A method and device for detecting a deep-well pump motor stator core

Abstract

The present application relates to a kind of deep well pump motor stator core detection method and device, it is related to the field of stator core, it includes: by from top to bottom illumination to the preset stacking table, and the product stacking image of stator core stacking on stacking table is collected;Product stacking image is darkened and the center shadow profile of each stator core is identified to obtain;Based on center shadow profile determines clamping position, controls preset transfer mechanism in any clamping position to stator core is clamped, stator core is moved from stacking table to preset detection table position;Industrial alcohol is sprayed in the inner cavity of stator core, and preset backlight is controlled from stator core by from bottom to top and is irradiated;Under the condition of irradiation, stator core is imaged at multiple angles and obtains core image set;Core image set is analyzed to obtain detection result, and output detection result.The present application has the effect of improving the detection efficiency of deep well pump motor stator core.

Description

Technical Field

[0001] This invention relates to the field of stator cores, and in particular to a method and apparatus for testing the stator core of a deep well pump motor. Background Technology

[0002] The stator core is typically made of multiple high-permeability silicon steel sheets stacked together, with internal slotted structures for housing the stator windings. The machining precision and quality of the stator core directly determine the operating efficiency, energy consumption, noise level, and service life of the deep well pump motor. To ensure the product quality of the deep well pump motor and prevent substandard stator cores from entering the assembly stage, a comprehensive and precise inspection must be performed on the stator core after production and machining.

[0003] Currently, most deep well pump manufacturers in China still rely on traditional manual inspection methods for stator core testing. This involves inspectors manually measuring and visually inspecting key indicators such as the inner diameter, roundness, lamination unevenness, and inner surface smoothness of the stator core using tools like feeler gauges, depth gauges, and dial indicators.

[0004] This manual, handheld tool inspection method relies entirely on the operator's experience, resulting in low inspection efficiency and a long inspection time per item, making it difficult to adapt to the mass production needs of modern production lines. Summary of the Invention

[0005] To improve the efficiency of deep well pump motor stator core testing, this invention provides a method and apparatus for testing deep well pump motor stator cores.

[0006] In a first aspect, the present invention provides a method for detecting the stator core of a deep well pump motor, employing the following technical solution: A method for testing the stator core of a deep well pump motor includes: The preset stacking platform is illuminated from top to bottom, and images of the products stacked on the platform with stator cores are captured. The product stacking image is shaded and the center shadow outline of each stator core is identified; The clamping position is determined based on the central shadow contour, and the preset transfer mechanism is controlled to clamp the stator core at any clamping position, moving the stator core from the stacking platform to the preset detection platform position. Industrial alcohol is sprayed into the inner cavity of the stator core, and a preset backlight source is controlled to irradiate the stator core from bottom to top. Image sets of the stator core were obtained by acquiring images of the stator core from multiple angles under illumination conditions. Image analysis is performed on the iron core image set to obtain the detection results, and the detection results are output.

[0007] By adopting the above technical solution, the stator core is automatically fed and inspected, thus accelerating the inspection efficiency. Furthermore, the system can acquire images of the stator core from multiple angles, and then simultaneously inspect multiple parameters of the stator core, which is more efficient than manual inspection. Before inspection, industrial alcohol is sprayed on the inner wall of the stator core. The spraying force removes impurities from the inner wall of the stator core, preventing impurities from affecting image acquisition and inspection accuracy. At the same time, the industrial alcohol evaporates under the illumination of the backlight and will not affect the stator core.

[0008] Optional methods for acquiring images of the stator core from multiple angles include: The vertical shooting position is set based on the location of the detection station; The stator core is inspected from a vertical shooting position, and during the inspection process, the stator core is rotated to a preset overlap angle to obtain two backlit images of the core. A vertical descent path is generated using the vertical shooting position as the high point and the preset center point of the detection platform position as the low point; After obtaining the backlight image of the iron core, the stator is descended along a vertical path and the inner wall of the stator is scanned to obtain the inner wall scan image. The iron core image set is obtained based on the backlight image of the iron core and the scanned image of the inner wall.

[0009] By adopting the above technical solution, and using a detection method that combines fixed-point acquisition with moving scanning, the stator core can be detected from multiple angles, enabling complete image acquisition and recognition of both the top surface and inner wall of the stator core, thereby improving detection accuracy.

[0010] Optionally, image analysis methods for the backlit images of the iron core in the iron core image set include: Shadows are deepened and shadow and highlight features are identified in the backlit image of the iron core; Remove highlight features from the backlit image of the iron core while retaining shadow features; Compare whether the shadow features in the two backlit images of the iron core overlap after rotation; If they overlap, extract the outer and inner ring contours of the iron core from the shadow features; The outer circle center is determined based on the outer circle profile of the iron core, and the inner circle center is determined based on the inner circle profile of the iron core. When the center of the outer circle coincides with the center of the inner circle, the coaxiality parameter in the test result is marked as qualified, and the test result is output.

[0011] Optional, also includes: The inner ring profile of the iron core is analyzed to extract the groove features and groove width values; When the width of the slot is consistent with the preset baseline slot width, the stacking quality in the test result is marked as qualified, and the test result is output. When the width of the groove is inconsistent with the width of the reference groove, the stacking misalignment feature can be identified from the inner wall scan image; The upper and lower contour features of the inner wall are obtained by analyzing the scanned images of the inner wall. Based on the lamination misalignment features, the upper contour features of the inner wall, and the lower contour features of the inner wall, the misalignment position information of the lamination misalignment features on the inner wall of the stator core is obtained. Output the misalignment location information.

[0012] By adopting the above technical solution, after identifying the abnormality in the slot width in the backlight image of the iron core, the abnormality can be further located in the inner wall scanning image, thereby determining the location of the misalignment of the laminations that caused the abnormality. This allows for targeted repair of the abnormal stator iron core without the need to separate all the pressed steel sheets.

[0013] Optional, also includes: Industrial alcohol is sprayed into the inner cavity of the stator core, and an inner wall scanning image is acquired after a preset evaporation time. The backlight image of the core is acquired within the evaporation time. Bright ripple features were obtained by analyzing the scanned images of the inner wall; The total number of pixels is obtained by pixelating the scanned image of the inner wall; Bright ridge pixels are obtained based on the inner wall scan image and bright ridge features; The proportion of bright ripples is obtained based on the number of bright ripple pixels and the total number of pixels. When the proportion of bright lines is not greater than the preset baseline proportion, the internal smoothness parameter in the test result is marked as qualified, and the test result is output.

[0014] By adopting the above technical solution, the evaporation rate of alcohol in the gap is slower than that of the inner wall surface of the stator core. Based on the above principle, the reflection of alcohol in the gap is detected, thereby enabling more efficient detection of the smoothness of the inner wall.

[0015] Optional, also includes: Analyze the scanned images of the inner wall to determine whether there are blocky bright streaks; When blocky bright freckle features exist, blocky pixels are determined based on the blocky bright freckle features, and the blocky bright freckle features are removed from the inner wall scan image; The total number of pixels and the bright ridge pixels are corrected based on the block-shaped pixels.

[0016] Optionally, the testing station has two testing areas, each with a backlight; it also includes: After obtaining the test results, the stator cores that passed the test were used as the comparison samples; When conducting the next round of stator core testing, the comparison sample is fixed in one of the testing areas, while the stator core to be tested is placed in another testing area. Record the test results of the stator core to be tested and compare them with the control sample to obtain the trend information of the test results; When the test result of the stator core to be tested is qualified, the comparison sample is removed and the stator core to be tested that has been tested is used as the new comparison sample.

[0017] Secondly, this application provides a deep well pump motor stator core testing device, which adopts the following technical solution: A deep well pump motor stator core testing device, controlled by the aforementioned deep well pump motor stator core testing method, includes a stacking platform for stacking stator cores to be tested, a testing platform for testing the stator cores, and a transfer mechanism for moving the stator cores from the stacking platform to the testing platform; the testing platform has a backlight, and the transfer mechanism has an industrial camera that cooperates with the backlight to acquire images.

[0018] Optionally, the transfer mechanism includes a fixed base, a three-coordinate moving assembly that drives the fixed base to reciprocate between the stacking platform and the testing platform, and a clamping assembly mounted on the fixed base to clamp the stator core; the industrial camera is mounted on the fixed base.

[0019] Optionally, the clamping assembly includes a rotating seat rotatably mounted on the fixed base, a drive motor for driving the rotating seat to rotate, and a clamping head mounted on the bottom of the rotating seat; The clamping head includes a clamping shell, an expansion block telescopically mounted on the circumferential sidewall of the clamping shell for clamping the inner wall of the stator core, and an expansion column vertically mounted inside the clamping shell for driving the expansion block to extend and retract; the expansion block and the expansion column have a relatively sliding inclined surface structure; a drive cylinder for driving the expansion column to rise and fall is mounted on the rotating seat.

[0020] In summary, this application includes at least one of the following beneficial technical effects: The system automates the feeding and inspection of stator cores, accelerating inspection efficiency. Furthermore, the system can acquire images of the stator cores from multiple angles, enabling simultaneous inspection of multiple parameters of the stator cores, which is more efficient than manual inspection. Before testing, industrial alcohol is sprayed onto the inner wall of the stator core. The spraying force removes impurities from the inner wall of the stator core, preventing impurities from affecting image acquisition and testing accuracy. At the same time, the industrial alcohol evaporates under the backlight and will not affect the stator core. The alcohol in the gap evaporates more slowly than the alcohol on the inner wall of the stator core. Based on this principle, the reflection of the alcohol in the gap is detected, which can efficiently detect the smoothness of the inner wall. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the deep well pump motor stator core detection device according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the transfer mechanism according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the clamping assembly according to an embodiment of the present invention; Figure 4 This is a cross-sectional view of the clamping assembly according to an embodiment of the present invention; Figure 5 This is a flowchart of a method for detecting the stator core of a deep well pump motor according to an embodiment of the present invention.

[0022] The parts referred to by the numbers in the above attached figures are as follows: 1. Stacking platform; 2. Inspection platform; 21. Backlight; 3. Transfer mechanism; 31. Three-coordinate moving assembly; 32. Fixed base; 33. Clamping assembly; 331. Rotating base; 332. Drive motor; 333. Clamping head; 3331. Clamping shell; 3332. Expansion block; 3333. Expansion column; 3334. Drive cylinder; 3335. Ejection groove; 3336. Inclined surface structure; 334. Industrial camera. Detailed Implementation

[0023] 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.

[0024] This application discloses a device for testing the stator core of a deep well pump motor.

[0025] Reference Figure 1 A deep well pump motor stator core testing device includes a stacking platform 1, a testing platform 2, and a transfer mechanism 3. The stacking platform 1 is used to place the stator core to be tested, and the testing platform 2 is used to test the stator core. The transfer mechanism 3 is used to clamp the stator core to be tested on the stacking platform 1 and move it to the testing platform 2 for testing.

[0026] Reference Figure 1 and Figure 2The transfer mechanism 3 includes a three-coordinate moving component 31, a fixed base 32, and a clamping component 33. The three-coordinate moving component 31 is mounted above and spans the stacking platform 1 and the inspection platform 2. The output end of the three-coordinate moving component 31 can move arbitrarily in the X, Y, and Z axes. The three-coordinate moving component 31 can be driven by a linear module, a cylinder, or a motor.

[0027] The fixed base 32 is fixedly connected to the output end of the three-coordinate moving component 31, and the clamping component 33 is mounted on the fixed base 32, so that the clamping component 33 can move in space under the drive of the three-coordinate moving component 31.

[0028] Reference Figure 2 and Figure 3 The clamping assembly 33 includes a rotating base 331, a drive motor 332, and a clamping head 333. The rotating base 331 is rotatably mounted on a fixed base 32. The drive motor 332 is fixedly mounted on the fixed base 32, and the drive motor 332 and the rotating base 331 are driven by a pulley. The clamping head 333 is fixedly mounted on the bottom of the rotating base 331. Driven by the drive motor 332, the clamping head 333 can rotate synchronously with the rotating base 331. In this embodiment, the rotating base 331 includes an upper base, a lower base, and a connecting rod connecting the two, and a fixed cavity is provided between the upper base and the lower base.

[0029] Reference Figure 2 , Figure 3 and Figure 4 The clamping head 333 includes a clamping shell 3331, an expansion block 3332, an expansion column 3333, and a drive cylinder 3334. The drive cylinder 3334 is installed in a fixed cavity, and its output end extends downward through a lower seat. The clamping shell 3331 is a hollow cylinder with an outer diameter matching the inner diameter of the stator core. The clamping shell 3331 has circumferentially spaced ejection slots 3335 that extend into its interior. The expansion column 3333 is connected to the output end of the drive cylinder 3334 and is vertically mounted inside the clamping shell 3331; the height of the expansion column 3333 is less than the height of the internal cavity of the clamping shell 3331. The expansion block 3332 is telescopically mounted within the ejection slot 3335.

[0030] The expansion column 3333 abuts against the expansion block 3332, and the abutment point of the two has a relatively sliding inclined surface structure 3336. Specifically, the expansion column 3333 has a first inclined surface in the circumferential direction, and the end of the expansion block 3332 inside the clamping shell 3331 has a second inclined surface that slides and engages with the first inclined surface of the expansion column 3333.

[0031] When the drive cylinder 3334 drives the expansion column 3333 to descend, the expansion column 3333 can drive the expansion block 3332 to extend outward in the circumferential direction of the clamping shell 3331.

[0032] In this embodiment, each ejector groove 3335 contains a spring. When the expansion column 3333 returns to its original position, the spring drives the expansion block 3332 to retract and return to its original position.

[0033] When the stator core is picked up by the clamping assembly 33, the clamping shell 3331 is driven into the inner cavity of the stator core by the three-coordinate moving assembly 31, and then the expansion block 3332 is indirectly driven to expand outward by the driving cylinder 3334 so as to support the inner wall of the stator core to clamp the stator core.

[0034] In this embodiment, the fixing base 32 is a rectangular plate, the clamping assembly 33 is located at one end of the fixing base 32, and an industrial camera 334 is mounted at the other end of the fixing base 32. The industrial camera 334 is used to perform image detection on the stator core to be inspected. The industrial camera 334 is lifted and lowered on the fixing base 32 by a drive device, thereby allowing the position of the industrial camera 334 for image detection to be adjusted. The drive device can be any of a cylinder, a motor, or other structures capable of lifting and lowering.

[0035] Reference Figure 1 In this embodiment, the testing platform 2 has two testing areas, each with a backlight 21. The backlight 21 is designed as a disc-shaped structure that can provide support and provides bottom-up illumination. The backlight 21 is rotatably mounted on the testing platform 2, which has a drive mechanism to rotate it. This drive mechanism can be a motor or other devices capable of outputting rotational motion.

[0036] When the transfer mechanism 3 places the stator core to be tested on the backlight 21, the backlight 21 can cooperate with the industrial camera 334 to test the stator core.

[0037] Based on the same inventive concept, this invention provides a method for detecting the stator core of a deep well pump motor.

[0038] Reference Figure 5 A method for testing the stator core of a deep well pump motor includes the following steps: Step S1: Illuminate the preset stacking platform 1 from top to bottom and capture images of the products stacked on the stacking platform 1 with stator cores.

[0039] The product stacking image refers to an image captured by an industrial camera 334 mounted on the transfer mechanism 3, showing the stator cores to be inspected placed on the stacking platform 1. The image contains multiple stacked stator cores, and due to top-down lighting, the top surface of the stator cores is brighter due to reflection, while the inner cavity of the stator cores is darker due to deep shadows. Here, the device illuminating the stacking platform 1 can be located on the transfer mechanism 3 and move synchronously, or it can be located on the stacking platform 1 and provide fixed illumination.

[0040] Step S2: Add shadows to the product stacking image and identify the center shadow outline of each stator core.

[0041] Shadow détente is a method in image processing to enhance the shadows in an image.

[0042] The central shadow outline refers to the outline of the shadow located at the center of the stator core in the image.

[0043] After the shadows in the product stacking image are deepened by image processing technology, the shadow color becomes darker, making the color of the inner cavity of the stator core more distinct from the color of the top surface. Then, the feature of the inner cavity of the stator core is extracted from the image to obtain the outline of the central shadow.

[0044] Step S3: Determine the clamping position based on the central shadow outline, control the preset transfer mechanism 3 to clamp the stator core at any clamping position, and move the stator core from the stacking platform 1 to the preset detection platform position.

[0045] The clamping position refers to the position on the stator core where the clamping assembly 33 clamps the stator. The clamping position is determined by the central shaded outline, which determines the center point of the outline. The clamping position is also centered on the center point of the outline.

[0046] Since a large number of stator cores are stacked on the stacking platform 1, multiple clamping positions can be identified in the image. The system randomly selects one clamping position from all the positions to determine the stator core to be clamped. Then, it controls the clamping component 33 in the transfer mechanism 3 to clamp the stator core at the selected clamping position. After the stator core is clamped, the system transfers the stator core to the detection platform position via the transfer mechanism 3. The detection platform position is the location of the backlight 21 on the detection platform 2. The transfer mechanism 3 places the stator core on the backlight 21 and aligns it coaxially with the backlight 21.

[0047] Step S4: Spray industrial alcohol into the inner cavity of the stator core and control the preset backlight 21 to irradiate the stator core from bottom to top.

[0048] After the stator core to be tested is completed, a certain amount of industrial alcohol is sprayed into the inner cavity of the stator core through a nozzle set on the transfer mechanism 3. This is done to clean impurities and oil stains from the inner wall of the stator core, and also to reflect light through the industrial alcohol to facilitate subsequent testing procedures.

[0049] After the industrial alcohol is sprayed, the backlight 21 simultaneously irradiates the stator core from bottom to top. In this embodiment, the backlight 21 is always on.

[0050] Step S5: Under illumination conditions, acquire images of the stator core from multiple angles to obtain a core image set.

[0051] The stator core image set refers to the collection of images taken by the industrial camera 334 from multiple angles during the inspection process. These multiple angles primarily involve overhead shots and scanning inside the stator core cavity. Specific multi-angle acquisition methods will be detailed in subsequent embodiments and will not be elaborated upon here.

[0052] Step S6: Perform image analysis on the iron core image set to obtain the detection results, and output the detection results.

[0053] In this embodiment, the coaxiality of the stator core, the lamination of the stator core, and the smoothness of the inner wall of the stator core are mainly detected by analyzing the image set of the stator core. The detection results include the pass / fail status of the above three aspects.

[0054] The method for acquiring images of the stator core from multiple angles includes the following steps: Step S500: Set the vertical shooting position based on the position of the detection station.

[0055] The vertical shooting position refers to the shooting position of the industrial camera 334 when it takes a top-down shot of the stator core. The center point of the vertical shooting position is obtained by moving the center point of the inspection platform upwards by a preset fixed distance. The fixed position is a parameter set in the system by the technicians in advance, and will not be elaborated here.

[0056] Step S501: Detect the stator core from a vertical shooting position, and drive the stator core to rotate at a preset overlap angle during the detection process to obtain two backlit images of the core.

[0057] Because the cross-section of the stator core is a symmetrical circular shape, it can be superimposed on the original shape after being rotated by a certain angle. The angle of coincidence is set by the technicians to make the cross-sectional image of the stator core coincide with the original shape after being rotated in a circle.

[0058] The stator core backlit image refers to an image obtained by an industrial camera 334 taking a top-down shot of the stator core against the light. Due to the backlit environment, the resulting image is a silhouette image, with the top surface of the stator core in black shadow and the central cavity of the stator core in highlight area.

[0059] When the industrial camera 334 is shooting in a vertical position, it takes one backlit image of the stator core before and after the stator core rotates.

[0060] Step S502: Generate a vertical descent path with the vertical shooting position as the high point and the preset detection platform center point as the low point.

[0061] The vertical descent path refers to the downward movement path of the industrial camera 334 when scanning and photographing the inner cavity of the stator core. The vertical descent path is the line path connecting the vertical shooting position and the center point of the inspection table.

[0062] Step S503: After obtaining the backlight image of the iron core, descend along the vertical descent path and scan the inner wall of the stator iron core to obtain the inner wall scan image.

[0063] The internal wall scan image refers to the image obtained by the industrial camera 334, driven by a drive unit, extending into the inner cavity of the stator core to scan and capture images. During the internal wall scan image capture, the industrial camera 334 descends while simultaneously capturing images. The industrial camera 334 captures multiple images of the internal wall, and all images are superimposed to obtain the final internal wall scan image.

[0064] Step S504: Obtain the core image set based on the core backlight image and the inner wall scan image.

[0065] The core image set includes backlit images of the core and scanned images of the inner wall.

[0066] The image analysis method for the backlit images of iron cores in the iron core image set includes the following steps: Step S510: Deepen the shadows of the iron core backlight image and identify shadow features and highlight features.

[0067] Similar to step S2, the shadows of the iron core backlight image are first deepened to make the contrast between dark and light areas in the image more obvious.

[0068] The shadow feature refers to the lower-brightness shadowed areas in the backlit image of the stator core, which represent the top surface of the stator core. The highlight feature refers to the higher-brightness highlight areas in the backlit image of the stator core, which represent the inner cavity of the stator core.

[0069] After shadow deepening, both shadow features and highlight features can be obtained from the iron core backlight image through image analysis and recognition.

[0070] Step S511: Remove the bright features from the iron core backlight image and retain the shadow features.

[0071] To facilitate the processing of shadow features, the bright features are first removed from the backlit image of the iron core, and only the shadow features are retained.

[0072] Step S512: Compare whether the shadow features in the two backlit images of the iron core overlap after rotation.

[0073] In this embodiment, the shadow features in two backlit images of the stator core taken before and after rotation are compared. If the stator core is qualified, the shadow features in the two images should overlap. By determining whether the two overlap, the first step of coaxiality detection is performed.

[0074] Step S513: If they overlap, extract the outer ring contour and inner ring contour of the iron core from the shadow features.

[0075] The fact that the shadow features in the two images do not overlap indicates that there is a coaxiality problem in the stator core, and the test result is unqualified.

[0076] The outer ring profile of the stator core refers to the outline of the outer ring of the stator core, which is also the shaded outer ring profile. The inner ring profile of the stator core refers to the outline of the inner cavity of the stator core, which is also the shaded inner ring profile.

[0077] When the shadow features in the two images overlap, the outer and inner ring contours of the iron core are identified again from the shadow features.

[0078] Step S514: Determine the center of the outer ring based on the outer ring profile of the iron core, and determine the center of the inner ring based on the inner ring profile of the iron core.

[0079] The outer ring of the iron core is circular, and the center of the outer ring is the coordinate position of the center of the outer ring of the iron core. Similarly, the center of the inner ring is the coordinate position of the center of the inner ring of the iron core.

[0080] Step S515: When the center of the outer circle coincides with the center of the inner circle, mark the coaxiality parameter in the test result as qualified and output the test result.

[0081] The first step of coaxiality testing is verified by re-checking whether the centers of the outer and inner rings coincide. If the first step of coaxiality testing is successful, and the centers of the outer and inner rings coincide, then the coaxiality parameters of the stator core are qualified.

[0082] The detection method for stacked misalignment includes the following steps: This embodiment detects the misalignment of the stator core laminations. The stator core is formed by stacking steel sheets, and each sheet needs to be circumferentially aligned. Lamination misalignment means that the steel sheets are not circumferentially aligned, indicating an anomaly in the cable slots.

[0083] Step S520: Analyze the inner ring profile of the iron core to extract the groove features and groove width values.

[0084] The slotted features are circumferentially arranged slots within the stator core cavity, and these features can be identified in backlit images of the core. The slotted features are circumferentially distributed along the inner contour of the core; they can be obtained by analyzing this inner contour.

[0085] The slot width value is the width of the slot feature, which is obtained by image recognition of the slot feature from the inner ring contour of the iron core.

[0086] Step S521: When the width of the wire groove is consistent with the preset baseline wire groove width, mark the stacking quality in the test result as qualified and output the test result.

[0087] The baseline slot width is the slot width of a qualified stator core, which is measured by technicians and stored in the database.

[0088] The actual measured slot width value is compared with the baseline slot width. If the two are consistent, it indicates that the lamination quality of the stator core is qualified and there is no lamination misalignment. The qualified test result is output and the test can proceed to the next test.

[0089] Step S522: When the width of the groove is inconsistent with the width of the reference groove, the stacking misalignment feature is identified from the inner wall scan image.

[0090] If the two are inconsistent, it indicates that one or more steel sheets in the stator core are misaligned and protrude into the slot, causing the slot width value in the shaded feature to be smaller than the normal value. In this case, the misaligned steel sheets need to be located to facilitate rework of the abnormal stator core.

[0091] After detecting an abnormality in the slot width in the backlit image of the iron core, the inner wall scanning image was analyzed after it was captured. Since the inner wall scanning image contains an image of the entire inner wall of the stator iron core, misalignment of steel sheets can be identified in the inner wall scanning image.

[0092] The lamination misalignment feature refers to the misaligned steel laminations in the stator core. By analyzing the scanned images of the inner wall, the protruding parts in the slots are used as identification features, and the protruding parts in the slots are the misaligned steel laminations.

[0093] Step S523: Analyze the scanned image of the inner wall to obtain the upper contour features and lower contour features of the inner wall.

[0094] The upper and lower contour features of the inner wall are the upper and lower edge contours of the entire inner wall image of the stator core, respectively. Both can be obtained directly by analyzing the scanned image of the inner wall.

[0095] Step S524: Based on the lamination misalignment features, the upper contour features of the inner wall, and the lower contour features of the inner wall, obtain the misalignment position information of the lamination misalignment features on the inner wall of the stator core.

[0096] After locating the lamination misalignment feature, the upper contour feature, and the lower contour feature in the inner wall scan image, the specific position of the lamination misalignment feature in the stator core can be obtained based on the positional relationship of the three. The misalignment position information is the position of the lamination misalignment feature on the inner wall of the stator core.

[0097] Step S525: Output the misalignment position information.

[0098] After determining the misalignment location information, the system provides feedback on the misalignment location information, and the staff can remove the stator core and directly process the misaligned steel sheet located at the misalignment location.

[0099] The method for detecting the smoothness of the inner wall of the stator core includes the following steps: Step S530: Spray industrial alcohol into the inner cavity of the stator core and acquire an inner wall scanning image after a preset evaporation time. The backlight image of the core is acquired within the evaporation time.

[0100] The evaporation time is the time set by the technician for the alcohol to evaporate. In this embodiment, the backlight 21 is a heat source, and the alcohol can be heated and evaporated under the illumination of the backlight 21. After the evaporation time, the alcohol on the inner wall surface of the stator core is completely evaporated, while the alcohol in the gaps evaporates more slowly and remains because it is not directly illuminated by the backlight 21.

[0101] After the industrial alcohol is sprayed, the backlight image of the stator core is acquired during the evaporation time. At this time, the industrial camera 334 is not inside the stator core cavity and is not affected by alcohol evaporation. After the backlight image acquisition is completed, that is, after the evaporation time has elapsed, the alcohol on the inner wall of the stator core has basically evaporated. At this time, the industrial camera 334 is then controlled to extend into the inner cavity of the stator core to acquire the inner wall scanning image.

[0102] In this embodiment, the alcohol in the gap reflects light. When the industrial camera 334 takes a picture of the inner wall of the stator core, the area where the alcohol is present has higher brightness, indicating that there is a gap and the surface is not smooth.

[0103] Step S531: Analyze the scanned image of the inner wall to obtain bright ripple features.

[0104] Bright streaks refer to bright lines formed when the inner wall of the stator core is not smooth and contains alcohol residue. Bright streaks can be identified and analyzed from scanned images of the inner wall based on brightness characteristics.

[0105] Step S532: Pixelate the inner wall scan image to obtain the total number of pixels.

[0106] Total pixels refer to the total number of pixels occupied by the entire inner wall of the stator core in the inner wall scan image. The total number of pixels is determined by the parameters used by the system to pixelate the inner wall scan image.

[0107] Step S533: Obtain bright ridge pixels based on the inner wall scan image and bright ridge features.

[0108] Bright fringe pixels refer to the total number of pixels occupied by all bright fringe features in the entire scanned image of the inner wall. Bright fringe pixels are counted by the system from the scanned image of the inner wall.

[0109] Step S534: Obtain the proportion of bright ripples based on the bright ripple pixels and the total number of pixels.

[0110] The bright ripple ratio, calculated as the ratio of bright ripple pixels to total pixels, measures the degree of roughness of the stator core. A higher bright ripple ratio indicates a rougher inner wall of the stator core.

[0111] Step S535: When the proportion of bright lines is not greater than the preset benchmark proportion, mark the internal smoothness parameter in the test result as qualified and output the test result.

[0112] The benchmark ratio is a parameter obtained by technicians through pre-testing of qualified stator cores with smooth inner walls, and is used to measure whether the inner cavity is smooth.

[0113] If the proportion of bright lines is not greater than the reference proportion, it indicates that the inner wall of the stator core is relatively smooth and the smoothness parameter test is qualified.

[0114] Conversely, if the proportion of bright lines is greater than the reference proportion, it indicates that there are many gaps and the inner wall of the stator core is not smooth, resulting in more alcohol residue in the gaps. In this case, the stator core fails the test and needs to be reworked.

[0115] The correction method for contamination of the lens of industrial camera 334 due to alcohol evaporation includes the following steps: In this embodiment, due to the evaporation of alcohol, the evaporated alcohol may form water droplets on the lens of the industrial camera 334, resulting in errors in the acquired image.

[0116] Step S540: Analyze the scanned image of the inner wall to determine whether there are blocky bright lines.

[0117] During image acquisition, water droplets refract or reflect light, causing large bright spots to appear in the image at the locations corresponding to the water droplets. These bright spots are known as blocky bright streaks. The difference between the bright streaks formed by water droplets and those formed by alcohol is that the bright streaks formed by water droplets are circular and blocky, while the bright streaks produced by alcohol appear as lines because alcohol seeps along gaps.

[0118] By scanning the image from the inner wall to identify the presence of blocky bright lines, it can be determined whether there are evaporated alcohol droplets on the surface of the industrial camera 334 lens. Cases without alcohol droplets are disregarded, meaning the industrial camera 334 can acquire images normally and the system can analyze them correctly.

[0119] Step S541: When blocky bright ripple features exist, determine blocky pixel points based on the blocky bright ripple features and remove the blocky bright ripple features from the inner wall scan image.

[0120] If blocky bright freckle features are present, they must first be identified from the inner wall scan image, and the blocky pixels of these features must be identified simultaneously. These blocky bright freckle features need to be removed from the inner wall scan image.

[0121] Step S542: Correct the total number of pixels and the bright ripple pixels based on the block pixels.

[0122] To avoid interference from blocky pixels, they are directly removed from both the total number of pixels and the bright ripple pixels. The proportion of bright ripples is then calculated based on the data after removing the blocky pixels. In cases where blocky pixels and bright ripple pixels overlap, the blocky pixels are removed from the bright ripple pixels based on their shape.

[0123] After the smoothness of the inner wall of the stator core is tested, the lens of the industrial camera 334 is wiped. The transfer mechanism 3 is equipped with a cleaning cloth that automatically wipes the lens of the industrial camera 334.

[0124] It also includes the following steps: Step S7: After obtaining the test results, use the stator core with qualified test results as the comparison sample.

[0125] In this embodiment, after all the test indicators of the stator core have passed the test, the stator core is first placed on the test platform 2 and used as a comparison sample for comparison with the stator core to be tested in the next round. During this process, the backlight 21 continues to bake away the alcohol from the inner wall of the stator core.

[0126] Step S70: When conducting the next round of stator core testing, the comparison sample is fixed in one of the testing areas, and the stator core to be tested is placed in another testing area.

[0127] During the next round of stator core testing, the stator core that passed the previous round of testing remains in place. The system first removes the stator core that passed the previous round of testing, and then replaces it with the stator core to be tested in the next round. This ensures that there are always two stator cores in the two testing areas of testing station 2, one of which is a qualified product that has already been tested, and the other is a product to be tested.

[0128] Step S71: Record the test results of the stator core to be tested and compare them with the control sample to obtain the test result trend information.

[0129] The test result trend information refers to the trend of the test results of the stator core that has been tested so far relative to the test results of the qualified stator core in the previous round. The trend can be worse or better.

[0130] Step S72: When the test result of the stator core to be tested is qualified, the comparison sample is removed and the stator core to be tested that has been tested is used as the new comparison sample.

[0131] After the stator core to be tested is completed, if the test result of the stator core is unqualified, the stator core from the previous round will continue to be used as the control sample, and the stator core from the previous round will not be removed. This process continues until the test result of the stator core to be tested is qualified, at which point the stator core will be replaced with a new control sample.

[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 testing the stator core of a deep well pump motor, characterized in that, include: The pre-set stacking platform (1) is illuminated from top to bottom, and images of the products stacked on the stacking platform (1) are collected. The product stacking image is shaded and the center shadow outline of each stator core is identified; Based on the central shadow contour, the clamping position is determined, and the preset transfer mechanism (3) is controlled to clamp the stator core at any clamping position, moving the stator core from the stacking platform (1) to the preset detection platform position. Industrial alcohol was sprayed into the inner cavity of the stator core, and the preset backlight (21) was controlled to irradiate from bottom to top of the stator core. Image sets of the stator core were obtained by acquiring images of the stator core from multiple angles under illumination conditions. Image analysis is performed on the iron core image set to obtain the detection results, and the detection results are output. Methods for acquiring images of the stator core from multiple angles include: The vertical shooting position is set based on the location of the detection station; The stator core is inspected from a vertical shooting position, and during the inspection process, the stator core is rotated to a preset overlap angle to obtain two backlit images of the core. A vertical descent path is generated using the vertical shooting position as the high point and the preset center point of the detection platform position as the low point; After obtaining the backlight image of the iron core, the stator is descended along a vertical path and the inner wall of the stator is scanned to obtain the inner wall scan image. The iron core image set is obtained based on the backlight image of the iron core and the scanned image of the inner wall; Image analysis methods for backlit images of iron cores in an iron core image set include: Shadows are deepened and shadow and highlight features are identified in the backlit image of the iron core; Remove highlight features from the backlit image of the iron core while retaining shadow features; Compare whether the shadow features in the two backlit images of the iron core overlap after rotation; If they overlap, extract the outer and inner ring contours of the iron core from the shadow features; The outer circle center is determined based on the outer circle profile of the iron core, and the inner circle center is determined based on the inner circle profile of the iron core. When the center of the outer circle coincides with the center of the inner circle, the coaxiality parameter in the test result is marked as qualified, and the test result is output.

2. The method for detecting the stator core of a deep well pump motor according to claim 1, characterized in that, Also includes: The inner ring profile of the iron core is analyzed to extract the groove features and groove width values; When the width of the slot is consistent with the preset baseline slot width, the stacking quality in the test result is marked as qualified, and the test result is output. When the width of the groove is inconsistent with the width of the reference groove, the stacking misalignment feature can be identified from the inner wall scan image; The upper and lower contour features of the inner wall are obtained by analyzing the scanned images of the inner wall. Based on the lamination misalignment features, the upper contour features of the inner wall, and the lower contour features of the inner wall, the misalignment position information of the lamination misalignment features on the inner wall of the stator core is obtained. Output the misalignment location information.

3. The method for detecting the stator core of a deep well pump motor according to claim 1, characterized in that, Also includes: Industrial alcohol is sprayed into the inner cavity of the stator core, and an inner wall scanning image is acquired after a preset evaporation time. The backlight image of the core is acquired within the evaporation time. Bright ripple features were obtained by analyzing the scanned images of the inner wall; The total number of pixels is obtained by pixelating the scanned image of the inner wall; Bright ridge pixels are obtained based on the inner wall scan image and bright ridge features; The proportion of bright ripples is obtained based on the number of bright ripple pixels and the total number of pixels. When the proportion of bright lines is not greater than the preset baseline proportion, the internal smoothness parameter in the test result is marked as qualified, and the test result is output.

4. The method for detecting the stator core of a deep well pump motor according to claim 3, characterized in that, Also includes: Analyze the scanned images of the inner wall to determine whether there are blocky bright streaks; When blocky bright freckle features exist, blocky pixels are determined based on the blocky bright freckle features, and the blocky bright freckle features are removed from the inner wall scan image; The total number of pixels and the bright ridge pixels are corrected based on the block-shaped pixels.

5. The method for detecting the stator core of a deep well pump motor according to claim 1, characterized in that, The testing station (2) has two testing areas, each with a backlight (21); it also includes: After obtaining the test results, the stator cores that passed the test were used as the comparison samples; When conducting the next round of stator core testing, the comparison sample is fixed in one of the testing areas, while the stator core to be tested is placed in another testing area. Record the test results of the stator core to be tested and compare them with the control sample to obtain the trend information of the test results; When the test result of the stator core to be tested is qualified, the comparison sample is removed and the stator core to be tested that has been tested is used as the new comparison sample.

6. A deep well pump motor stator core testing device, controlled by a deep well pump motor stator core testing method as described in any one of claims 1 to 5, characterized in that, It includes a stacking platform (1) for stacking stator cores to be tested, a testing platform (2) for testing stator cores, and a transfer mechanism (3) for moving stator cores from the stacking platform (1) to the testing platform (2); the testing platform (2) has a backlight (21), and the transfer mechanism (3) has an industrial camera (334) that cooperates with the backlight (21) to acquire images.

7. The deep well pump motor stator core testing device according to claim 6, characterized in that, The transfer mechanism (3) includes a fixed base (32), a three-coordinate moving component (31) that drives the fixed base (32) to reciprocate between the stacking platform (1) and the testing platform (2), and a clamping component (33) that is mounted on the fixed base (32) to clamp the stator core; the industrial camera (334) is mounted on the fixed base (32).

8. The deep well pump motor stator core testing device according to claim 7, characterized in that, The clamping assembly (33) includes a rotating seat (331) rotatably mounted on the fixed base (32), a drive motor (332) for driving the rotating seat (331) to rotate, and a clamping head (333) mounted on the bottom of the rotating seat (331). The clamping head (333) includes a clamping shell (3331), an expansion block (3332) telescopically installed on the circumferential sidewall of the clamping shell (3331) for clamping the inner wall of the stator core, and an expansion column (3333) vertically installed inside the clamping shell (3331) for driving the expansion block (3332) to extend and retract; the expansion block (3332) and the expansion column (3333) have a relatively sliding inclined surface structure (3336); a drive cylinder (3334) for driving the expansion column (3333) to rise and fall is installed on the rotating seat (331).

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