Motor stator and rotor coaxial press-fitting and detection integrated assembly system and method

Abstract

The application discloses a motor stator-rotor coaxial press-fitting and detection integrated assembly system and method, and belongs to the technical field of motor assembly. The system comprises a rack, a rotating disc assembly, a press-fitting assembly, a floating centering assembly, a coaxiality detection assembly, a press-fitting force monitoring unit and a control unit. The press-fitting assembly cooperates with the floating centering assembly to realize adaptive coaxial press-fitting of the stator and the rotor. The press-fitting force monitoring unit collects press-fitting data in real time, realizes press-fitting defect identification and precision correction in combination with an AI algorithm and a temperature compensation algorithm, and the coaxiality detection assembly detects the precision after press-fitting. The feeding assembly and the discharging sorting assembly realize automatic operation. The application solves the problem of large coaxiality deviation of traditional rigid press-fitting through the floating centering assembly, guarantees press-fitting precision and stability through multi-dimensional working condition monitoring and intelligent compensation, and realizes high-precision and automatic assembly operation of the motor stator and rotor through integrated station design, which simplifies operation procedures and improves assembly efficiency.

Description

Technical Field

[0001] This invention relates to the field of motor assembly technology, specifically to an integrated assembly system and method for coaxial press fitting and testing of motor stator and rotor. Background Technology

[0002] The stator and rotor press-fitting assembly of an electric motor is a core process in motor manufacturing. The coaxiality accuracy of the stator and rotor directly determines the motor's operating noise, vibration, operating efficiency, and service life. If the coaxiality deviation between the stator and rotor is too large, a series of problems will occur during motor operation, such as rotor rubbing, uneven electromagnetic force, severe overheating, and increased energy consumption, seriously affecting the quality and reliability of the finished motor.

[0003] Currently, traditional motor stator and rotor assembly processes mostly adopt a split operation mode, where loading, pressing, inspection, and unloading are completed separately. This results in low equipment integration and a fragmented production process. Traditional pressing equipment often uses a rigid pressing structure, which cannot achieve self-alignment during the pressing process. Affected by factors such as tooling positioning errors, part machining tolerances, and assembly alignment deviations, stator and rotor coaxial misalignment is prone to occur, making it difficult to guarantee pressing coaxiality accuracy. At the same time, existing processes mostly rely on end-point sampling inspection to determine product quality, and cannot monitor key process parameters such as pressing force and pressing stroke in real time. This makes it easy for hidden quality defects such as under-pressurization, over-pressurization, and false pressurization to occur, resulting in poor product consistency and a high defect rate.

[0004] Furthermore, traditional production lines suffer from low automation and poor multi-station coordination. After pressing, coaxiality testing and sorting of good and defective products largely rely on manual labor. Manual inspection has significant errors and low sorting efficiency, making it unsuitable for the large-scale, high-precision, and automated production demands of motors. To address these shortcomings of existing technologies, there is an urgent need to design an integrated, high-precision, fully monitored, and automatically sorting stator and rotor pressing and testing assembly solution. Summary of the Invention

[0005] The purpose of this invention is to provide an integrated assembly system and method for coaxial press-fitting and testing of motor stator and rotor, in order to solve the problems of low coaxiality accuracy and low process separation efficiency of stator and rotor press-fitting mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0007] In a first aspect, the present invention provides an integrated assembly system for coaxial pressing and testing of motor stator and rotor, the system comprising a frame, a turntable assembly, a pressing assembly, a floating self-aligning assembly, a coaxiality detection assembly, a pressing force monitoring unit, and a control unit;

[0008] The turntable assembly is rotatably mounted on the frame. Multiple bearing stations are spaced apart along the circumference of the turntable assembly. Each bearing station is configured to simultaneously bear and position the stator assembly and rotor assembly of the motor.

[0009] The pressing assembly is fixedly mounted on the frame and located at the second preset station. The pressing assembly includes a pressing drive and a pressing head driven by the pressing drive. The pressing head is configured to apply a preset axial pressing force to the stator assembly and the rotor assembly.

[0010] The floating self-aligning assembly is disposed between the pressing head and the rotor assembly. The floating self-aligning assembly is configured to allow the rotor assembly to float radially relative to the stator assembly during the pressing process, so that the axes of the rotor assembly and the stator assembly are automatically aligned and coaxial.

[0011] The coaxiality detection component is fixedly mounted on the frame and located at the third preset station. The coaxiality detection component is configured to detect the coaxiality of the rotor assembly relative to the stator assembly after press-fitting.

[0012] The pressing force monitoring unit is electrically connected to the pressing assembly and is configured to collect the pressing force data of the pressing head in real time during the pressing process and determine whether the pressing is in place.

[0013] The control unit is electrically connected to the turntable assembly, the pressing assembly, the coaxiality detection assembly, and the pressing force monitoring unit, respectively, and is configured to control the coordinated operation of each component. The control unit is also provided with a manufacturing execution system communication interface.

[0014] Furthermore, each of the aforementioned bearing stations includes a stator positioning seat, a rotor positioning seat, and an elastic clamping member; the stator positioning seat is fixedly mounted on the turntable assembly and configured to radially position and axially limit the stator assembly; the rotor positioning seat is located inside the stator positioning seat and coaxially mounted with the stator positioning seat, and the rotor positioning seat has a positioning hole for the shaft end of the rotor assembly to be inserted; both the stator positioning seat and the rotor positioning seat adopt a detachable quick-change structure to adapt to stator and rotor assemblies of different specifications; the elastic clamping member is located inside the rotor positioning seat and configured to apply a radial clamping force to the rotor assembly after the rotor assembly is inserted; the elastic clamping member includes a plurality of elastic claws evenly distributed circumferentially, the inner wall of each elastic claw is provided with anti-slip texture, and the inner wall of the rotor positioning seat is provided with a conical surface that cooperates with each elastic claw; when the shaft end of the rotor assembly is inserted into the rotor positioning seat, each elastic claw retracts radially inward under the guidance of the conical surface to clamp the shaft end.

[0015] Furthermore, the floating self-aligning assembly includes a floating seat, a floating block, and an elastic reset member; the floating seat is fixedly connected to the pressing head; the floating block is movably disposed within the floating seat, a radial floating gap is provided between the floating block and the floating seat, and the lower end of the floating block is provided with a pushing surface for pushing against the rotor assembly; the elastic reset member is disposed between the floating seat and the floating block, configured to provide a radial reset force to the floating block; the floating block is configured to be able to move radially relative to the floating seat within the radial floating gap when the pushing surface is subjected to a non-uniform load. Preferably, the elastic reset member is a disc spring assembly or multiple evenly distributed helical springs to provide a uniform radial reset force with suitable stiffness.

[0016] Furthermore, the pressing assembly also includes a flexible buffer pad, which is disposed between the pressing head and the floating block. The upper end face of the flexible buffer pad is fixedly connected to the pressing head, and the lower end face of the flexible buffer pad abuts against the upper end face of the floating block. This buffer pad is used to buffer the impact force during the pressing process and transmit the pressing force to the floating block. The pressing head has a cooling channel inside, which extends to the connection between the pressing head and the flexible buffer pad. The flexible buffer pad is made of a high-temperature resistant, low-hysteresis loss composite elastomer material, and the flexible buffer pad has several axially penetrating honeycomb heat dissipation holes inside.

[0017] In traditional rigid press-fitting methods, the press-fitting head and rotor assembly are in rigid contact, which cannot compensate for radial position deviations caused by tooling positioning errors, part machining tolerances, and initial misalignment of the stator and rotor. In this situation, the axial force applied by the press-fitting drive is directly transmitted to the rotor assembly, forcibly pressing it into the stator assembly. This can easily lead to rotor shaft bending, bearing inner ring scratches, or damage to the stator winding insulation layer. Furthermore, the coaxiality of the stator and rotor after press-fitting depends entirely on the loading positioning accuracy, typically only reaching 0.1mm to 0.3mm, which is insufficient to meet the assembly requirements of high-performance motors. This invention incorporates a floating self-aligning assembly with a radial floating clearance between the press-fitting head and the rotor assembly. Its core principle is as follows: a small radial clearance is reserved between the floating block and the floating seat, allowing the floating block to move freely in a plane perpendicular to the press-fitting axis. During the initial press-fitting stage, as the press-fitting head descends and the pushing surface of the floating block contacts the upper end face of the rotor assembly, if there is an initial coaxiality deviation between the stator and rotor, the rotor assembly axis will shift relative to the press-fitting head axis, resulting in a non-uniformly distributed normal load on the contact surface between the floating block and the rotor assembly. The horizontal component of this load drives the floating block to adaptively slide within the radial floating gap until the axis of the rotor assembly is substantially coincident with the axis of the stator assembly (i.e., the rotor shaft end automatically aligns within the stator inner hole). The press-fitting force is vertically transmitted to the rotor assembly through the floating block, achieving coaxial press-fitting without deviation. After press-fitting is completed, the elastic reset component pushes the floating block back to its initial centered position, awaiting the next operation.

[0018] Furthermore, the coaxiality detection component includes a detection bracket and multiple displacement detection sensors; the detection bracket is fixedly mounted on the frame; the multiple displacement detection sensors are evenly arranged circumferentially on the detection bracket, with the probes of each displacement detection sensor facing the outer peripheral surface or end face of the rotor assembly; the control unit is configured to receive detection data from each displacement detection sensor, calculate the coaxiality deviation value of the rotor assembly relative to the stator assembly, and determine whether the coaxiality deviation value is within a preset threshold range. Preferably, the displacement detection sensor is a laser displacement sensor or a non-contact inductive micrometer.

[0019] Furthermore, the pressing force monitoring unit includes a force sensor, a displacement sensor, and a temperature sensor; the force sensor is disposed between the pressing head and the pressing drive component, configured to detect the axial pressing force output by the pressing head in real time; the displacement sensor is disposed on the pressing drive component, configured to detect the pressing stroke of the pressing head in real time; the temperature sensor adopts an embedded indirect temperature measurement structure, the end of the pressing head has an axial blind hole, a high thermal conductivity metal probe is tightly embedded in the axial blind hole, the flexible buffer pad has a thermally conductive blind hole corresponding to the position of the high thermal conductivity metal probe, the length of the thermally conductive blind hole is less than the length of the flexible buffer pad, and the tip of the high thermal conductivity metal probe extends into the thermally conductive blind hole. The control unit is configured to generate a pressing force-stroke curve based on the pressing stroke and the axial pressing force, and to analyze the pressing force-stroke curve using an AI adaptive judgment algorithm. The AI ​​adaptive judgment algorithm automatically identifies defect modes such as foreign object jamming, abnormal interference, or bearing misalignment by calculating the envelope area difference or root mean square error between the real-time curve and the preset standard curve. When the identified deviation value exceeds a preset threshold, a pressing abnormality is determined. The control unit is also configured with a temperature-deformation compensation algorithm. The control unit dynamically corrects the pressing termination position of the pressing drive component based on the real-time operating temperature collected by the temperature sensor to offset the stroke error caused by thermal deformation of the flexible buffer pad.

[0020] The pressing force monitoring unit of this invention collects the axial force F and pressing stroke S in real time during the pressing process, and the control unit generates a real-time pressing force-stroke (FS) curve. The control unit pre-stores a standard FS curve trained on a large amount of qualified product data and its allowable tolerance band. The core of the AI ​​adaptive judgment algorithm is to quantify the degree of deviation by calculating the difference in the envelope area between the real-time curve and the standard curve (i.e., the area enclosed by the two curves, or using the root mean square error RMSE), and automatically classifies defect patterns by combining the local morphological features of the curve. Specifically:

[0021] Foreign object jamming defect mode: When foreign objects such as metal shavings and sand particles fall into the stator-rotor gap during the pressing process, they will hinder the smooth pressing of the rotor. On the FS curve, this manifests as a sudden and abnormal increase in pressing force within a short stroke range, forming a sharp local protrusion. Because the duration of this protrusion is short and the force value changes drastically, the resulting difference in the envelope area is small (local contribution), but the first derivative (slope) of the curve will show abrupt changes. The AI ​​algorithm calculates the rate of change of the slope at each point on the curve. When it detects that the slope exceeds a preset threshold and the protrusion width is less than a preset stroke window, it determines it as a "foreign object jamming" defect.

[0022] Interference Anomaly Defect Mode: When the interference (the fit between the rotor's outer diameter and the stator's inner diameter) exceeds the design range, the resistance during the entire press-fitting process will be systematically too high or too low. On the FS curve, this manifests as the curve lying above (excessive interference) or below (insufficient interference) the entire stroke, with a similar overall shape but a general force value shift. At this time, the difference in the envelope area between the real-time curve and the standard curve increases significantly, and this difference is evenly distributed throughout the entire stroke range, not limited to a specific local interval. The AI ​​algorithm calculates the total envelope area difference, and when this difference exceeds a preset global threshold, it determines it as an "abnormal interference" defect. Furthermore, the direction of curve deviation (positive or negative deviation) can further distinguish whether the interference is too high or too low.

[0023] Bearing misalignment defect mode: When the rotor assembly enters the stator inner bore in an inclined posture at the beginning of press fitting, the press fitting force will exhibit an asymmetrical and gradually increasing characteristic. On the FS curve, this is manifested as the initial force value being close to normal, but from the middle section onwards, the force value gradually deviates from the standard curve, and the deviation increases rapidly with the increase of stroke, showing an "upward" trend in the curve. The AI ​​algorithm calculates the proportion of the difference in the envelope area between the latter half of the curve (e.g., the 75%~100% stroke range) and the standard curve to the total stroke difference. If this proportion exceeds a set threshold (e.g., >60%), it is judged as a "bearing misalignment" defect.

[0024] Furthermore, the system also includes a feeding assembly, which is fixedly mounted on the frame and located at the first preset station. The feeding assembly includes a stator feeding mechanism, a rotor feeding mechanism, and a vision positioning system. The stator feeding mechanism is configured to automatically feed the stator assembly to the bearing station. The rotor feeding mechanism is configured to automatically feed the rotor assembly to the bearing station. The vision positioning system is configured to perform pre-centering and angle recognition when gripping materials and send a position compensation signal to the control unit.

[0025] Furthermore, the system also includes a material unloading and sorting component, which is fixedly mounted on the frame and located at the fourth preset workstation. The material unloading and sorting component includes a material unloading robot and a sorting mechanism. The material unloading robot is configured to move the motor assembly that has completed pressing and testing out of the bearing workstation. The sorting mechanism is electrically connected to the control unit and is configured to transport good products and defective products to the good product collection area and the defective product collection area respectively according to the detection results of the coaxiality detection component.

[0026] Furthermore, the turntable assembly includes a turntable body, a turntable drive motor, and an indexing and positioning mechanism; the turntable body is rotatably mounted on the frame via a slewing bearing; the turntable drive motor is fixedly mounted on the frame and is drively connected to the turntable body; the indexing and positioning mechanism is located between the turntable body and the frame, and is configured to lock the turntable body when each of the bearing stations rotates to each preset station.

[0027] Secondly, the present invention provides an integrated assembly method for coaxial press-fitting and testing of motor stator and rotor, applied to the aforementioned integrated assembly system for coaxial press-fitting and testing of motor stator and rotor, comprising the following steps:

[0028] S1 Pre-positioning of material loading: The control unit controls the stator loading mechanism and rotor loading mechanism of the loading assembly to automatically load the stator assembly and rotor assembly onto the bearing station of the turntable assembly, respectively; during the loading process, the vision positioning system performs pre-centering and angle recognition of the material and sends the position compensation signal to the control unit; wherein, the stator assembly is positioned in the stator positioning seat, and the shaft end of the rotor assembly is inserted into the rotor positioning seat and clamped by the elastic clamping member;

[0029] S2 Floating Press Fitting: The control unit controls the turntable assembly to rotate at a preset angle, causing the bearing station carrying the stator assembly and the rotor assembly to rotate to the second preset station; the indexing and positioning mechanism locks the turntable body; the control unit starts the pressing assembly, the pressing drive drives the pressing head to move downward, and the pressing head applies a preset axial pressing force to the rotor assembly through the floating self-aligning assembly. The floating block of the floating self-aligning assembly moves radially adaptively within the radial floating gap, so that the axis of the rotor assembly and the stator assembly are automatically aligned and coaxial, and the rotor assembly is coaxially pressed into the stator assembly;

[0030] S3 Pressing Process Monitoring and Compensation: The pressing force monitoring unit collects data in real time during the pressing process: a force sensor detects the axial pressing force, a displacement sensor detects the pressing stroke, and a temperature sensor detects the real-time operating temperature near the flexible buffer pad through a high thermal conductivity metal probe; the control unit generates a pressing force-stroke curve based on the pressing stroke and axial pressing force, and uses an AI adaptive judgment algorithm to calculate the envelope area difference or root mean square error between the real-time curve and the preset standard curve; the control unit simultaneously executes a temperature-deformation compensation algorithm to dynamically correct the pressing termination position of the pressing drive component based on the real-time temperature collected by the temperature sensor, in order to offset the stroke error caused by thermal deformation of the flexible buffer pad; when the envelope area difference or root mean square error exceeds a preset threshold, a pressing abnormality is determined and an alarm signal is issued;

[0031] S4 Coaxiality Detection: The control unit controls the turntable assembly to continue rotating by a preset angle, so that the motor assembly that has completed the pressing rotates to the third preset position, and the indexing and positioning mechanism locks again; the control unit starts the coaxiality detection assembly, the displacement detection sensor detects the position of the outer peripheral surface or end face of the rotor assembly, calculates the coaxiality deviation value of the rotor assembly relative to the stator assembly, and determines whether the deviation value is within the preset threshold range.

[0032] S5 Unloading and Sorting: The control unit controls the unloading robot to move the inspected motor assembly out from the bearing workpiece; the sorting mechanism, based on the coaxiality test results and pressing monitoring results, transports good products and defective products to the good product collection area and the defective product collection area respectively.

[0033] S6 Data Upload: The control unit uploads the pressing force-stroke curve, coaxiality deviation data, temperature compensation records, and sorting results to the manufacturing execution system via the manufacturing execution system communication interface for quality traceability and equipment parameter optimization.

[0034] Beneficial effects

[0035] By adopting the above technical solution, the technical progress achieved by this invention compared to the prior art is as follows:

[0036] 1. The present invention is equipped with a floating self-aligning component, which can realize the rotor radial adaptive floating during the pressing process, automatically complete the coaxial alignment of the stator and rotor axes, solve the coaxiality error problem caused by rigid pressing, greatly improve the assembly accuracy of the motor stator and rotor, and reduce the probability of motor operating noise and vibration failure.

[0037] 2. This invention is equipped with a multi-dimensional press-fitting force monitoring unit, which integrates pressure, displacement and temperature synchronous detection functions. Combined with an AI adaptive judgment algorithm, it can accurately identify various press-fitting defects such as foreign object jamming, abnormal interference, and bearing misalignment. At the same time, it is equipped with a temperature-deformation compensation algorithm to effectively offset the press-fitting stroke error caused by the thermal deformation of the flexible buffer pad, ensuring the stability of press-fitting accuracy during long-term continuous operation.

[0038] 3. The bearing station of this invention adopts a stator positioning seat with quick mold change and elastic clamping structure, which can be adapted to the assembly of stator and rotor of motors of different specifications, and the equipment has strong versatility; the material feeding process integrates vision pre-positioning compensation, which reduces material clamping deviation from the source and further improves assembly accuracy.

[0039] 4. This invention adopts a rotary multi-station integrated structure, which integrates automatic feeding, adaptive coaxial pressing, full-process working condition monitoring, coaxiality accuracy detection, and intelligent sorting functions. It abandons the traditional split operation mode, realizes full-process automated operation of stator and rotor assembly, greatly shortens the process flow time, and significantly improves production efficiency.

[0040] 5. This invention sets up an independent coaxiality detection station and an intelligent sorting mechanism to realize automatic detection of accuracy after pressing and automatic classification of good and defective products, preventing defective products from flowing into the next process; at the same time, the control unit is equipped with an MES communication interface, which can realize the uploading, storage and traceability of production data throughout the process, which facilitates production quality control and iterative optimization of equipment parameters, and adapts to the needs of intelligent industrial production. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the overall structure of the assembly system of the present invention;

[0042] Figure 2 This is a schematic diagram of the turntable assembly.

[0043] Figure 3 This is a structural diagram of the workstation.

[0044] Figure 4 This is a structural schematic diagram of the press-fit assembly;

[0045] Figure 5 This is a schematic diagram of the structure of a floating self-aligning component;

[0046] Figure 6 This is a schematic diagram of the coaxiality detection component.

[0047] Figure 7 This is a flowchart of the assembly method of the present invention.

[0048] In the diagram: 1 - rack;

[0049] 2-Turntable assembly; 21-Stator positioning seat; 22-Rotor positioning seat; 221-Positioning hole; 222-Conical surface; 23-Elastic clamping element; 231-Elastic gripper; 24-Turntable body; 25-Turntable drive motor; 26-Indexing and positioning mechanism;

[0050] 3-Pressure fitting assembly; 31-Pressure fitting drive component; 32-Pressure fitting head; 321-Cooling channel; 322-Axial blind hole; 33-Flexible buffer pad; 331-Honeycomb heat dissipation hole; 332-Heat-conducting blind hole;

[0051] 4-Floating self-aligning component; 41-Floating seat; 42-Floating block; 421-Pushing surface; 43-Elastic reset component;

[0052] 5-Coaxiality detection assembly; 51-Detection bracket; 52-Displacement detection sensor;

[0053] 6-Pressure force monitoring unit; 61-Force sensor; 62-Displacement sensor; 63-Temperature sensor; 631-High thermal conductivity metal probe;

[0054] 7-Control unit;

[0055] 8-Feeding assembly; 81-Stator feeding mechanism; 82-Rotor feeding mechanism; 83-Vision positioning system;

[0056] 9-Unloading and sorting assembly; 91-Unloading robot; 92-Sorting mechanism;

[0057] 100 - Stator assembly; 200 - Rotor assembly. Detailed Implementation

[0058] The present invention will be further described in detail below with reference to embodiments:

[0059] Example 1

[0060] like Figures 1 to 6 As shown, this embodiment provides an integrated assembly system for coaxial pressing and testing of motor stator and rotor. The system includes a frame 1, a turntable assembly 2, a pressing assembly 3, a floating self-aligning assembly 4, a coaxiality detection assembly 5, a pressing force monitoring unit 6, a control unit 7, a feeding assembly 8, and a discharging and sorting assembly 9.

[0061] The frame 1 serves as the load-bearing base for the entire equipment. It is constructed from high-strength steel and welded together, resulting in high overall rigidity and low operating vibration, ensuring the long-term stable operation of all functional components. Multiple preset workstations are arranged in a ring on the frame 1, integrating automatic feeding, coaxial pressing, precision testing, and intelligent unloading functions to achieve automated precision assembly of the motor stator assembly 100 and the rotor assembly 200.

[0062] The turntable assembly 2 is rotatably mounted on the frame 1. The turntable assembly 2 includes a turntable body 24, a turntable drive motor 25, and an indexing and positioning mechanism 26. The turntable body 24 is rotatably mounted on the top of the frame 1 via a slewing bearing. The turntable body 24 has four sets of bearing stations evenly arranged circumferentially. The four sets of bearing stations correspond to the loading station, pressing station, inspection station, and unloading station, respectively. The four stations operate synchronously, effectively improving the overall production cycle of the equipment. The turntable drive motor 25 is fixed on the frame 1 and is connected to the turntable body 24 for transmission. In this embodiment, the turntable drive motor 25 is a servo motor, which can accurately control the rotation angle and start / stop cycle of the turntable body 24. The indexing and positioning mechanism 26 is located between the turntable body 24 and the frame 1. In this embodiment, the indexing and positioning mechanism 26 adopts a pneumatic precision pin positioning structure, which automatically locks and positions itself after the turntable body 24 rotates to the preset station, ensuring the positioning accuracy of each station.

[0063] Each bearing station includes a stator positioning seat 21, a rotor positioning seat 22, and an elastic clamping element 23. The stator positioning seat 21 is fixed to the surface of the turntable body 24. The stator positioning seat 21 can achieve radial full-enclosure positioning and axial limiting constraint of the stator assembly 100, preventing the stator assembly 100 from shifting or moving during the pressing process. The rotor positioning seat 22 is coaxially nested inside the stator positioning seat 21. The rotor positioning seat 22 has a positioning hole 221 in the center for inserting and limiting the shaft end of the rotor assembly 200 to achieve the initial positioning of the rotor assembly 200. Both the stator positioning seat 21 and the rotor positioning seat 22 adopt a detachable quick-change structure. In this embodiment, a pneumatic quick-change connector is used, which can be quickly replaced according to different models and specifications of stators and rotors. The elastic clamping element 23 is integrated inside the rotor positioning seat 22 and consists of multiple sets of elastic claws 231 evenly arranged in the circumferential direction. The inner wall of each elastic claw 231 is provided with an anti-slip texture structure. The inner wall of the rotor positioning seat 22 is machined with a conical surface 222 that matches the elastic claw 231. During the process of inserting the shaft end of the rotor assembly 200 into the positioning hole 221, the shaft end squeezes the elastic gripper 231, causing the elastic gripper 231 to contract radially inward along the conical surface 222, forming a uniform radial flexible clamping force on the rotor shaft end. This ensures that the rotor assembly 200 is stably positioned, avoids shaft end wear and damage caused by rigid clamping, and does not affect the subsequent radial adaptive fine adjustment action of the rotor.

[0064] The feeding assembly 8 is fixed at the first preset station of the frame 1, including the stator feeding mechanism 81, the rotor feeding mechanism 82 and the vision positioning system 83, which can realize the automated and precise feeding of the stator assembly 100 and the rotor assembly 200 respectively. During the feeding and gripping process, the vision positioning system 83 collects the workpiece posture and position information in real time, completes angle correction and pre-alignment, and transmits the position compensation signal to the control unit 7 to realize high-precision automatic feeding, reduce the load of the subsequent floating self-aligning assembly 4, and improve the assembly cycle.

[0065] The pressing assembly 3 is fixed at the second preset station of the frame 1, and includes a pressing drive 31, a pressing head 32, and a flexible buffer pad 33. In this embodiment, the pressing drive 31 is a servo press driven by a servo motor, which can accurately control the pressing stroke and pressing force. The pressing head 32 has a through-type cooling channel 321 inside, which extends to the lower end face of the pressing head 32 and can be connected to a circulating cooling medium to achieve continuous heat dissipation of the pressing head 32. The lower end of the pressing head 32 is equipped with a flexible buffer pad 33, which is made of a high-temperature resistant, low-hysteresis, and high-resilience composite elastomer. Several axially through honeycomb-shaped heat dissipation holes 331 are opened inside, which can quickly dissipate the frictional heat and extrusion heat generated by the pressing operation, greatly reduce the structural deformation caused by heat accumulation, and buffer the pressing impact force.

[0066] The floating self-aligning assembly 4 is installed between the press head 32 and the rotor assembly 200, and includes a floating seat 41, a floating block 42 and an elastic reset member 43. The floating seat 41 is fixedly connected to the lower end face of the pressing head 32. The floating block 42 is intermittently assembled inside the floating seat 41, with a small radial floating gap reserved between them. The lower end of the floating block 42 is provided with a flat pushing surface 421 for fitting and pressing against the upper end face of the rotor assembly 200. The elastic reset member 43 is evenly arranged between the floating seat 41 and the floating block 42 to provide radial reset constraint force for the floating block 42, ensuring that the floating block 42 is initially centered. In this embodiment, the elastic reset member 43 adopts a disc spring assembly. During the pressing process, if there is an initial coaxiality deviation between the stator assembly 100 and the rotor assembly 200, the pushing surface 421 is subjected to non-uniform load. The floating block 42 can adaptively offset radially within the radial floating gap, automatically correcting the axial position of the rotor assembly 200, and realizing automatic coaxial alignment of the stator and rotor. After the pressing is completed, the elastic reset member 43 drives the floating block 42 to reset and center, waiting for the next pressing operation.

[0067] The pressing force monitoring unit 6 includes a force sensor 61, a displacement sensor 62, and a temperature sensor 63. The force sensor 61 is installed between the pressing drive component 31 and the pressing head 32 to collect axial pressing force data in real time; the displacement sensor 62 is installed at the moving end of the pressing drive component 31 to detect the pressing stroke of the pressing head 32 in real time; the temperature sensor 63 adopts an embedded indirect temperature measurement structure. An axial blind hole 322 is opened at the lower end of the pressing head 32. A high thermal conductivity metal probe 631 is interference-fitted into the axial blind hole 322. A thermally conductive blind hole 332 is opened on the flexible buffer pad 33 corresponding to the probe position. The tip of the high thermal conductivity metal probe 631 extends into the thermally conductive blind hole 332 to collect the real-time temperature of the pressing operation area at close range and with high precision, avoiding the squeezing damage to the sensor caused by direct temperature measurement. The control unit 7 incorporates an AI adaptive judgment algorithm and a temperature-deformation compensation algorithm. During operation, it can automatically generate a real-time pressing force-stroke curve based on real-time collected pressing pressure and pressing stroke data. By calculating the difference in envelope area and root mean square error between the real-time curve and the preset standard curve, it accurately identifies pressing defects such as foreign object jamming, abnormal interference fit, and rotor skew. Simultaneously, the control unit 7 dynamically corrects the pressing termination position based on real-time temperature data, offsetting stroke errors caused by the thermal deformation of the flexible buffer pad 33, ensuring consistent accuracy in batch pressing operations.

[0068] The coaxiality detection assembly 5 is fixed at the third preset station of the frame 1, including a detection bracket 51 and four circumferentially evenly distributed displacement detection sensors 52. In this embodiment, the displacement detection sensors 52 are laser displacement sensors. The detection bracket 51 spans above the bearing station, and the probes of each displacement detection sensor 52 face the outer circumferential surface of the rotor assembly 200. After the workpiece is pressed and transferred to the detection station with the turntable body 24, multiple sets of displacement detection sensors 52 synchronously collect circumferential position data. The control unit 7 fits the relative position of the axis of the rotor assembly 200 and the axis of the stator assembly 100 through data calculation, accurately calculates the coaxiality deviation value, compares it with the preset accuracy threshold, and automatically determines whether the assembly is qualified.

[0069] The unloading and sorting assembly 9 is fixed at the fourth preset station of the frame 1, and includes an unloading robot 91 and a sorting mechanism 92. The unloading robot 91 is used to remove the inspected motor assembly from the bearing station. The sorting mechanism 92 receives the detection result signal from the control unit 7 and automatically transports good and defective products to the corresponding collection areas according to the pressing process monitoring results and coaxiality detection results, thereby realizing automated sorting and classification.

[0070] Control unit 7 employs a PLC programmable controller. As the core control component of the equipment, control unit 7 is electrically connected to all execution and detection components, enabling fully automated and collaborative control of the entire equipment process. Simultaneously, control unit 7 reserves a standardized manufacturing execution system communication interface, allowing real-time uploading of production data such as pressing curve data, coaxiality detection data, temperature compensation records, and sorting results for each product to the manufacturing execution system. This ensures full traceability of production data, facilitating process iteration optimization and quality control.

[0071] like Figure 7 This embodiment also provides an integrated assembly method for coaxial press-fitting and testing of motor stator and rotor. After the equipment is initially powered on, the control unit 7 completes the system self-test, loads the preset standard press-fitting force-stroke curve, coaxiality threshold, temperature compensation coefficient and parameters of each process station, and the equipment enters the standby production state, which specifically includes the following steps:

[0072] S1 Pre-positioning of loading: Control unit 7 drives the loading component 8 of the first preset station to move. Stator loading mechanism 81 and rotor loading mechanism 82 respectively grab the stator component 100 and rotor component 200 to be processed. During the loading and grabbing process, vision positioning system 83 collects the workpiece posture, angle and position information in real time, completes the workpiece pre-alignment and angle deviation identification, and generates a position compensation signal to feed back to control unit 7. Control unit 7 corrects the loading and placement coordinates according to the compensation signal and accurately places stator component 100 inside stator positioning seat 21 of bearing station. The stator positioning seat 21 realizes the radial positioning and axial limiting of stator component 100. At the same time, the shaft end of rotor component 200 is inserted into the positioning hole 221 of rotor positioning seat 22. During the insertion of rotor component 200, the elastic gripper 231 is squeezed. The elastic gripper 231 contracts radially along the conical surface 222, forming a uniform flexible clamping force on the shaft end of rotor component 200, and completing the workpiece clamping and positioning.

[0073] S2 Floating Press Fitting: Control unit 7 starts turntable assembly 2, turntable drive motor 25 drives turntable body 24 to rotate at a preset station angle, so that the carrying station of stator assembly 100 and rotor assembly 200 is accurately transferred to the pressing station. After the station is in place, indexing and positioning mechanism 26 is activated to mechanically lock and position turntable body 24, eliminating turntable gap deviation and station shaking, and providing a stable working benchmark for precision pressing.

[0074] Control unit 7 starts press assembly 3, press drive 31 drives press head 32 to descend at a constant speed, and applies a preset constant axial press force to rotor assembly 200 through floating self-aligning assembly 4. During the press operation, if there is an initial coaxiality deviation between stator assembly 100 and rotor assembly 200, floating block 42 bears non-uniform axial load and can achieve adaptive radial micro-movement offset within the radial floating gap between floating block 42 and floating seat 41, automatically correcting the axial center position of rotor assembly 200, so that the axial center of rotor assembly 200 and stator assembly 100 are completely coincident, realizing deviation-free coaxial press assembly; after press is in place, press drive 31 stops feeding and holds pressure for a short time to ensure tight interference fit between stator and rotor. After holding pressure, press head 32 moves upward to reset, and floating block 42 resets and centers under the action of elastic reset component 43, waiting for the next press operation.

[0075] S3 Pressing Process Monitoring and Compensation: The pressing force monitoring unit 6 continuously and synchronously collects operating parameters to achieve real-time monitoring and dynamic compensation of the pressing process. Specifically, force sensor 61 collects axial pressing force data in real time, displacement sensor 62 collects real-time pressing stroke data of the pressing head 32, and temperature sensor 63 collects real-time operating temperature of the pressing area through a high thermal conductivity metal probe 631. Based on the real-time collected pressing force and stroke data, control unit 7 dynamically generates a real-time pressing force-stroke curve and calls the built-in AI adaptive judgment algorithm. By calculating the difference in the envelope area or root mean square error between the real-time curve and the preset standard curve, it automatically identifies defects such as foreign object jamming, abnormal assembly interference, and rotor bearing misalignment during the operation. When the calculated deviation exceeds the system's preset threshold, it immediately determines a pressing abnormality and triggers an audible and visual alarm. Simultaneously, it records the abnormal data and locks the workstation to prevent defective products from flowing into the next process. Meanwhile, the control unit 7 runs a temperature-deformation compensation algorithm to dynamically correct the pressing termination position of the pressing drive component 31 based on the real-time collected operating temperature, and to offset the thermal deformation stroke error of the flexible buffer pad 33 caused by continuous operation temperature rise in real time, so as to ensure the consistency of pressing depth and assembly accuracy during mass production.

[0076] S4 Coaxiality Detection: Control unit 7 controls turntable assembly 2 to index and rotate, transferring the press-fitted motor assembly to the third preset detection station. Indexing and positioning mechanism 26 locks and positions again to ensure the accuracy of the detection station.

[0077] Multiple sets of circumferentially distributed displacement detection sensors 52 synchronously collect position data of the outer circumferential surface or end face of the rotor assembly 200. The control unit 7 performs fitting calculations on multiple sets of circumferential data to accurately calculate the coaxiality deviation value of the rotor assembly 200 relative to the stator assembly 100. The measured deviation value is compared with the preset accuracy threshold to automatically determine whether the coaxiality accuracy of the assembled workpiece is qualified, generate the corresponding detection judgment result, and record the detection data.

[0078] S5 Unloading and Sorting: The turntable assembly 2 continues indexing and rotating, transferring the inspected motor assemblies to the fourth preset unloading station. The control unit 7 controls the unloading robot 91 to precisely remove the inspected motor assemblies from the carrying station; the sorting mechanism 92 receives the pressing condition judgment result and coaxiality detection result output by the control unit 7, and according to the dual judgment results, transports good and defective workpieces to the corresponding good and defective collection areas respectively, realizing automated classification and storage, and completing the isolation and control of defective products.

[0079] S6 Data Upload: Control Unit 7 aggregates production data from the entire assembly process of a single motor, including real-time press-fit force-stroke curve data, coaxiality deviation detection data, real-time temperature acquisition data, temperature deformation compensation and correction records, press-fit defect judgment records, and workpiece sorting results. All production data is uploaded to the Manufacturing Execution System (MES) in real time via the MES communication interface, enabling full traceability and archiving of assembly data for each product. This provides data support for production quality analysis, process parameter iterative optimization, and equipment operation status monitoring, achieving intelligent closed-loop production control.

[0080] It should be noted that, in the description of this disclosure, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joint" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0081] The present invention has been described in detail above. However, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, any modifications or improvements that do not depart from the spirit of the present invention are within the scope of protection of the present invention.

Claims

1. An integrated assembly system for coaxial press fitting and testing of motor stator and rotor, characterized in that, The system includes: Rack (1); The turntable assembly (2) is rotatably mounted on the frame (1). The turntable assembly (2) has multiple bearing stations spaced apart along the circumference. Each bearing station is configured to bear and position the stator assembly (100) and rotor assembly (200) of the motor respectively. The pressing assembly (3) is fixedly mounted on the frame (1) and located at the second preset station. The pressing assembly (3) includes a pressing drive (31) and a pressing head (32) driven by the pressing drive (31). The pressing head (32) is configured to apply an axial pressing force to the stator assembly (100) and the rotor assembly (200). A floating self-aligning assembly (4) is disposed between the pressing head (32) and the rotor assembly (200). The floating self-aligning assembly (4) is configured to allow the rotor assembly (200) to move radially relative to the stator assembly (100) during the pressing process, so that the axes of the rotor assembly (200) and the stator assembly (100) are automatically aligned and coaxial. The coaxiality detection component (5) is fixedly installed on the frame (1) and located at the third preset station. The coaxiality detection component (5) is configured to detect the coaxiality of the rotor assembly (200) relative to the stator assembly (100) after press-fitting. The pressing force monitoring unit (6) is electrically connected to the pressing assembly (3) and is configured to collect the pressing force data of the pressing head (32) in real time during the pressing process; The control unit (7) is electrically connected to the turntable assembly (2), the pressing assembly (3), the coaxiality detection assembly (5) and the pressing force monitoring unit (6), respectively, and is configured to control the coordinated operation of each assembly. The control unit (7) is also provided with a manufacturing execution system communication interface.

2. The integrated assembly system for coaxial press fitting and testing of motor stator and rotor according to claim 1, characterized in that, Each of the aforementioned bearing stations includes a stator positioning seat (21), a rotor positioning seat (22), and an elastic clamping member (23); The stator positioning seat (21) is fixedly disposed on the turntable assembly (2) and configured to perform radial positioning and axial limiting on the stator assembly (100); The rotor positioning seat (22) is disposed inside the stator positioning seat (21) and coaxially disposed with the stator positioning seat (21). The rotor positioning seat (22) has a positioning hole (221) for the shaft end of the rotor assembly (200) to be inserted. The stator positioning seat (21) and the rotor positioning seat (22) both adopt a detachable quick-change structure to adapt to stator assemblies (100) and rotor assemblies (200) of different specifications. The elastic clamping member (23) is disposed in the rotor positioning seat (22) and configured to apply a radial clamping force to the rotor assembly (200) after the rotor assembly (200) is inserted. The elastic clamping member (23) includes a plurality of elastic claws (231) evenly distributed in the circumferential direction. The inner wall of each elastic claw (231) is provided with anti-slip texture. The inner wall of the rotor positioning seat (22) is provided with a conical surface (222) that cooperates with each elastic claw (231). When the shaft end of the rotor assembly (200) is inserted into the rotor positioning seat (22), each elastic claw (231) retracts radially inward under the guidance of the conical surface (222) to clamp the shaft end of the rotor assembly (200).

3. The integrated assembly system for coaxial press fitting and testing of motor stator and rotor according to claim 1, characterized in that, The floating self-aligning assembly (4) includes a floating seat (41), a floating block (42), and an elastic reset member (43). The floating seat (41) is fixedly connected to the pressing head (32); The floating block (42) is movably disposed within the floating seat (41), and a radial floating gap is provided between the floating block (42) and the floating seat (41). The lower end of the floating block (42) is provided with a pushing surface (421) for pushing against the rotor assembly (200). The floating block (42) is configured to be able to move radially relative to the floating seat (41) within the radial floating gap when the pushing surface (421) is subjected to a non-uniform load. The elastic reset member (43) is disposed between the floating seat (41) and the floating block (42) and is configured to provide a radial reset force to the floating block (42).

4. The integrated assembly system for coaxial press fitting and testing of motor stator and rotor according to claim 3, characterized in that, The pressing assembly (3) further includes a flexible buffer pad (33), which is disposed between the pressing head (32) and the floating block (42). The upper end face of the flexible buffer pad (33) is fixedly connected to the pressing head (32), and the lower end face abuts against the upper end face of the floating block (42). The pressing head (32) is provided with a cooling channel (321) inside, which extends to the connection between the pressing head (32) and the flexible buffer pad (33). The flexible buffer pad (33) is made of a composite elastomer material with high temperature resistance and low hysteresis loss, and the flexible buffer pad (33) is provided with a number of honeycomb heat dissipation holes (331) that run through the axial direction.

5. The integrated assembly system for coaxial press fitting and testing of motor stator and rotor according to claim 1, characterized in that, The coaxiality detection component (5) includes a detection bracket (51) and multiple displacement detection sensors (52). The detection bracket (51) is fixedly mounted on the frame (1); Multiple displacement detection sensors (52) are evenly arranged on the detection bracket (51) along the circumference, and the probes of each displacement detection sensor (52) face the outer peripheral surface of the rotor assembly (200) or the end face of the rotor assembly (200). The control unit (7) is configured to receive detection data from each of the displacement detection sensors (52), calculate the coaxiality deviation value of the rotor assembly (200) relative to the stator assembly (100), and determine whether the coaxiality deviation value is within a preset threshold range.

6. The integrated assembly system for coaxial press fitting and testing of motor stator and rotor according to claim 4, characterized in that, The press-fitting force monitoring unit (6) includes a force sensor (61), a displacement sensor (62), and a temperature sensor (63). The force sensor (61) is disposed between the pressing head (32) and the pressing drive (31) and is configured to detect the axial pressing force output by the pressing head (32) in real time. The displacement sensor (62) is disposed on the press-fitting drive component (31) and configured to detect the press-fitting stroke of the press-fitting head (32) in real time; The temperature sensor (63) adopts an embedded indirect temperature measurement structure. The end of the pressing head (32) is provided with an axial blind hole (322). A high thermal conductivity metal probe (631) is tightly embedded in the axial blind hole (322). The flexible buffer pad (33) is provided with a thermally conductive blind hole (332) corresponding to the position of the high thermal conductivity metal probe (631). The length of the thermally conductive blind hole (332) is less than the length of the flexible buffer pad (33). The top end of the high thermal conductivity metal probe (631) extends into the thermally conductive blind hole (332). The control unit (7) is configured to generate a pressing force-stroke curve based on the pressing stroke and the axial pressing force, and to analyze the pressing force-stroke curve using an AI adaptive judgment algorithm. The AI ​​adaptive judgment algorithm automatically identifies defect modes such as foreign object jamming, abnormal interference, or bearing misalignment by calculating the envelope area difference or root mean square error between the real-time curve and the preset standard curve. When the identified deviation value exceeds the preset threshold, it determines that the pressing is abnormal. The control unit (7) is also configured with a temperature-deformation compensation algorithm. The control unit (7) dynamically corrects the pressing termination position of the pressing drive (31) based on the real-time working temperature collected by the temperature sensor (63) to offset the stroke error caused by the thermal deformation of the flexible buffer pad (33).

7. The integrated assembly system for coaxial press fitting and testing of motor stator and rotor according to claim 1, characterized in that, The system also includes a feeding assembly (8), which is fixedly mounted on the frame (1) and located at the first preset station. The feeding assembly (8) includes a stator feeding mechanism (81), a rotor feeding mechanism (82), and a vision positioning system (83). The stator feeding mechanism (81) is configured to automatically feed the stator assembly (100) to the bearing station; The rotor loading mechanism (82) is configured to automatically load the rotor assembly (200) to the bearing station; The visual positioning system (83) is configured to perform pre-centering and angle recognition when grasping materials and send a position compensation signal to the control unit (7).

8. The integrated assembly system for coaxial press fitting and testing of motor stator and rotor according to claim 1, characterized in that, The system also includes a material unloading and sorting component (9), which is fixedly installed on the frame (1) and located at the fourth preset station. The material unloading and sorting component (9) includes a material unloading robot (91) and a sorting mechanism (92). The unloading robot (91) is configured to move the motor that has completed pressing and inspection from the bearing workpiece; The sorting mechanism (92) is electrically connected to the control unit (7) and is configured to transport good products and defective products to the good product collection area and the defective product collection area respectively according to the detection result of the coaxiality detection component (5).

9. The integrated assembly system for coaxial press fitting and testing of motor stator and rotor according to claim 1, characterized in that, The turntable assembly (2) includes a turntable body (24), a turntable drive motor (25), and an indexing and positioning mechanism (26). The turntable body (24) is rotatably mounted on the frame (1) via a slewing bearing; The turntable drive motor (25) is fixedly mounted on the frame (1) and is connected to the turntable body (24) in a transmission manner; The indexing and positioning mechanism (26) is located between the turntable body (24) and the frame (1) and is configured to lock the turntable body (24) when each of the bearing stations rotates to the preset station.

10. A method for integrating coaxial press-fitting and testing of motor stator and rotor, characterized in that, The integrated assembly system for coaxial press-fitting and testing of motor stator and rotor as described in any one of claims 1 to 9 includes the following steps: S1 Pre-positioning of loading: The control unit (7) controls the loading assembly (8) to automatically load the stator assembly (100) and rotor assembly (200) onto the bearing station of the turntable assembly (2); During the feeding process, the visual positioning system (83) pre-aligns and identifies the angle of the material and sends the position compensation signal to the control unit (7); the control unit (7) adjusts the placement coordinates of the feeding component (8) according to the position compensation signal to complete the pre-positioning; The stator assembly (100) is positioned on the stator positioning seat (21), and the shaft end of the rotor assembly (200) is inserted into the rotor positioning seat (22) and clamped by the elastic clamping member (23). S2 Floating Press Fitting: The control unit (7) controls the turntable assembly (2) to rotate at a preset angle, so that the bearing station carrying the stator assembly (100) and the rotor assembly (200) rotates to the second preset station; The control unit (7) starts the pressing assembly (3), the pressing head (32) moves downward, and the pressing head (32) applies a preset axial pressing force to the rotor assembly (200) through the floating self-aligning assembly (4). The floating block (42) of the floating self-aligning assembly (4) moves radially adaptively within the radial floating gap, so that the axis of the rotor assembly (200) and the stator assembly (100) are automatically aligned and coaxial, and the rotor assembly (200) is coaxially pressed into the stator assembly (100). S3 Pressing Process Monitoring and Compensation: Pressing Force Monitoring Unit (6) collects data in real time during the pressing process; The control unit (7) generates a pressing force-stroke curve based on the pressing stroke and axial pressing force, and uses an AI adaptive judgment algorithm to calculate the envelope area difference or root mean square error between the real-time curve and the preset standard curve. The control unit (7) simultaneously executes the temperature-deformation compensation algorithm to dynamically correct the pressing end position of the pressing drive (31) based on the real-time temperature collected by the temperature sensor (63) in order to offset the stroke error caused by the thermal deformation of the flexible buffer pad (33). When the difference in envelope area or root mean square error exceeds the preset threshold, the pressing is determined to be abnormal and an alarm signal is issued. S4 coaxiality detection: The control unit (7) controls the turntable assembly (2) to continue rotating at a preset angle, so that the motor assembly that has completed the pressing can rotate to the third preset position; The control unit (7) activates the coaxiality detection component (5), the displacement detection sensor (52) detects the position of the outer peripheral surface or end face of the rotor assembly (200), calculates the coaxiality deviation value of the rotor assembly (200) relative to the stator assembly (100), and determines whether the deviation value is within the preset threshold range. S5 Unloading and Sorting: The control unit (7) controls the unloading robot (91) to move the motor assembly that has completed the inspection out of the bearing workpiece; The sorting mechanism (92) transports good products and defective products to the good product collection area and the defective product collection area respectively based on the coaxiality test results and the pressing monitoring results; S6 data upload: The control unit (7) uploads the pressing force-stroke curve, coaxiality deviation data, temperature compensation record and sorting results to the manufacturing execution system through the manufacturing execution system communication interface for quality traceability and equipment parameter optimization.

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