A visual detection device for fine polishing of surface flaws of a stator and rotor lamination

Abstract

This invention relates to the field of industrial visual inspection technology and discloses a visual inspection device for surface defects of stator and rotor laminations after fine grinding. It aims to solve the problems of neglecting burr detection on the lamination surface of existing stator laminations, and the issues of reflective interference, efficiency bottlenecks, and difficulty in balancing reliability and high cycle time in double-sided inspection. The device includes a conveying component, a support frame, a limiting component, a visual recognition component, and a projection lamp. By vertically conveying and positioning the motor stator and rotor laminations and fixing them with a V-shaped clamp, combined with a dual inspection method of projected shadows and direct imaging of the lamination surface, it overcomes reflective interference and reduces the risk of false positives and missed detections. The visual inspection sensor dynamically scans to achieve continuous inspection, improving inspection cycle time and throughput, adapting to large-scale online production, avoiding missed detections, preventing insulation damage during lamination, and ensuring motor efficiency, reliability, and service life.

Description

Technical Field

[0001] This invention relates to the field of industrial visual inspection technology, and in particular to a visual inspection device for surface defects after fine grinding of stator and rotor laminations. Background Technology

[0002] In the network layer of the Industrial Internet architecture, the intelligent upgrading of key equipment is the core support for promoting the digital and refined development of manufacturing. Intelligent sensors, as a core component of key network layer equipment, undertake the important functions of data acquisition, transmission, and preliminary perception in the physical world, serving as the core hub connecting physical production and the digital network. In the specific applications of intelligent sensors, industrial vision intelligence, with its high-precision and real-time perception advantages, has widely penetrated into high-end equipment production scenarios such as motor manufacturing, becoming a key technological path to ensure product quality and improve production efficiency. In the production process of motor stator and rotor laminations, intelligent sensors in the field of industrial vision intelligence, such as visual inspection sensors, are the core execution components for detecting surface defects in the laminations. Their detection accuracy and efficiency directly determine the processing quality of the motor core and the production line cycle time. The inner and outer slot surfaces and tooth profiles of the motor stator laminations directly determine the slot accuracy, tooth width consistency, and lamination alignment of the core, significantly affecting the fit between the laminations and windings and the magnetic circuit distribution. Defects in these areas can be quickly identified using conventional optical imaging intelligent sensors in the field of industrial vision intelligence, forming a relatively mature detection solution.

[0003] However, current intelligent sensor applications in key network layer devices still have significant shortcomings in industrial vision intelligence detection solutions: existing detection systems overemphasize the detection of defects on the lamination slot surface, neglecting the detection of burrs and abnormal protrusions on the stacked surface. Tiny defects on the stacked surface can puncture the insulating coating during core stacking, leading to inter-laminate short circuits, increased motor iron losses, and decreased efficiency, severely impacting motor reliability and lifespan. Furthermore, facing the demand for large-volume lamination inspection, existing industrial vision intelligence sensors suffer from the challenges of a large number of laminations, extremely thin individual pieces, and the time-consuming process of inspecting both sides, significantly slowing down production line cycles and contradicting the network layer's requirements for efficient data transmission and high-speed production adaptation. Moreover, the stacked surface is a bare metal surface with strong reflective properties; conventional industrial vision intelligence sensors are prone to specular glare during high-speed online imaging, obscuring the true shape of burrs and resulting in insufficient detection accuracy, failing to meet the precision requirements of intelligent sensors in the refined production of motors. Summary of the Invention

[0004] The technical problem to be solved by the present invention is that the existing technology ignores the detection of burrs on the stator lamination stacking surface, while double-sided detection faces the efficiency bottleneck caused by reflective interference and a large number of laminations, making it difficult to balance reliability and high cycle time online. To this end, we propose a visual inspection device for surface defects of stator and rotor laminations after fine grinding.

[0005] To achieve the above objectives, this application adopts the following technical solution: a visual inspection device for surface defects of stator and rotor laminations after fine grinding, comprising: a conveying assembly, the conveying assembly including a mounting plate, two sets of conveyor belts symmetrically arranged inside the mounting plate, three sets of support structures arranged between the two sets of conveyor belts, the support structure including support rollers, and the outer wall of the support rollers having several annular grooves at equal intervals, the top of the annular grooves supporting motor stator and rotor laminations, a support frame arranged on the side of the support structure, a limiting assembly installed inside the support frame, the limiting assembly including a second motor fixedly connected to the support frame, a transmission rod fixedly connected to the output end of the second motor, several V-shaped structures sleeved on the outside of the transmission rod, and the V-shaped structures corresponding one-to-one with the motor stator and rotor laminations, two sets of visual recognition components symmetrically arranged on the top of the support frame, the visual recognition components including a drive structure and visual inspection sensors, the two sets of visual inspection sensors facing the two sides of the V-shaped structures respectively;

[0006] A projection lamp is installed above the motor stator and rotor laminations. The light emitted by the projection lamp is parallel to the motor stator and rotor laminations, casting the shadows of the motor stator and rotor laminations onto the V-shaped structure.

[0007] Preferably, the surface of the conveyor belt is provided with a number of positioning grooves, and the positioning grooves correspond one-to-one with the motor stator and rotor laminations. A number of support belts are mounted above the conveyor belt, and the support belts are spaced apart from the motor stator and rotor laminations.

[0008] Preferably, the width of the annular groove corresponds to the thickness of the motor stator and rotor laminations, and the inner wall of the annular groove is wrapped with an anti-slip pad.

[0009] Preferably, both ends of the support roller are provided with lifting rods, and a first motor is installed on the top of one set of lifting rods, and the output end of the first motor is fixedly connected to the support roller.

[0010] Preferably, the limiting component further includes a guide rod arranged parallel to the transmission rod, and the guide rod is fixedly connected to the support frame.

[0011] Preferably, the V-shaped structure includes a first clamping plate and a second clamping plate clamped on both sides of the motor stator and rotor laminations, wherein a second guide cylinder is fixedly connected to the end of the first clamping plate and a first guide cylinder is fixedly connected to the end of the second clamping plate.

[0012] Preferably, a first ball nut is fixedly connected to the end of the first clamping plate away from the second guide cylinder, and a second ball nut is fixedly connected to the end of the second clamping plate away from the first guide cylinder.

[0013] Preferably, the outer wall of the transmission rod is provided with a threaded groove, and the threaded groove located inside the first ball nut has the opposite spiral direction to the threaded groove located inside the second ball nut.

[0014] Preferably, the drive structure includes a lead screw and a slide rod arranged in parallel, the slide rod is fixedly connected to the support frame, the lead screw is rotatably connected to the support frame, and a third motor is installed at one end of the lead screw.

[0015] Preferably, a movable block is sleeved on the outside of the lead screw, the movable block is slidably connected to the slide rod, and the movable block is fixedly connected to the vision inspection sensor.

[0016] The technical effects and advantages of this invention are as follows:

[0017] This invention employs a dual detection method combining upright conveying and positioning with V-shaped clamping and fixing, along with projection shadows and direct imaging of the stacked surface. This amplifies the signal of minute protrusions, overcomes the problem of insufficient contrast caused by reflection, and reduces the risk of false alarms and missed alarms through data comparison and verification, thereby improving the reliability and robustness of burr identification. Simultaneously, the visual inspection sensor's dynamic linear scanning enables continuous inspection, completing multi-angle data acquisition for multiple sets of laminations in parallel, significantly increasing the inspection cycle and throughput, adapting to the needs of large-scale online production. Furthermore, comprehensive regional inspection avoids missed detections, effectively preventing damage to the insulation coating and short circuits between laminations during stacking, reducing motor iron losses and eddy current losses, and improving motor efficiency, reliability, and service life. Attached Figure Description

[0018] The disclosure of this invention is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings, the same reference numerals are used to refer to the same parts:

[0019] Figure 1 This is a three-dimensional structural diagram of the entire invention;

[0020] Figure 2 This is a top-view three-dimensional structural diagram of the transmission component, limiting component, and visual recognition component of the present invention;

[0021] Figure 3 This is a three-dimensional structural diagram of the support roller of the conveying component of the present invention in the raised state;

[0022] Figure 4 This is a three-dimensional structural diagram of the support roller of the conveying component of the present invention in the lowered state;

[0023] Figure 5 This is a three-dimensional structural diagram of the supporting structure portion of the present invention;

[0024] Figure 6 This is a three-dimensional structural diagram of the component portion of the present invention;

[0025] Figure 7 This is a three-dimensional structural diagram of the V-shaped structure portion of the present invention;

[0026] Figure 8 This is a three-dimensional structural diagram of the visual recognition component of the present invention.

[0027] Legend: 1. Conveying assembly; 2. Support frame; 3. Limiting assembly; 4. Vision recognition assembly; 5. Projection lamp; 6. Motor stator and rotor laminations; 101. Mounting plate; 102. Conveyor track; 103. Positioning groove; 104. Support track; 105. Support roller; 106. Annular groove; 107. First motor; 108. Lifting rod; 301. Second motor; 302. Transmission rod; 303. First clamping plate; 304. Second clamping plate; 305. First ball nut; 306. Second ball nut; 307. Threaded groove; 308. First guide cylinder; 309. Second guide cylinder; 310. Guide rod; 401. Vision inspection sensor; 402. Third motor; 403. Lead screw; 404. Moving block; 405. Slide rod. Detailed Implementation

[0028] It is readily understood that, based on the technical solution of this invention, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of this invention.

[0029] The inner and outer slot surfaces and tooth profiles of the motor stator laminations directly determine the slot accuracy, tooth width consistency, and lamination alignment of the iron core, significantly impacting the fit between the laminations and windings and the magnetic circuit distribution. Furthermore, slot surface defects are easily identified quickly using conventional optical imaging. In contrast, while burrs or abnormal protrusions on the lamination surface are less likely to be noticed during routine inspection, their hazards are equally serious: during the iron core lamination process, tiny protrusions can puncture the insulating coating on adjacent lamination surfaces under high voltage, leading to inter-laminar short circuits, significantly increasing eddy current losses, and consequently causing increased iron losses, decreased efficiency, and even localized overheating. Long-term operation can also exacerbate insulation aging, ultimately reducing the reliability and lifespan of the motor.

[0030] Motor cores are typically composed of dozens to hundreds of silicon steel laminations stacked together. Comprehensive inspection of the stacked surfaces of each lamination is extremely difficult. Firstly, the sheer number of laminations and their extremely thin thickness mean that scanning both the upper and lower stacked surfaces one by one would severely slow down the production line. Secondly, the stacked surfaces are usually bare metal surfaces with strong reflective properties, easily producing specular glare during high-speed online imaging, thus obscuring the true morphology of burrs. To address these technical problems, this application makes the following improvements:

[0031] Reference Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the present invention provides a technical solution: a visual inspection device for surface defects of stator and rotor laminations after fine grinding, comprising: a conveying assembly 1, the conveying assembly 1 including a mounting plate 101, two sets of conveying tracks 102 symmetrically arranged inside the mounting plate 101, three sets of support structures arranged between the two sets of conveying tracks 102, a plurality of positioning grooves 103 opened on the surface of the conveying tracks 102, and the positioning grooves 103 correspond one-to-one with the motor stator and rotor laminations 6, a plurality of support tracks 104 are mounted above the conveying tracks 102, and the support tracks 104 are spaced apart from the motor stator and rotor laminations 6, the support tracks 104 are used to transport and inspect the motor stator and rotor laminations 6 in an upright state, the first set of conveying tracks 102 is used to transport the motor stator and rotor laminations 6 to be tested to the support structure for inspection, after the inspection is completed, the support structure transfers the motor stator and rotor laminations 6 above it to the second set of conveying tracks 102 and then conveys them to the stacking mechanism to complete subsequent processing;

[0032] Please see Figure 2 , Figure 5 , Figure 6 and Figure 7 As shown, the support structure includes a support roller 105, and the outer wall of the support roller 105 is provided with several annular grooves 106 at equal intervals. The top of the annular grooves 106 supports the motor stator and rotor laminations 6. The width of the annular grooves 106 corresponds to the thickness of the motor stator and rotor laminations 6. The inner wall of the annular grooves 106 is wrapped with anti-slip pads. The side of the support structure is provided with a support frame 2. The inside of the support frame 2 is equipped with a limiting component 3. The limiting component 3 includes a second motor 301 fixedly connected to the support frame 2. The output end of the second motor 301 is fixedly connected to a transmission rod 302. Several V-shaped structures are sleeved on the outside of the transmission rod 302, and the V-shaped structures correspond one-to-one with the motor stator and rotor laminations 6. Each set of V-shaped structures is used to clamp and fix the motor stator and rotor laminations 6 that are transported to the top of the support structure, so that they are kept in a stable upright state for testing.

[0033] Please see Figure 1As shown, a projection lamp 5 is provided above the motor stator and rotor laminations 6. The light emitted by the projection lamp 5 is parallel to the motor stator and rotor laminations 6, casting the shadow of the motor stator and rotor laminations 6 onto the V-shaped structure. Two sets of visual recognition components 4 are symmetrically arranged on the top of the support frame 2. The visual recognition components 4 include a drive structure and a visual detection sensor 401. The two sets of visual detection sensors 401 face the two sides of the V-shaped structure respectively.

[0034] Please see Figure 6 and Figure 7 As shown, the limiting component 3 also includes a guide rod 310 arranged parallel to the transmission rod 302. The guide rod 310 is fixedly connected to the support frame 2. The V-shaped structure includes a first clamping plate 303 and a second clamping plate 304 clamped on both sides of the motor stator and rotor laminations 6. A second guide cylinder 309 is fixedly connected to the end of the first clamping plate 303, and a first guide cylinder 308 is fixedly connected to the end of the second clamping plate 304. A first ball nut 305 is fixedly connected to the end of the first clamping plate 303 away from the second guide cylinder 309, and a second ball nut 306 is fixedly connected to the end of the second clamping plate 304 away from the first guide cylinder 308. A threaded groove 307 is provided on the outer wall of the transmission rod 302. The threaded groove 307 located inside the first ball nut 305 has an opposite spiral direction to the threaded groove 307 located inside the second ball nut 306.

[0035] Please see Figure 8 As shown, the drive structure includes a lead screw 403 and a slide rod 405 arranged in parallel. The slide rod 405 is fixedly connected to the support frame 2, and the lead screw 403 is rotatably connected to the support frame 2. A third motor 402 is installed at one end of the lead screw 403. A moving block 404 is sleeved on the outside of the lead screw 403. The moving block 404 is slidably connected to the slide rod 405, and the moving block 404 is fixedly connected to the vision detection sensor 401.

[0036] The drive mechanism is used to drive the visual inspection sensor 401 to perform linear motion. During the linear motion, the visual inspection sensor 401 will sequentially face each motor stator and rotor lamination 6, thereby identifying whether there are abnormal shadows on the first clamping plate 303 and the second clamping plate 304 on both sides to determine whether there are burrs or abnormal protrusions. When the visual inspection sensor 401 is facing other groups on both sides of the same group of motor stator and rotor laminations 6, the visual inspection sensor 401 can also capture the superimposed surface of the group of motor stator and rotor laminations 6, and compare and verify the projection data of the group of motor stator and rotor laminations 6 with the direct image data of the superimposed surface.

[0037] The dual detection method, combining projected shadows and direct imaging of the superimposed surface, significantly improves the reliability and robustness of burr identification. When the camera is directly facing the stator and rotor laminations 6 of the motor, the shadow imaging based on the first clamping plate 303 and the second clamping plate 304 is extremely sensitive to minute protrusions, amplifying the slight height changes of the burrs into projection signals, effectively overcoming the problem of insufficient contrast in direct imaging caused by reflections from the metal superimposed surface. When the camera is in other positions, the original image of the superimposed surface captured from the side provides real-time evidence of the surface morphology. The comparison and verification between the two methods can significantly reduce the risk of false alarms and missed alarms caused by a single detection method. This approach utilizes the high sensitivity of the projection method to protruding defects while retaining the intuitive confirmation of the overall surface condition through direct vision, thereby achieving higher detection accuracy and stronger anti-interference capabilities in high-speed motion detection.

[0038] The visual inspection sensor 401, moving in a linear motion, continuously scans multiple sets of upright motor stator and rotor laminations 6, achieving dynamic, continuous inspection. This eliminates the positioning, pausing, and triggering waiting time required for traditional piece-by-piece inspection, freeing the inspection cycle from being limited by the processing time of a single piece and significantly increasing the inspection throughput per unit time. Simultaneously, the visual inspection sensor 401 alternately faces and sides different sets of motor stator and rotor laminations 6 during its movement, enabling parallel acquisition of shadow projection and direct imaging data. This further reduces the additional time required for multi-angle information acquisition, making it suitable for high-volume, high-cycle online production scenarios.

[0039] Please see Figure 4 and Figure 5 As shown, both ends of the support roller 105 are provided with lifting rods 108. A first motor 107 is installed on the top of one set of lifting rods 108, and the output end of the first motor 107 is fixedly connected to the support roller 105. The lifting rods 108 are used to control the lifting and lowering of the support roller 105, and assist in the transfer of the motor stator and rotor laminations 6 from the three sets of support structures facing each other on the conveyor belt 102.

[0040] Working principle: After grinding, the motor stator and rotor laminations 6 to be tested are conveyed to the testing area along the positioning groove 103. At this time, each set of support rollers 105 is in a lowered state, and its height is slightly lower than the conveyor belt 102. When the motor stator and rotor laminations 6 move to the top of the support rollers 105 and are stuck in the annular groove 106 for limiting, the support rollers 105 rise up, and the two sets of support rollers on the side rise up slightly higher than the middle set, in a semi-enclosed state to support the motor stator and rotor laminations 6. Each set of motor stator and rotor laminations 6 is located between the first clamping plate 303 and the second clamping plate 304 of the V-shaped structure. At this time, the second motor 301 drives the transmission rod 302 to rotate, and the first ball nut 305 and the second ball nut 306 can drive the first clamping plate 303 and the second clamping plate 304 to move closer to each other, clamping and fixing the motor stator and rotor laminations 6 in the middle, so that the motor stator and rotor laminations 6 form a fan-shaped testing area between the V-shaped structures.

[0041] The projection lamp 5 shines light from directly above the motor stator and rotor laminations 6, and the light is parallel to the superimposed surface of the motor stator and rotor laminations 6. The shadow of the motor stator and rotor laminations 6 is cast directly downwards. If there are burrs or abnormal protrusions on the superimposed surface of the motor stator and rotor laminations 6, the shadow of the protrusion will appear on the first clamping plate 303 or the second clamping plate 304.

[0042] The output of the third motor 402 drives the lead screw 403 to rotate, which in turn drives the visual inspection sensor 401 to move in a straight line through the moving block 404. During the linear movement, the visual inspection sensor 401 will face each motor stator and rotor lamination 6 in turn. For the motor stator and rotor lamination 6 it faces, the visual inspection sensor 401 can identify whether there are abnormal shadows on the first clamping plate 303 and the second clamping plate 304 on both sides. At the same time, it can also capture the superimposed surface of the motor stator and rotor lamination 6 on the front and rear sides, and can directly identify whether there are burrs or abnormal protrusions on the superimposed surface. When the visual inspection sensor 401 continues to move forward and is facing the group of motor stator and rotor laminations 6, it can compare and verify the projection data of the group of motor stator and rotor laminations 6 and the direct captured data of the superimposed surface. The dual detection method is used to identify whether there are burrs or abnormal protrusions in the motor stator and rotor laminations 6.

[0043] Once the visual inspection sensor 401 completes one pass and the fan-shaped detection area of ​​the motor stator and rotor lamination 6 is identified, the second motor 301 drives the transmission rod 302 to rotate in the opposite direction, causing the first clamping plate 303 and the second clamping plate 304 to move away from each other and lose their clamping and fixing effect on the motor stator and rotor lamination 6. At this time, the first motor 107 drives the support roller 105 to rotate, adjusting the rotation of the motor stator and rotor lamination 6 so that its other positions are rotated to the fan-shaped test area to be tested. The included angle of the V-shaped structure is set to 130 degrees, and the entire motor stator and rotor lamination 6 is tested in three steps. It also has a certain degree of redundancy design to avoid missed detections.

[0044] The technical scope of this invention is not limited to the content described above. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the protection scope of this invention.

Claims

1. A visual inspection device for surface defects of stator and rotor laminations after fine grinding, characterized in that, The system includes a conveying assembly, which includes a mounting plate. Two sets of conveyor belts are symmetrically arranged inside the mounting plate. Three sets of support structures are arranged between the two sets of conveyor belts. Each support structure includes a support roller, and the outer wall of the support roller has several annular grooves at equal intervals. A motor stator and rotor lamination is supported at the top of each annular groove. A support frame is arranged on the side of the support structure. A limiting component is installed inside the support frame. The limiting component includes a second motor fixedly connected to the support frame. A transmission rod is fixedly connected to the output end of the second motor. Several V-shaped structures are sleeved on the outside of the transmission rod, and each V-shaped structure corresponds one-to-one with a motor stator and rotor lamination. Two sets of visual recognition components are symmetrically arranged at the top of the support frame. Each visual recognition component includes a drive structure and a visual detection sensor, with the two sets of visual detection sensors facing opposite sides of the V-shaped structures. A projection lamp is installed above the motor stator and rotor laminations. The light emitted by the projection lamp is parallel to the motor stator and rotor laminations, casting the shadows of the motor stator and rotor laminations onto the V-shaped structure.

2. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 1, characterized in that: The surface of the conveyor track is provided with several sets of positioning grooves, and the positioning grooves correspond one-to-one with the motor stator and rotor laminations. Several sets of support tracks are mounted above the conveyor track, and the support tracks are spaced apart from the motor stator and rotor laminations.

3. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 1, characterized in that: The width of the annular groove corresponds to the thickness of the motor stator and rotor laminations, and the inner wall of the annular groove is covered with an anti-slip pad.

4. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 1, characterized in that: Both ends of the support roller are provided with lifting rods, and a first motor is installed on the top of one set of lifting rods, and the output end of the first motor is fixedly connected to the support roller.

5. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 1, characterized in that: The limiting component also includes a guide rod arranged parallel to the transmission rod, and the guide rod is fixedly connected to the support frame.

6. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 1, characterized in that: The V-shaped structure includes a first clamping plate and a second clamping plate clamped on both sides of the stator and rotor laminations of the motor. The end of the first clamping plate is fixedly connected to a second guide cylinder, and the end of the second clamping plate is fixedly connected to a first guide cylinder.

7. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 6, characterized in that: A first ball nut is fixedly connected to the end of the first clamping plate away from the second guide cylinder, and a second ball nut is fixedly connected to the end of the second clamping plate away from the first guide cylinder.

8. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 1, characterized in that: The outer wall of the transmission rod is provided with a threaded groove, and the threaded groove located inside the first ball nut has the opposite spiral direction to the threaded groove located inside the second ball nut.

9. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 1, characterized in that: The drive structure includes a lead screw and a slide rod arranged in parallel. The slide rod is fixedly connected to the support frame, and the lead screw is rotatably connected to the support frame. A third motor is installed at one end of the lead screw.

10. The visual inspection device for surface defects after fine grinding of stator and rotor laminations according to claim 9, characterized in that: A movable block is sleeved on the outside of the lead screw. The movable block is slidably connected to the slide rod, and the movable block is fixedly connected to the vision inspection sensor.

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