Motor rotor welding device

Abstract

The application relates to the technical field of welding devices, and particularly discloses a motor rotor welding device which comprises a rack main body, an electrode lifting sliding table, an electrode head, a detection assembly and a grinding assembly. The electrode head is connected with the electrode lifting sliding table, the detection assembly is connected with the electrode lifting sliding table, and the grinding assembly is connected with the detection assembly. The motor rotor welding device converts the contact resistance of the electrode head into a mechanical displacement signal through a detection loop, so as to quantify the deterioration degree of the contact surface of the electrode head. The grinding pressure of the grinding assembly is controlled through a sliding rheostat, the self-adaptive grading grinding of the more serious deterioration, the greater grinding range is realized, low pressure light grinding is adopted when the deterioration is slight, the electrode base material is maximally reserved, the pressure is increased for deep grinding when the deterioration is serious, and the working surface recovery precision is ensured, so that the excessive loss of fixed period grinding is avoided, and the risk of virtual welding caused by insufficient grinding is eliminated.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, specifically to a motor rotor welding device. Background Technology

[0002] Motor rotor welding equipment is a process equipment in the field of motor manufacturing. It is used to complete the welding connection of various core components of motor rotor. It is a core processing equipment to ensure the mechanical strength, electrical conductivity, dynamic balance accuracy and long-term operational reliability of rotor. It is widely integrated into automated motor production lines.

[0003] The term "motor rotor welding equipment" encompasses all welding processes for rotor components. Among them, the motor rotor commutator spot welding machine is specifically designed for welding the commutator to the armature winding ends in the production of brushed DC motors and series-wound motors. During operation, the rotor is conveyed to the loading station by the production line conveyor belt. A robotic arm moves the rotor to the welding station, where the head and tail centers automatically extend to clamp the rotating shaft. Then, the servo indexing mechanism of the spot welding machine drives the rotor to rotate, aligning the first commutator segment to be welded with the center of the spot welding electrode. After alignment, the electrode is pressed down vertically, tightly pressing the enameled wire onto the welding surface of the commutator segment. A small preheating current is then applied, and resistance heating is used for slow heating. The insulating varnish film on the surface of the enameled wire is melted, ablated, and decomposed. Then, the current is increased to the set main welding current. The high current density generates concentrated Joule heat at the contact surface between the commutator segment and the enameled wire, causing the copper base material to partially melt and form a molten pool. The metals of the enameled wire and the commutator segment are fully fused. After the welding current is cut off, the electrode continues to apply the set pressure, causing the molten metal to cool and crystallize under pressure, forming a dense weld nugget. After the pressure holding time ends, the electrode is lifted and reset. The servo indexing mechanism drives the rotor to precisely rotate one commutator segment angle, aligning the next commutator segment with the electrode. The above steps are repeated, and the equipment automatically counts the number of welded segments until all commutator segments are welded, at which point the cycle automatically stops.

[0004] The resistance of the electrode tip during spot welding consists of the contraction resistance (the concentrated resistance of current through tiny contact points) and the surface film resistance (the resistance of the contact surface oxidation and contamination layer). However, during spot welding, the temperature at the center of the weld joint is close to the melting point of copper (approximately 1083℃). Under high temperature and pressure, copper atoms on the surface of the workpiece (enameled wire, copper hook) diffuse towards the electrode tip, forming tiny adhesions. This copper adhesion makes the electrode tip surface rough and uneven. What actually contacts the workpiece is no longer a smooth plane, but rather several tiny points formed by the copper adhesion protrusions. This causes the current to only pass through these tiny points during spot welding, resulting in a local current density far exceeding the set value, leading to Joule heating (Q=I). 2 Rt) is at its maximum at the contact point, resulting in heat being generated on the surface of the electrode tip and the commutator segment weld hook, causing tiny spatters that fly away copper shavings. However, the actual melting point between the enameled wire and the copper hook fails to form a weld nugget due to current dispersion and insufficient heat, leaving only a scrambled, false solder joint.

[0005] In the industry, addressing incomplete welds caused by electrode tip deterioration primarily involves periodic electrode tip repair or replacement and online inspection. However, online inspection can only intercept defective products, not prevent them from occurring. The rate of electrode tip deterioration is continuously and gradually influenced by various factors such as workpiece cleanliness, cooling effect, and parameter fluctuations. Quality remains stable in the first half of the maintenance cycle, but the defect rate gradually increases in the second half as the electrode condition deteriorates. Shortening the repair cycle to maintain quality would significantly increase electrode consumable costs and downtime, reducing production efficiency. Therefore, we propose a motor rotor welding device. Summary of the Invention

[0006] The purpose of this invention is to provide a motor rotor welding device to solve the problem mentioned in the background art that the quality is stable in the first half of the maintenance cycle, but the defect rate gradually increases in the second half as the electrode condition deteriorates. If the grinding cycle is shortened to maintain quality, the cost of electrode consumables and downtime will be greatly increased, reducing production efficiency.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a motor rotor welding device, comprising a frame body and an electrode lifting slide, the electrode lifting slide being connected to the frame body; and further comprising an electrode head, the electrode head being connected to the electrode lifting slide, the electrode lifting slide driving the electrode head to move in the vertical direction; The detection component is connected to the electrode lifting slide. Each time the electrode lifting slide moves the electrode head to reset, the detection component automatically contacts the contact surface of the electrode head and detects the degree of deterioration of the contact surface of the electrode head. The grinding component is connected to the detection component. When the detection component detects that the deterioration of the electrode head contact surface exceeds a preset threshold, the grinding component automatically grinds the contact surface of the electrode head. The greater the deterioration of the electrode head contact surface, the greater the grinding range of the grinding component.

[0008] The detection assembly includes an insulating mounting base located outside the electrode head. The insulating mounting base is fixedly connected to the electrode lifting slide by bolts. An electrode chuck is fixedly connected to the inner side of the insulating mounting base, and the inner side of the electrode chuck is in contact with the outer side of the electrode head. A detection power supply is installed on the surface of the electrode lifting slide. A movable seat is provided outside the electrode head, and a wear-resistant conductive reference plate is slidably connected to the inner wall of the movable seat. One end of the detection power supply is connected to the electrode chuck, and the other end of the detection power supply is connected to the wear-resistant conductive reference plate. A driving component is provided outside the movable seat to drive the wear-resistant conductive reference plate to contact the electrode head when the electrode head is reset. The detection power supply, electrode chuck, electrode head, and wear-resistant conductive reference plate form a closed detection circuit. A detection component for detecting changes in the resistance of the electrode head is provided on the inner wall of the movable seat.

[0009] The driving component includes a support frame, the top of which is fixedly connected to the electrode lifting slide. A limit box is provided on the outside of the moving seat, and the moving seat is slidably connected to the inner wall of the limit box. A moving component is provided inside the limit box to push the moving seat to move in the vertical direction. A pneumatic telescopic rod is fixedly connected to the surface of the support frame, and the telescopic end of the pneumatic telescopic rod is fixed to the limit box. A control component is provided on the surface of the main body of the frame to control the extension and retraction of the pneumatic telescopic rod when the electrode head is reset.

[0010] The movable component includes a pneumatic telescopic rod 2 that is fixedly connected to the bottom of the limit box. The telescopic end of the pneumatic telescopic rod 2 is fixedly connected to the movable seat. A trigger plate 2 is fixedly connected to the outside of the telescopic end of the pneumatic telescopic rod 1. A limit switch 2 is installed on the surface of the support frame. The limit switch 2 is connected to the pneumatic telescopic rod 2. The limit switch 2 is located at the end of the stroke of the trigger plate 2. After the trigger plate 2 presses the limit switch 2, the pneumatic telescopic rod 2 extends.

[0011] The control components include a control box fixedly connected to the surface of the main frame, a trigger plate fixedly connected to the bottom of the electrode lifting slide, a trigger rod slidably connected to the inner wall of the control box, a return spring fixedly connected to the bottom of the trigger rod, the end of the return spring away from the trigger rod being fixed to the inner wall of the control box, the trigger plate being located above the trigger rod, a limit switch being installed on the inner wall of the control box, the limit switch being connected to a pneumatic telescopic rod, when the trigger plate descends with the electrode lifting slide, the trigger plate drives the trigger rod to descend, and after the trigger rod presses the limit switch, the pneumatic telescopic rod retracts.

[0012] The testing component includes a testing box fixedly connected to the inner wall of the movable base. An electromagnet is fixedly connected to the inner wall of the testing box. The electromagnet is connected in series in the circuit where the wear-resistant conductive reference plate is located. An armature is slidably connected to the inner wall of the testing box. The armature is located above the electromagnet. A movable frame is fixedly connected to the end of the armature away from the electromagnet. A sliding rheostat is fixedly connected to the top of the testing box. The movable frame is fixedly connected to the slider of the sliding rheostat. A reset component is provided on the inner wall of the testing box to drive the movable frame to reset after a delay.

[0013] The reset component includes a reset spring two fixedly connected to the outside of the moving frame. The end of the reset spring two away from the moving frame is fixedly connected to the inner wall of the detection box. An air storage cylinder is fixedly connected to the inner wall of the detection box. A piston plate is slidably and sealingly connected to the inner wall of the air storage cylinder. A connecting rod is fixedly connected to the top of the piston plate. One end of the connecting rod passes through the air storage cylinder and is fixedly connected to the moving frame. A one-way air inlet valve and a one-way air outlet valve are installed on the surface of the piston plate. The inner diameter of the one-way air inlet valve is smaller than that of the one-way air outlet valve.

[0014] The grinding assembly includes a servo motor that is slidably connected to the inner wall of the moving base. A fiber oilstone is fixedly connected to the output end of the servo motor. The fiber oilstone is located below the wear-resistant conductive reference sheet. A double-pole single-throw limit switch is installed on the inner wall of the detection box. The double-pole single-throw limit switch is located in the moving path of the moving frame. When the moving frame triggers the double-pole single-throw limit switch, the output shaft of the servo motor drives the fiber oilstone to rotate. The inner wall of the moving base is provided with a separation component that pulls the wear-resistant conductive reference sheet apart from the electrode head when the double-pole single-throw limit switch is triggered. The outer side of the servo motor is provided with a lifting component that drives the fiber oilstone to contact the electrode head when the wear-resistant conductive reference sheet is separated from the electrode head.

[0015] The separating component includes an insulating plate fixedly connected to a wear-resistant conductive reference sheet. The insulating plate is slidably connected to the inner wall of the movable seat. A compression spring is fixedly connected between the insulating plate and the inner wall of the movable seat. A pull rope is fixedly connected to the outer side of the insulating plate. A rotating shaft is rotatably connected to the inner wall of the movable seat. A winding wheel is fixedly connected to the outer side of the rotating shaft. The end of the pull rope away from the insulating plate is wound around the outer side of the winding wheel. A transmission gear is fixedly connected to the outer side of the rotating shaft. A transmission gear plate meshes with the outer side of the transmission gear. The transmission gear plate is slidably connected to the inner wall of the movable seat. A pneumatic telescopic rod three is fixedly connected to the inner wall of the movable seat. The telescopic end of the pneumatic telescopic rod three is fixed to the transmission gear plate. The pneumatic telescopic rod three is connected to a double-pole single-throw limit switch. When the double-pole single-throw limit switch is triggered, the pneumatic telescopic rod three pushes the transmission gear plate to move.

[0016] The lifting component includes a reset spring three fixedly connected to the outside of the servo motor. The end of the reset spring three away from the servo motor is fixedly connected to the inner wall of the moving seat. An electromagnet two is fixedly connected to the inner wall of the moving seat. A sliding rheostat is connected in series in the circuit where the electromagnet two is located. An armature two is fixedly connected to the end of the servo motor close to the electromagnet two. A limit switch three is installed on the inner wall of the moving seat. When the transmission gear plate triggers the limit switch three, the electromagnet two is energized.

[0017] This invention has at least the following beneficial effects: 1. In use, the detection component converts the contact resistance of the electrode head into a mechanical displacement signal through the detection circuit, thereby quantifying the degree of degradation of the electrode head contact surface. The grinding pressure of the grinding component is controlled by the sliding rheostat to achieve adaptive graded grinding: low-pressure light grinding is used for mild degradation to preserve the electrode base material to the maximum extent; and increased pressure deep grinding is used for severe degradation to ensure the accuracy of the working surface restoration. This avoids excessive wear from fixed-cycle grinding and eliminates the risk of poor welding caused by insufficient grinding.

[0018] 2. This application integrates the detection component and the grinding component on the side of the electrode lifting slide. By utilizing the gap when the electrode head is lifted and reset after welding, the electrode deterioration detection and grinding actions are completed simultaneously. This is performed in parallel with the rotor indexing process without additional downtime. Furthermore, the grinding is triggered immediately when the contact surface of the electrode head deteriorates beyond the standard, restoring the flatness and conductivity stability of the electrode working surface before the occurrence of false welds, thereby improving production efficiency and reducing the quality risk of batch false welds. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a side view of the main frame structure of the present invention; Figure 3 This is a cross-sectional view of the control component of the present invention; Figure 4 This is a schematic diagram of the main structure of the frame of the present invention; Figure 5 This is a schematic diagram of the detection component structure of the present invention; Figure 6 for Figure 5 Enlarged diagram of area A in the middle; Figure 7 This is a schematic cross-sectional view of the movable seat of the present invention; Figure 8 This is a cross-sectional view of the limiting box structure of the present invention; Figure 9 for Figure 8 Enlarged diagram of area B in the middle; Figure 10 This is a cross-sectional view of the gas storage cylinder of the present invention.

[0020] In the diagram: 1. Main frame; 2. Electrode lifting slide; 3. Electrode head; 4. Detection assembly; 40. Insulating mounting base; 41. Electrode chuck; 42. Detection power supply; 43. Moving base; 44. Wear-resistant conductive reference plate; 45. Driving component; 46. Detection component; 47. Support frame; 48. Limit box; 49. Moving component; 410. Pneumatic telescopic rod one; 411. Control component; 412. Pneumatic telescopic rod two; 413. Trigger plate two; 414. Limit switch two; 415. Control box; 416. Trigger plate one; 417. Trigger rod; 418. Return spring one; 419. Limit switch one; 420. Detection box; 421. Electromagnet one; 422. Armature one. 423. Moving frame; 424. Sliding rheostat; 425. Reset component; 426. Reset spring II; 427. Air tank; 428. Piston plate; 429. Connecting rod; 430. One-way inlet valve; 431. One-way exhaust valve; 5. Grinding assembly; 50. Servo motor; 51. Fiber oilstone slab; 52. Double-pole single-throw limit switch; 53. Separator; 54. Lifting component; 55. Insulating board; 56. Compression spring; 57. Pull rope; 58. Rotating shaft; 59. Rewinding wheel; 510. Transmission gear; 511. Transmission gear plate; 512. Pneumatic telescopic rod III; 513. Reset spring III; 514. Electromagnet II; 515. Limit switch III; 516. Armature II. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figures 1 to 10 This invention provides a technical solution: a motor rotor welding device, including a frame body 1 and an electrode lifting slide 2, the electrode lifting slide 2 being connected to the frame body 1; it also includes an electrode head 3, the electrode head 3 being connected to the electrode lifting slide 2, the electrode lifting slide 2 driving the electrode head 3 to move vertically; a detection component 4, the detection component 4 being connected to the electrode lifting slide 2, the detection component 4 automatically contacting the contact surface of the electrode head 3 and detecting the degree of deterioration of the contact surface of the electrode head 3 each time the electrode lifting slide 2 drives the electrode head 3 to reset; and a grinding component 5, the grinding component 5 being connected to the detection component 4, the grinding component 5 automatically grinding the contact surface of the electrode head 3 when the detection component 4 detects that the degree of deterioration of the contact surface of the electrode head 3 exceeds a preset threshold, the greater the degree of deterioration of the contact surface of the electrode head 3, the greater the grinding range of the contact surface of the electrode head 3 by the grinding component 5.

[0023] In the PLC control system of the main frame 1, the welding cycle interval, electrode lifting delay, and indexing waiting time are all open and settable parameters that can be freely set in the range of tens of milliseconds to several seconds. The operator can preset the welding cycle interval through the PLC control system to adapt to the working requirements of the detection component 4 and the grinding component 5.

[0024] During use, the operator sets the parameters in advance through the PLC of the main frame 1. The rotor to be welded is rotated and aligned by the indexing mechanism of the main frame 1. After the target commutator is aligned with the electrode head 3, the electrode lifting slide 2 drives the electrode head 3 to descend vertically, pressing the enameled wire onto the welding surface of the commutator. The preheating current and the main welding current are sequentially applied. Resistance heating is used to remove the enamel from the enameled wire and achieve metallurgical fusion. After pressure holding and cooling, single-point spot welding is completed. During this process, the detection component 4 and the grinding component 5 stay outside the electrode head 3 to avoid it. The detection circuit of the detection component 4 is disconnected throughout the process and physically isolated from the main welding circuit.

[0025] After the single-point spot welding pressure holding is completed, the electrode lifting slide 2 drives the electrode head 3 to reset and lift upward. The detection component 4 automatically contacts the contact surface of the electrode head 3. The detection component 4 converts the contact resistance of the electrode head 3 into a mechanical displacement signal through the detection circuit, thereby quantifying the degree of degradation of the contact surface of the electrode head 3. Based on the detection results, the grinding pressure of the grinding component 5 is controlled to achieve adaptive graded grinding: low pressure light grinding is used for mild degradation to preserve the electrode base material to the maximum extent; for severe degradation, the pressure is increased for deep grinding to ensure the accuracy of the working surface restoration. This avoids excessive wear from fixed-cycle grinding and eliminates the risk of false welding caused by insufficient grinding.

[0026] As the grinding process continues, the copper and oxide layers on the working surface of electrode head 3 are gradually removed, and the contact surface gradually returns to a smooth state.

[0027] After a preset time, the electrode lifting slide 2 drives the electrode head 3 to descend vertically. At this time, the detection component 4 and the grinding component 5 move to the outer clearance position of the electrode head 3, and the electrode head 3 enters the next welding cycle.

[0028] This application extends the online mode of spot welding intervals, dispersing maintenance time into the gaps between each weld point. After each weld is completed, the state of the electrode head 3 is checked and repaired, ensuring that the contact resistance and end face flatness of the electrode head 3 are always controlled within the qualified threshold. This stabilizes the heat input of the weld point throughout the process, improves the consistency of weld point quality across the entire batch, reduces poor welds from the source, lowers the cost of scrapping workpieces and the risk of after-sales quality issues, and eliminates the need for manual intervention. This reduces the amount of manual work required for on-site maintenance and also eliminates the inconsistencies caused by manual assembly and manual grinding.

[0029] The detection component 4 includes an insulating mounting base 40, which is located outside the electrode head 3. The insulating mounting base 40 is fixedly connected to the electrode lifting slide 2 by bolts. An electrode chuck 41 is fixedly connected to the inner side of the insulating mounting base 40, and the inner side of the electrode chuck 41 is in contact with the outer side of the electrode head 3. A detection power supply 42 is installed on the surface of the electrode lifting slide 2. A movable seat 43 is provided on the outer side of the electrode head 3. A wear-resistant conductive reference plate 44 is slidably connected to the inner wall of the movable seat 43. One end of the detection power supply 42 is connected to the electrode chuck 41, and the other end of the detection power supply 42 is connected to the wear-resistant conductive reference plate 44. A driving component 45 is provided on the outer side of the movable seat 43 to drive the wear-resistant conductive reference plate 44 to contact the electrode head 3 when the electrode head 3 is reset. The detection power supply 42, the electrode chuck 41, the electrode head 3, and the wear-resistant conductive reference plate 44 form a closed detection circuit. A detection component 46 for detecting the resistance change of the electrode head 3 is provided on the inner wall of the movable seat 43.

[0030] The detection power supply 42 adopts a 24V low-voltage DC constant voltage source. Its positive terminal is connected to the electrode clamp 41, and its negative terminal is connected to the wear-resistant conductive reference plate 44. The wear-resistant conductive reference plate 44 is made of tungsten copper alloy, which is wear-resistant and has stable conductivity.

[0031] The drive unit 45 includes a support frame 47, which is an L-shaped sheet metal structure. The top of the support frame 47 is fixed to the side wall of the electrode lifting slide 2. A limit box 48 is provided on the outside of the moving seat 43. The moving seat 43 is slidably connected to the inner wall of the limit box 48. The limit box 48 is provided with a moving part 49 that pushes the moving seat 43 to move in the vertical direction. A pneumatic telescopic rod 410 is fixedly connected to the surface of the support frame 47. The telescopic end of the pneumatic telescopic rod 410 is fixed to the limit box 48. The surface of the frame body 1 is provided with a control part 411 that controls the extension and retraction of the pneumatic telescopic rod 410 when the electrode head 3 is reset.

[0032] The movable component 49 includes a second pneumatic telescopic rod 412 fixedly connected to the bottom of the limiting box 48. The telescopic end of the second pneumatic telescopic rod 412 is fixedly connected to the movable seat 43. A trigger plate 413 is fixedly connected to the outer side of the telescopic end of the first pneumatic telescopic rod 410. A limit switch 414 is installed on the surface of the support frame 47. The limit switch 414 is connected to the second pneumatic telescopic rod 412. The limit switch 414 is located at the end of the stroke of the trigger plate 413. When the first pneumatic telescopic rod 410 extends to the end, the trigger plate 413 presses the limit switch 414, and the second pneumatic telescopic rod 412 extends accordingly.

[0033] The control unit 411 includes a control box 415 fixedly connected to the surface of the frame body 1, a trigger plate 416 fixedly connected to the bottom of the electrode lifting slide 2, a trigger rod 417 slidably connected to the inner wall of the control box 415, a return spring 418 fixedly connected to the bottom of the trigger rod 417, the end of the return spring 418 away from the trigger rod 417 being fixed to the inner wall of the control box 415, the trigger plate 416 being located above the trigger rod 417, and a limit switch 419 installed on the inner wall of the control box 415, the limit switch 419 being connected to the pneumatic telescopic rod 410.

[0034] When the electrode lifting slide 2 descends, the trigger plate 416 pushes the trigger rod 417 downwards to press the limit switch 419. The trigger rod 417 compresses the reset spring 418, and the pneumatic telescopic rod 410 retracts, causing the detection assembly 4 to move out of the welding position as a whole, thus avoiding interference with the welding operation. When the electrode is lifted and reset, the limit switch 419 resets, and the pneumatic telescopic rod 410 automatically extends to the detection position.

[0035] The detection component 46 includes a detection box 420 fixedly connected to the inner wall of the movable base 43. An electromagnet 421 is fixedly connected to the inner wall of the detection box 420. The electromagnet 421 is connected in series in the circuit where the wear-resistant conductive reference plate 44 is located. An armature 422 is slidably connected to the inner wall of the detection box 420. The armature 422 is located above the electromagnet 421. A movable frame 423 is fixedly connected to the end of the armature 422 away from the electromagnet 421. A sliding rheostat 424 is fixedly connected to the top of the detection box 420. The movable frame 423 is fixedly connected to the slider of the sliding rheostat 424. A reset component 425 is provided on the inner wall of the detection box 420 to drive the movable frame 423 to reset after a delay.

[0036] The reset component 425 includes a reset spring 426 fixedly connected to the outside of the moving frame 423. The end of the reset spring 426 away from the moving frame 423 is fixedly connected to the inner wall of the detection box 420. An air storage cylinder 427 is fixedly connected to the inner wall of the detection box 420. A piston plate 428 is slidably and sealingly connected to the inner wall of the air storage cylinder 427. A connecting rod 429 is fixedly connected to the top of the piston plate 428. One end of the connecting rod 429 passes through the air storage cylinder 427 and is fixedly connected to the moving frame 423. A one-way air intake valve 430 and a one-way air exhaust valve 431 are installed on the surface of the piston plate 428. The inner diameter of the one-way air intake valve 430 is smaller than that of the one-way air exhaust valve 431, forming a delayed reset structure with smooth downward movement and damped upward movement. The specific delay time can be set by adjusting the size ratio of the one-way air intake valve 430 and the one-way air exhaust valve 431 or the volume of the air storage cylinder 427 to provide working time for the grinding component 5.

[0037] The grinding assembly 5 includes a servo motor 50 slidably connected to the inner wall of the movable base 43. A fiber oilstone 51 is fixedly connected to the output end of the servo motor 50. The fiber oilstone 51 is made of silicon carbide fiber oilstone and is located below the wear-resistant conductive reference plate 44. A double-pole single-throw limit switch 52 is installed on the inner wall of the detection box 420. The double-pole single-throw limit switch 52 is located on the movement path of the movable frame 423. When the movement range of the movable frame 423 is large, the movable frame 423 first presses the double-pole single-throw limit switch 52, and then engages with the double-pole single-throw limit switch. When switch 52 is disengaged, it indicates that the contact resistance of electrode head 3 is low and the contact surface of electrode head 3 does not need to be ground. When the moving frame 423 triggers the double-pole single-throw limit switch 52, the output shaft of the servo motor 50 drives the fiber oilstone plate 51 to rotate. The inner wall of the moving seat 43 is provided with a separation component 53 that pulls the wear-resistant conductive reference plate 44 and the electrode head 3 apart when the double-pole single-throw limit switch 52 is triggered. The outer side of the servo motor 50 is provided with a lifting component 54 that drives the fiber oilstone plate 51 to contact the electrode head 3 when the wear-resistant conductive reference plate 44 and the electrode head 3 are separated.

[0038] Separator 53 includes an insulating plate 55 fixedly connected to the wear-resistant conductive reference sheet 44. The insulating plate 55 is slidably connected to the inner wall of the movable seat 43. A compression spring 56 is fixedly connected between the insulating plate 55 and the inner wall of the movable seat 43. A pull rope 57 is fixedly connected to the outer side of the insulating plate 55. A rotating shaft 58 is rotatably connected to the inner wall of the movable seat 43. A winding wheel 59 is fixedly connected to the outer side of the rotating shaft 58. The end of the pull rope 57 away from the insulating plate 55 is wound around the outer side of the winding wheel 59. The outer side of the rotating shaft 58 is fixed. A transmission gear 510 is connected, and a transmission gear plate 511 meshes with the outer side of the transmission gear 510. The transmission gear plate 511 is slidably connected to the inner wall of the movable seat 43. A pneumatic telescopic rod 512 is fixedly connected to the inner wall of the movable seat 43. The telescopic end of the pneumatic telescopic rod 512 is fixed to the transmission gear plate 511. The pneumatic telescopic rod 512 is connected to a double-pole single-throw limit switch 52. When the double-pole single-throw limit switch 52 is triggered, the pneumatic telescopic rod 512 pushes the transmission gear plate 511 to move.

[0039] The lifting component 54 includes a return spring 513 fixedly connected to the outside of the servo motor 50. The end of the return spring 513 away from the servo motor 50 is fixedly connected to the inner wall of the moving base 43. An electromagnet 514 is fixedly connected to the inner wall of the moving base 43. A sliding rheostat 424 is connected in series in the circuit where the electromagnet 514 is located. The more severe the deterioration, the greater the displacement of the slider. An armature 516 is fixedly connected to the end of the servo motor 50 close to the electromagnet 514. The smaller the resistance of the sliding rheostat 424, the stronger the attraction of the electromagnet 514, the greater the grinding pressure of the fiber oilstone slab 51, and the larger the grinding range. A limit switch 515 is installed on the inner wall of the moving base 43. When the transmission tooth plate 511 triggers the limit switch 515, the electromagnet 514 is energized. Only after the wear-resistant conductive reference plate 44 is completely avoided is the limit switch 515 triggered, and the electromagnet 514 is energized to lift the servo motor 50, ensuring accurate timing.

[0040] When the electrode head 3 is spot welding, the trigger plate 416 descends synchronously with the electrode lifting slide 2, pushing the trigger rod 417 down to compress the reset spring 418. The trigger rod 417 presses the limit switch 419, keeping the pneumatic telescopic rod 410 in a retracted state. This causes the limit box 48, the moving seat 43, and the grinding assembly 5 to remain in the outer clearance position, completely separating them from the welding station. The detection circuit is disconnected throughout the process, physically isolated from the main welding circuit.

[0041] After the single-point spot welding pressure holding is completed, the electrode lifting slide 2 drives the electrode head 3 to reset and lift upward. The trigger plate 416 moves upward synchronously, the reset spring 418 pushes the trigger rod 417 to rise and reset, the limit switch 419 contacts reset, and the pneumatic telescopic rod 410 extends, pushing the limit box 48 and the moving seat 43 to move horizontally to directly below the electrode head 3. This process is performed in parallel with the rotor indexing action and does not occupy additional production time.

[0042] When the pneumatic telescopic rod 410 is fully extended, the trigger plate 413 presses the limit switch 414, and the pneumatic telescopic rod 412 immediately extends to a fixed length, pushing the moving seat 43 vertically upward along the inner wall of the limit box 48, so that the top surface of the wear-resistant conductive reference plate 44 and the bottom working surface of the electrode head 3 are tightly attached with constant light pressure. The detection power supply 42, electrode chuck 41, electrode head 3, wear-resistant conductive reference plate 44, and electromagnet 421 together form a closed low-voltage detection circuit.

[0043] After the detection circuit is turned on, under the action of constant voltage, the magnitude of the circuit current is determined by the contact resistance between the electrode head 3 and the wear-resistant conductive reference plate 44.

[0044] When the working surface of electrode head 3 is flat, clean, and has a low degree of deterioration, the contact resistance is small, the circuit current is large, the attraction force generated by electromagnet 421 is strong, the adsorption armature 422 and the moving frame 423 are kept in a low position, the resistance of sliding rheostat 424 increases, the moving frame 423 will not touch the double-pole single-throw limit switch 52, the fiber oilstone slab 51 will not contact the electrode head 3, and after a preset time, the equipment directly enters the next welding cycle.

[0045] When copper adhesion, oxidation, or carbon buildup appears on the surface of electrode head 3, and the contact surface is uneven, the contact resistance increases, the circuit current decreases, and the attraction force of electromagnet 421 weakens. If the contact resistance rises to a preset threshold, the preset threshold is achieved through the electromagnetic conversion structure and the installation position of the double-pole single-throw limit switch 52. No additional complex data acquisition module is required; the threshold determination can be completed by a purely mechanical and electrical structure. The specific implementation logic is as follows: The detection power supply 42 adopts a low-voltage DC constant voltage output. The detection circuit current is negatively correlated with the contact resistance of the electrode head 3. The change in the contact resistance of the electrode head 3 will be converted into a change in the circuit current, which will in turn change the electromagnetic attraction of the electromagnet 421, causing the moving frame 423 to generate a vertical displacement corresponding to the resistance value. The preset threshold is calibrated at the installation height on the inner wall of the detection box 420 by the double-pole single-throw limit switch 52. The calibration steps are as follows: First, using a brand-new, flat-faced standard electrode head 3, the detection circuit is connected under standard detection pressure, and the initial height position of the moving frame at this time is recorded. This position corresponds to the reference contact resistance of the electrode head 3. Based on the preset degradation ratio (such as 1.8 times the reference resistance), calculate the attraction force of electromagnet 421 under the corresponding circuit current, and the displacement of moving frame 423 under the action of reset spring 426, and fix double-pole single-throw limit switch 52 at the corresponding height position on the inner wall of detection box 420.

[0046] When the electrode head 3 deteriorates to the point that the contact resistance reaches the threshold, the moving frame 423 moves to that height and presses to trigger the double-blade single-throw limit switch 52, automatically starting the grinding program.

[0047] The slider of the sliding rheostat 424 moves synchronously, the resistance of the sliding rheostat 424 decreases, and the air damping structure of the air storage cylinder 427 extends the reset time of the moving frame 423.

[0048] After the double-pole single-throw limit switch 52 is triggered, the first signal controls the pneumatic telescopic rod 512 to extend, pushing the transmission gear plate 511 to move horizontally, meshing the transmission gear 510 to rotate, and the winding wheel 59 to rotate synchronously to wind up the pull rope 57, pulling the insulating plate 55 to slide against the wear-resistant conductive reference plate 44. The insulating plate 55 squeezes and compresses the spring 56, so that the reference plate is completely separated from the bottom surface of the electrode head 3, making room for grinding and avoiding damage to the reference working surface during the grinding process and affecting the subsequent detection accuracy.

[0049] When the transmission gear plate 511 moves to the end of its stroke, it triggers the limit switch 3 515, and the power supply circuit of the electromagnet 2 514 is turned on. The electromagnet 2 514 generates an upward attraction, which attracts the armature 2 516 to drive the servo motor 50 to move upward as a whole, compressing the reset spring 3 513, so that the top surface of the fiber oilstone plate 51 is in close contact with the working surface of the electrode head 3.

[0050] At the same time, the second signal of the double-pole single-throw limit switch 52 controls the servo motor 50 to start, driving the fiber oilstone plate 51 to rotate and grind the electrode working surface.

[0051] During the grinding process, the resistance of the sliding rheostat 424 changes in real time with the height of the moving frame 423. The more severe the electrode deterioration, the greater the contact resistance. When the double-pole single-throw limit switch 52 is triggered, the higher the position of the moving frame 423, the smaller the resistance of the sliding rheostat 424 connected to the electromagnet 2 514 circuit. The larger the working current of the electromagnet 2 514 and the stronger the attraction, the greater the contact pressure of the fiber oilstone slab 51 on the electrode head 3, the more material is removed per unit time, and the greater the grinding range. This achieves an adaptive match between the degree of deterioration and the grinding intensity. Due to the air damping structure of the air storage cylinder 427, the grinding pressure gradually decreases during the grinding process, achieving light-pressure polishing in the later stage of grinding and avoiding excessive electrode wear.

[0052] As the grinding process continues, the copper and oxide layers on the working surface of electrode head 3 are gradually removed, and the contact surface gradually returns to a smooth state. After a preset time, the electrode lifting slide 2 drives electrode head 3 to descend vertically. At this time, the detection component 4 and the grinding component 5 move to the outer clearance position of electrode head 3, and electrode head 3 enters the next welding cycle.

[0053] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0054] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A motor rotor welding apparatus, comprising: The frame body and the electrode lifting slide are connected to the frame body; Its characteristic is that it further includes an electrode head, which is connected to an electrode lifting slide, and the electrode lifting slide drives the electrode head to move in the vertical direction; The detection component is connected to the electrode lifting slide. Each time the electrode lifting slide drives the electrode head to reset, the detection component automatically contacts the contact surface of the electrode head and detects the degree of deterioration of the contact surface of the electrode head. A grinding component is connected to a detection component. When the detection component detects that the deterioration of the electrode head contact surface exceeds a preset threshold, the grinding component automatically grinds the contact surface of the electrode head. The greater the deterioration of the electrode head contact surface, the greater the grinding range of the electrode head contact surface.

2. The motor rotor welding device according to claim 1, characterized in that: The detection assembly includes an insulating mounting base located outside the electrode head. The insulating mounting base is fixedly connected to the electrode lifting slide by bolts. An electrode chuck is fixedly connected to the inner side of the insulating mounting base, and the inner side of the electrode chuck fits against the outer side of the electrode head. A detection power supply is mounted on the surface of the electrode lifting slide. A movable seat is provided outside the electrode head, and a wear-resistant conductive reference plate is slidably connected to the inner wall of the movable seat. One end of the detection power supply is connected to the electrode chuck, and the other end of the detection power supply is connected to the wear-resistant conductive reference plate. A driving component is provided outside the movable seat to drive the wear-resistant conductive reference plate to contact the electrode head when the electrode head is reset. The detection power supply, electrode chuck, electrode head, and wear-resistant conductive reference plate form a closed detection circuit. A detection component for detecting changes in the resistance of the electrode head is provided on the inner wall of the movable seat.

3. The motor rotor welding device according to claim 2, characterized in that: The driving component includes a support frame, the top of which is fixedly connected to the electrode lifting slide. A limiting box is provided on the outside of the movable seat, and the movable seat is slidably connected to the inner wall of the limiting box. A moving component that pushes the movable seat to move in the vertical direction is provided inside the limiting box. A pneumatic telescopic rod is fixedly connected to the surface of the support frame, and the telescopic end of the pneumatic telescopic rod is fixed to the limiting box. A control component that controls the extension and retraction of the pneumatic telescopic rod is provided on the surface of the main body of the frame when the electrode head is reset.

4. The motor rotor welding device according to claim 3, characterized in that: The movable component includes a pneumatic telescopic rod 2 fixedly connected to the bottom of the limiting box. The telescopic end of the pneumatic telescopic rod 2 is fixedly connected to the movable seat. A trigger plate 2 is fixedly connected to the outer side of the telescopic end of the pneumatic telescopic rod 1. A limit switch 2 is installed on the surface of the support frame. The limit switch 2 is connected to the pneumatic telescopic rod 2. The limit switch 2 is located at the end of the stroke of the trigger plate 2. After the trigger plate 2 presses the limit switch 2, the pneumatic telescopic rod 2 extends.

5. The motor rotor welding device according to claim 3, characterized in that: The control unit includes a control box fixedly connected to the surface of the main frame. A trigger plate is fixedly connected to the bottom of the electrode lifting slide. A trigger rod is slidably connected to the inner wall of the control box. A return spring is fixedly connected to the bottom of the trigger rod. The end of the return spring away from the trigger rod is fixed to the inner wall of the control box. The trigger plate is located above the trigger rod. A limit switch is installed on the inner wall of the control box. The limit switch is connected to a pneumatic telescopic rod. When the trigger plate descends with the electrode lifting slide, it drives the trigger rod to descend. After the trigger rod presses the limit switch, the pneumatic telescopic rod retracts.

6. The motor rotor welding device according to claim 2, characterized in that: The detection component includes a detection box fixedly connected to the inner wall of the movable base. An electromagnet is fixedly connected to the inner wall of the detection box. The electromagnet is connected in series with the circuit containing the wear-resistant conductive reference plate. An armature is slidably connected to the inner wall of the detection box. The armature is located above the electromagnet. A movable frame is fixedly connected to the end of the armature away from the electromagnet. A sliding rheostat is fixedly connected to the top of the detection box. The movable frame is fixedly connected to the slider of the sliding rheostat. A reset component is provided on the inner wall of the detection box to drive the movable frame to reset after a delay.

7. The motor rotor welding device according to claim 6, characterized in that: The reset component includes a reset spring two fixedly connected to the outside of the movable frame. The end of the reset spring two away from the movable frame is fixedly connected to the inner wall of the detection box. An air storage cylinder is fixedly connected to the inner wall of the detection box. A piston plate is slidably and sealingly connected to the inner wall of the air storage cylinder. A connecting rod is fixedly connected to the top of the piston plate. One end of the connecting rod passes through the air storage cylinder and is fixedly connected to the movable frame. A one-way air inlet valve and a one-way air outlet valve are installed on the surface of the piston plate. The inner diameter of the one-way air inlet valve is smaller than that of the one-way air outlet valve.

8. The motor rotor welding device according to claim 6, characterized in that: The grinding assembly includes a servo motor slidably connected to the inner wall of the moving base. A fiber oilstone is fixedly connected to the output end of the servo motor. The fiber oilstone is located below the wear-resistant conductive reference sheet. A double-pole single-throw limit switch is installed on the inner wall of the detection box. The double-pole single-throw limit switch is located in the moving path of the moving frame. When the moving frame triggers the double-pole single-throw limit switch, the output shaft of the servo motor drives the fiber oilstone to rotate. The inner wall of the moving base is provided with a separation component that pulls the wear-resistant conductive reference sheet apart from the electrode head when the double-pole single-throw limit switch is triggered. The outer side of the servo motor is provided with a lifting component that drives the fiber oilstone to contact the electrode head when the wear-resistant conductive reference sheet is separated from the electrode head.

9. The motor rotor welding device according to claim 8, characterized in that: The separating component includes an insulating plate fixedly connected to a wear-resistant conductive reference sheet. The insulating plate is slidably connected to the inner wall of the movable seat. A compression spring is fixedly connected between the insulating plate and the inner wall of the movable seat. A pull rope is fixedly connected to the outer side of the insulating plate. A rotating shaft is rotatably connected to the inner wall of the movable seat. A winding wheel is fixedly connected to the outer side of the rotating shaft. The end of the pull rope away from the insulating plate is wound around the outer side of the winding wheel. A transmission gear is fixedly connected to the outer side of the rotating shaft. A transmission gear plate meshes with the outer side of the transmission gear. The transmission gear plate is slidably connected to the inner wall of the movable seat. A pneumatic telescopic rod three is fixedly connected to the inner wall of the movable seat. The telescopic end of the pneumatic telescopic rod three is fixed to the transmission gear plate. The pneumatic telescopic rod three is electrically connected to a double-pole single-throw limit switch. When the double-pole single-throw limit switch is triggered, the pneumatic telescopic rod three pushes the transmission gear plate to move.

10. The motor rotor welding apparatus according to claim 9, characterized in that: The lifting component includes a return spring three fixedly connected to the outside of the servo motor. The end of the return spring three away from the servo motor is fixedly connected to the inner wall of the moving seat. An electromagnet two is fixedly connected to the inner wall of the moving seat. A sliding rheostat is connected in series in the circuit where the electromagnet two is located. An armature two is fixedly connected to the end of the servo motor near the electromagnet two. A limit switch three is installed on the inner wall of the moving seat. When the transmission gear plate triggers the limit switch three, the electromagnet two is energized.

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