An automatic bundling method for motor stator coils

Abstract

The application discloses an automatic bundling method for motor stator coils. The method comprises the following steps: firstly, fixing the motor stator and establishing a space reference system based on the positioning structure characteristics of the motor stator; secondly, performing a forming treatment on the end part of the bundling tape to form a guide head, and pre-positioning the guide head at the entrance of the coil gap; then, driving the bundling tape to enter the gap in a segmented variable-speed motion mode, which at least comprises a low-speed approach stage and a fast penetration stage, and synchronously adjusting the posture of the bundling tape during the penetration process, and the coordination between the penetration speed and the rotation angular velocity can be dynamically adjusted according to the real-time monitored penetration resistance; finally, after the bundling tape is penetrated, the bundling tape is pulled to the winding fixing position and the fixing is completed. Through the segmented variable-speed and coordinated dynamic adjustment, the problem that the bundling tape is prone to be stuck and has a low success rate when penetrating in the tiny gap is effectively solved, and the automatic bundling is high in efficiency, reliable and self-adaptive.

Description

Technical Field

[0001] This invention relates to the field of motor manufacturing technology, and more specifically, to an automatic bundling method for motor stator coils. Background Technology

[0002] The stator, as the core component of a motor, contains coils wound with insulated wires. To prevent the coils from loosening, deforming, or rubbing against each other under high-speed operation or electromagnetic forces, the stator coils need to be effectively bundled and secured. Sturdy bundling is crucial for ensuring the long-term reliability of the motor, reducing vibration and noise, and improving insulation performance.

[0003] Currently, the bundling of motor stator coils traditionally relies heavily on manual operation. Operators manually thread the cable ties through the narrow gaps between the coils in the stator core teeth, then wrap them tightly to secure them. This method is labor-intensive, inefficient, and the tightness and consistency of the bundling depend heavily on the worker's skill level, making it difficult to guarantee the uniformity of quality in batches. With the increasing automation in manufacturing, using automated equipment for stator coil bundling has become a clear trend.

[0004] However, achieving fully automated cable ties faces significant technical challenges. The core difficulty lies in how to reliably drive the flexible cable ties through the tiny, tortuous gaps between coils, which may contain burrs or dimensional fluctuations. Existing automation attempts often encounter the following problems: First, the cable tie end is prone to impacting the iron core due to alignment misalignment when approaching the gap entrance, leading to guidance failure or damage to the coil insulation; second, at the moment of insertion, the static friction generated between the cable tie head and the gap edge can easily cause jamming, preventing the cable tie from entering smoothly; third, during the insertion process, the cable tie may deflect, twist, or even jam due to irregular friction with the gap wall, resulting in low insertion success rate and poor stability; in addition, there is a lack of adaptive adjustment capability for different stator models or dimensional tolerances within the same model, resulting in poor equipment versatility.

[0005] Therefore, the industry urgently needs a method that can efficiently, reliably, and adaptively complete the automatic bundling of motor stator coils to solve the aforementioned technical problems of difficulty in threading with small gaps, easy jamming, unstable success rate, and insufficient adaptability. Summary of the Invention

[0006] To overcome the above-mentioned defects of the prior art, embodiments of the present invention provide an automatic bundling method for motor stator coils.

[0007] To achieve the above objectives, the innovative aspects of this invention are as follows: It includes the following steps: S1. Positioning and Reference Establishment: Fix the motor stator and, based on the positioning structure characteristics of the motor stator, identify and determine the spatial position and direction of its coil gap in order to establish a reference system for subsequent alignment operations. S2. Cable tie preparation and pre-alignment: A cable tie is provided, one end of which is shaped to form a guide head suitable for insertion into the coil gap, and the guide head is moved and pre-aligned at the entrance of the coil gap. S3, Segmented speed-changing insertion: Drive the cable tie to insert into the coil gap in a segmented speed-changing motion. The segmented speed-changing motion includes at least a low-speed approach stage and a fast insertion stage, and the insertion posture of the cable tie is adjusted synchronously during the insertion process. S4. Insertion, Positioning, and Fixing: After the cable tie passes through the coil gap, pull it to the winding fixing position and fix the cable tie to complete the binding of the stator coil.

[0008] Furthermore, in step S1, establishing a reference system based on the positioning structural features of the motor stator includes: Using the axial positioning surface and / or circumferential positioning mark of the motor stator as a reference, determine the orientation coordinates of the coil gap relative to the reference.

[0009] Furthermore, in step S2, the molding process includes: The end of the cable tie is pressed into a guide head with a cross-sectional dimension smaller than the width of the coil gap. The guide head is shaped as a pointed cone or a flat wedge with a guiding function.

[0010] Furthermore, in step S2, pre-alignment includes: Move the guide head to a first preset distance from the coil gap inlet; Adjust the angle and position of the cable tie so that the angular deviation between the central axis of the guide head and the extension direction of the coil gap is less than the preset angle threshold.

[0011] Furthermore, in step S3, the segmented speed-changing motion includes the following steps executed sequentially: Low-speed approach phase: Drive the end of the cable tie to approach the coil gap entrance at a constant speed with a first speed V1; Rapid insertion phase: When the end of the cable tie is detected to be in contact with the coil gap inlet, the speed is switched to a second speed V2, which is higher than the first speed V1, to drive the cable tie to accelerate into the coil gap. The ratio of the second speed V2 to the first speed V1 ranges from 5:1 to 50:1. This ratio range is selected based on the following technical principle: when the ratio is below 5:1, the kinetic energy provided by the second speed V2 is insufficient to effectively overcome the maximum static friction between the cable tie guide head and the edge of the coil gap entrance, resulting in the initial jamming problem still existing; while when the ratio is above 50:1, the second speed V2 is too fast, which will generate uncontrollable impacts on the cable tie itself and the coil insulation layer, easily leading to bending and deformation of the cable tie or damage to the coil surface. Therefore, the ratio range of 5:1 to 50:1 is the key range for balancing "resistance breaking capability" and "operational safety".

[0012] Furthermore, in step S3, the insertion posture is adjusted synchronously as follows: During the process of the cable tie being inserted into the gap of the coil, the cable tie is synchronously driven to rotate around its own central axis, and the angular velocity of the rotation is related to the insertion speed of the cable tie.

[0013] Furthermore, the rotational angular velocity is adjusted based on the resistance detected in real time during the penetration process; when the resistance increases, the rotational angular velocity is increased.

[0014] Furthermore, step S3 also includes a resistance feedback control step: The system monitors the force or current value driving the cable tie insertion in real time. Specifically, the system can be configured with a force sensor connected in series with the cable tie drive mechanism to directly measure the axial thrust; this method offers high accuracy and fast response. Alternatively, the current value of the driving servo motor can be sampled in real time, and the current value can be converted into force based on the motor torque constant. This method requires no additional sensors, has a simple structure, and high reliability. The specification discloses both methods side-by-side to provide those skilled in the art with alternative solutions suitable for different cost and application scenarios. Both are conventional and equivalent means in the art for obtaining axial load signals. Skilled personnel can uniquely select and implement the method based on the existing configuration of their equipment.

[0015] When the force or current value exceeds a preset safety threshold, the cable tie is controlled to perform at least one action, including a brief retraction or adjustment of the rotation angle, and then attempts to thread it through again.

[0016] Furthermore, in step S4, pulling the wire to the fixed winding position includes: After the cable tie passes through the coil gap, continue to move the preset passing distance along the passing direction; Subsequently, following the predetermined binding path, the traction cable moves around the stator coil at least once.

[0017] Furthermore, in step S3, a collaborative control strategy is implemented by adjusting the ratio K of the cable tie insertion speed V to the rotational angular velocity ω in real time, where K = V / ω, so that the ratio K is dynamically adjusted according to the resistance detected in real time during the insertion process.

[0018] The physical quantities and unit references for the K value are as follows: the insertion speed V is measured in millimeters per second (mm / s), and the rotational angular velocity ω is measured in radians per second (rad / s). Therefore, the dimension of the ratio K is millimeters per radian (mm / rad). This ratio K intuitively represents the distance the cable tie travels per radian of rotation, and can be understood as the "lead" parameter of the cable tie's "screwing" motion. A larger lead indicates that the cable tie tends to advance quickly and rotate slowly, resulting in high insertion efficiency but weak resistance resistance; a smaller lead indicates that the cable tie tends to advance slowly and rotate quickly, resulting in strong resistance resistance but lower insertion efficiency.

[0019] When the real-time resistance exceeds a first set threshold, the ratio K is reduced; when the real-time resistance is below a second set threshold, the ratio K is increased.

[0020] The first set threshold F high Second set threshold F low The determination method is as follows: after the cable tie guide head smoothly enters the gap and the penetration depth reaches a preset value (e.g., 5mm), the system recognizes that it has entered the initial stable penetration stage, and during this stage, the average penetration resistance F is collected and calculated in real time. avg As a benchmark, based on the principle of identifying abnormal changes in operating conditions in engineering practice, the first set threshold Fhigh is set to 1.2 to 1.5 times Favg to identify the precursors of jamming with a significant increase in resistance; the second set threshold F... low Set to 0.7 to 0.9 times F avg This is used to identify unloaded or detached states where resistance decreases abnormally. The setting of this multiple range is directly related to the physical characteristics of the cable tie insertion process: when the resistance exceeds the upper limit of the normal fluctuation range (i.e., 120%-150% of the normal average), the system has sufficient reason to judge it as a sign of abnormal friction; when the resistance is below the lower limit of the normal fluctuation range (i.e., 70%-90% of the normal average), the system can determine that there is redundancy space for speed optimization. If encountering long gaps with continuously changing materials or dimensions, the system can recalculate and update F every preset time period or preset distance. avg This allows for dynamic adaptation of the threshold.

[0021] The dynamic adjustment range and boundary conditions of the ratio K follow the following explicit control logic: the real-time resistance F is inversely proportional to the adjustment amount ΔK of the ratio K, i.e., ΔK = -C × (FF). avgWhere C is a preset positive constant representing the control gain, the value of which must ensure system stability and avoid oscillations. Meanwhile, the ratio K is limited to a preset safe range [K]. min K max [Inside. K] min To ensure the cable ties do not stop moving due to excessive rotation, K max Ensure the cable tie does not lose its drag-reducing advantage due to excessive forward speed. When the K value calculated using the above formula is lower than K... min When the system executes K min Simultaneously trigger an alarm or exception handling procedure; when the calculated K value is higher than K max When the system executes K max .

[0022] The technical effects and advantages of this invention are as follows: 1. Significantly Improved Success Rate and Efficiency of Cable Tie Insertion into Coil Gap: By employing a segmented, variable-speed insertion strategy that includes low-speed approach and rapid insertion phases, especially by driving the cable tie to accelerate insertion at a second speed significantly higher than the approach speed, this method can effectively overcome the maximum static friction between the cable tie end and the edge of the coil gap entrance using high-speed kinetic energy, fundamentally avoiding initial jamming. According to the kinetic energy formula E=½mv², when V2 is 5-50 times V1, the kinetic energy of the cable tie guide head at the moment of contact is increased by 25 to 2500 times at low speed. This transient high-energy input can reliably overcome the static friction barrier. Simultaneously, combined with an attitude adjustment mechanism that synchronously drives the cable tie to rotate around its axis during insertion, the motion mode is transformed from pure sliding to a "sliding-rotation" composite motion. Its equivalent friction coefficient is significantly lower than that of pure sliding friction, further reducing the dynamic friction resistance during insertion. Theoretical analysis shows that when the linear velocity of the rotational component is comparable to the axial velocity, the effective axial resistance can be reduced by more than 30%-50%. This combined technology directly solves the core problem of threading cable ties through narrow gaps, enabling the cable ties to pass through narrow and tortuous gaps quickly and smoothly. This significantly improves the success rate of single-pass threading, reduces downtime for adjustment due to jamming, and significantly improves overall work efficiency.

[0023] 2. Enhancing the Adaptability and Reliability of the Bundling Process: Based on resistance feedback control and collaborative control strategies, this method constructs a closed-loop control system. This system can monitor the insertion resistance in real time and dynamically adjust the ratio of the insertion speed to the rotational angular velocity of the cable tie. When the resistance increases, the system automatically reduces the ratio of insertion speed to rotational angular velocity (i.e., increases rotation and decreases forward speed); when the resistance decreases, it increases this ratio (i.e., decreases rotation and increases forward speed). This directional collaborative control mechanism essentially solves the optimization problem of "maintaining insertion motion with minimum energy consumption" in real time. It can adaptively compensate for microscopic changes in manufacturing tolerances and gap dimensions, and intelligently respond to abnormal working conditions such as irregular coil insulation layers, burrs, or uneven lubrication. Compared with strategies that only use speed variation without rotation, or only rotation without speed coordination, this method achieves the optimal balance between insertion force and insertion speed through bidirectional dynamic adjustment. This avoids the defect of a single speed variation strategy easily getting stuck when encountering local high friction, and solves the problem of low efficiency of a single rotation strategy in low-resistance sections. This adaptive intelligent control mechanism greatly enhances the method's ability to adapt to tolerance fluctuations in different batches of stators or within the same model, ensuring high reliability of the bundling process and consistency of results under diverse production conditions. Attached Figure Description

[0024] Figure 1 This is a flowchart illustrating the overall process of the automatic bundling method for motor stator coils according to the present invention.

[0025] Figure 2a To demonstrate the inherent structural features on the motor stator used for axial positioning.

[0026] Figure 2b To demonstrate the inherent structural features on the motor stator used for circumferential (angular) positioning.

[0027] Figure 3 for Figure 1 A schematic diagram of the speed-time curve for step S3 (segmented speed change entry).

[0028] Figure 4 for Figure 1 A schematic diagram of the collaborative control strategy in step S3.

[0029] The following numbers are labeled in the figure: motor stator 1, stator core 11, coil 12, main axial positioning surface 13, secondary axial positioning surface 14, axial positioning hole 15, uniform tooth groove 16, special marking tooth 17, 0° reference line 18. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Example 1: Basic Method Flow This embodiment details the complete process of the automatic bundling method for motor stator coils. Figure 1 The overall steps of the method are shown.

[0032] S1. Positioning and Reference Establishment First, the motor stator 1 is fixed onto a special fixture. The key to this step is to utilize the inherent mechanical characteristics of the motor stator 1 to establish a high-precision, repeatable spatial reference system, such as... Figure 2a and Figure 2b As shown.

[0033] Specifically, the system identifies the axial positioning characteristics of the motor stator 1 using visual sensors or contact probes. For example... Figure 2a As shown, the axial positioning feature includes a primary axial positioning surface 13 serving as the main reference, and at least two axial positioning holes 15. The primary axial positioning surface 13 is a precision-machined end face on the stator core 11, possessing high flatness to provide a stable axial reference. The axial positioning holes 15 are symmetrically distributed near this surface, used to engage with positioning pins on the fixture to achieve precise axial positioning and constraint. In a more preferred embodiment, the flatness of the primary axial positioning surface 13 can be machined to no more than 0.05 mm, and the positional tolerance of the axial positioning holes 15 can be controlled within ±0.02 mm, thereby ensuring extremely high repeatability of axial positioning in batch operations.

[0034] Simultaneously, the system identifies the circumferential positioning marks on motor stator 1. For example... Figure 2b As shown, the circumferential positioning mark can be a special marking tooth 17 with visual or physical identification characteristics, set in the uniform grooves 16 of the stator core 11. This special marking tooth 17 defines the 0° baseline 18 of the circumferential angle. For example, it can be made significantly different from other teeth in visual inspection by coating with matte black paint, laser marking, or using inserts of different materials. By identifying this special marking tooth 17, the system can uniquely and accurately determine the circumferential angular orientation of the motor stator 1.

[0035] Based on the identified main axial positioning surface 13, axial positioning hole 15, and circumferential special marking teeth 17, the control system establishes a fixed three-dimensional coordinate system within the computer, with the physical features of the motor stator 1 as the origin. This coordinate system precisely maps the spatial position coordinates of the gaps between each coil 12 to the direction of the central axis, providing a unified geometric reference for all subsequent alignment and insertion operations. The fixture is designed to strictly match these features, ensuring that the spatial relationship between the motor stator 1 and the actuator is completely consistent after each loading.

[0036] S2. Cable tie preparation and pre-alignment A cable tie is provided, and its front end is shaped to form a guide head with a cross-sectional dimension smaller than the width of the target coil gap to facilitate insertion.

[0037] The specific shape of the guide head can be optimized according to the geometric characteristics of the target coil gap. For smaller gaps with an approximately circular cross-section, a pointed conical guide head can be used. This guide head gradually narrows from the end of the cable tie to a sharp tip, with a cone angle α preferably between 20° and 40°, and a guide head length L1 preferably 1.5 to 3 times the width of the cable tie. The pointed conical design facilitates self-centering during initial contact and effectively cuts through burrs or minor interferences, reducing penetration resistance. For flat or slit-like narrow gaps, a flat wedge-shaped guide head can be used. This guide head gradually thins in the thickness direction and gradually narrows in the width direction, forming a wedge shape, with a wedge angle β preferably between 10° and 30°, a thickness T less than the original thickness of the cable tie, and a length... L2 Ideally, the cable tie width should be 1-2 times the width of the cable tie. The flat wedge design provides better lateral support during insertion, maintaining stability.

[0038] After forming, a drive mechanism (such as a robotic arm) grips the cable tie and moves the formed guide head to the front of the entrance to the target coil gap, for example, maintaining a first preset distance of 1-3 mm from the entrance. Subsequently, fine spatial orientation adjustment is performed: by rotating and / or translating the cable tie, the central axis of the guide head is precisely aligned with the extension direction of the coil gap calculated in step S1. This pre-alignment process requires the final angular deviation to be less than a preset angular threshold (e.g., 2°), thereby creating optimal initial conditions for the next insertion step.

[0039] S3, segmented speed change entry This step is the core of the invention, designed to drive the cable ties through narrow coil gaps in an efficient and reliable manner. Figure 3 The speed-time curves of the segmented variable speed control strategy used in this step are shown.

[0040] 1. Low-speed approach phase: The cable tie guide head moves at a low initial speed V1 (e.g., 5 mm / s) towards the coil gap entrance at a constant speed. Figure 3(Section A→B). This low speed ensures a smooth and controllable process from the pre-alignment position to the actual contact point, avoiding collisions or deviations due to inertia.

[0041] 2. Rapid insertion phase: When the contact sensor detects that the guide head has made contact with the gap inlet ( Figure 3 At point B, the control system immediately issues a command, driving the cable tie to accelerate to a significantly higher second speed V2 (e.g., 10 times V1, i.e., 50 mm / s) in a very short time, and then rapidly inserts it into the gap at that speed. Figure 3 (C→D section). The core purpose of this "instant acceleration" strategy is to use high-speed kinetic energy to overcome the maximum static friction between the guide head and the edge of the gap inlet, effectively preventing initial jamming.

[0042] 3. Synchronous Rotation and Attitude Adjustment: Throughout the entire insertion process, the system synchronously drives the cable tie to rotate around its own central axis. This rotational motion plays the following key roles: a) changing the frictional contact surface to avoid localized continuous wear or heat generation; b) utilizing the "tightening" effect of rotation to convert part of the axial forward resistance into circumferential rotational force, thereby reducing the effective insertion resistance. The angular velocity ω of this rotation can be correlated with the current insertion speed V.

[0043] 4. Penetration Resistance Feedback and Dynamic Adjustment: The system monitors the current of the drive motor or the value of the thrust sensor in real time, using it as a feedback signal for the penetration resistance F (corresponding to...). Figure 3 (The fluctuation in the D→E segment). When the resistance F exceeds the preset safety threshold, it indicates a risk of jamming. The system can immediately execute protective actions, such as instructing the cable tie to briefly retract a small distance, change the rotation direction or angle, and then re-attempt insertion. During normal insertion, the system can also adaptively fine-tune the insertion speed V based on minor fluctuations in resistance (e.g., Figure 3 As shown in the figure, this allows for a smoother insertion process.

[0044] 5. Exit deceleration and threading: When the sensor located on the gap exit side detects that the cable tie is about to thread out ( Figure 3 (Midpoint E), the control system decelerates the cable tie to a third speed V3 (e.g., 20 mm / s, between V1 and V2), allowing it to pass through the gap smoothly. Figure 3 (From F to G) to avoid impact on the coil or itself due to excessive speed. After the cable tie is fully extended, continue moving it a preset extension distance in the extension direction to ensure sufficient length for subsequent bundling and securing operations.

[0045] S4. Insertion, positioning, and fixation After the cable tie is successfully threaded through the gap in the coil, the final binding and securing stage begins.

[0046] A traction mechanism (such as a mechanical gripper or hook) captures the protruding end of the cable tie and first straightens it. Then, the mechanism pulls the cable tie around the coil bundle at least once in a predetermined three-dimensional spatial trajectory (such as a closed loop or figure-eight path) around the end of the motor stator coil, so that the main part of the cable tie fits tightly against and binds all the target coils 12.

[0047] Finally, secure the cable ties reliably to complete the bundling. The securing method can be selected based on the cable tie material and process requirements, including but not limited to: Adhesive fixing: Quick-drying adhesive is automatically applied to the overlapping parts of the cable ties.

[0048] Hot melt fixing: For cable ties made of thermoplastic materials such as nylon, use a hot air knife or heating block to heat the joint area to fuse and bond them together.

[0049] Mechanical fastening: The cable tie itself uses locking teeth and buckle structure to tighten and lock it.

[0050] After the fixing is completed, all actuators (grippers, drive wheels, etc.) are reset to their initial positions, and the securely bundled motor stator 1 can be removed from the fixture. The entire automatic bundling cycle is completed, and the machine is ready to work on the next workpiece.

[0051] Example 2: Optimized Implementation Based on Cooperative Control Strategy This embodiment, based on Embodiment 1, further focuses on and refines the advanced control logic in step S3, the core principle of which is as follows: Figure 4 The closed-loop control block diagram is shown below.

[0052] In this optimized embodiment, each stage of the segmented speed-changing entry is precisely defined by sensor signals: Time t1: Triggered by the contact sensor, marking the end of the low-speed approach phase.

[0053] Time t2: Determined based on the penetration depth sensor or preset timing logic, marking the start of the high-speed penetration phase.

[0054] Time t3: This is entirely determined dynamically by the resistance feedback control system, marking the beginning and changes of the adaptive adjustment phase.

[0055] t4: Triggered by the exit detection sensor, marking the start of the exit deceleration phase.

[0056] More importantly, it introduces a coordinated closed-loop control of velocity V and rotational angular velocity ω. The coordinated control strategy in this embodiment constructs a complete dynamic closed-loop feedback system, the technical architecture of which and its working principle are explained in detail below: 1. Sensing Layer: Real-time Resistance Detection Unit The system uses a high-precision thrust sensor or servo motor current detection module to collect and process the axial resistance F encountered during the cable tie insertion process in real time. This resistance signal accurately reflects the friction state between the cable tie and the inner wall of the coil gap, and is the core input for the control system to make intelligent decisions. Both of the above detection methods are conventional techniques in this field, and technicians can choose either one or a combination of both based on equipment cost and accuracy requirements.

[0057] 2. Decision-making level: Intelligent collaborative controller The collaborative controller receives the real-time resistance signal F and executes the following intelligent decision-making logic: Benchmark establishment: After the cable tie guide head successfully enters the gap and the insertion depth reaches a preset value (e.g., 5mm), the system recognizes that it has entered the initial stable insertion stage, and during this stage, the average insertion resistance F is collected and calculated in real time. avg As a benchmark.

[0058] Threshold setting: based on this benchmark F avg Preset first threshold F high 1.3 times F avg The second set threshold F low 0.8 times F avg .

[0059] Core control algorithm: Calculates in real-time the ratio K (mm / rad) of the current penetration velocity V (mm / s) to the rotational angular velocity ω (rad / s), and makes the following decisions based on the real-time drag F: When F>F high When resistance increases abnormally, posing a risk of jamming: the output command decreases the ratio K. Specifically, the adjustment is to decrease the current K value by one step ΔK. down The step size is the same as (FF). high It is proportional to the value of K, but the amount of reduction in a single instance shall not exceed 10% of the current value of K, in order to prevent over-adjustment.

[0060] When F <F low When (resistance is too low, there is room for optimization): the output command increases the ratio K. Specifically, the adjustment is to increase the current K value by a step size ΔK. up The step size is related to (F) low -F) is proportional, but the single increase does not exceed 10% of the current K value.

[0061] When F low ≤F≤F high At this time: the current motion parameters are maintained, and the system is in a stable penetration state.

[0062] The specific implementation strategy for adjusting the ratio K: When resistance increases (F>F) high): Prioritize significantly increasing the rotational angular velocity ω to enhance the "tightening" effect and overcome resistance; at the same time, the insertion speed V can be appropriately reduced to avoid forced entry that could cause the cable tie to deform or be damaged.

[0063] When the resistance decreases (F) <F low ): Prioritize reducing the rotational angular velocity ω to minimize unnecessary mechanical wear and energy consumption; at the same time, appropriately increase the penetration speed V to improve operational efficiency if resistance allows.

[0064] The execution of the ratio K is strictly limited to a preset safety range [K]. min ,K max [Within]. For example, let K be set. min Set to 0.1 mm / rad to prevent the cable tie from rotating without advancing; set K max The value is set at 10 mm / rad to prevent the cable ties from losing their drag-reducing effect due to insufficient rotation. When the calculated target K value exceeds this range, the corresponding boundary value is applied.

[0065] 3. Execution layer: High-precision motion control unit The speed and rotation control unit receives instructions from the coordination controller and precisely adjusts them separately through the dual servo motor drive system: Linear drive servo motor: controls the insertion speed V of the cable tie.

[0066] Rotary drive servo motor: controls the rotational angular velocity ω of the cable ties.

[0067] The two-axis motion can be precisely synchronized through electronic gear mode, ensuring the accurate execution of the ratio K and the coordination of the two-axis motion.

[0068] 4. Closed-loop feedback and dynamic optimization mechanism The adjusted motion parameters (V,ω) are applied during the insertion process, immediately changing the interaction state between the cable tie and the gap, thereby generating a new real-time resistance F'. This signal is then collected again by the resistance detection unit and fed back to the collaborative controller, forming a closed-loop control loop of "detection (sensing) - decision-execution - re-detection".

[0069] This continuous dynamic optimization enables the system to: Adaptive compensation for microscopic variations in manufacturing tolerances and clearance dimensions.

[0070] It can intelligently handle abnormal operating conditions such as irregular coil insulation, burrs, or uneven lubrication.

[0071] Maintain the optimal penetration state in real time to maximize penetration efficiency while ensuring reliability.

[0072] Comparative Example To clearly illustrate the necessity of the various technical features of the present invention and their synergistic effects, the following comparative examples are provided, with the same operating objects and working conditions as in Examples 1 and 2.

[0073] Comparative Example 1: A threading method using uniform speed and no rotation is adopted.

[0074] In step S3 of this method, the cable tie is driven through at a constant speed of 5 mm / s without any rotation around the axis. In repeated tests, it was observed that the cable tie guide head frequently jammed at the contact gap inlet, requiring multiple attempts or manual intervention to continue. Even when successfully inserted, encountering minor burrs or dimensional changes in the middle of the insertion point caused a sharp increase in resistance due to the lack of rotation to change the friction direction and reduce effective resistance, triggering overload protection and leading to insertion failure. This comparison demonstrates that while relying solely on low speed provides stability, it is completely insufficient to overcome the maximum static friction and dynamic localized high resistance; the success rate and cycle time of the strapping are far from meeting the requirements of automated production.

[0075] Comparative Example 2: A belt threading method that uses only segmented speed change but without rotational coordination.

[0076] This method employs the same segmented speed-changing strategy as Example 1 (approximately 5 mm / s for initial insertion, 50 mm / s for final insertion), but without driving the cable tie to rotate around the axis throughout the process. Results show that the initial jamming problem is significantly improved compared to Comparative Example 1, as the high-speed kinetic energy effectively overcomes the static friction at the inlet. However, in the middle section of the insertion process, when encountering areas with rough inner walls or residual adhesive that increase local friction, the cable tie cannot "twist" or "let go" of the resistance point through rotation, and jamming still occurs. The insertion process thus becomes unstable, and although the success rate is improved, it remains unsatisfactory.

[0077] Comparative Example 3: A threading method combining segmented speed variation and fixed rotation speed.

[0078] This method, based on Example 1, maintains the cable tie rotating at a fixed angular velocity (e.g., 2π rad / s). Its insertion effect is superior to the previous two comparative examples, indicating that rotation has a positive effect on continuous drag reduction. However, when encountering areas with significant drag changes, the fixed rotation speed cannot provide additional overcoming capability; the drag still spikes to near the safety threshold, causing the system to frequently trigger backtracking protection, thus lowering the average operating speed. In low-resistance sections, the fixed high rotation speed leads to energy waste and unnecessary mechanical wear. This demonstrates that without coordinated dynamic adjustment based on drag feedback, the system cannot achieve an optimal balance between efficiency and reliability.

[0079] By comparing with the above comparative examples, it can be clearly seen that the "segmented speed change" provided by the present invention is used to solve the initial jamming, "synchronous rotation" is used to reduce the continuous insertion resistance, and "V / ω collaborative dynamic adjustment based on resistance feedback" is used to adaptively maintain the optimal insertion state under changing working conditions. There is a functional progression and synergy among these three, which together constitute a complete technical solution to solve the problem of small gap tape insertion. Its overall technical effect is better than any simple combination of any single or double technology.

[0080] Summary of working principles The automatic strapping method described in this invention follows a logical framework of "precise positioning - pre-guidance - intelligent insertion - reliable fixation." First, by leveraging the high-precision machining features (planes, holes, marking teeth) on the motor stator, an absolute coordinate reference is established, fundamentally ensuring consistency in the reference for each operation. Second, targeted shaping and precise pre-alignment of the straps create favorable initial conditions for insertion. Then, through a segmented speed-changing strategy (especially high-speed breakthrough of static friction), synchronous rotation to reduce resistance, and dynamic adjustment based on real-time resistance feedback—particularly a three-pronged intelligent insertion technology that adjusts the ratio of insertion speed to rotational angular velocity according to the direction of resistance changes—the problem of inserting straps into small, tortuous gaps is effectively solved. Finally, through programmed wrapping and multiple fixing methods, a secure and consistent strapping is achieved. The entire system, through multi-sensor feedback and closed-loop control algorithms, achieves full automation, high success rate, and strong adaptability.

[0081] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change. Secondly: The accompanying drawings of the embodiments disclosed in this invention only involve the structures involved in the embodiments disclosed in this invention. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other. In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automatic bundling method for motor stator coils, characterized in that: Includes the following steps: S1. Positioning and Reference Establishment: Fix the motor stator, and based on the positioning structure characteristics of the motor stator, identify and determine the spatial position and direction of its coil gap in order to establish a reference system for subsequent alignment operations. S2. Cable tie preparation and pre-alignment: A cable tie is provided, one end of which is shaped to form a guide head suitable for insertion into the coil gap, and the guide head is moved and pre-aligned at the entrance of the coil gap. S3, Segmented speed-changing insertion: Drive the cable tie to insert into the coil gap in a segmented speed-changing motion. The segmented speed-changing motion includes at least a low-speed approach phase and a fast insertion phase, and the insertion posture of the cable tie is adjusted synchronously during the insertion process. S4. Insertion, Positioning, and Fixing: After the cable tie passes through the gap between the coils, it is pulled to the winding fixing position and fixed to complete the binding of the stator coil.

2. The automatic bundling method for motor stator coils according to claim 1, characterized in that: In step S1, establishing a reference system based on the positioning structural features of the motor stator includes: Using the axial positioning surface and / or circumferential positioning mark of the motor stator as a reference, the orientation coordinates of the coil gap relative to the reference are determined.

3. The automatic bundling method for motor stator coils according to claim 1, characterized in that: In step S2, the molding process includes: The end of the cable tie is pressed into a guide head with a cross-sectional dimension smaller than the width of the coil gap. The guide head is shaped as a pointed cone or a flat wedge with a guiding function.

4. The automatic bundling method for motor stator coils according to claim 3, characterized in that: In step S2, the pre-alignment includes: Move the guide head to a first preset distance from the coil gap inlet; Adjust the angle and position of the cable tie so that the angular deviation between the central axis of the guide head and the extension direction of the coil gap is less than a preset angle threshold.

5. The automatic bundling method for motor stator coils according to claim 1, characterized in that: In step S3, the segmented speed-changing motion includes the following steps executed sequentially: Low-speed approach phase: The end of the cable tie is driven at a first speed to approach the coil gap inlet at a uniform speed; Rapid insertion phase: When it is detected that the end of the cable tie is in contact with the inlet of the coil gap, the speed is switched to a second speed higher than the first speed, and the cable tie is driven to accelerate into the coil gap; The ratio of the second speed to the first speed ranges from 5:1 to 50:

1.

6. The automatic bundling method for motor stator coils according to claim 5, characterized in that: In step S3, the synchronous adjustment of the penetration posture is as follows: During the process of the cable tie being inserted into the gap of the coil, the cable tie is synchronously driven to rotate around its own central axis, and the angular velocity of the rotation is related to the insertion speed of the cable tie.

7. The automatic bundling method for motor stator coils according to claim 6, characterized in that: The angular velocity of rotation is adjusted according to the resistance detected in real time during the penetration process. When the resistance increases, the angular velocity of rotation is increased.

8. The automatic bundling method for motor stator coils according to claim 1, characterized in that: The S3 step also includes a penetration resistance feedback control step: Real-time monitoring of the force or current value driving the cable tie to insert; When the force or current value exceeds a preset safety threshold, the cable tie is controlled to perform at least one action, including a brief retraction or adjustment of the rotation angle, and then attempts to thread it through again.

9. The automatic bundling method for motor stator coils according to claim 1, characterized in that: In step S4, the pulling to the winding fixing position includes: After the cable tie passes through the gap in the coil, it continues to move a preset distance along the passing direction; Subsequently, following the predetermined binding path, the cable tie is pulled to move around the stator coil at least once.

10. The automatic bundling method for motor stator coils according to claim 1, characterized in that: In step S3, a collaborative control strategy is implemented by adjusting the ratio K of the insertion speed V of the cable tie to the rotational angular velocity ω in real time, where K = V / ω, so that the ratio K is dynamically adjusted according to the resistance detected in real time during the insertion process. Specifically, when the real-time resistance exceeds a first set threshold, the ratio K is decreased; when the real-time resistance is below a second set threshold, the ratio K is increased.

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