A welding device for a generator rotor fan blade

Abstract

The application discloses a generator rotor fan blade welding device which is used for spot welding front fans and rear fans with a rotor, and comprises a lower spot welding die assembly and an upper spot welding die assembly. The lower spot welding die assembly is installed on a lower electrode base plate of a spot welding machine, and the upper spot welding die assembly is installed on an upper electrode base plate of the spot welding machine. The lower spot welding die assembly comprises a lower spot welding die base, a lower spot welding die electrode fixedly installed on the top of the lower spot welding die base, a lower rotor positioning core used for positioning the rotor, and a front fan positioning core and a magnet assembly used for positioning the front fan. The application realizes the change from manual placement of fan blades and the rotor to automatic placement of the machine, effectively reduces the labor intensity of operators, significantly reduces the labor cost, and improves the production efficiency since the automatic equipment can continuously operate without being limited by the physical strength of the operators.

Description

Technical Field

[0001] This invention belongs to the field of automated welding equipment technology, and specifically relates to a generator rotor blade welding device. Background Technology

[0002] The rotor assembly is an important component of an automotive alternator, consisting of front and rear claw poles, slip rings, shaft, magnetic field coil assembly, fan blades, retaining rings, etc. With the increasing labor costs in the manufacturing industry and the rapid development of automation technology, replacing manual labor with machines has become a clear trend.

[0003] In the existing technology, the process of welding rotor fan blades usually needs to be completed manually. The specific operation process is as follows: First, the operator manually removes the lower fan blade and places it on the lower spot welding fixture; then, the upper fan blade is put on the rotor and the upper spot welding mold is placed on it; next, the rotor with the upper fan blade and upper spot welding mold placed on it is placed on the lower spot welding mold with the lower fan blade placed on it; finally, the medium frequency welding machine is started to perform welding.

[0004] The existing operating procedure described above has the following technical problems:

[0005] First, manually placing the fan blades and rotor carries the risk of misalignment and collisions, which can affect product quality. Since manual operation makes it difficult to ensure that the position and angle of placement are completely consistent every time, it can easily lead to deviations in the relative position between the fan blades and the rotor, which in turn affects the welding quality or even causes the product to be scrapped.

[0006] Secondly, the rotor is relatively heavy, and continuous operation is labor-intensive, making it suitable only for male operators. Operators are prone to fatigue. As the core component of the generator, the rotor assembly usually weighs from several kilograms to more than ten kilograms. Long-term manual handling and operation will bring serious physical burden to the operators, affecting work efficiency and operational safety.

[0007] Third, manual welding suffers from poor consistency and is prone to errors, posing quality and safety risks. Due to differences in skill levels, operating habits, and physical conditions among different operators, it is difficult to guarantee consistent welding quality. In addition, errors such as missing steps or incorrect welding parameter settings may occur during manual operation, posing potential risks to product quality and equipment safety.

[0008] In view of this, there is an urgent need to design a generator rotor blade welding device to improve the above problems. Summary of the Invention

[0009] In view of the shortcomings of the prior art, the purpose of this invention is to provide a generator rotor blade welding device, which aims to solve the problems of high labor intensity and poor welding consistency caused by the manual operation of generator rotor blades in the prior art.

[0010] To solve the above-mentioned technical problems, the present invention provides a generator rotor blade welding device for spot welding the front fan and the rear fan to the rotor. The welding device includes a lower spot welding mold assembly and an upper spot welding mold assembly. The lower spot welding mold assembly is installed on the lower electrode base plate of the spot welding machine, and the upper spot welding mold assembly is installed on the upper electrode base plate of the spot welding machine.

[0011] The lower spot welding mold assembly includes a lower spot welding mold base, a lower spot welding mold spot welding electrode fixedly installed on the top of the lower spot welding mold base, a lower rotor positioning core for positioning the rotor, and a front fan positioning core and magnet assembly for positioning the front fan.

[0012] The upper spot welding mold assembly includes an upper spot welding mold base, an upper spot welding mold spot welding electrode fixedly installed at the bottom of the upper spot welding mold base, an upper rotor positioning core for cooperating with the positioning rotor, a rear fan positioning core for positioning the rear fan, and a second magnet.

[0013] The upper spot welding mold assembly can move up and down relative to the lower spot welding mold assembly to drive the rear fan to move downward and contact the rotor;

[0014] It also includes robotic arms for automatically placing the front fan on the lower spot welding mold assembly, for automatically placing the rear fan on the upper spot welding mold assembly, and for automatically placing the rotor on the lower spot welding mold assembly.

[0015] Preferably, the lower spot welding mold base is provided with a first mounting hole, and the lower rotor positioning core is slidably installed in the first mounting hole of the lower spot welding mold base;

[0016] The spot welding electrode of the lower spot welding mold is sleeved on the outside of the lower rotor positioning core;

[0017] The front fan positioning core is fixedly connected to the top of the lower rotor positioning core.

[0018] Preferably, the lower rotor positioning core has an axially oriented lower rotor positioning core hole at its center, and the front fan positioning core has an axially oriented front fan positioning core hole at its center that communicates with the lower rotor positioning core hole.

[0019] The front fan positioning core has a front fan positioning groove circumferentially formed on the outer side of its top end.

[0020] Preferably, the bottom end of the lower rotor positioning core hole of the lower rotor positioning core is provided with a first spring limiting step groove, and a second spring is provided in the lower spring limiting step groove. One end of the second spring abuts against the inner wall of the lower spring limiting step groove, and the other end abuts against the lower electrode base plate of the spot welding machine.

[0021] Preferably, the magnet assembly includes a magnet mounting post, a first magnet is embedded at the top of the magnet mounting post, a second mounting hole is provided on the lower spot welding mold base outside the first mounting hole, the magnet mounting post is slidably mounted in the second mounting hole, and a first spring is provided at the bottom of the magnet mounting post.

[0022] Preferably, the bottom end of the magnet mounting post is provided with a protruding limiting part, the bottom end of the second mounting hole is provided with a magnet mounting post limiting groove, the protruding limiting part of the magnet mounting post is placed in the magnet mounting post limiting groove, a retaining cover is fixedly connected to the bottom opening of the magnet mounting post limiting groove, and the first spring is placed in the magnet mounting post limiting groove and located between the magnet mounting post and the retaining cover.

[0023] Preferably, the upper spot welding mold base is provided with a third mounting hole, and the upper rotor positioning core is slidably installed in the third mounting hole of the upper spot welding mold base;

[0024] The spot welding electrode of the upper spot welding mold is sleeved on the outside of the upper rotor positioning core;

[0025] The rear fan positioning core is fixedly connected to the bottom end of the upper rotor positioning core.

[0026] Preferably, the upper rotor positioning core has an axially oriented upper rotor positioning core hole at its center, and the rear fan positioning core has an axially oriented rear fan positioning core hole at its center that communicates with the upper rotor positioning core hole.

[0027] Preferably, the rear fan positioning core has a rear fan positioning groove circumferentially formed on the outer side of its bottom end, and multiple second magnets are symmetrically embedded in the rear fan positioning groove.

[0028] Preferably, the top of the upper rotor positioning core hole of the upper rotor positioning core is provided with a second spring limiting step groove, and a third spring is provided in the second spring limiting step groove. One end of the third spring abuts against the inner wall of the second spring limiting step, and the other end abuts against the upper electrode base plate of the spot welding machine.

[0029] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0030] This invention transforms the manual placement of fan blades and rotors through spot welding into automated machine placement, effectively reducing the labor intensity of operators and significantly lowering labor costs. Because the automated equipment can operate continuously without being limited by operator physical strength, it improves production efficiency. The operating speed of the automated equipment can be precisely controlled by a program, maintaining a stable working rhythm and avoiding the waiting and adjustment time required for manual operation. The equipment automatically presses the rotor, ensuring high stability and significantly reducing human error and inconsistent welding. Through precise mechanical positioning and sensor detection, the automated equipment ensures that the position, pressure, and time parameters of each weld are completely consistent, effectively improving product quality stability. The automated equipment places the rotor accurately without any bumps or knocks during placement. The precise positioning core and magnet assembly ensure accurate relative positioning between the fan blades and rotor, avoiding collisions and positional deviations that may occur during manual operation. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the overall structure of the generator rotor blade welding device of the present invention;

[0032] Figure 2 This is a schematic diagram of the assembly state of the front fan and the lower spot welding mold assembly in this invention;

[0033] Figure 3 This is a schematic diagram of the three-dimensional structure of the lower spot welding mold of the present invention;

[0034] Figure 4 This is a top view of the lower spot welding mold assembly of the present invention;

[0035] Figure 5 for Figure 4 Schematic diagram of the AA-direction cross-section structure;

[0036] Figure 6 for Figure 4 Schematic diagram of the BB-direction cross-section structure in the middle;

[0037] Figure 7 This is a schematic diagram of the assembly structure of the rear fan and the upper spot welding mold assembly in this invention;

[0038] Figure 8 This is a schematic diagram of the three-dimensional structure of the upper spot welding mold of the present invention;

[0039] Figure 9 This is a bottom view of the upper spot welding mold assembly of the present invention;

[0040] Figure 10 for Figure 9 A schematic diagram of the CC-direction cross-sectional structure.

[0041] The labels in the attached diagram are:

[0042] 1. Lower spot welding mold assembly; 11. Lower spot welding mold base; 12. Lower spot welding mold spot welding electrode; 13. Magnet assembly; 131. Magnet mounting post; 132. First magnet; 133. First spring; 134. Fixing cover; 14. Lower rotor positioning core; 141. Lower rotor positioning core hole; 15. Front fan positioning core; 151. Front fan positioning groove; 152. Front fan positioning core hole; 16. Second spring; 2. Upper spot welding mold assembly; 21. Upper spot welding mold base; 22. Upper spot welding mold spot welding electrode; 23. Upper rotor positioning core; 231. Upper rotor positioning core hole; 24. Rear fan positioning core; 241. Rear fan positioning groove; 242. Rear fan positioning core hole; 25. Second magnet; 26. Third spring; a. Rotor; b. Front fan; c. Rear fan. Detailed Implementation

[0043] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0044] Example: Please refer to Figures 1-10 This embodiment provides a generator rotor blade welding device for spot welding the front fan b and the rear fan c to the rotor a. The welding device includes a lower spot welding mold assembly 1 and an upper spot welding mold assembly 2. The lower spot welding mold assembly 1 is mounted on the lower electrode base plate of the spot welding machine, serving as a fixed support base for the entire welding device. The upper spot welding mold assembly 2 is mounted on the upper electrode base plate of the spot welding machine. The upper spot welding mold assembly 2 and the lower spot welding mold assembly 1 are vertically corresponding. The welding device also includes a robot arm for automatically placing the front fan b on the lower spot welding mold assembly 1, automatically placing the rear fan c on the upper spot welding mold assembly 2, and automatically placing the rotor a on the lower spot welding mold assembly 1. Driven by the spot welding machine, the upper spot welding mold assembly 2 can move up and down relative to the lower spot welding mold assembly 1 to drive the rear fan c to move downward and contact the rotor a. Through the coordinated work of the lower spot welding mold assembly 1 and the upper spot welding mold assembly 2, the automated welding of the fan blades in the generator rotor assembly is completed.

[0045] In the specific implementation process, three sets of robotic arms can be set up to grab rotor a, front fan b and rear fan c respectively. Rotor a, front fan b and rear fan c are automatically grabbed from the conveyor line and positioned and assembled in the lower spot welding mold assembly 1 and upper spot welding mold assembly 2. The robotic arms are existing technology and can be six-axis articulated robotic arms, Cartesian coordinate robotic arms, etc. Their specific structure and principle do not need to be elaborated in detail here. The entire process of handling and placing generator rotor parts is completed by the robotic arms, replacing manual operation, greatly reducing labor intensity and labor costs.

[0046] In this embodiment, the lower spot welding mold assembly 1 includes a lower spot welding mold base 11, a lower spot welding mold electrode 12 fixedly installed on the top of the lower spot welding mold base 11, a lower rotor positioning core 14 for positioning rotor a, a front fan positioning core 15 for positioning front fan b, and a magnet assembly 13. The lower spot welding mold base 11 is fixedly installed on the lower electrode base plate of the spot welding machine by bolts. A first mounting hole is provided on the lower spot welding mold base 11. The lower rotor positioning core 14 is slidably installed in the first mounting hole of the lower spot welding mold base 11. The lower spot welding mold electrode 12 is sleeved on the outside of the lower rotor positioning core 14. The front fan positioning core 15 is fixedly connected to the top of the lower rotor positioning core 14. The rotor positioning core 14 and the front fan positioning core 15 are fixedly connected by bolts. The magnet assembly 13 is installed on the lower spot welding mold base 11 and corresponds to the position of the front fan b. The lower spot welding mold base 11 is the mounting base of the entire lower spot welding mold assembly 1 and is made of high-strength steel. With good electrical conductivity and mechanical strength, it can withstand the large current and high pressure during the welding process. The lower spot welding die electrode 12 is electrically connected to the lower electrode base plate of the spot welding machine. The lower spot welding die electrode is the output end of the welding current, responsible for transmitting the welding current to the front fan b and rotor a. The front fan positioning core 15 is used to position and guide the front fan b to ensure that the front fan b is placed in the correct position. The magnet assembly 13 is used to attract and fix the angle position of the front fan. The lower rotor positioning core 14 is used to accurately position the rotor a to ensure that the rotor a and the front fan b maintain a concentric relative position. The position and angle of the front fan b and the coaxiality of the rotor a are defined respectively to avoid the problems of offset, bumping and angular misalignment caused by manual placement, and to ensure that the welding position of each group of workpieces is uniform, and the consistency of the finished product is significantly improved. The lower spot welding die assembly 1 can stably and reliably support and position the front fan b and rotor a, providing a precise assembly benchmark for subsequent welding operations.

[0047] In this embodiment, a front fan positioning groove 151 is provided on the outer side of the top of the front fan positioning core 15. When the robot moves the front fan b above the lower spot welding mold assembly 1 and lowers it, the center hole of the front fan b slides down along the top of the front fan positioning core 15 and is precisely embedded in the front fan positioning groove 151. The side wall of the annularly arranged front fan positioning groove 151 forms a full-circumferential radial constraint on the inner hole of the front fan, completing the center positioning of the front fan and keeping it coaxial with the lower rotor positioning core 141.

[0048] As a preferred embodiment of this invention, the top of the front fan positioning core 15 is chamfered, which helps to assemble the front fan b with the front fan positioning core 15. The size of the front fan positioning groove 151 is adapted to the inner hole of the front fan b, which has a more precise radial constraint capability. This can prevent the front fan b from being placed skewed, ensure the coaxiality of the front fan b and the rotor a, and make the position and fusion area of ​​the circumferential weld points uniform and consistent, effectively improving the consistency of the welded products.

[0049] In this embodiment, a lower rotor positioning core hole 141 is provided axially at the center of the lower rotor positioning core 14, and a front fan positioning core hole 152 communicating with the lower rotor positioning core hole 141 is provided axially at the center of the front fan positioning core 15. When the robot moves the rotor a to be welded to the lower spot welding mold assembly 1 and lowers it, the shaft at the end of the rotor a is inserted into the front fan positioning core hole 152 and the lower rotor positioning core hole 141 in sequence. The two sections of the hole wall that are connected vertically together form a radial constraint on the rotor shaft, restricting the radial offset of the rotor a, effectively avoiding the rotor a from being placed skewed, determining the installation position of the rotor a, and further ensuring the coaxiality of the rotor a and the front fan b.

[0050] In a preferred embodiment of this invention, the size of the front fan positioning core hole 152 is larger than the size of the lower rotor positioning core hole 141. The size of the lower rotor positioning core hole 141 is adapted to the size of the shaft at the end of rotor a. A chamfer is provided at the bottom of the front fan positioning core hole 152 near the lower rotor positioning core hole 141. The front fan positioning core hole 152 and the lower rotor positioning core hole 141 cooperate to form a graded guiding structure with a large opening for induction and a small opening for precision positioning. When rotor a is loaded, the shaft first enters the larger front fan positioning core hole 152 to obtain a larger centering tolerance space, reducing the positioning accuracy requirements of the robot. With the chamfer transition guide at the bottom of the hole, the shaft can smoothly slide into the lower rotor positioning core hole 141, which is adapted to its own size, improving the smoothness of rotor a assembly.

[0051] In this embodiment, the magnet assembly 13 includes a magnet mounting post 131. A first magnet 132 is embedded in the top of the magnet mounting post 131. A second mounting hole is provided on the lower spot welding mold base 11 outside the first mounting hole. The magnet mounting post 131 is slidably installed in the second mounting hole. A first spring 133 is provided at the bottom of the magnet mounting post 131, so that the magnet assembly 13 forms an elastic floating structure. Its main function is to compensate for the wear of the spot welding electrode 12 of the lower spot welding mold during use and the height difference between different batches of workpieces. In actual production, the head of the spot welding electrode will gradually wear down with the increase of the number of uses, resulting in changes in the effective welding depth. At the same time, there may be a certain tolerance range in the size of the rotor and fan blades of different batches. In its natural state, the first spring 133 pushes the magnet mounting post 131 upward, causing the magnet mounting post 131 to float up to the upper limit position along the second mounting hole. At this time, the upper surface of the first magnet 132 slightly protrudes from the upper surface of the lower spot welding die electrode 12, and is in a high-position waiting-to-adhere state. When the robot moves the front fan b to the lower spot welding die assembly 1 for lowering, the lower end face of the front fan b first contacts the protruding first magnet 132. The magnetic attraction directly attracts and fixes the end face of the front fan b. Together with the radial centering of the front fan positioning core 15, it completes the circumferential angle limit and position fixation of the front fan b, preventing the front fan b from rotating or shifting laterally. The upper spot welding die assembly 2 applies pressure downward, and the rotor a drives the front fan b to move downward synchronously. b pushes the first magnet 132 and the magnet mounting post 131 to slide downward along the second mounting hole, simultaneously compressing the first spring 133 at the bottom. During the floating process, the first magnet 132 always adheres to the end face of the front fan to maintain the attraction force. At the same time, it adaptively compensates for the wear of the lower spot welding die electrode 12 and the workpiece height tolerance, so that the lower end face of the front fan b and the welding working surface of the lower spot welding die electrode 12 are completely and tightly attached. After pressing in place, the front fan b and the lower spot welding die electrode 12 are in full contact. The welding current is smoothly conducted to the workpiece through the electrode, forming a complete circuit with the upper spot welding die assembly 2, and completing the spot welding operation. The elastic floating structure of the magnet assembly 13 avoids rigid support of the workpiece and eliminates the problem of poor contact leading to false welding.

[0052] In a preferred embodiment of this invention, the bottom end of the magnet mounting post 131 is provided with a protruding limiting part, and the bottom end of the second mounting hole is provided with a magnet mounting post limiting groove. The size of the magnet mounting post limiting groove is larger than the size of the two mounting holes. The protruding limiting part of the magnet mounting post 131 is placed in the magnet mounting post limiting groove. A retaining cover 134 is fixedly connected to the bottom opening of the magnet mounting post limiting groove. The first spring 133 is placed in the magnet mounting post limiting groove and is located between the magnet mounting post 131 and the retaining cover 134. The protruding limiting part at the bottom of the mounting column 131 forms a stepped limiting fit with the magnet mounting column limiting groove in the lower spot welding mold base 11, which can accurately limit the upward stroke of the magnet mounting column 131. When the first spring 133 rebounds and resets, the protruding limiting part is blocked by the upper step of the magnet mounting column limiting groove, preventing the magnet mounting column 131 from popping out and falling off from the upper end of the second mounting hole. Under long-term high-frequency reciprocating floating operation, the fixing cover 134 is used to limit the position of the first spring 133 and ensure the use of the first spring 133.

[0053] In this preferred embodiment, the number of magnet components 13 is no less than two sets, symmetrically distributed on both sides of the front fan positioning core 15. This can form a symmetrical magnetic attraction field on both sides of the front fan b, avoiding the problem of the front fan b tilting and circumferential deflection caused by the single set of magnets adsorbing on one side. The constraint effect of multi-point symmetrical adsorption is stronger, and the circumferential angle of the front fan b can be accurately fixed.

[0054] In this embodiment, a first spring limiting stepped groove is provided at the bottom end of the lower rotor positioning core hole 141 of the lower rotor positioning core 14. The size of the first spring limiting stepped groove is larger than the size of the lower rotor positioning core hole 141. A second spring 16 is provided in the lower spring limiting stepped groove. One end of the second spring 16 abuts against the inner wall of the lower spring limiting stepped groove, and the other end abuts against the lower electrode base plate of the spot welding machine. The lower rotor positioning core 14 has a lower rotor positioning core limiting part at its bottom end, and the bottom end of the first spring limiting stepped groove has a part for accommodating the lower rotor positioning core limiting part. Under the elastic force of the second spring 16, the lower rotor positioning core 14 floats up to the upper limit position along the first mounting hole of the lower spot welding mold base 11, causing the top front fan positioning core 15 to be in a high-position waiting state. The upper spot welding mold assembly 2 applies downward pressure, and the rotor a is driven by the downward pressure to slide the lower rotor positioning core 14 down along the first mounting hole, simultaneously compressing the second spring 16. During the floating process, the second spring 16 continuously provides reverse elastic force to ensure that the front fan b and the end face of rotor a, and the rotor a and the end face of rear fan c are always in close contact.

[0055] In this embodiment, the upper spot welding mold assembly 2 includes an upper spot welding mold base 21, an upper spot welding mold electrode 22 fixedly installed at the bottom of the upper spot welding mold base 21, an upper rotor positioning core 23 for cooperating with the positioning rotor a, a rear fan positioning core 24 for positioning the rear fan c, and a second magnet 25. The upper spot welding mold base 21 is the mounting base of the entire upper spot welding mold assembly 2, made of high-strength steel, with good conductivity and mechanical strength, and can withstand the large current and high pressure during the welding process. The upper spot welding mold base 21 is fixedly installed on the upper electrode base plate of the spot welding machine by bolts. The upper electrode base plate can move the entire upper spot welding mold assembly 2 up and down in the vertical direction. When the upper electrode base plate moves the upper spot welding mold assembly 2 up and down, the upper spot welding mold assembly 2 can move up and down in the vertical direction. When the welding mold assembly 2 moves upward, it leaves enough operating space for the robot to place the front fan b, rotor a and rear fan c. When the upper electrode base plate moves downward with the upper spot welding mold assembly 2, it drives the upper spot welding mold assembly 2 and the rear fan c to move downward together, so that the rear fan c is in close contact with the rotor a and the front fan b, forming a complete current path. The rear fan positioning core 24 is used to accurately center and position the rear fan c. The rear fan positioning core 24 is also equipped with a second magnet 25, which is used to attract and fix the rear fan to prevent the rear fan from falling off during transportation and positioning. The upper spot welding mold spot welding electrode 22 is electrically connected to the upper electrode base plate of the spot welding machine and is responsible for transmitting the welding current to the rear fan c and rotor a.

[0056] In this embodiment, a rear fan positioning groove 241 is annularly formed on the outer side of the bottom end of the rear fan positioning core 24. Multiple second magnets 25 are symmetrically embedded and installed within the rear fan positioning groove 241. A third mounting hole is formed on the upper spot welding mold base 21. The upper rotor positioning core 23 is slidably installed within the third mounting hole of the upper spot welding mold base 21. The upper spot welding mold spot welding electrode 22 is sleeved on the outer side of the upper rotor positioning core 23. The rear fan positioning core 24 is fixedly connected to the bottom end of the upper rotor positioning core 23. The rear fan positioning core 24 and the upper rotor positioning core 23 are fixedly connected by bolts. The robot arm moves the rear fan c below the upper spot welding mold assembly 2, with the upper surface of the rear fan c aligned with the rear fan positioning groove 24. 1. The symmetrically arranged second magnets 25 are fed in and simultaneously generate magnetic attraction, firmly adsorbing the rear fan c into the rear fan positioning groove 241. The annular rear fan positioning groove 241 sidewalls form a full-circumferential radial constraint on the inner hole of the rear fan. After completion, the center of the fan c is centered and the circumferential angle is limited, so that the rear fan c hangs upside down at the bottom of the upper spot welding mold assembly 2 without offset or rotational allowance, and will not fall off with the movement of the upper mold. Preferably, four second magnets 25 are provided, with two embedded on each side of the rear fan positioning groove 241, generating a uniform adsorption force on the rear fan c. The appropriate number of second magnets 25 can be selected according to the requirements based on the magnitude of the magnet adsorption force and the weight of the rear fan c.

[0057] As a preferred embodiment of this invention, the bottom end of the rear fan positioning core 24 is chamfered, which helps to assemble the rear fan c with the rear fan positioning core 24. The size of the rear fan positioning groove 241 is adapted to the inner hole of the rear fan c, which has a more precise radial constraint capability. This can prevent the rear fan c from being placed skewed, ensure the coaxiality of the rear fan c and the rotor a, and make the position and fusion area of ​​the circumferential weld points uniform and consistent, effectively improving the consistency of the welded products.

[0058] In this embodiment, an upper rotor positioning core hole 231 is provided axially at the center of the upper rotor positioning core 23, and a rear fan positioning core hole 242 communicating with the upper rotor positioning core hole 231 is provided axially at the center of the rear fan positioning core 24. When the upper spot welding mold assembly 2 and the lower spot welding mold assembly 1 are pressed together, the rotating shaft at the upper end of the rotor a can smoothly extend into the interconnected rear fan positioning core hole 242 and upper rotor positioning core hole 231 to adapt to the mold closing operation of the upper spot welding mold assembly 2 and the lower spot welding mold assembly 1.

[0059] The upper rotor positioning core 23 has a second spring limiting step groove at its top end of the upper rotor positioning core hole 231. The size of the second spring limiting step groove is larger than the size of the rotor positioning core hole 231. A third spring 26 is installed inside the second spring limiting step groove. One end of the third spring 26 abuts against the inner wall of the second spring limiting step, and the other end abuts against the upper electrode base plate of the spot welding machine. The upper rotor positioning core 23 has an upper rotor positioning core limiting part at its top end, and the second spring limiting step groove has a limiting groove at its top end to accommodate the upper rotor positioning core limiting part. Under the elastic force of the third spring 26... When the upper rotor positioning core 23 slides down to the lower limit position along the third mounting hole of the upper spot welding mold base 21, it drives the rear fan positioning core 24 at the bottom to be in the initial low position. When the upper spot welding mold assembly 2 moves down and presses against the lower spot welding mold assembly 1, the rear fan c contacts the rotor a. The third spring is continuously compressed and provides a stable reverse elastic force, pressing the rear fan c tightly against the upper end face of the rotor a. The upper end face of the rear fan c is also in contact with the spot welding electrode 22 of the upper spot welding mold, so that the end faces of the rear fan c and the rotor a can be pressed tightly together, ensuring that the welding current can pass smoothly through the entire workpiece circuit.

[0060] In this embodiment, whether the front fan b, rear fan c, and rotor a are placed and fixed in place is detected by sensors on the spot welding machine. The sensors detect whether the front fan b is correctly attracted by the magnet assembly 13 and is not tilted, whether the rotor a is correctly placed on the lower spot welding mold assembly 1 and makes good contact with the front fan b, and whether the rear fan c is correctly attracted by the second magnet 25 and is located in a predetermined position. The sensor detection results are fed back to the control system of the spot welding machine. Only when all sensors confirm that the workpiece is placed correctly will the control system issue a welding start command. If any sensor detects an abnormality, the control system will issue an alarm signal and stop subsequent actions, waiting for manual intervention or automatic error correction. The control system of the spot welding machine can be implemented by those skilled in the art through programming, so the control method and circuit connection will not be explained in detail in this invention.

[0061] In the specific implementation process, sensors can be photoelectric sensors, proximity sensors, pressure sensors, vision sensors, etc. Photoelectric sensors are used to detect the presence of workpieces, proximity sensors are used to detect the position of workpieces, pressure sensors are used to detect the contact pressure between workpieces, and vision sensors are used to detect the angle and position deviation of workpieces. The combined use of multiple sensors can improve the reliability and accuracy of detection.

[0062] In this embodiment, the lower rotor positioning core 14 and the upper rotor positioning core 24 are fitted with positioning core insulating sleeves for electrical insulation to prevent welding current from flowing through unintended paths. The positioning core insulating sleeves are made of high-temperature resistant and high-strength insulating materials, such as ceramics, polyimide, or high-strength engineering plastics. In specific implementation, the shape of the positioning core insulating sleeves matches the lower rotor positioning core 14 and the upper rotor positioning core 24 to ensure insulation while not hindering the floating movement of the positioning cores. The temperature resistance of the positioning core insulating sleeves should meet the highest temperature requirements during the welding process, and they typically need to be able to work for a long time in environments above 300 degrees Celsius.

[0063] In this embodiment, the first magnet 132 and the second magnet 25 can be permanent magnets or electromagnets. Permanent magnets have a simple structure and do not require power supply, but their attraction force is not adjustable. Electromagnets can adjust the attraction force by adjusting the current, realizing remote control and automatic release of attraction. The preferred embodiment of the present invention uses permanent magnets, which have a simpler and more reliable structure and lower maintenance costs. In specific implementation, the magnetic strength of the magnets should be selected according to the weight of the front fan b and the rear fan c and the required safety factor. The installation position of the magnets should ensure that the resultant force of the attraction force is located near the center of gravity of the workpiece to avoid tilting or twisting of the workpiece. For workpieces with larger mass, the number of magnets can be increased or a stronger magnetic material, such as neodymium iron boron permanent magnet material, can be selected.

[0064] Working principle: When the spot welding machine is in the initial standby state, the upper electrode base plate of the spot welding machine drives the upper spot welding mold assembly 2 to move vertically upward to a high position, leaving sufficient operating space for workpiece loading. The lower spot welding mold assembly 1 is fixed to the lower electrode base plate and remains stationary. The robot arm moves the front fan b to directly above the lower spot welding mold assembly 1 and lowers it. The front fan b slides into the front fan positioning groove 151 along the chamfered top of the front fan positioning core 15 to complete radial centering. At the same time, the first magnet 132 in the magnet assembly 13 attracts the lower end face of the front fan b. With the help of multiple symmetrically arranged magnet assemblies 13, circumferential angle limiting is completed. The front fan b is stably fixed at the spot welding electrode 12 of the lower spot welding mold. The robot arm moves the rear fan c to directly below the upper spot welding mold assembly 2 and inserts it. The rear fan c moves along the rear fan positioning core 15. The bottom of the core 24 is chamfered and embedded into the rear fan positioning groove 241 to complete radial centering. Multiple second magnets 25 symmetrically embedded in the groove generate uniform magnetic attraction force, which firmly hangs the rear fan c upside down and adsorbs it onto the spot welding electrode 22 of the upper spot welding mold, ensuring that the rear fan will not fall off or shift during the lifting and lowering of the upper spot welding mold assembly 2. The robot arm grabs the rotor a to be welded and moves it to the top of the lower spot welding mold assembly 1 and lowers it. The shaft at the end of the rotor a first enters the large-diameter front fan positioning core hole 152 to complete rough guidance and centering. After a smooth transition through the chamfered bottom of the hole, it is inserted into the lower rotor positioning core hole 141 with a suitable size. The outer circular surface of the lower rotor positioning core and the center hole together form a double radial constraint on the rotor, so that the rotor a and the front fan b maintain a high-precision coaxial state, and complete the coaxial alignment and assembly of the workpiece.

[0065] The spot welding machine has multiple built-in sensors that independently detect the adsorption state of the front fan b, the placement position of the rotor a, and the inverted state of the rear fan c, and feed the detection signals back to the spot welding machine control system. If any workpiece is found to be misaligned, adsorption fails, or is not in place, the control system will immediately trigger an alarm and lock the subsequent welding action. Only when all sensors confirm that the three workpieces are in place and accurately positioned will the control system issue a welding start command.

[0066] The spot welding machine drives the upper electrode base plate to move the upper spot welding mold assembly 2 vertically downwards. The rear fan c moves synchronously with the upper spot welding mold assembly 2 and approaches the rotor a. After the end face of the rear fan c contacts the upper end face of the rotor a, the upper spot welding mold assembly 2 continues to move downwards. At this time, the upper and lower double-sided elastic floating structures simultaneously activate adaptive compensation. The rotor a is driven by downward pressure to slide the lower rotor positioning core 14 and the front fan positioning core 15 downwards along the first mounting hole, compressing the second spring 16. At the same time, the front fan b pushes the first magnet 132 and the magnet mounting post 131 to slide downwards along the second mounting hole, compressing the first spring 133. The rear fan c is driven by upward reaction force to slide the rear fan positioning core 24 and the upper rotor positioning core 23 upwards relative to each other along the third mounting hole, compressing the third spring 26. The double-sided springs continuously provide uniform reverse elastic force, automatically compensating for the wear of the upper and lower spot welding electrodes and the workpiece machining height tolerance. Finally, the end faces of the front fan b, rotor a, and rear fan c are tightly fitted together, and the lower spot welding mold spot welding electrode 12, the front fan b, the rotor a, the rear fan c, and the upper spot welding mold spot welding electrode 22 are connected. After a complete conductive current loop is formed, the control system of the spot welding machine confirms that the pressing is in place and the current path is normal, and then starts the spot welding machine to discharge. The large current is conducted through the upper and lower electrodes to the contact end face of the workpiece, causing the weld points at the contact points between the front fan b and the rear fan c and the rotor a to melt instantly, achieving a firm spot weld connection between the front fan b, the rear fan c and the end face of the rotor a. After welding is completed, the upper electrode base plate of the spot welding machine drives the upper spot welding mold assembly 2 to move vertically upward to reset, and the first spring 133, the second spring 16, and the third spring 26 spring back to reset. The positioning cores and magnet assembly 13 return to the initial standby position. At this time, the rear fan c has been welded to the rotor a, and the bonding force is greater than the magnetic attraction force of the second magnet 25. The rear fan c automatically detaches from the rear fan positioning core 24 and remains on the lower spot welding mold assembly 1 along with the rotor a. The robot arm picks up the welded rotor assembly from the lower spot welding mold assembly 1 and transports it to the next process. After the spot welding machine clears the station, it returns to the initial standby state and automatically enters the next round of workpiece loading and welding cycle, realizing continuous automated production.

[0067] The above embodiments are preferred implementations of the present invention. In addition, the present invention can be implemented in other ways. Any obvious substitutions without departing from the concept of the present technical solution are within the protection scope of the present invention.

Claims

1. A generator rotor blade welding device for spot welding a front fan (b) and a rear fan (c) to a rotor (a), characterized in that: The welding device includes a lower spot welding mold assembly (1) and an upper spot welding mold assembly (2). The lower spot welding mold assembly (1) is mounted on the lower electrode base plate of the spot welding machine, and the upper spot welding mold assembly (2) is mounted on the upper electrode base plate of the spot welding machine. The lower spot welding mold assembly (1) includes a lower spot welding mold base (11), a lower spot welding mold spot welding electrode (12) fixedly installed on the top of the lower spot welding mold base (11), a lower rotor positioning core (14) for positioning the rotor (a), a front fan positioning core (15) for positioning the front fan (b), and a magnet assembly (13). The upper spot welding mold assembly (2) includes an upper spot welding mold base (21), an upper spot welding mold spot welding electrode (22) fixedly installed at the bottom of the upper spot welding mold base (21), an upper rotor positioning core (23) for cooperating with the positioning rotor (a), a rear fan positioning core (24) for positioning the rear fan (c), and a second magnet (25). The upper spot welding mold assembly (2) can move up and down relative to the lower spot welding mold assembly (1) to drive the rear fan (c) to move downward and contact the rotor (a); It also includes a robotic arm for automatically placing the front fan (b) on the lower spot welding mold assembly (1), for automatically placing the rear fan (c) on the upper spot welding mold assembly (2), and for automatically placing the rotor (a) on the lower spot welding mold assembly (1).

2. The generator rotor blade welding device according to claim 1, characterized in that: The lower spot welding mold base (11) has a first mounting hole, and the lower rotor positioning core (14) is slidably installed in the first mounting hole of the lower spot welding mold base (11). The lower spot welding die spot welding electrode (12) is sleeved on the outside of the lower rotor positioning core (14); The front fan positioning core (15) is fixedly connected to the top of the lower rotor positioning core (14).

3. The generator rotor blade welding device according to claim 2, characterized in that: The lower rotor positioning core (14) has an axially oriented lower rotor positioning core hole (141) at its center, and the front fan positioning core (15) has an axially oriented front fan positioning core hole (152) at its center that communicates with the lower rotor positioning core hole (141). The front fan positioning core (15) has a front fan positioning groove (151) on the outer side of its top end.

4. The generator rotor blade welding device according to claim 3, characterized in that: The lower rotor positioning core (14) has a first spring limiting step groove at the bottom end of the lower rotor positioning core hole (141). A second spring (16) is provided in the lower spring limiting step groove. One end of the second spring (16) abuts against the inner wall of the lower spring limiting step groove, and the other end abuts against the lower electrode base plate of the spot welding machine.

5. The generator rotor blade welding device according to claim 2, characterized in that: The magnet assembly (13) includes a magnet mounting post (131), a first magnet (132) is embedded in the top of the magnet mounting post (131), a second mounting hole is provided on the lower spot welding mold base (11) outside the first mounting hole, the magnet mounting post (131) is slidably mounted in the second mounting hole, and a first spring (133) is provided at the bottom of the magnet mounting post (131).

6. The generator rotor blade welding device according to claim 5, characterized in that: The bottom end of the magnet mounting post (131) is provided with a protruding limiting part, and the bottom end of the second mounting hole is provided with a magnet mounting post limiting groove. The protruding limiting part of the magnet mounting post (131) is placed in the magnet mounting post limiting groove. A retaining cover (134) is fixedly connected to the bottom opening of the magnet mounting post limiting groove. The first spring (133) is placed in the magnet mounting post limiting groove and is located between the magnet mounting post (131) and the retaining cover (134).

7. The generator rotor blade welding device according to claim 1, characterized in that: The upper spot welding mold base (21) is provided with a third mounting hole, and the upper rotor positioning core (23) is slidably installed in the third mounting hole of the upper spot welding mold base (21); The upper spot welding die spot welding electrode (22) is sleeved on the outside of the upper rotor positioning core (23); The rear fan positioning core (24) is fixedly connected to the bottom end of the upper rotor positioning core (23).

8. The generator rotor blade welding device according to claim 7, characterized in that: The upper rotor positioning core (23) has an axially oriented upper rotor positioning core hole (231) at its center, and the rear fan positioning core (24) has an axially oriented rear fan positioning core hole (242) at its center that communicates with the upper rotor positioning core hole (231).

9. The generator rotor blade welding device according to claim 8, characterized in that: The rear fan positioning core (24) has a rear fan positioning groove (241) on the outer side of its bottom end, and the second magnet (25) is provided in multiple and symmetrically embedded in the rear fan positioning groove (241).

10. A generator rotor blade welding device according to claim 8, characterized in that: The upper rotor positioning core (23) has a second spring limiting step groove at the top of the upper rotor positioning core hole (231). A third spring (26) is provided in the second spring limiting step groove. One end of the third spring (26) abuts against the inner wall of the second spring limiting step, and the other end abuts against the upper electrode base plate of the spot welding machine.

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