reducing wear on the motor output end and the reducer input shaft 3 caused by vibration, thus improving transmission efficiency and the stability of the reducer.

[0046] A smart welding method for a split-type gearbox cover further includes: Step 106: When the vibration amplitude is greater than the preset wear threshold, extract the vibration direction from the running vibration.

[0047] Vibration direction refers to the angle value of the corresponding position on the motor where the vibration amplitude, such as radial or axial, is located. The vibration direction can be extracted from the running vibration. The method for extracting the vibration direction is selected by the staff according to the actual situation, and will not be elaborated here.

[0048] Step 107: Determine the amplitude ratio by combining the vibration direction and vibration amplitude.

[0049] Amplitude ratio refers to the ratio of vibration amplitudes in different vibration directions. It is calculated by taking the quotient of vibration amplitudes in different vibration directions as the amplitude ratio. The sum of the amplitude ratios corresponding to all vibration directions is 1. The calculation method of amplitude ratio is selected by the staff according to the actual situation, and will not be elaborated here.

[0050] Step 108: Determine the number of welds based on the number of connections and the amplitude ratio.

[0051] The number of welds refers to the number of weld points in different directions allocated according to the amplitude ratio. The number of welds can be calculated by multiplying the number of connections by the amplitude ratio.

[0052] Step 109: Update the welding position from the input image in response to the number of welds and the vibration direction.

[0053] Image recognition technology can be used to identify the welding points that are evenly distributed in different vibration directions as the welding positions.

[0054] The vibration amplitude in different vibration directions is detected, and different welding quantities are allocated in different directions according to the magnitude of the vibration amplitude. The welding position is updated synchronously according to the welding quantity, thereby reducing the situation where the welding fixation effect is low due to different vibration conditions in different directions, improving the stability of the connection between the motor output end and the reducer input shaft 3, and thus improving the transmission efficiency and the stability of the reducer.

[0055] A smart welding method for a split-type gearbox cover further includes: Step 110: When the vibration amplitude is greater than the preset wear threshold, the motor speed is retrieved.

[0056] Motor speed refers to the number of revolutions the motor output terminal makes per unit time. The motor speed can be retrieved from the motor control system. The method for retrieving the motor speed is selected by the staff according to the actual situation, and will not be elaborated here.

[0057] Step 111: Determine the rotational speed frequency based on the motor speed, and extract the vibration frequency from the operating vibration.

[0058] Speed ​​frequency refers to the frequency value of vibration caused by the rotation of a motor. For example, a motor speed of 1500 rpm has a speed frequency of approximately 25 Hz. The higher the motor speed, the higher the speed frequency. The speed frequency corresponding to the motor speed can be found in a frequency correspondence table, which is a data table that records different motor speeds and their corresponding speed frequencies.

[0059] Vibration frequency refers to the number of times the vibration signal on the motor repeats per unit time. Vibration frequency can be extracted from the vibration during operation. The method for extracting vibration frequency is selected by the staff according to the actual situation, and will not be elaborated here.

[0060] Step 112: Determine the frequency deviation by combining the rotational speed frequency and the vibration frequency.

[0061] Frequency deviation refers to a value used to show the difference between rotational speed frequency and vibration frequency. It can be calculated as the absolute value of the difference between rotational speed frequency and vibration frequency, and then the quotient of the frequency difference and the rotational speed frequency is calculated as the frequency deviation.

[0062] Step 113: If the frequency deviation is less than the preset error threshold, determine the axial peak value based on the vibration direction.

[0063] The error threshold refers to the maximum frequency deviation between the allowable rotational speed and vibration frequency when the motor is not eccentric. The error threshold is selected by the operator based on the actual situation and will not be elaborated here. A frequency deviation less than the error threshold indicates that the vibration is caused by the motor's rotation. Since the performance of the motor and reducer has already been verified, the presence of vibration at this point indicates an unstable connection between the motor and reducer, meaning the motor is eccentric. Furthermore, the insertion of the inner hole 5 at the motor output end indicates that the motor is difficult to deflect in the radial direction, meaning the motor has angular eccentricity. The axial peak value refers to the maximum displacement of the motor and reducer in the axial direction. The axial peak value can be determined by vibration sensors installed in the same radial direction. The method for determining the axial peak value is selected by the operator based on the actual situation and will not be elaborated here.

[0064] Step 114: Determine the degree of eccentricity based on the axial peak value.

[0065] Eccentricity refers to a numerical value used to show the eccentricity of a motor. The larger the axial peak value, the more severe the eccentricity of the motor, and the greater the eccentricity. The degree of eccentricity corresponding to the axial peak value of the motor can be found in the degree correspondence table, which is a data table that records different axial peak values ​​and their corresponding eccentricities.

[0066] Step 115: Generate and display a motor eccentricity prompt in response to the eccentricity level.

[0067] Motor eccentricity alert is a message used to notify staff that the motor is angularly eccentric. The method for generating motor eccentricity alerts is common knowledge in the field and will not be elaborated here.

[0068] The motor speed is determined by adjusting the motor speed and frequency, and the frequency is compared with the vibration frequency to obtain the frequency deviation. When the frequency deviation is low, it is determined that the vibration is caused by the motor, that is, the motor is eccentric. At this time, the degree of eccentricity is estimated according to the axial peak value of the axial vibration, so as to notify the staff of the motor eccentricity in time.

[0069] Reference Figure 3 Eccentricity correction methods include: Step 200: If the frequency deviation is less than the preset error threshold, determine the single peak value based on the axial peak value.

[0070] The single-peak value refers to the maximum distance from the zero baseline to a single peak or trough of the vibration signal. It is calculated by taking the quotient of the axial peak value and 2 as the single-peak value.

[0071] Step 201: Determine the displacement difference based on the single peak value, and identify the end face distance from the input image.

[0072] The displacement difference refers to the difference between the single-peak peak value of the motor and the single-peak peak value of the reducer. The calculation method for the displacement difference is selected by the staff according to the actual situation, and will not be elaborated here.

[0073] The end face distance refers to the straight-line distance between the end face of the motor output end and the end face of the input shaft 3 of the reducer. The end face distance can be determined by image recognition technology. The method of end face distance recognition is common knowledge to those in the field and will not be elaborated here.

[0074] Step 202: Determine the eccentricity angle by combining the displacement difference and the end face distance.

[0075] The eccentricity angle refers to the angle between the axis of the motor output end and the axis of the reducer input shaft 3. The larger the displacement difference and the smaller the end face distance, the larger the eccentricity angle. The eccentricity angle corresponding to the displacement difference and end face distance can be found in the angle correspondence table. The angle correspondence table is a data table that records different displacement differences and end face distances and their corresponding eccentricity angles.

[0076] Step 203: Update the motor eccentricity alert in response to the eccentricity angle.

[0077] The peak value of a single peak is determined based on the axial peak value, and the eccentric angle is accurately calculated by combining the displacement difference and the end face distance. This enables a quantitative analysis of the degree of angular eccentricity, solving the problem that the degree of eccentricity can only be qualitatively judged but not accurately quantified. This makes the eccentricity indication more valuable and provides accurate data for subsequent targeted correction, improving the accuracy and reliability of eccentricity diagnosis.

[0078] Eccentricity correction methods also include: Step 204: If the frequency deviation is less than a preset error threshold, determine the axial frequency based on the axial peak value.

[0079] Axial frequency refers to the number of times a vibration signal repeats in the axial direction. The axial frequency can be extracted from a vibration sensor that extracts the axial peak value. The method for determining the axial frequency is selected by the staff according to the actual situation, and will not be elaborated here.

[0080] Step 205: Determine the correction force by combining the axial frequency and axial peak value, and identify the correction direction from the input image based on the eccentric angle.

[0081] The correction force refers to the force required to make the axis of the motor output end parallel to the axis of the reducer input shaft 3. The higher the axial frequency and the larger the axial peak, the more severe the motor vibration, and the greater the correction force required to stabilize the motor. The correction force corresponding to the axial frequency and axial peak can be found in the force correspondence table. The force correspondence table is a data table that records different axial frequencies and axial peaks and their corresponding correction forces.

[0082] The correction direction refers to the angle value of the motor's emission offset. The correction direction can be identified through image recognition technology. The method for identifying the correction direction is common knowledge to those in the field and will not be elaborated here.

[0083] Step 206: Determine the correction stroke based on the correction force, correction direction, and eccentricity angle.

[0084] The straightening device is a device used to adjust the direction of the motor so that the axis of the motor output end is parallel to the axis of the input shaft 3 of the reducer. Generally, a robotic arm is used as the straightening device. The straightening device is selected by the staff according to the actual situation, which will not be elaborated here.

[0085] The correction stroke refers to the process by which the correction device drives the motor to rotate by an eccentric angle in the correction direction with a correction force. The method for generating the correction stroke is common knowledge to those in the field and will not be elaborated here.

[0086] Step 207: In response to the generation of the correction stroke, a motor correction command is sent, and in response to the generation of the welding stroke, a motor welding command is sent.

[0087] Motor correction command refers to the command that controls the correction device to adjust the orientation of the motor according to the correction stroke. The method of generating motor correction command is common knowledge to those in the field and will not be described in detail here.

[0088] By combining axial frequency and axial peak value to determine the correction force, lock the correction direction and generate the correction stroke, and send correction and welding commands simultaneously, the angular eccentricity is eliminated from the root cause first, and the fixing effect is consolidated by welding. This solves the problem of repeated loosening caused by eccentricity that cannot be completely cured by welding alone, improves the accuracy of the correction operation and the long-term effectiveness of the welding fixation, further ensures the coaxiality of the motor and reducer, and reduces the damage of vibration to the equipment.

[0089] Eccentricity correction methods also include: Step 208: If the frequency deviation is less than the preset error threshold, determine the reinforcement quantity based on the correction force.

[0090] The reinforcement quantity refers to the number of welding points required to prevent the motor from becoming eccentric again after adjusting the motor according to the correction stroke. The greater the correction force, the greater the reinforcement quantity is required. The reinforcement quantity corresponding to the correction force can be found in the reinforcement correspondence table, which is a data table that records different correction forces and their corresponding reinforcement quantities.

[0091] Step 209: Update the welding quantity based on the reinforcement quantity and the correction direction, and determine the normal direction based on the correction direction.

[0092] The normal direction refers to any direction other than the corrective direction. The method for determining the normal direction is common knowledge among those in the field and will not be elaborated here.

[0093] Step 210: Determine the normal amplitude based on the normal direction.

[0094] Normal amplitude refers to the vibration amplitude value in the normal direction. The method for obtaining the normal amplitude is selected by the staff according to the actual situation, and will not be elaborated here.

[0095] Step 211: Update the welding quantity based on the normal amplitude and normal direction.

[0096] The welding quantity can be updated by referring to steps 106 to 108 above. The method for updating the welding quantity is selected by the staff according to the actual situation, and will not be elaborated here.

[0097] The method strengthens the welding in the correction direction and rationally distributes the welding points according to the vibration amplitude in the normal direction. This solves the problems of unreasonable welding layout and insufficient reinforcement after correction, avoids stress concentration caused by excessive welding or fixation failure caused by insufficient welding, improves the scientific nature and stability of welding fixation, and effectively prevents the motor from becoming eccentric again.

[0098] Corrective guidance methods include: Step 300: When the eccentric angle is greater than the preset correction threshold, the loosening distance is determined according to the eccentric angle.

[0099] The correction threshold refers to the maximum angle that can be adjusted when the motor is fully inserted into the inner hole 5. The correction threshold is selected by the operator based on the actual situation and will not be elaborated here. An eccentric angle greater than the correction threshold means that it is difficult to adjust the orientation of the motor to drive the axis of the motor output end parallel to the axis of the reducer input shaft 3. The release distance refers to the distance that the motor needs to be pulled out of the inner hole 5 to adjust its orientation according to the eccentric angle. The larger the eccentric angle, the larger the release distance. The release distance corresponding to the eccentric angle can be found in the release correspondence table, which is a data table that records different eccentric angles and their corresponding release distances.

[0100] Step 301: In response to the release distance generation, a motor release command is sent, and in response to the correction stroke, a motor correction command is generated and sent, and the guide length is determined according to the release distance.

[0101] The motor release command refers to the command that controls the correction device to pull the motor out of the inner hole 5 according to the release distance. The method of generating the motor release command is common knowledge to those skilled in the art and will not be described in detail here.

[0102] The guide length refers to the length of the guide coil required to fix the relative position of the motor and reducer after the orientation is adjusted according to the correction stroke. The larger the loosening distance, the larger the guide length is used. The guide length corresponding to the loosening distance can be found in the guide correspondence table, which is a data table that records different loosening distances and their corresponding guide lengths.

[0103] Step 302: Generate a guide coil model by combining the guide length, eccentric angle and correction direction, and determine the wire number according to the guide length.

[0104] The guide coil model refers to the three-dimensional data of the guide coil formed by first winding the guide length of wire around the input shaft 3 of the reducer and then around the output end of the motor. The length of the wire wound on the input shaft 3 of the reducer and the output end of the motor is equal, and the guide coil is bent at the connection point of the input shaft 3 of the reducer and the output end of the motor in the correction direction according to the eccentric angle. The method of generating the guide coil model is common knowledge to those in the art and will not be described in detail here.

[0105] The wire number refers to the number of the wire whose length is exactly greater than the guide length. Generally, different lengths of wire are used. The wire number corresponding to the guide length can be found from the number correspondence table. The number correspondence table is a data table that records different wire numbers and their corresponding wire lengths.

[0106] Step 303: Generate the winding stroke by combining the wire number and the guide coil model.

[0107] The winding stroke refers to the process by which the straightening device winds the wire with the wire number onto the input shaft 3 of the reducer and the output end of the motor according to the guide coil model. The method for generating the winding stroke is common knowledge to those skilled in the art and will not be elaborated here.

[0108] Step 304: In response to the winding stroke generation, a motor winding command is sent, and in response to the welding stroke, a motor welding command is generated and sent.

[0109] The motor winding command refers to the instruction that controls the straightening device to wind the wire onto the input shaft 3 of the reducer and the output end of the motor according to the winding stroke. The method for generating the motor winding command is common knowledge to those skilled in the art and will not be elaborated here.

[0110] When the eccentric angle is too large, it is difficult to adjust the angle of the motor output end within the inner hole 5. At this time, a suitable loosening distance is selected according to the eccentric angle to pull the motor output end out of the inner hole 5. A suitable guide length is selected according to the loosening distance to generate a guide coil. The guide coil is used to assist in the correction and positioning, reducing the situation where the motor output end is easily shaken after being pulled out of the inner hole 5, which leads to a decrease in correction accuracy and improves the accuracy of eccentric correction.

[0111] Corrective guidance methods also include: Step 305: When the eccentricity angle is greater than the preset correction threshold, the motor correction command is generated and sent in response to the correction stroke, and the input image is updated.

[0112] After adjusting the motor's orientation according to the correction stroke, the input image is re-acquired to determine the connection between the reducer input shaft 3 and the motor output end after correction.

[0113] Step 306: Identify the output region from the input image.

[0114] The output area refers to the spatial range of the motor's output end. The output area can be identified through image recognition technology. The method for identifying the output area is common knowledge to those in the field and will not be elaborated here.

[0115] Step 307: Identify the contact location from the input image based on the output region.

[0116] The contact position refers to the position where the guide coil contacts the output area. The contact position can be identified by image recognition technology. The method for identifying the contact position is common knowledge to those in the field and will not be elaborated here.

[0117] Step 308: Identify the input position from the input image based on the contact position.

[0118] The input position refers to the position where the guide coil, which is in contact with the output end of the motor, contacts the input shaft 3 of the reducer. The input position can be determined by image recognition technology by finding the position where the contact position contacts the input shaft 3 of the reducer in the opposite direction of the rotation. The method for identifying the input position is common knowledge to those in the field and will not be elaborated here.

[0119] Step 309: Update the welding stroke in response to the input position.

[0120] At this point, the number of welding points is used to connect, and the input position and the corresponding contact position are used as welding positions. When the number of connection positions is odd or the number of welding positions is insufficient, the positions on the guide coil are selected evenly as welding positions.

[0121] When the inner hole 5 is pulled out of the motor output end, the contact area between the motor and the reducer input shaft 3 decreases, which makes it easy for the motor output end and the reducer input shaft 3 to slip. At this time, find the input position on the guide coil that is connected to both the motor output end and the reducer input shaft 3. Then, weld the guide coil and the motor output end at one end, and weld the guide coil and the reducer input shaft 3 at the other end, thereby improving the stability of the connection between the motor output end and the reducer input shaft 3.

[0122] Corrective guidance methods also include: Step 310: When the eccentricity angle is greater than the preset correction threshold, the motor volume is identified from the input image.

[0123] Motor volume refers to the volume of a motor. The motor volume can be identified using image recognition technology. The method for identifying motor volume is common knowledge to those in the field and will not be elaborated here.

[0124] Step 311: Determine the coil load based on the motor size and motor speed.

[0125] Coil load refers to the weight that the coil needs to bear. The larger the motor size and the higher the motor speed, the larger the coil load. You can look up the coil load corresponding to the motor size and motor speed in the load correspondence table. The load correspondence table is a data table that records different motor sizes and motor speeds and their corresponding coil loads.

[0126] Step 312: Determine the number of overlapping turns based on the coil load and guide length.

[0127] The number of overlap turns refers to the minimum number of guide coils required to carry the coil load. The larger the coil load and the shorter the guide length, the larger the number of overlap turns is used. The number of overlap turns corresponding to the coil load and guide length can be found in the number of overlap turns correspondence table. The number of overlap turns correspondence table records different coil loads and guide lengths and their corresponding number of overlap turns.

[0128] Step 313: Generate an overlapped coil model in response to the number of overlapped turns and the guide coil model.

[0129] An overlapping coil model refers to the three-dimensional data of a coil formed by overlapping the guide coil model according to the number of overlapping turns. The method for generating an overlapping coil model is common knowledge to those in the field and will not be elaborated here.

[0130] Step 314: Update the winding stroke based on the wire number and the overlapping coil model.

[0131] When the motor is too heavy, the load on the guide coil is too large, which can cause the guide coil to deform. In this case, the number of overlapping turns required to prevent the guide coil from deforming is determined according to the motor volume and motor speed. Multiple layers of guide coils are then stacked to form overlapping coils. This method reduces coil deformation and improves the stability of the connection between the motor output end and the reducer input shaft 3.

[0132] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for intelligent welding of a split-type gearbox cover, characterized in that, include: Step 100: Collect vibration data during operation; Step 101: Extract the vibration amplitude from the operational vibration; Step 102: When the vibration amplitude is greater than a preset wear threshold, determine the number of connections based on the vibration amplitude and acquire the input image; Step 103: Identify the welding positions from the input image based on the number of connections; Step 104: Generate the welding stroke based on the welding position; Step 105: In response to the welding stroke, generate and send a motor welding command.

2. The intelligent welding method for a split-type gearbox cover according to claim 1, characterized in that, Also includes: Step 106: When the vibration amplitude is greater than the preset wear threshold, extract the vibration direction from the operating vibration; Step 107: Determine the amplitude ratio by combining the vibration direction and vibration amplitude; Step 108: Determine the number of welds based on the number of connections and the amplitude ratio; Step 109: Update the welding position from the input image in response to the number of welds and the vibration direction.

3. The intelligent welding method for a split-type gearbox cover according to claim 2, characterized in that, Also includes: Step 110: When the vibration amplitude exceeds the preset wear threshold, the motor speed is retrieved; Step 111: Determine the rotational speed frequency based on the motor speed, and extract the vibration frequency from the operating vibration; Step 112: Determine the frequency deviation by combining the rotational speed frequency and the vibration frequency; Step 113: If the frequency deviation is less than a preset error threshold, determine the axial peak value based on the vibration direction; Step 114: Determine the degree of eccentricity based on the axial peak value; Step 115: Generate and display a motor eccentricity prompt in response to the eccentricity level.

4. The intelligent welding method for a split-type gearbox cover according to claim 3, characterized in that, It also includes eccentricity correction methods, which include: Step 200: If the frequency deviation is less than a preset error threshold, determine the single peak value based on the axial peak value; Step 201: Determine the displacement difference based on the single peak value, and identify the end face distance from the input image; Step 202: Determine the eccentricity angle by combining the displacement difference and the end face distance; Step 203: Update the motor eccentricity alert in response to the eccentricity angle.

5. The intelligent welding method for a split-type gearbox cover according to claim 4, characterized in that, The eccentricity correction method also includes: Step 204: If the frequency deviation is less than a preset error threshold, determine the axial frequency based on the axial peak value; Step 205: Determine the correction force by combining the axial frequency and axial peak value, and identify the correction direction from the input image based on the eccentricity angle; Step 206: Determine the correction stroke based on the correction force, correction direction, and eccentricity angle; Step 207: In response to the generation of the correction stroke, a motor correction command is sent, and in response to the generation of the welding stroke, a motor welding command is sent.

6. The intelligent welding method for a split-type gearbox cover according to claim 5, characterized in that, The eccentricity correction method also includes: Step 208: If the frequency deviation is less than the preset error threshold, determine the reinforcement quantity based on the correction force; Step 209: Update the welding quantity based on the reinforcement quantity and the correction direction, and determine the normal direction according to the correction direction; Step 210: Determine the normal amplitude based on the normal direction; Step 211: Update the welding quantity based on the normal amplitude and normal direction.

7. The intelligent welding method for a split-type gearbox cover according to claim 6, characterized in that, It also includes a corrective guidance method, which includes: Step 300: When the eccentric angle is greater than the preset correction threshold, determine the loosening distance based on the eccentric angle; Step 301: In response to the release distance generation, a motor release command is sent, and in response to the correction stroke, a motor correction command is generated and sent, and the guide length is determined according to the release distance; Step 302: Generate a guide coil model by combining the guide length, eccentricity angle and correction direction, and determine the wire number according to the guide length; Step 303: Generate the winding stroke by combining the wire number and the guide coil model; Step 304: In response to the winding stroke generation, a motor winding command is sent, and in response to the welding stroke, a motor welding command is generated and sent.

8. The intelligent welding method for a split-type gearbox cover according to claim 7, characterized in that, The corrective guidance method also includes: Step 305: When the eccentricity angle is greater than the preset correction threshold, in response to the correction stroke, a motor correction command is generated and sent, and the input image is updated; Step 306: Identify the output region from the input image; Step 307: Identify the contact location from the input image based on the output region; Step 308: Identify the input position from the input image based on the contact position; Step 309: Update the welding stroke in response to the input position.

9. The intelligent welding method for a split-type gearbox cover according to claim 8, characterized in that, The corrective guidance method also includes: Step 310: When the eccentricity angle is greater than the preset correction threshold, the motor volume is identified from the input image; Step 311: Determine the coil load based on the motor size and motor speed; Step 312: Determine the number of overlapping turns based on the coil load and guide length; Step 313: Generate an overlapping coil model in response to the number of overlapping turns and the guide coil model; Step 314: Update the winding stroke based on the wire number and the overlapping coil model.

10. A smart welding device for a split-type gearbox cover (2), employing a smart welding method for a split-type gearbox cover (2) as described in any one of claims 1 to 9, comprising a housing (1), characterized in that: The housing (1) is provided with a cover (2) for closing the housing (1). The housing (1) is provided with an input shaft (3) connected to the power supply on the side of the cover (2). The cover (2) is provided with a communication groove (4) for the output shaft (6) to communicate with the outside. The input shaft (3) is provided with an inner hole (5) for the power supply to be inserted. The housing (1) is provided with an output shaft (6) for outputting power on the side away from the cover (2).

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