Compatible motor assembly production line and compatible motor assembly process

Abstract

The application relates to the technical field of motor automatic production equipment, and particularly discloses a compatible motor assembly production line and a compatible motor assembly process. The production line comprises a rotor feeding station, a stator feeding station, an assembly station and a carrier circulation station which are sequentially arranged. The assembly station is sequentially provided with a first bracket assembly device, a stator assembly device and a second bracket assembly device. The carrier circulation station comprises a first circulation line, a second circulation line and a transfer device arranged between the two circulation lines. The first circulation line is used for circulating and transferring a first carrier for carrying a first bracket, and the second circulation line is used for circulating and transferring a second carrier for carrying a second bracket. When the structures of the first bracket and the second bracket are different, the two circulation lines independently operate, the transfer device overturns and transfers a motor module assembled from the first carrier to the second carrier, and the motor module is circulated and transferred by the second circulation line. When the structures of the first bracket and the second bracket are the same, the two circulation lines cooperatively form a combined circulation line.

Description

Technical Field

[0001] This invention relates to the field of automated motor production equipment technology, and in particular discloses a compatible motor assembly production line and a compatible motor assembly process. Background Technology

[0002] In the field of automated motor assembly, assembly line operations are typically employed to achieve high-efficiency production. However, when different motor models require different first and second brackets with varying assembly structures, the limitations of existing single assembly line structures become apparent. Either separate production lines are needed for different products, leading to high equipment investment costs and large space requirements; or compatibility is achieved on a single line through frequent fixture changes, which significantly slows down production and reduces overall efficiency. Furthermore, in existing technologies, the assembly precision of the stator and rotor, as well as the attitude adjustment and wiring harness management of the motor modules during transit, are also key challenges affecting assembly yield and automation levels. Summary of the Invention

[0003] In order to overcome the shortcomings and deficiencies of the existing technology, the purpose of this invention is to provide a flexible motor assembly solution that can intelligently adapt to different product structures and ensure high precision and high efficiency.

[0004] To achieve the above objectives, the present invention provides a compatible motor assembly production line, comprising a rotor loading station, a stator loading station, an assembly station, a carrier return station, and a locking station used in cooperation with each other; the assembly station is provided with a first bracket assembly device, a stator assembly device, and a second bracket assembly device in sequence; the carrier return station includes a first return line, a second return line, and a transfer device disposed between the first return line and the second return line used in cooperation with each other. The first return line is used to circulate a first carrier, which carries a first support; the second return line is used to circulate a second carrier, which carries a second support; the carrier return station is configured to have at least two operating modes: In the first working mode, when the first support and the second support have different structures, the first return line and the second return line operate independently; the transfer device is used to flip and transfer the motor module that has been assembled on the second support from the first carrier of the first return line to the second carrier of the second return line, and the second return line drives the second carrier to transfer the motor module transferred by the transfer device to the locking station; In the second working mode, when the first support and the second support have the same structure, the first return line and the second return line work together to form a combined return line; the transfer device flips the motor module that has been assembled on the second support from the first carrier and transfers it to the second carrier on the combined return line, and the second carrier transfers the motor module it carries to the locking station.

[0005] Furthermore, a connecting conveyor belt is provided between the first return line and the second return line, and the connecting conveyor belt constitutes part of the combined return line; a first separation mechanism is provided on one side of the connecting conveyor belt, and the first separation mechanism drives the second carrier on the connecting conveyor belt to move in a direction that intersects with the conveying direction of the connecting conveyor belt in the first working mode, so as to block the second carrier from flowing into the first return line via the connecting conveyor belt.

[0006] Furthermore, the rotor loading station is provided with a rotor storage mechanism and a first conveying mechanism; the assembly station is also provided with a spring assembly device, a first transfer platform and a first assembly fixture, the first conveying mechanism being used to transfer the rotor from the rotor storage mechanism to the first transfer platform; the assembly station is also provided with a second conveying mechanism for transferring the rotor on the first transfer platform to the first assembly fixture; the spring assembly device includes a spring storage mechanism and a first robotic arm, the first robotic arm being used to assemble the external springs in the spring storage mechanism to the first end of the rotor shaft limited by the first assembly fixture.

[0007] Furthermore, the spring assembly device is provided in two sets, which are located on both sides of the first rotating mechanism, and are used to assemble two springs to the first end and the second end of the rotor shaft before and after the rotor rotates.

[0008] Furthermore, the first bracket assembly device includes a first bracket storage mechanism, a second robotic arm, and a third transport mechanism. The third transport mechanism has multiple first grippers. The second robotic arm is used to assemble the first bracket in the first bracket storage mechanism onto the first end of the rotor that has been fitted with a spring sheet. The third transport mechanism is used to drive the multiple grippers to move sequentially between multiple first assembly fixtures to cooperate in the assembly of the spring sheet and the first bracket.

[0009] Furthermore, the first return line is provided with a first carrier transport mechanism, the output end of which has multiple second grippers for transferring multiple first carriers. The first carrier transport mechanism is used to drive the multiple second grippers to move sequentially on the first return line to cooperate with the second bracket assembly device and the stator assembly device. The second return line is provided with a second carrier transport mechanism, the output end of which has a third gripper for transferring multiple second carriers. The second carrier transport mechanism is used to drive the multiple third grippers to move sequentially on the second return line to cooperate with the locking station and the transfer device.

[0010] Furthermore, the first bracket assembly device includes a first bracket storage mechanism, a second robotic arm, and a third conveying mechanism. The third conveying mechanism has multiple first grippers. The second robotic arm is used to assemble the first bracket in the first bracket storage mechanism to the first end of the rotor that has been fitted with spring clips. The third conveying mechanism is used to drive the multiple first grippers to hold the rotor to cooperate with the assembly of the first bracket. A first rotating mechanism is provided between the stator assembly device and the first bracket assembly device. The first gripper of the third conveying mechanism near the stator assembly device is used to transfer the rotor that has completed the first bracket assembly to the first rotating mechanism. The first rotating mechanism drives the rotor that has completed the first bracket assembly to rotate by a set angle so that the second end of the rotor equipped with the first bracket cooperates with the assembly action of the stator assembly device.

[0011] Furthermore, the stator assembly device includes a stator storage mechanism, a third robotic arm, and a fourth transport mechanism; the third robotic arm includes a stator gripper unit, a calibration module that cooperates with the stator gripper unit, and a first wire harness clamping unit; the calibration module includes calibration fingers for extending into the assembly holes of the stator and an alignment sleeve for holding the rotor shaft, the alignment sleeve being reciprocated relative to the third robotic arm to align the stator and rotor; the fourth transport mechanism is used to transfer the rotor that has completed the first bracket assembly to the first carrier flowing on the first return line; The first wire harness clamping unit is provided in two sets. The two sets of first wire harness clamping units are respectively used to clamp the wire harnesses on both sides of the stator in the stator storage mechanism. The third robot arm is used to pick up the stator in the stator storage mechanism in coordination with the rotation action of the first carrier on the first return line, and assemble it into the rotor with the first support that is limited by the first carrier.

[0012] Furthermore, the second bracket assembly device includes a second bracket storage mechanism and a fourth robotic arm, the fourth robotic arm being used to pick up the second bracket in the second bracket picking mechanism and assemble it to the other end of the rotor limited by the first carrier on the first return line to form a motor module.

[0013] Furthermore, the transfer device includes a support transverse module, a lifting module disposed at the output end of the support transverse module, a rotary drive module disposed at the output end of the lifting module, a motor gripper disposed at the output end of the rotary drive module, and a second wire harness clamping unit disposed in cooperation with the motor gripper. The motor gripper is used to clamp the middle part of the motor module, and the second wire harness clamping unit is used to clamp the wire harnesses on both sides of the stator in the motor module. Under the linkage of the support transverse module and the lifting module, the rotary drive module is used to drive the motor gripper and the second wire harness clamping unit to rotate the motor module they are clamping by a set angle and then return it to the second carrier, so that the rotated motor module can cooperate with the locking station operation.

[0014] Furthermore, the assembly station also includes an ear assembly device and a second separation mechanism. The ear assembly device includes an ear storage mechanism and an ear transport mechanism. The ear transport mechanism is used to pick up the ear from the ear storage mechanism and align it with the first bracket of the motor module. The ear assembly device is provided in two sets, which are located on both sides of the second separation mechanism. The second separation mechanism is used to drive the second carrier on the second return line to the alignment action between the two sets of ear assembly devices to cooperate with the ear transport mechanism.

[0015] Furthermore, the locking station is equipped with two locking devices, each including a locking robot and a locking component storage mechanism. The locking robot is used to pick up the locking components in the locking component storage mechanism and lock the first bracket, the second bracket, and the lugs of the motor module carried by the second carrier to form the finished module.

[0016] Furthermore, a misalignment detection mechanism, a defective product unloading robot, and a defective product conveyor belt are also provided between the locking device and the finished product unloading robot; the misalignment detection mechanism is used to detect the axial movement clearance of the rotor shaft of the motor module; a rubber ring loading mechanism for inserting rubber rings on both sides of the ear is also provided between the misalignment detection mechanism and the finished product unloading robot.

[0017] Furthermore, the compatible motor assembly line also includes a finished product unloading robot, a finished product conveyor belt configured in conjunction with the finished product unloading robot, a defective product unloading robot, and a defective product conveyor belt configured in conjunction with the defective product unloading robot.

[0018] A compatible motor assembly process includes the following steps: S1: Provide the first return line and the second return line, and determine whether the structures of the first bracket and the second bracket to be assembled are the same; S2: If the first support and the second support have different structures, the control vehicle return station enters the first working mode, so that the first return line and the second return line run independently; if the first support and the second support have the same structure, the control vehicle return station enters the second working mode, so that the first return line and the second return line run together to form a joint return line. S3: At the assembly station, the first bracket assembly, stator assembly, and second bracket assembly of the rotor are completed sequentially to form the motor module; S4: The motor module with the second bracket assembly completed is flipped from the first carrier of the first return line and transferred to the second carrier of the second return line or the second carrier of the combined return line by the transfer device; S5: At the locking station, the first bracket, the second bracket, and the lug of the motor module are locked together to form the finished module.

[0019] The core principle of this invention lies in constructing a flexible assembly system with dual return lines and intelligent mode switching capabilities. The core technical solution of this system is: setting up a first return line and a second return line that are independent of each other but can be coupled via a linked conveyor belt, and configuring a central transfer device; by determining whether the structures of the first support and the second support are the same, switching between two working modes is possible.

[0020] When the two components have different structures, the dual return lines operate independently, forming two independent assembly rings. A transfer device handles the flipping and handover of the motor modules between different rings, enabling parallel production and physical isolation of dissimilar support products and avoiding interference. When the two components have the same structure, the dual return lines work together to form a longer combined return line, simplifying the material flow path and improving the production smoothness of similar support products. This design solves the compatibility problem at the system architecture level, achieving a flexible layout of "one becoming two, two becoming one".

[0021] Based on this core architecture, this invention further integrates multiple high-precision assembly units. Its stator assembly device innovatively employs a calibration module with calibration fingers and a centering ferrule, simultaneously positioning the stator inner hole and rotor shaft from the inside out, ensuring coaxiality of the assembly and significantly improving assembly accuracy and product performance. Simultaneously, the transfer device and each robotic arm are equipped with dedicated dual-wire harness clamping units, enabling full-process management of the motor wire harness and preventing damage or inaccurate positioning caused by wire harness pulling or tangling during automated transfer. The entire system, through modular workstation design, systematically integrates the assembly and final locking of the rotor, springs, brackets, stator, and lugs, forming a closed-loop automated production process.

[0022] In summary, the beneficial effects of this invention are significant and multifaceted: First, the dual-mode return line design enables a single set of equipment to meet the production needs of multiple motor varieties at low cost and high efficiency, greatly improving equipment utilization and return on investment. Second, through a precise calibration mechanism and end-to-end wiring harness management, the assembly quality and consistency of products, especially precision motors, are effectively guaranteed, reducing the defect rate. Third, the entire process is highly automated, reducing manual intervention, which not only stabilizes the production cycle and improves efficiency but also lays a solid foundation for realizing an intelligent and digital production workshop. Attached Figure Description

[0023] Figure 1 This is a partial side view of the compatible motor assembly line of the present invention. Figure 2 This is a partial three-dimensional structural diagram of the compatible motor assembly production line of the present invention; Figure 3 This is a three-dimensional structural diagram of the carrier return station of the present invention; Figure 4 for Figure 3 A magnified structural diagram of part A in the middle; Figure 5 This is a schematic diagram of the planar structure of the carrier return station of the present invention; Figure 6 This is a three-dimensional structural diagram of the third robotic arm in the stator assembly device of the present invention; Figure 7 This is a schematic diagram of the calibration module in the third robotic arm of the present invention; Figure 8 This is a three-dimensional structural diagram of the transfer device of the present invention; Figure 9 This is a partial planar structural diagram of the compatible motor assembly production line of the present invention; Figure 10 This is a schematic diagram of the assembly process of the compatible motor of the present invention; Figure 11 This is a schematic diagram of the structure of the first bracket assembly device of the present invention.

[0024] The reference numerals in the figures include: 100. First support; 200. Second support; 300. First carrier; 400. Second carrier; 1. First return line; 2. Second return line; 3. Transfer device; 40. First support assembly device; 401. First support storage mechanism; 402. Second manipulator; 403. Third handling mechanism; 4. Second support assembly device; 5. Stator assembly device; 6. Ear assembly device; 7. Locking device; 8. Finished product unloading manipulator; 9. Defective product unloading manipulator; 10. Linkage conveyor belt; 101. First separation mechanism; 102. Y-axis separation module; 103. Z-axis separation module; 11. First carrier handling mechanism; 12. Second gripper; 21. Second carrier handling mechanism; 22. Third gripper; 31. Support transverse movement module; 32. Lifting module; 33. Rotation drive module; 34. Motor jaw; 35. Second wire harness clamping unit; 41. Second support storage mechanism; 42. Fourth manipulator; 51. Stator storage mechanism; 52. Third manipulator; 520. Biaxial drive module; 521. Stator jaw unit; 522. Calibration module; 5221. Calibration finger; 5222. Centering bushing; 523. First wire harness clamping unit; 61. Ear storage mechanism; 62. Ear handling mechanism; 71. Locking manipulator; 72. Locking part storage mechanism; 80. Void detection mechanism; 81. Finished product conveyor belt; 82. Defective product conveyor belt. Detailed implementation manners

[0025] For the convenience of understanding by those skilled in the art, the present invention will be further described below in conjunction with embodiments and the accompanying drawings. The content mentioned in the implementation manners does not limit the present invention.

[0026] Please refer to Figures 1 to 11 As shown, the specific structure of a compatible motor assembly production line of the present invention is as follows: The rotor loading station, stator loading station, assembly station, carrier return station, and locking station are arranged in sequence according to the production process flow, and each station is connected by a transfer mechanism. Among them, the assembly station is sequentially provided with a first support assembly device, a stator assembly device 5, and a second support assembly device 4. These three devices are arranged in a straight line to form a continuous assembly process. The carrier return station adopts a unique double return line design. Both the first return line 1 and the second return line 2 adopt a rectangular closed-loop track structure, that is, a "return" - shaped layout. This layout can make the most of the space and achieve the continuous circulation of the carrier.

[0027] Specifically, a transfer device 3 is provided between the first return line 1 and the second return line 2. This device spans the two return lines and can reciprocate between them. A specially designed first carrier 300 circulates on the first return line 1. The first carrier 300 has a precise positioning structure for supporting and fixing the first bracket 100 of the motor, thereby supporting the first bracket 100 and the rotor to cooperate with the assembly actions of subsequent stations. A second carrier 400 runs on the second return line 2. Its structure is similar to that of the first carrier 300, but it has been adjusted accordingly based on the characteristics of the second bracket 200.

[0028] The core innovation of this invention lies in the fact that the carrier return station has two switchable working modes: when production requires the assembly of the first support 100 and the second support 200 with different structures, the system enters the first working mode. At this time, the first return line 1 and the second return line 2 operate independently without interfering with each other. The transfer device 3 removes the motor module that has completed the assembly of the second support 200 from the first carrier 300, and after a 180-degree flip, accurately places it on the second carrier 400, which is then transported to the locking station by the second return line 2. When the first support 100 and the second support 200 have the same structure, the system enters the second working mode. At this time, the control system connects the two return lines into a longer combined return line. The transfer device 3 only needs to transfer the motor module from the first carrier 300 to the second carrier 400 on the combined return line.

[0029] This design allows the same production line to flexibly adapt to the production needs of different products, greatly improving equipment utilization and production flexibility. Through a switchable dual-return line mode, a single production line can be used to produce a variety of products with compatible structures, avoiding the huge costs of purchasing multiple production lines and solving the inefficiency problem caused by frequent fixture changes.

[0030] The linked conveyor belt 10 between the first return line 1 and the second return line 2 adopts a belt drive system, with a motor driving the rollers to move the belt. The belt surface is provided with anti-slip texture to ensure the stability of the carrier transport. Guide rails are installed on both sides of the linked conveyor belt 10. These rails are adjustable and can be widened according to the size of the carrier.

[0031] Specifically, in the first working mode, the first separation mechanism 101 is activated. This mechanism adopts a cylinder-driven pusher plate structure, and the surface of the pusher plate is covered with polyurethane cushioning material. When the second carrier 400 reaches the designated position via the linkage conveyor belt 10, the cylinder quickly actuates, and the pusher plate pushes the second carrier 400 toward a lateral track perpendicular to the conveying direction, thereby effectively blocking the path of the second carrier 400 into the first return line 1. The movement trajectory of the pusher plate is precisely calculated to ensure that the pushing stroke can completely separate the carrier without damaging the carrier due to excessive impact.

[0032] Specifically, in this embodiment, the first return line 1 and the second return line 2 have the same structure and are provided with four tracks in total to form a "hui" character shape. Among them, the linkage conveyor belt 10 is used as one track and is carried by the machine frame for the track opposite to the linkage conveyor belt 10. The second carrier handling mechanism 21 is composed of a plurality of second grippers 12 driven by a cylinder, and its structure is the same as that of the first carrier handling mechanism 11. Its function is to use the plurality of second grippers 12 to clamp the second carrier 400 on the track and move it step by step in the X-axis direction to cooperate with the subsequent station operations. The first separation mechanism 101 has a Y-axis separation module 102 and a Z-axis separation module 103. Both the Y-axis separation module 102 and the Z-axis separation module 103 adopt a push plate structure driven by a cylinder, but the driving directions are perpendicular to each other.

[0033] Specifically, there are four groups of the first separation mechanism 101 in total. The first group of the first separation mechanism 101 and the second group of the first separation mechanism 101 are respectively used to drive the left and right sides (the track heights on the left and right sides of the return line are lower than those on the front and back sides). The Y-axis separation module 102 of the first group of the first separation mechanism 101 drives the first carrier 300 to move forward step by step, and the Z-axis separation module 103 of the first group of the first separation mechanism 101 then receives the first carrier 300 and drives it to move up one position. Then, the first gripper on the leftmost side of the first carrier handling mechanism 11 clamps the first carrier 300 and moves it one position to the right.

[0034] At the same time, the first gripper on the rightmost side of the first carrier handling mechanism 11 clamps the rightmost first carrier 300 and transfers it to the motor gripper 34 of the transfer device 3. After being flipped 180° by the transfer device 3, it is transferred to the second carrier 400 of the second return line 2. At this time, the rightmost first carrier 300 on the first return line 1 is空载 (empty), and is received by the Z-axis separation module 103 of the second group of the first separation mechanism 101 and descends one position. Then, the Y-axis separation module 102 of the second group of the first separation mechanism 101 drives the empty first carrier 300 to move backward step by step to dock with the linkage conveyor belt 10 and move it step by step to the left. This cycle constitutes the return structure and operation of the first return line 1. The return structure and operation of the second return line 2 are the same as those of the first return line 1, and will not be elaborated here.

[0035] In the second working mode, the first separation mechanism 101 remains in the retracted state, and the linkage conveyor belt 10 remains unobstructed, so that the first return line 1 and the second return line 2 form a complete circulation system. This design realizes a flexible and variable connection relationship between the two return lines, which not only ensures the physical isolation during the production of different products, but also realizes the smooth connection during the production of the same product, greatly improving the adaptability and intelligent level of the production line.

[0036] The first carrier transport mechanism 11, installed on the first return line 1, uses a cylinder as a power source and a linear slide rail module as a transmission mechanism. A specially designed gripper mounting plate is installed on the module slider, with six second grippers 12 evenly distributed on the plate. These second grippers 12 are designed to mate with the corresponding slots on both sides of the first carrier 300 or are slightly wider than the width of both sides of the first carrier 300. The inner side of the fingers of the second grippers 12 can be inlaid with polyurethane soft pads, which can provide sufficient gripping force without damaging the surface of the carrier.

[0037] Specifically, the first carrier transport mechanism 11 achieves intermittent movement through a precision control system, moving one station distance in each work cycle to ensure precise positioning of the carrier at the assembly station. The second carrier transport mechanism 21 on the second return line 2 adopts a similar structure, but its third gripper 22 is specially designed according to the shape characteristics of the second carrier 400. For example, the gripping part adopts a V-groove structure, which can better adapt to the contour of the second carrier 400.

[0038] Both conveying mechanisms are equipped with photoelectric sensors for position detection, ensuring that the grippers perform gripping and releasing actions at the correct time. This design, through a dedicated carrier conveying mechanism, enables precise step-by-step movement of the carrier on the return line, providing a stable work cycle for each assembly station and ensuring the continuity and reliability of the assembly process.

[0039] The specific structure of the first support assembly device 40 includes: a first support storage mechanism 401, which adopts a combination of a vibratory feeder and a linear feeder. The vibratory feeder has a spiral track inside, which arranges the disordered first supports 100 in an orderly manner and transports them to the linear feeder through electromagnetic vibration. The second robotic arm 402 is a four-axis horizontal articulated robot, and its end effector is a customized pneumatic gripper. The inner side of the gripper has a cavity that matches the shape of the first support 100 to ensure the stability of gripping.

[0040] Specifically, the third conveying mechanism 403 adopts a cylinder-driven linear slide, on which fifteen first grippers are installed. These grippers are driven by double-acting cylinders and can simultaneously grip and release fifteen rotors. The first rotation mechanism is directly driven by a DD motor and, in conjunction with a high-precision encoder, can achieve 180-degree precise rotation positioning.

[0041] During operation, the first gripper of the third conveying mechanism 403 moves the rotor to the assembly station. The second robotic arm 402 retrieves the material from the first support storage mechanism 401, corrects its position using a vision positioning system, and precisely presses the first support 100 onto the rotor. After assembly, the first gripper closest to the stator assembly device 5 transfers the assembled component to the first rotating mechanism for orientation adjustment. This design achieves full automation of the first support 100 assembly, significantly improving production efficiency through multi-station parallel operation while ensuring consistent assembly precision.

[0042] The detailed structure of the stator assembly device 5 is as follows: The stator storage mechanism 51 adopts a stacked hopper design, and the bottom of the hopper has a lifting mechanism that can periodically lift the stator to the picking position. The third robot arm 52 includes a dual-axis drive module 520, which adopts a gantry structure and consists of two linear modules, Y and Z. The lower end of the Z-axis module is equipped with a stator gripper unit 521. The calibration module 522 is the core component. Its two calibration fingers 5221 are fixedly installed on one side of the upper part of the two grippers of the stator gripper unit 521. The finger tips have a conical guide structure to facilitate insertion into the stator assembly hole.

[0043] Specifically, the centering sleeve 5222 is installed in the middle of the two grippers and is supported by a transmission rod driven by a servo motor. A spring is sleeved on the outside of the transmission rod, and the centering sleeve 5222 is sleeved on the end of the transmission rod and abuts against the spring. During operation, the motor first drives the transmission rod to move forward in a straight line, causing the entire assembly (rod, spring, sleeve) to move as a whole towards the rotor shaft end. When the guide port of the sleeve contacts the rotor shaft, if there is a slight deviation, the sleeve will stop moving forward due to obstruction. At this time, the motor continues to push the transmission rod, which will compress the spring.

[0044] The uniform radial force generated by the compression of the spring guides the ferrule to make slight movements, automatically correcting its position and angle until its inner hole is completely fitted into the rotor shaft. After fitting, the spring maintains a certain amount of compression, allowing the ferrule to maintain precise alignment while avoiding damage to the parts due to rigid contact, thus completing a smooth and precise positioning and clamping process.

[0045] The first wire harness clamping unit 523 is divided into left and right groups, each group containing two pneumatic clamping fingers. The inner side of the clamping fingers is provided with anti-slip teeth, which can firmly clamp the wire harness without damaging the insulation layer. The fourth transport mechanism has the same structure as the first carrier transport mechanism 11 and is used to transfer the rotor on which the first support 100 is mounted. The rotor on which the first support 100 is mounted flows through the primary carrier on the primary return line. The structure of the primary return line is similar to that of the first return line 1 and the second return line 2, and will not be described in detail here.

[0046] During operation, the fourth transport mechanism first places the rotor and the first support 100 onto the first carrier 300. Then, the third robotic arm 52 moves above the stator storage mechanism 51. Two sets of first wire harness clamping units 523 first clamp the stator wire harness, and then the stator gripper unit 521 clamps the stator core. After the entire assembly is lifted, it moves to the assembly position. At this time, the centering sleeve 5222 moves forward and fits into the rotor shaft end, and the calibration finger 5221 is inserted into the stator bearing chamber. After precise coaxiality adjustment, the pressing is completed. This design, through a multi-level positioning and calibration mechanism, ensures extremely high coaxiality of the stator and rotor assembly, while specialized wire harness management avoids cable damage during the assembly process.

[0047] The specific implementation structure of the second support assembly device 4 includes: the second support storage mechanism 41 adopts a chain conveyor belt in conjunction with a positioning fixture. The conveyor belt moves intermittently, transporting one second support 200 to the picking station each time. The fourth robot arm 42 also adopts a dual-axis linear module, with a special gripper installed at its end. The gripper adopts a two-finger pneumatic structure, and a pressure sensor is embedded on the inner side of each finger to monitor the gripping force in real time and prevent overload.

[0048] When the first carrier 300 moves to the assembly station of the second support 200, the photoelectric sensor of the equipment detects that the carrier is in place and sends a signal to the fourth robot arm 42. The robot arm first moves to the storage mechanism 41 of the second support, accurately grasps the second support 200, and then moves above the first carrier 300. After being accurately positioned by the vision system, the second support 200 is pressed onto the other end of the rotor.

[0049] The entire pressing process is divided into three stages: rapid approach, slow closing, and precise pressing. The pressure curve is monitored in real time to ensure assembly quality. This design enables automated precision assembly of the second bracket 200, and the reliability and consistency of the assembly process are guaranteed through the cooperation of force control and vision systems.

[0050] The specific mechanical structure of the transfer device 3 is as follows: The support transverse module 31 uses high-rigidity aluminum profiles as the guide rail base, and is driven by a cylinder in conjunction with a precision ball screw transmission. The lifting module 32 is installed on the slide of the transverse module, adopts a single-rod structure, and is powered by a cylinder. The rotary drive module 33 adopts a hollow rotary platform, and its core components are a servo motor, rack and pinion, and gears, with the gears serving as the final output structure for rotational power.

[0051] Specifically, the motor gripper 34 adopts a parallel opening and closing pneumatic gripper, and the gripper arm is designed to be extended to ensure that it can cross the vehicle boundary to grip the motor module. The second wiring harness clamping unit 35 is symmetrically arranged on both sides of the motor gripper 34. Each unit contains two independently controlled gripping fingers, driven by a miniature cylinder.

[0052] During operation, with the coordinated action of the support transverse module 31 and the lifting module 32, the rotary drive module 33, carrying the clamping mechanism, moves above the first carrier 300. It first descends to a predetermined height, where the motor gripper 34 clamps the middle housing of the motor module, while the second wiring harness clamping unit 35 clamps the wiring harnesses on both sides of the stator. Then, the lifting mechanism lifts the entire module, and the transverse module transports it above the second carrier 400. At this point, the rotary drive module 33 rotates 180 degrees according to the program settings, and finally, the motor module is precisely placed onto the second carrier 400.

[0053] This design enables smooth transfer and precise flipping of the motor module between different vehicles, and avoids cable interference during the transfer process through specialized wiring harness management, ensuring product safety.

[0054] Specifically, the ear-shaped material storage mechanism 61 uses a linear feeder to centrifugally sort and output the ear-shaped parts to the picking position. The ear-shaped material handling mechanism 62 uses a cylinder-driven linear pushing structure, which can adapt to different models of ear-shaped parts. The second separation mechanism uses an electric push rod to drive a flow divider plate. The surface of the flow divider plate is covered with a low-friction coefficient material. When the second carrier 400 arrives, the push rod pushes the carrier into the designated track according to the control system command. The two sets of ear-shaped part assembly devices 6 are arranged in a mirror symmetrical manner, respectively responsible for assembling the ear-shaped parts on both sides of the motor.

[0055] When the second carrier 400 is positioned between the two sets of ear assembly devices 6 by the second separation mechanism, the ear handling mechanisms 62 on both sides operate simultaneously, retrieving materials from their respective storage mechanisms. Using a vision positioning system to identify the mounting holes on the first bracket 100, the ear is precisely assembled into its predetermined position. The entire assembly process employs a force-position hybrid control system to ensure appropriate assembly force, guaranteeing proper placement without damaging the parts. This design, through a symmetrical dual-station arrangement and a precise positioning system, achieves efficient and accurate ear assembly, significantly improving production efficiency and product quality.

[0056] The specific implementation method of the locking station is as follows: Two locking devices 7 are symmetrically arranged and supported by a plate driven by a dual-axis linear module. An electric screwdriver head is installed at the end of the plate, equipped with a torque sensor and depth detection function. The locking component storage mechanism 72 uses a tubular vibratory feeder to arrange the screws in an orderly manner and transport them to the feeding port through an air pipe. The working range of the locking device 7 covers the entire second carrier 400 and is located above the ear-shaped assembly mechanism 62. When the second carrier 400 is positioned between the two sets of ear-shaped assembly devices 6 by the second separation mechanism, the ear-shaped assembly mechanisms 62 on both sides operate simultaneously, and then the locking device 7 begins to operate.

[0057] The locking robot 71 first moves to the locking component storage mechanism 72 to retrieve screws. It uses a magnetic screwdriver bit to pick up the screws, then moves them above the locking point. After the position is corrected by a vision system, the locking operation begins. Torque and angle are monitored in real time during the locking process to ensure the locking quality of each screw. After all locking operations are completed, the finished module continues to the next station via the second carrier 400. This design, through parallel operation at two stations and intelligent locking control, achieves an efficient and reliable locking process, ensuring the stability and consistency of the product structure.

[0058] The specific implementation process of the compatible motor assembly process of the present invention is as follows: In step S1, the production line is first initialized, and the first return line 12 and the second return line 2 run unloaded for one cycle for self-testing. The operator inputs the product specifications of the current production order through the human-machine interface, and the control system automatically determines whether the structural features of the first support 100 and the second support 200 are the same.

[0059] In step S2, different control strategies are executed according to the judgment result: when the structures are different, the control system starts the first separation mechanism 101 to keep the two return lines running independently, and at the same time adjusts the working mode of the transfer device 3 to cross-line transfer; when the structures are the same, the first separation mechanism 101 remains in the retracted state, the linkage conveyor belt 10 works normally, and the two return lines form a joint system.

[0060] Step S3 includes three sub-processes: First, at the first bracket 100 assembly station, the third transport mechanism coordinates multiple first grippers to move the rotor stepwise between different fixtures, while simultaneously completing the spring sheet pressing and the first bracket 100 assembly; then at the stator assembly station, the fourth transport mechanism transfers the rotor assembly to the first carrier 300, and the third robot 52 completes the stator assembly through the precise positioning of the calibration module 522; finally, at the second bracket 200 assembly station, the fourth robot 42 picks up the material and completes the pressing of the second bracket 200.

[0061] In step S4, the transfer device 3 selects the target location according to the current working mode: in the first mode, it transfers the motor module to the independent second return line 2; in the second mode, it transfers it to the subsequent vehicle on the combined return line.

[0062] Step S5 completes the final assembly at the locking station. The two locking devices 7 work together to complete the locking operations at all locking points according to the preset locking sequence and process parameters. The beneficial effect of this process design is that it establishes a complete and flexible assembly process flow, and through intelligent mode switching and precise process control, it realizes efficient mixed-flow production of multiple models of motor products on the same production line.

[0063] The above description is only a preferred embodiment of the present invention. For those skilled in the art, there will be changes in the specific implementation and application scope based on the ideas of the present invention. The content of this specification should not be construed as a limitation of the present invention.

Claims

1. A compatible motor assembly production line, comprising a rotor loading station, a stator loading station, an assembly station, and a carrier return station used in conjunction with each other; characterized in that: The assembly station is successively provided with a first bracket assembly device, a stator assembly device (5), and a second bracket assembly device (4); the carrier return station includes a first return line (1), a second return line (2) that are used in cooperation, and a transfer device (3) disposed between the first return line (1) and the second return line (2). The first return line (1) and the second return line (2) are both arranged in a "loop" shape; The first return line (1) is used for circulating and transferring a first carrier (300). The first carrier (300) is used for carrying a first bracket (100) and a rotor to cooperate with the assembly actions of the second bracket assembly device (4) and the stator assembly device (5); the second return line (2) is used for circulating and transferring a second carrier (400). The second carrier (400) is used for carrying a motor module formed after being processed by the stator assembly device (5) and the second bracket assembly device. The motor module includes a rotor, a stator, a first bracket, and a second bracket; the carrier return station is configured to have at least two working modes: In the first working mode, when the structures of the first bracket (100) and the second bracket (200) are different, the first return line (1) and the second return line (2) operate independently; the transfer device (3) is used to flip and transfer the motor module formed by assembling the second bracket (200) from the first carrier (300) of the first return line (1) to the second carrier (400) of the second return line (2), and the second return line (2) drives the second carrier (400) to move to convey the motor module transferred by the transfer device (3); In the second working mode, when the structures of the first bracket (100) and the second bracket (200) are the same or the first carrier (300) and the second carrier (400) can be used interchangeably, the first return line (1) and the second return line (2) operate in cooperation to form a combined return line; the transfer device (3) flips and transfers the motor module that has completed the assembly of the second bracket (200) from the first carrier (300) to the second carrier (400) on the combined return line, and the combined return line drives the second carrier (400) to move to convey the motor module carried by it.

2. The compatible motor assembly production line according to claim 1, characterized in that: A linkage conveyor belt (10) is provided between the first return line (1) and the second return line (2). The linkage conveyor belt (10) forms a part of the combined return line; a first separation mechanism (101) is provided on one side of the linkage conveyor belt (10). The first separation mechanism (101) drives the first carrier (300) and the second carrier (400) on the linkage conveyor belt (10) to move in a direction intersecting the transfer direction of the linkage conveyor belt (10) in the first working mode, so that the first carrier (300) and the second carrier (400) circulate on the first return line (1) and the second return line (2) respectively.

3. The compatible motor assembly production line according to claim 1, characterized in that: The first return line (1) is provided with a first carrier transport mechanism (11). The output end of the first carrier transport mechanism (11) has a plurality of second grippers (12) for transferring a plurality of first carriers (300). The first carrier transport mechanism (11) is used to drive the plurality of second grippers (12) to move sequentially on the first return line (1) to cooperate with the second bracket assembly device (4) and the stator assembly device (5). The second return line (2) is provided with a second carrier transport mechanism (21). The output end of the second carrier transport mechanism (21) has a third gripper (22) for transferring a plurality of second carriers (400). The second carrier transport mechanism (21) is used to drive the plurality of third grippers (22) to move sequentially on the second return line (2) to cooperate with the transfer device (3).

4. The compatible motor assembly production line according to claim 1, characterized in that: The first support assembly device (40) includes a first support storage mechanism (401), a second manipulator (402), and a third transport mechanism (403). The third transport mechanism (403) has multiple first grippers. The second manipulator (402) is used to assemble the first support (100) in the first support storage mechanism (401) to the first end of the rotor that has been fitted with spring clips. The third transport mechanism (403) is used to drive the multiple first grippers to hold the rotor to cooperate with the assembly of the first support (100). A first rotating mechanism is provided between the stator assembly device (5) and the first bracket assembly device (40). The first gripper of the third transport mechanism (403) near the stator assembly device (5) is used to transfer the rotor that has completed the assembly of the first bracket (100) to the first rotating mechanism. The first rotating mechanism drives the rotor that has completed the assembly of the first bracket (100) to rotate by a set angle so that the second end of the rotor equipped with the first bracket (100) cooperates with the assembly action of the stator assembly device (5).

5. The compatible motor assembly production line according to claim 1, characterized in that: The stator assembly device (5) includes a stator storage mechanism (51), a third robotic arm (52), and a fourth transport mechanism. The third robotic arm (52) includes a stator gripper unit (521), a calibration module (522) configured to cooperate with the stator gripper unit (521), and a first wire harness clamping unit (523). The calibration module (522) includes calibration fingers (5221) for extending into the assembly hole of the stator and a centering sleeve (5222) for holding the rotor shaft. The centering sleeve (5222) is reciprocated relative to the third robotic arm (52) to center and cooperate with the rotor. The fourth transport mechanism is used to transfer the rotor after the first bracket (100) assembly is completed to the first carrier (300) flowing on the first return line (1) to cooperate with the third robotic arm (52) to assemble the stator. The first wire harness clamping unit (523) is provided in two sets. The two sets of first wire harness clamping units (523) are respectively used to clamp the wire harnesses on both sides of the stator in the stator storage mechanism (51) with the movement of the third robot (52). The third robot (52) is used to pick up the stator in the stator storage mechanism (51) in coordination with the rotation movement of the first carrier (300) on the first return line (1) and assemble it into the rotor with the first bracket (100) limited by the first carrier (300).

6. The compatible motor assembly production line according to claim 1, characterized in that: The second bracket assembly device (4) includes a second bracket storage mechanism (41) and a fourth robot (42). The fourth robot (42) is used to pick up the second bracket (200) in the second bracket storage mechanism (41) and assemble it to the other end of the rotor limited by the first carrier (300) on the first return line (1) to form a motor module.

7. The compatible motor assembly production line according to claim 6, characterized in that: The transfer device (3) includes a support transverse module (31), a lifting module (32) disposed at the output end of the support transverse module (31), a rotary drive module (33) disposed at the output end of the lifting module (32), a motor gripper (34) disposed at the output end of the rotary drive module (33), and a second wire harness clamping unit (35) disposed in cooperation with the motor gripper (34). The motor gripper (34) is used to clamp the middle part of the motor module, and the second wire harness clamping unit (35) is used to clamp the wire harnesses on both sides of the stator in the motor module. Under the linkage of the support transverse module (31) and the lifting module (32), the rotary drive module (33) is used to drive the motor gripper (34) and the second wire harness clamping unit (35) to rotate the motor module it clamps by a set angle and then return it to the second carrier (400), so that the rotated motor module can cooperate with the locking station process operation.

8. The compatible motor assembly production line according to claim 7, characterized in that: The assembly station also includes an ear assembly device (6) and a second separation mechanism. The ear assembly device (6) includes an ear storage mechanism (61) and an ear transport mechanism (62). The ear transport mechanism (62) is used to pick up the ear in the ear storage mechanism (61) and align it with the first bracket (100) of the motor module. The ear assembly device (6) is provided in two sets. The two sets of ear assembly devices (6) are located on both sides of the second separation mechanism. The second separation mechanism is used to transfer the second carrier (400) on the second return line (2) to the two sets of ear assembly devices (6) to cooperate with the alignment action of the ear transport mechanism (62).

9. The compatible motor assembly production line according to claim 8, characterized in that: The compatible motor assembly line also includes a locking station used in conjunction with the carrier return station. The locking station is equipped with two locking devices (7). The locking device (7) includes a locking robot (71) and a locking component storage mechanism (72). The locking robot (71) is used to pick up the locking components in the locking component storage mechanism (72) and lock the first bracket (100), the second bracket (200) and the lug of the motor module carried by the second carrier (400) to form a finished module.

10. A compatible motor assembly process, characterized in that, Includes the following steps: S1: Provide a first return line (1) and a second return line (2), and determine whether the structures of the first bracket (100) and the second bracket (200) to be assembled are the same; S2: If the first support (100) and the second support (200) have different structures, the control vehicle return station enters the first working mode, so that the first return line (1) and the second return line (2) run independently; if the first support (100) and the second support (200) have the same structure, the control vehicle return station enters the second working mode, so that the first return line (1) and the second return line (2) run together to form a joint return line; S3: The first bracket (100) of the rotor, the stator, and the second bracket (200) are assembled sequentially at the assembly station to form a motor module; S4: The motor module obtained in step S3 is flipped from the first carrier (300) of the first return line (1) and transferred to the second carrier (400) of the second return line (2) or the second carrier (400) of the combined return line by the transfer device (3). S5: At the locking station, the first bracket (100), the second bracket (200), and the lug of the motor module are locked together to form the finished module.

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