Reactor disc core assembling device and assembling method thereof

Abstract

The application discloses an electric reactor large pie iron core assembling device and an assembling method thereof. The device comprises an equipment rack, an adjusting unit, a positioning unit, a detecting unit and a control unit. The adjusting unit is installed at the upper end of the equipment rack and is used for bearing the silicon steel sheet and driving the silicon steel sheet to rotate and tilt. The positioning unit is embedded in the adjusting unit and can tightly position the bakelite cylinder from the inside of the bakelite cylinder to stably fix the bakelite cylinder and visually position the center of the silicon steel sheet through the positioning unit. The detecting unit is installed on the outside of the adjusting unit and is used for monitoring the assembling posture of the silicon steel sheet in real time and calculating the perpendicularity deviation of the plane where the silicon steel sheet is located relative to the axis of the bakelite cylinder to ensure the consistency of the silicon steel sheet assembling. The adjusting unit, the positioning unit and the detecting unit are electrically connected with the control unit to improve the automation and the intelligence of the assembling process, reduce the labor intensity, and improve the assembling precision and the assembling quality.

Description

Technical Field

[0001] This application relates to the field of reactor manufacturing and processing technology, and more specifically, to a reactor core assembly device and assembly method. Background Technology

[0002] Reactors are core electrical equipment in power transmission and distribution systems. The disc-shaped iron core is a key magnetic component of dry-type reactors and special oil-immersed reactors. The disc-shaped iron core is assembled from multiple layers of silicon steel sheets. During the assembly process, the verticality of the silicon steel sheets and the coaxiality of the entire iron core directly determine the electromagnetic loss, insulation performance and operational stability of the reactor.

[0003] However, the current assembly of iron cores for large discs generally uses fixed iron square tables as platforms. During operation, the bakelite cylinders are fixed by simple buckles, which are prone to radial displacement, resulting in deviations in the coaxiality of the iron core. Operators need to repeatedly bend over and walk around the table to place materials and check the assembly effect, which makes the manual labor intensity high. Verticality detection relies entirely on manual visual comparison, resulting in low assembly accuracy and quality.

[0004] In conclusion, how to reduce labor intensity and improve assembly precision and quality is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] In view of this, the purpose of this application is to provide a reactor core assembly device and assembly method, which reduces labor intensity and improves assembly accuracy and quality.

[0006] To achieve the above objectives, this application provides the following technical solution:

[0007] A reactor core assembly device is provided for assembling a core consisting of stacked silicon steel sheets, each sheet being assembled using a bakelite cylinder as a reference. The device includes: a frame; an adjustment unit mounted on the upper end of the frame, used to support the silicon steel sheets and rotate and tilt them; a positioning unit embedded within the adjustment unit, used to support and position the bakelite cylinder from within, and capable of visually locating the center of the silicon steel sheets; a detection unit mounted on the outside of the adjustment unit, used to monitor the assembly posture of the silicon steel sheets in real time and calculate the perpendicularity deviation of the plane containing the silicon steel sheets relative to the axis of the bakelite cylinder; and a control unit, electrically connected to the adjustment unit, positioning unit, and detection unit.

[0008] In some embodiments, the adjustment unit includes a rotating component, a tilting component, and an assembly platform; the rotating component is installed inside the equipment frame, and the output end of the rotating component is connected to the tilting component for driving the tilting component and the assembly platform to rotate synchronously around a vertical axis; the output end of the tilting component is fixedly connected to the assembly platform for driving the assembly platform to tilt at multiple angles; the assembly platform is used to carry the silicon steel sheet and drive the carried silicon steel sheet to rotate and tilt together with it.

[0009] In some embodiments, the rotating assembly includes a rotating drive and a rotating platform; the rotating drive is fixedly mounted on the equipment frame, and the rotating platform is drivenly connected to the output end of the rotating drive and is used to support the tilting assembly.

[0010] In some embodiments, the tilting assembly includes a bidirectional electro-hydraulic cylinder and a tilting platform; the two ends of the bidirectional electro-hydraulic cylinder are rotatably connected between the tilting platform and the rotating platform, and there are at least two bidirectional electro-hydraulic cylinders, which are symmetrically or circumferentially distributed to drive the tilting platform to achieve multi-angle tilting through the differential extension and retraction of the at least two bidirectional electro-hydraulic cylinders.

[0011] In some embodiments, the bearing surface of the assembly platform is provided with an alloy coating, and the edges of the assembly platform are provided with protective guards.

[0012] In some embodiments, the assembly platform has a central mounting cavity for mounting the positioning unit; the positioning unit includes a visual positioning component and a locking component; the visual positioning component includes an infrared industrial camera to acquire the outline of the silicon steel sheet and fit the center coordinates of the silicon steel sheet; the locking component is coaxially arranged with the visual positioning component and is used to tighten and position the bakelite cylinder from the inside of the bakelite cylinder.

[0013] In some embodiments, the locking assembly includes a tensioning drive arm; there are at least three tensioning drive arms, which are evenly distributed circumferentially, and the tensioning drive arms are used to tension the inner wall of the bakelite cylinder from the inside to the outside along the radial direction of the bakelite cylinder, and the abutting end of the tensioning drive arm is covered with a cushioning rubber pad.

[0014] In some embodiments, the detection unit includes a mounting bracket, a vision camera, a light source supplementary lighting module, a data processing module, and an audible and visual alarm module. The mounting bracket is fixedly installed on the side of the assembly platform. The vision camera is adjustablely mounted on the mounting bracket, and its height and angle can be adjusted relative to the mounting bracket so that the lens of the vision camera faces the silicon steel sheet. The light source supplementary lighting module is a ring-shaped cold light source used to eliminate reflective interference from the silicon steel sheet. The data processing module is used to calculate the perpendicularity deviation of the plane containing the silicon steel sheet relative to the axis of the bakelite cylinder based on the edge pixel information of the silicon steel sheet collected by the vision camera. The audible and visual alarm module is used to issue a light and buzzer warning when the perpendicularity deviation exceeds a threshold.

[0015] In some embodiments, the control unit includes: a PLC controller electrically connected to the adjustment unit, the positioning unit, and the detection unit respectively; a touch screen electrically connected to the PLC controller for setting assembly parameters and displaying the assembly status in real time, wherein the assembly parameters include at least the tilt angle and rotation speed of the adjustment unit, and the verticality deviation threshold of the detection unit; a data storage module electrically connected to the PLC controller for storing detection data during the assembly process to achieve quality traceability; and a communication transmission module electrically connected to the PLC controller for data interaction to achieve intelligent production control.

[0016] A method for assembling a reactor core, characterized by employing the reactor core assembly device described above, comprising:

[0017] S100, the equipment is powered on and performs a self-test. The PLC controller checks the working status of the adjustment unit, positioning unit and detection unit one by one, calibrates the visual detection reference surface of the detection unit, and manually sets the verticality deviation threshold and the clamping pressure parameter of the positioning unit through the touch screen.

[0018] S200. Place the bakelite tube and silicon steel sheet on the assembly platform, so that the bakelite tube is fitted around the outer periphery of the positioning unit. Start the positioning program, and the vision positioning component scans the outline of the silicon steel sheet, automatically calibrates the center of the silicon steel sheet, and completes the centering and alignment.

[0019] S300. After positioning, the locking assembly drives the tensioning drive arm to open synchronously along the radial direction of the bakelite cylinder from the middle of the inner cavity of the bakelite cylinder, and flexibly tensions it from the inner wall of the bakelite cylinder with constant tensioning pressure, thus locking the bakelite cylinder in the center.

[0020] S400: Adjust the tilt angle of the assembly platform according to the number of stacked silicon steel sheets. Increase the tilt angle as the number of stacked layers increases. This is done in conjunction with manual stacking of silicon steel sheets layer by layer. At the same time, the rotating component drives the assembly platform to rotate as needed.

[0021] During the assembly process of S500, the vision camera continuously acquires the posture images of the silicon steel sheet, the data processing module calculates the perpendicularity deviation of the plane on which the silicon steel sheet is located relative to the axis of the bakelite cylinder in real time, and the detection data is stored in the data storage module.

[0022] S600 When the calculated verticality deviation exceeds the set threshold, the audible and visual alarm module issues an alarm signal and the operation interface is locked. The alarm is deactivated and assembly can continue after the silicon steel sheet position is manually corrected and the verticality deviation returns to the threshold range.

[0023] After all S700 and silicon steel sheets are stacked, the assembly platform automatically resets to a horizontal state, the locking components radially and synchronously retract and reset, the finished iron core is removed, the system automatically generates a production inspection report, and the single assembly operation is completed.

[0024] The reactor core assembly device provided in this application is used to assemble a core consisting of several stacked silicon steel sheets. Each silicon steel sheet is assembled using a bakelite cylinder as a reference. The device includes a frame, an adjustment unit, a positioning unit, a detection unit, and a control unit. The adjustment unit, installed at the top of the frame, supports the silicon steel sheets and rotates and tilts them. The positioning unit, embedded within the adjustment unit, provides internal support and positioning to the bakelite cylinder, ensuring stable installation and accuracy of the subsequent silicon steel sheet assembly. The positioning unit also visually positions the center of the silicon steel sheets to further ensure assembly accuracy. The detection unit, installed outside the adjustment unit, monitors the assembly posture of the silicon steel sheets in real time and calculates the perpendicularity deviation of the plane containing the silicon steel sheet relative to the bakelite cylinder axis, ensuring consistent assembly. The adjustment unit, positioning unit, and detection unit are all electrically connected to the control unit, improving automation and intelligence in the assembly process, reducing labor intensity, and enhancing assembly accuracy and quality. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of the reactor core assembly device provided in the embodiments of this application;

[0027] Figure 2 This is a schematic diagram of the structure of the adjustment unit provided in the embodiments of this application;

[0028] Figure 3 A top view of the positioning unit provided in an embodiment of this application;

[0029] Figure 4 A flowchart illustrating the assembly method of the reactor core for the application embodiment.

[0030] Explanation of reference numerals in the attached figures:

[0031] 100 - Equipment rack;

[0032] 200 - Adjustment unit, 210 - Rotating assembly, 220 - Tilting assembly, 230 - Assembly platform;

[0033] 300 - Positioning unit, 310 - Tensioning drive arm;

[0034] 400 - Detection Unit;

[0035] 500 - Control Unit. Detailed Implementation

[0036] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0037] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. The terminology used in the following embodiments is for the purpose of describing specific embodiments only and is not intended to be a limitation of this application. As used in the specification and appended claims of this application, the singular expressions "a," "an," "the," "the," "the," and "this" are intended to also include expressions such as "one or more," unless the context clearly indicates otherwise. It should also be understood that in the embodiments of this application, "one or more" refers to one, two, or more; "and / or" describes the relationship between related objects, indicating that three relationships may exist; for example, A and / or B can represent: A alone, A and B simultaneously, or B alone, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship.

[0038] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0039] The "multiple" mentioned in the embodiments of this application refers to two or more. It should be noted that in the description of the embodiments of this application, terms such as "first" and "second" are used only for the purpose of distinguishing descriptions and should not be construed as indicating or implying relative importance, nor should they be construed as indicating or implying order.

[0040] The terms "parallel" and "perpendicular" used in this application refer to "basically parallel" and "basically perpendicular" in practical operation. "Basically parallel" can be understood as parallelism with a certain degree of error, and similarly, "basically perpendicular" can be understood as perpendicularity with a certain degree of error.

[0041] like Figure 1 As shown in the embodiment of this application, the reactor core assembly device is used to assemble a core consisting of several stacked silicon steel sheets. Each silicon steel sheet is assembled using a bakelite cylinder as a reference. The device includes a frame 100, an adjustment unit 200, a positioning unit 300, a detection unit 400, and a control unit 500. The adjustment unit 200 is installed on the upper end of the frame 100 to support the silicon steel sheets and drive them to rotate and tilt. The positioning unit 300 is embedded within the adjustment unit 200 and can tighten and position the bakelite cylinder from within, thus stably fixing the bakelite cylinder. To ensure the assembly accuracy of subsequent silicon steel sheets, the positioning unit 300 visually positions the center of the silicon steel sheet to further ensure assembly accuracy. The detection unit 400 is installed outside the adjustment unit 200 and is used to monitor the assembly posture of the silicon steel sheet in real time. The detection unit 400 calculates the perpendicularity deviation of the plane where the silicon steel sheet is located relative to the axis of the bakelite cylinder to ensure the consistency of silicon steel sheet assembly. The adjustment unit 200, positioning unit 300, and detection unit 400 are all electrically connected to the control unit 500 to improve the automation and intelligence of the assembly process, reduce labor intensity, and improve assembly accuracy and quality.

[0042] like Figure 2 As shown, the adjustment unit 200 includes a rotating component 210, a tilting component 220, and an assembly platform 230.

[0043] The rotating component 210 is installed inside the equipment frame 100. The output end of the rotating component 210 is connected to the tilting component 220. When the rotating component 210 is working, its output end drives the tilting component 220 and the assembly platform 230 fixed above the tilting component 220 to rotate synchronously around the vertical axis. By driving the assembly platform 230 to rotate horizontally through the rotating component 210, the operator does not need to walk around the platform during the assembly process. He only needs to control the platform to rotate to the required position through the control unit 500 to complete the stacking operation of silicon steel sheets at various angles at a fixed workstation, which significantly reduces the physical exertion caused by back-and-forth walking and turning.

[0044] The tilting component 220 is positioned between the rotating component 210 and the assembly platform 230, with its output end fixedly connected to the assembly platform 230. It drives the assembly platform 230 to tilt at multiple angles. The tilting adjustment function of the tilting component 220 has a dual purpose: firstly, it can adaptively adjust the platform tilt angle according to the current stacking layer of silicon steel sheets. A smaller tilt angle is used for lower stacking layers, facilitating close-range precision operation by the operator. For higher stacking layers, the tilt angle is increased so that the upper assembly surface faces the operator, avoiding the need to tilt one's head or stand on tiptoe due to increased height. Secondly, it can provide personalized tilt angle adjustment based on the height differences of different operators, ensuring that the assembly viewing angle is always within an ergonomically comfortable range.

[0045] The assembly platform 230 is used to carry silicon steel sheets. The assembly platform 230 is fixedly connected to the output end of the tilting component 220, so that it can tilt together with the tilting component 220 and rotate together with the rotating component 210, thereby driving the silicon steel sheets it carries to complete the rotation and tilting actions synchronously.

[0046] In this application, the rotating assembly 210 includes a rotating drive and a rotating platform. The rotating drive is fixedly mounted on the equipment frame 100, and the rotating platform is connected to the output end of the rotating drive. When the rotating drive is working, its output end drives the rotating platform to rotate around the vertical axis. The rotating platform is used to support the tilting assembly 220 and transmits the rotational driving force to the tilting assembly 220 and the assembly platform 230 above, thereby realizing the horizontal rotational movement of the entire adjustment unit 200.

[0047] It should be noted that the rotary drive component can use a high-precision servo motor to control the rotation accuracy to ≤0.5°, thereby improving the assembly accuracy.

[0048] The tilting assembly 220 includes at least two bidirectional electro-hydraulic cylinders, positioned between the rotating platform and the tilting platform. One end of each bidirectional electro-hydraulic cylinder is rotatably connected to the rotating platform, and the other end is rotatably connected to the tilting platform. The at least two bidirectional electro-hydraulic cylinders are symmetrically or circumferentially distributed to ensure stable support for the tilting platform at any tilt angle. Multi-angle tilting is achieved by differentially extending and retracting the at least two bidirectional electro-hydraulic cylinders. Specifically, when the extension and retraction amounts of each bidirectional electro-hydraulic cylinder are the same, the tilting platform remains horizontal; when the extension and retraction amounts of each bidirectional electro-hydraulic cylinder are different, differential extension and retraction are formed, and the tilting platform tilts accordingly. Precise control of the tilting angle and tilting direction of the tilting platform can be achieved by precisely adjusting the extension and retraction amounts of each bidirectional electro-hydraulic cylinder through the control unit 500.

[0049] It should be noted that the angle adjustment range of the tilting component 220 is 0°~30°, in order to provide an assembly angle while ensuring the stability of the silicon steel sheet.

[0050] In this application, the bearing surface of the assembly platform 230 is provided with an alloy coating. The alloy coating has excellent anti-slip and wear-resistant properties, which can increase the friction between the bearing surface and the bottom silicon steel sheet, prevent the silicon steel sheet from accidentally slipping due to platform rotation or tilting during the assembly process, ensure the stability of the stacking position, and effectively resist the scratching and wear caused by repeated handling of silicon steel sheets on the platform surface.

[0051] Furthermore, the assembly platform 230 is equipped with protective guards along its edges, arranged in a ring or segmented pattern along the outer perimeter of the platform. When the platform is tilted, the protective guards act as a physical limiting structure, effectively preventing the silicon steel sheets from slipping off the platform edge. They can also serve as an auxiliary positioning reference for silicon steel sheets of different outer diameters. During initial placement, operators can quickly and roughly position the silicon steel sheets by aligning them with the guards, thus improving loading efficiency.

[0052] In this application, the assembly platform 230 has a mounting cavity at its center, so that the positioning unit 300 is embedded in the center of the assembly platform 230, ensuring that the axis of the positioning unit 300 coincides with the rotation axis of the assembly platform 230. This ensures that when silicon steel sheets are stacked using the bakelite cylinder supported by the positioning unit 300 as a reference, the iron core as a whole remains coaxial with the rotation axis, providing accurate reference conditions for subsequent rotational assembly.

[0053] The positioning unit 300 includes a vision positioning component and a locking component; the vision positioning component includes an infrared industrial camera, which is embedded in the mounting cavity with its lens facing upwards. When the bakelite cylinder and the silicon steel sheet are placed on the assembly platform 230, the vision positioning component is activated, the infrared industrial camera acquires an image of the inner hole contour of the silicon steel sheet, and uses a built-in contour recognition algorithm to fit the center coordinates of the silicon steel sheet, thereby automatically calibrating the center and completing the centering alignment.

[0054] The locking component and the vision positioning component are set coaxially. After the vision positioning component completes the calibration of the silicon steel sheet center, the locking component uses the calibration center as a reference to tighten and position the bakelite tube from the inside, ensuring that the axis of the tightened bakelite tube is precisely aligned with the center of the silicon steel sheet.

[0055] Specifically, the locking assembly includes at least three tensioning drive arms 310, which are evenly distributed circumferentially to ensure that the inner wall of the bakelite cylinder is subjected to balanced forces in all directions. This avoids eccentric displacement or local stress concentration of the bakelite cylinder caused by applying force at a single point or on one side, and ensures that the bakelite cylinder automatically centers during the tensioning process, maintaining coaxiality with the rotation axis of the assembly platform 230.

[0056] The contact end of the tensioning drive arm 310 is covered with a buffer pad. The buffer pad is made of elastic insulating material, which can absorb the impact force during the tensioning process, so that the tensioning drive arm 310 and the inner wall of the bakelite cylinder form a flexible contact to protect the inner wall of the bakelite cylinder. At the same time, the coefficient of friction of the buffer pad is higher than that of the metal surface, which increases the friction between the tensioning drive arm 310 and the inner wall of the bakelite cylinder and improves the locking reliability.

[0057] For example, there can be three, four, five, etc., of the tensioning drive arms 310 to ensure the tensioning and fixing effect on the bakelite cylinder. This application embodiment does not limit this.

[0058] like Figure 1 As shown, the detection unit 400 includes a mounting bracket, a vision camera, a light source supplement module, a data processing module, and an audible and visual alarm module.

[0059] The mounting bracket is fixedly installed on the side of the assembly platform 230, serving as the supporting foundation for the detection unit 400. The vision camera is adjustablely mounted on the mounting bracket, allowing for height and angle adjustments relative to the bracket to ensure the camera lens faces the silicon steel sheet, maintaining the optimal viewing position between the lens and the side of the silicon steel sheet being tested. The light source supplement module is a ring-shaped cold light source, installed at the front of the vision camera lens and coaxially arranged with the lens. This eliminates local overexposure or shadow interference caused by the high reflectivity of the silicon steel sheet's metal surface, ensuring a clear light-dark boundary line for the edge contour of the silicon steel sheet in the image. This provides a high-quality original image for subsequent edge pixel extraction and perpendicularity calculation. The data processing module calculates the perpendicularity deviation of the plane containing the silicon steel sheet relative to the axis of the bakelite cylinder based on the edge pixel information of the silicon steel sheet acquired by the vision camera. The audible and visual alarm module issues a light and buzzer warning when the perpendicularity deviation exceeds a threshold, ensuring that every silicon steel sheet with perpendicularity deviation is detected and corrected in a timely manner, preventing defective iron cores from flowing into subsequent processes and improving assembly quality.

[0060] In this application, the control unit 500 includes a PLC controller, a touch screen display, a data storage module, and a communication transmission module. The PLC controller is electrically connected to the adjustment unit 200, the positioning unit 300, and the detection unit 400, respectively. As the core control device of the control unit 500, it can receive assembly parameter setting instructions from the touch screen display, send rotation angle and tilt angle control signals to the adjustment unit 200 according to the preset program, send visual positioning start and tensioning pressure adjustment instructions to the positioning unit 300, and receive verticality deviation detection data returned by the detection unit 400.

[0061] The touchscreen display is electrically connected to the PLC controller, serving as a human-machine interface for setting assembly parameters and displaying the assembly status in real time. Assembly parameters include at least the tilt angle and rotation speed of the adjustment unit 200, and the perpendicularity deviation threshold of the detection unit 400. Before each assembly operation, the operator can input the corresponding tilt angle and rotation speed values ​​via the touchscreen display, based on the specifications, stacking layers, and process requirements of the current batch of core discs, and set the allowable tolerance range for perpendicularity deviation.

[0062] The data storage module is electrically connected to the PLC controller to retain inspection data during the assembly process, enabling quality traceability. During each assembly operation, the data storage module automatically records data such as the verticality deviation of each layer of silicon steel sheet, assembly time, operator information, and product batch number, forming a complete assembly inspection file for each product. When quality problems occur during subsequent operation, the assembly inspection data of that product can be retrieved by product number to trace the root cause of the problem.

[0063] The communication transmission module is electrically connected to the PLC controller for data exchange, enabling intelligent production control. The communication transmission module can also establish a data link with the workshop's MES (Manufacturing Execution System).

[0064] The reactor core assembly device provided in this embodiment solves the problem of operators having to repeatedly walk around the table and bend over to work on a traditional fixed workbench by setting up a rotatable and tiltable adjustment unit 200, thus reducing labor intensity and improving human-machine adaptability. By setting up a positioning unit 300 with integrated visual positioning and internal support locking functions, it solves the problem of core coaxiality deviation caused by unstable bakelite cylinder fixing, thus improving assembly accuracy. By setting up a detection unit 400 that can calculate verticality deviation in real time, it solves the problem of strong subjectivity and poor consistency of manual visual inspection, thus ensuring product quality. By setting up a control unit 500 that electrically connects each unit, it realizes automated control and data management of the assembly process, meeting the quality traceability requirements of intelligent manufacturing.

[0065] like Figure 4 As shown in the embodiments of this application, a method for assembling a reactor core disc is also provided. This method for assembling the reactor core disc uses the reactor core disc assembly device described in the above embodiments, and includes:

[0066] S100: The equipment is powered on and performs a self-test. The PLC controller checks the working status of the adjustment unit 200, positioning unit 300 and detection unit 400 one by one, calibrates the visual detection reference surface of the detection unit 400, and manually sets the verticality deviation threshold and the tensioning pressure parameter of the positioning unit 300 through the touch screen.

[0067] S200. Place the bakelite tube and silicon steel sheet on the assembly platform 230, so that the bakelite tube is fitted around the outer periphery of the positioning unit 300. Start the positioning program, and the vision positioning component scans the outline of the silicon steel sheet, automatically calibrates the center of the silicon steel sheet, and completes the centering and alignment.

[0068] S300. After positioning, the locking assembly drives the tensioning drive arm 310 to open synchronously along the radial direction of the bakelite cylinder from the middle of the inner cavity of the bakelite cylinder, and flexibly tensions it from the inner wall of the bakelite cylinder with constant tensioning pressure, thus locking the bakelite cylinder in the center.

[0069] S400. Adjust the tilt angle of the assembly platform 230 according to the number of stacked silicon steel sheets. The tilt angle increases with the number of stacked layers. This is done in conjunction with manual stacking of silicon steel sheets layer by layer. At the same time, the rotating component 210 drives the assembly platform 230 to rotate as needed.

[0070] Specifically, in the low-level stacking stage, the silicon steel sheets are stacked at a relatively low height, and the assembly platform 230 is tilted at a small angle of 5° to 15°, such as around 10°, so that the operator can clearly observe the stacking area at close range, which is convenient for precise operation. As the number of stacking layers gradually increases and the iron core height continues to rise, the tilt angle of the assembly platform 230 is increased accordingly to 20° to 30°, such as around 25° when stacking high layers, so that the upper assembly surface faces the operator, and the operator can smoothly complete the stacking of high-level silicon steel sheets without having to look up, stand on tiptoe or bend over excessively.

[0071] During the assembly process of S500, the vision camera continuously acquires the posture images of the silicon steel sheet, and the data processing module calculates the perpendicularity deviation of the plane where the silicon steel sheet is located relative to the axis of the bakelite cylinder in real time. The detection data is stored in the data storage module.

[0072] Throughout the assembly process, the detection unit 400 operates continuously. The vision camera continuously acquires attitude images of the side of the currently stacked silicon steel sheets at a fixed frame rate. A ring-shaped cold light source provides uniform illumination to the imaging area, ensuring clear imaging of the silicon steel sheet edge contours. The data processing module processes each frame in real time, obtaining the straight-line equation of the silicon steel sheet's side edge using an edge pixel extraction method. This equation is then compared with the axial direction of the bakelite cylinder to calculate the perpendicularity deviation of the plane containing the silicon steel sheet relative to the bakelite cylinder axis.

[0073] When the verticality deviation value is within the preset threshold range of S100, it indicates that the assembly posture of the current layer of silicon steel sheet is qualified. The detection data is silently stored in the data storage module without triggering an alarm, and the assembly operation proceeds normally. The data storage module synchronously records information such as the current layer number, deviation value, and detection time, forming a complete layer-by-layer detection data chain, providing a data foundation for subsequent quality traceability.

[0074] S600 When the calculated verticality deviation exceeds the set threshold, the audible and visual alarm module issues an alarm signal and the operation interface is locked. The alarm is deactivated and assembly can continue after the silicon steel sheet position is manually corrected and the verticality deviation returns to the threshold range.

[0075] After all S700 and silicon steel sheets are stacked, the assembly platform 230 automatically resets to a horizontal state, the locking assembly radially retracts and resets, the finished iron core is removed, the system automatically generates a production inspection report, and the single assembly operation is completed.

[0076] The system's data storage module automatically aggregates all inspection data from the current assembly operation, generating a production inspection report containing information such as product number, assembly time, operator, verticality deviation values ​​for each layer, and out-of-tolerance alarm records. This report can be uploaded to the workshop's MES production management system via the communication transmission module, incorporated into the product quality archive, and enabling permanent traceability of assembly quality.

[0077] The reactor core assembly method provided in this embodiment integrates three major functions—intelligent rotational adjustment, automatic centering and locking, and visual online inspection—into the entire assembly process. This involves a complete workflow encompassing equipment self-inspection and parameter setting, workpiece loading and center positioning, bakelite cylinder internal support and locking, platform posture adjustment and layer-by-layer stacking, online detection and data retention, out-of-tolerance alarm and manual correction, and assembly completion and resetting. This method effectively reduces the labor intensity of operators, improves assembly accuracy and product consistency, and achieves quality traceability in the assembly process. It is suitable for the mass production and high-quality assembly of reactor cores.

[0078] The above description of the embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A reactor core assembly device for assembling a core consisting of stacked silicon steel sheets, wherein the silicon steel sheets are assembled using a bakelite cylinder as a reference, characterized in that... include: Equipment rack (100); An adjustment unit (200) is installed on the upper end of the equipment frame (100). The adjustment unit (200) is used to support the silicon steel sheet and drive the silicon steel sheet to rotate and tilt. Positioning unit (300), which is embedded in the adjustment unit (200), is used to tighten and position the bakelite tube from the inside of the bakelite tube, and the positioning unit (300) can visually position the center of the silicon steel sheet. The detection unit (400) is installed on the outside of the adjustment unit (200). The detection unit (400) is used to monitor the assembly posture of the silicon steel sheet in real time and calculate the perpendicularity deviation of the plane where the silicon steel sheet is located relative to the axis of the bakelite cylinder. The control unit (500), the adjustment unit (200), the positioning unit (300), and the detection unit (400) are all electrically connected to the control unit (500).

2. The reactor core assembly device according to claim 1, characterized in that, The adjustment unit (200) includes a rotating component (210), a tilting component (220), and an assembly platform (230). The rotating component (210) is installed inside the equipment frame (100), and the output end of the rotating component (210) is connected to the tilting component (220) to drive the tilting component (220) and the assembly platform (230) to rotate synchronously around the vertical axis. The output end of the tilting component (220) is fixedly connected to the assembly platform (230) and is used to drive the assembly platform (230) to tilt at multiple angles. The assembly platform (230) is used to carry the silicon steel sheet and drive the silicon steel sheet carried to rotate and tilt together.

3. The reactor core assembly device according to claim 2, characterized in that, The rotating assembly (210) includes a rotating drive and a rotating platform; The rotary drive is fixedly installed on the equipment frame (100), and the rotary platform is connected to the output end of the rotary drive and is used to support the tilting component (220).

4. The reactor core assembly device according to claim 3, characterized in that, The tilting assembly (220) includes a bidirectional electro-hydraulic cylinder and a tilting platform; The two ends of the bidirectional electric hydraulic cylinder are rotatably connected between the tilting platform and the rotating platform. There are at least two bidirectional electric hydraulic cylinders, which are symmetrically or circumferentially distributed to drive the tilting platform to achieve multi-angle tilting through the differential extension and retraction of the at least two bidirectional electric hydraulic cylinders.

5. The reactor core assembly device according to claim 2, characterized in that, The assembly platform (230) has an alloy coating on its bearing surface and a protective guard is provided on the edge of the assembly platform (230).

6. The reactor core assembly device according to claim 2, characterized in that, The assembly platform (230) has an installation cavity at its center for installing the positioning unit (300). The positioning unit (300) includes a visual positioning component and a locking component; The visual positioning component includes an infrared industrial camera to acquire the outline of the silicon steel sheet and fit the center coordinates of the silicon steel sheet. The locking component is coaxially arranged with the visual positioning component, and the locking component is used to tighten and position the bakelite cylinder from the inside of the bakelite cylinder.

7. The reactor core assembly device according to claim 6, characterized in that, The locking assembly includes a tensioning drive arm (310). There are at least three tensioning drive arms (310), which are evenly distributed circumferentially. The tensioning drive arms (310) are used to tension the inner wall of the bakelite cylinder from the inside to the outside along the radial direction of the bakelite cylinder, and the abutting end of the tensioning drive arm (310) is covered with a cushioning rubber pad.

8. The reactor core assembly device according to claim 2, characterized in that, The detection unit (400) includes a mounting bracket, a vision camera, a light source supplement module, a data processing module, and an audible and visual alarm module; The mounting bracket is fixedly installed on the side of the assembly platform (230), and the vision camera is adjustablely mounted on the mounting bracket. The vision camera can be adjusted in height and angle relative to the mounting bracket so that the lens of the vision camera faces the silicon steel sheet. The light source supplement module is a ring-shaped cold light source, used to eliminate the reflective interference of the silicon steel sheet; The data processing module is used to calculate the perpendicularity deviation of the plane containing the silicon steel sheet relative to the axis of the bakelite cylinder based on the edge pixel information of the silicon steel sheet acquired by the vision camera. The sound and light alarm module is used to issue a light and buzzer warning when the verticality deviation exceeds the threshold.

9. The reactor core assembly device according to claim 1, characterized in that, The control unit (500) includes: The PLC controller is electrically connected to the adjustment unit (200), the positioning unit (300), and the detection unit (400), respectively; The touch screen is electrically connected to the PLC controller and is used to set assembly parameters and display the assembly status in real time. The assembly parameters include at least the tilt angle and rotation speed of the adjustment unit (200) and the verticality deviation threshold of the detection unit (400). The data storage module is electrically connected to the PLC controller and is used to retain the test data during the assembly process to achieve quality traceability. The communication transmission module is electrically connected to the PLC controller for data interaction and to achieve intelligent production control.

10. A method for assembling a reactor core, characterized in that, The reactor core assembly device according to any one of claims 1-9 includes: S100, the equipment is powered on and performs a self-test. The PLC controller checks the working status of the adjustment unit (200), positioning unit (300) and detection unit (400) one by one, calibrates the visual detection reference surface of the detection unit (400), and manually sets the verticality deviation threshold and the tensioning pressure parameter of the positioning unit (300) through the touch screen. S200. Place the bakelite tube and silicon steel sheet on the assembly platform (230), so that the bakelite tube is fitted around the outer periphery of the positioning unit (300), start the positioning program, the visual positioning component scans the outline of the silicon steel sheet, automatically marks the center of the silicon steel sheet, and completes the centering and alignment. S300. After positioning, the locking assembly drives the tensioning drive arm (310) to open synchronously along the radial direction of the bakelite cylinder from the middle of the inner cavity of the bakelite cylinder, and flexibly tensions the inner wall of the bakelite cylinder with constant tensioning pressure, locking the bakelite cylinder in the center. S400. Adjust the tilt angle of the assembly platform (230) according to the number of stacked silicon steel sheets. Increase the tilt angle as the number of stacked layers increases. Work with manual stacking of silicon steel sheets layer by layer. At the same time, the rotating component (210) drives the assembly platform (230) to rotate as needed. During the assembly process of S500, the vision camera continuously acquires the posture images of the silicon steel sheet, the data processing module calculates the perpendicularity deviation of the plane on which the silicon steel sheet is located relative to the axis of the bakelite cylinder in real time, and the detection data is stored in the data storage module. S600 When the calculated verticality deviation exceeds the set threshold, the audible and visual alarm module issues an alarm signal and the operation interface is locked. The alarm is deactivated and assembly can continue after the silicon steel sheet position is manually corrected and the verticality deviation returns to the threshold range. After all S700 and silicon steel sheets are stacked, the assembly platform (230) automatically resets to a horizontal state, the locking components radially and synchronously retract and reset, the finished iron core is removed, the system automatically generates a production inspection report, and the single assembly operation is completed.

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