A horizontal plane detection system and method for motor stator mounting position

Abstract

This invention discloses a horizontal plane detection system and method for the stator mounting position of a motor, characterized by: a detection platform, an air source device, and a displacement sensor; the detection platform includes a base, several detection columns mounted on the base, and guide columns; each detection column has an internal air passage, and an air outlet is opened on its top end face; the base has several air inlets that correspond one-to-one with the air passage of each detection column; the invention supplies air to each detection column through the air source device; when there is unevenness on the stator mounting surface, the gas flows out from the gap between the top surface of the detection column and the stator mounting surface; the displacement sensor detects the back pressure change at the air outlet and converts the back pressure change into a corresponding displacement value output; multiple detection columns can simultaneously detect different positions of the stator, completing the detection of multiple positions at once, improving detection efficiency; compared with traditional plug gauge detection, it avoids subjective bias of manual operation, and can detect micron-level unevenness, with objective, reliable, and highly accurate detection results.

Description

Technical Field

[0001] This invention relates to the field of stator testing equipment technology, specifically to a system and method for detecting the horizontal plane of a motor stator mounting position. Background Technology

[0002] The stator is one of the core components of electric motors and generators, and the flatness of its mounting surface directly affects the assembly accuracy and operational stability of the motor. During stator assembly, there are strict process requirements for the flatness of the stator's bottom mounting surface. If the stator mounting surface is uneven, it will lead to poor fit between the stator and the housing or other components, generating assembly stress. In severe cases, this can affect the uniformity of the air gap in the motor, causing increased operating noise, intensified vibration, and even shortening the motor's service life.

[0003] Currently, the industry primarily uses traditional manual plug gauge testing to inspect the flatness of stator mounting surfaces. This involves inserting plug gauges of varying thicknesses into the gap between the stator bottom and the mounting base, attempting to determine the gap size step by step. However, this method has the following problems: 1. When manually operating plug gauges, factors such as insertion force and angle can affect the test results. The test data of different operators have large deviations, making it difficult to ensure the consistency of the test results.

[0004] 2. Each stator requires measurement at multiple locations one by one, and it is necessary to repeatedly try plug gauges of different thicknesses, which is time-consuming and difficult to meet the high-efficiency testing requirements of mass production.

[0005] 3. The test results rely on manual reading and recording, which is inefficient and prone to recording errors, and cannot achieve automated and information-based management of test data.

[0006] 4. Due to inefficiency, companies can often only conduct random inspections, making it difficult to perform full inspections on each stator, which poses potential quality risks.

[0007] 5. The test data is scattered and lacks systematic data accumulation and analysis methods, making it difficult to trace and predict systemic quality problems in the production process.

[0008] Furthermore, existing technologies also include pneumatic flatness inspection solutions, such as using a handheld probe to scan the surface of the inspected part. However, this method cannot accurately locate defects and relies on manual data reading, making it unsuitable for inspection scenarios like stator mounting surfaces, which have specific annular structures and require multi-point precise positioning. Existing pneumatic measurement technologies are mostly single-point measurements or handheld scanning measurements, making it difficult to simultaneously inspect multiple preset positions on the stator mounting surface and automatically record data. They also cannot perform statistical analysis of inspection data from the same batch of products to trace mold failures.

[0009] To address this, a system and method for detecting the horizontal plane of the motor stator mounting position are proposed. Summary of the Invention

[0010] The purpose of this invention is to provide a system and method for detecting the horizontal plane of the motor stator mounting position in order to solve the above problems.

[0011] To achieve the above objectives, the present invention provides the following technical solution: a horizontal plane detection system for the stator mounting position of a motor, characterized in that: it includes a detection platform, a gas source device that supplies compressed gas to the detection platform through a pipeline, and a displacement sensor installed on the pipeline for detecting the flatness of the stator; the detection platform includes a base, a plurality of detection columns installed on the base for supporting the bottom mounting surface of the stator, and a guide column installed in the middle of the plurality of detection columns; the detection columns have an internal ventilation channel, and the top end face of the detection column has an air outlet communicating with the ventilation channel; the base has a plurality of air inlets corresponding to and communicating with the ventilation channels of each detection column; Preferably, the displacement sensor is a pneumatic gap detection sensor.

[0012] Preferably, the pipeline includes a main gas pipeline connected to the gas source device and multiple branch pipelines connected to the main gas pipeline and each air inlet via a reversing valve, and the displacement sensor is installed on each branch pipeline.

[0013] Preferably, a controller electrically connected to the directional valve and the displacement sensor is also included.

[0014] Preferably, the system also includes a positioning mechanism disposed on the base and the stator to limit the circumferential orientation of the stator.

[0015] Preferably, the positioning mechanism includes a positioning platform disposed on the base and a positioning groove disposed on the stator that is adapted to the positioning platform.

[0016] Preferably, several detection columns are evenly distributed around the guide column, and the top end face of each detection column is located in the same horizontal plane.

[0017] A method for detecting the horizontal plane of the motor stator mounting position, characterized by comprising the following steps: S1: Place the stator on the testing platform, so that the central through hole of the stator fits into the guide post, and place the bottom mounting surface of the stator on the top end face of multiple testing posts. The circumferential placement posture of the stator is defined by the positioning table on the base being embedded in the positioning groove of the stator. S2: Start the gas source device to allow compressed gas to enter the ventilation channel inside each detection column through the pipeline and flow out from the air outlet on the top end face of each detection column; S3: Displacement sensors installed on each pipeline collect back pressure signals in each gas path in real time. The back pressure signal reflects the change in gas escape at the gas vent due to the flatness deviation of the stator bottom surface. The real-time collected back pressure signal is converted into the corresponding displacement value output. The displacement value represents the size of the gap between the top end face of the corresponding detection column and the bottom mounting surface of the stator. S4: The controller compares each displacement value obtained in step S3 with the preset standard displacement threshold range. If any displacement value exceeds the threshold range, it is determined that there is a flatness defect at the corresponding position of the bottom mounting surface of the stator.

[0018] Preferably, in step S2, the gas supply detection for each branch pipeline is performed sequentially and individually or simultaneously by means of a reversing valve.

[0019] The beneficial effects of this invention are as follows: This system inserts the central through hole of the stator into the guide post, and the diameter of the guide post is adapted to the inner diameter of the central through hole of the stator. If the laminations of the stator are not on the same axis, the stator will not be able to be smoothly inserted into the guide post. This allows for a quick determination of the stator's perpendicularity defect and enables auxiliary detection of perpendicularity.

[0020] Air is supplied to each detection column via an air source device, and the gas flows out from the vent at the top of the column. If the stator mounting surface is flat, the vent is completely sealed, preventing gas from escaping; if the stator mounting surface is uneven, the gas flows out through the gap between the top surface of the detection column and the stator mounting surface. A displacement sensor detects the back pressure change at the vent and converts it into a corresponding displacement value. Multiple detection columns can simultaneously detect different positions on the stator, completing the detection of multiple positions at once, thus improving detection efficiency. Compared to traditional plug gauge inspection, this system avoids subjective bias from manual operation and can detect micron-level unevenness, providing objective, reliable, and highly accurate results.

[0021] With the positioning mechanism in place, when the stator is placed on the testing platform, the positioning table on the base is embedded in the positioning groove of the stator, which effectively restricts the circumferential movement of the stator. At the same time, it ensures that the stator is placed in the same position each time it is tested, so that the top end face of each test column corresponds to the same circumferential position of the bottom mounting surface of the stator each time, thus ensuring the comparability and consistency of the test data of each batch of stators. Attached Figure Description

[0022] Figure 1 This is a schematic diagram illustrating the overall principle of the present invention.

[0023] Figure 2 This is a schematic diagram of the stator of the present invention placed on the testing platform; Figure 3 This is a schematic diagram of the detection platform structure of the present invention; Figure 4This is a cross-sectional view of the detection platform of the present invention; Figure 5 This is a schematic diagram of the stator structure of the present invention.

[0024] Legend: 1. Detection platform; 11. Base; 111. Air inlet; 12. Detection column; 121. Ventilation channel; 122. Air outlet; 13. Guide column; 2. Air source device; 3. Pipeline; 31. Main air pipeline; 32. Branch pipeline; 4. Displacement sensor; 5. Reversing valve; 6. Controller; 7. Positioning mechanism; 71. Positioning platform; 72. Positioning groove; 8. Pressure regulating valve; 9. Stator. Detailed Implementation

[0025] The following description, in conjunction with the accompanying drawings, further illustrates the horizontal plane detection system and method for the motor stator mounting position according to the present invention.

[0026] See appendix Figure 1 - Appendix Figure 5 As shown in this embodiment, a horizontal plane detection system and method for the mounting position of a motor stator 9 is characterized by: a detection platform 1, a gas source device 2 that provides compressed gas to the detection platform 1 through a pipeline 3, and a displacement sensor 4 installed on the pipeline 3 for detecting the flatness of the stator 9; the detection platform 1 includes a base 11, a plurality of detection columns 12 installed on the base 11 for supporting the bottom mounting surface of the stator 9, and a guide column 13 installed among the plurality of detection columns 12; the detection column 12 has an internal ventilation channel 121, and the top end face of the detection column 12 has an air outlet 122 communicating with the ventilation channel 121; the base 11 has a plurality of air inlets 111 corresponding to and communicating with the ventilation channels 121 of each detection column 12; the detection column 12, the guide column 13 and the base 11 are integrally formed structures, which are realized by casting or integral machining to ensure the airtightness of the air circuit system.

[0027] The displacement sensor 4 is a pneumatic gap detection sensor, and its detection principle is a back pressure measurement method. The displacement sensor 4 integrates a throttling element and a pressure-sensitive element. Compressed gas enters the displacement sensor 4 after being regulated by the pressure regulating valve 8, and after being throttled by the throttling element, it is ejected from the nozzle at the detection end of the displacement sensor 4. During detection, the nozzle at the detection end of the displacement sensor 4 is connected one-to-one with the air inlet 111 of each detection column 12 through pipes 3, so that the gas state at the outlet 122 is connected to the internal air path of the displacement sensor 4.

[0028] When the stator 9 mounting surface is flat, the vent 122 is completely sealed, preventing gas from escaping, and the back pressure at the nozzle of the displacement sensor 4 rises to its maximum value. When the stator 9 mounting surface is uneven (e.g., protrusion or depression), a gap is created between the vent 122 and the mounting surface, allowing gas to escape through the gap. Consequently, the back pressure at the nozzle of the displacement sensor 4 decreases, with the change in back pressure corresponding to the size of the gap. The pressure-sensitive element inside the displacement sensor 4 detects the back pressure value in front of the nozzle in real time and converts it into a corresponding analog electrical signal output. The displacement sensor 4 also integrates a signal processing circuit and a display screen. Based on the pre-calibrated back pressure-displacement correspondence, the back pressure value is converted into the corresponding displacement value and displayed in real time on the display screen. Simultaneously, the displacement sensor 4 outputs the displacement value to the controller 6 in the form of an analog electrical signal or a digital signal. The controller 6 receives the displacement value signal and controls the opening and closing of each branch pipe 32 of the reversing valve 5, records the detection data of each displacement value, and compares each displacement value with the preset standard displacement threshold range for judgment. The standard displacement threshold range is determined according to the assembly process requirements of the motor stator 9. When any displacement value exceeds the threshold range, it is determined that there is an unevenness defect on the stator 9 mounting surface at the corresponding position of the detection column 12.

[0029] This system inserts the central through hole of the stator 9 into the guide post 13, the diameter of the guide post 13 being matched with the inner diameter of the central through hole of the stator 9. If the laminations of the stator 9 are not on the same axis, the stator 9 will not be able to be smoothly inserted into the guide post 13. This allows for a quick determination of the perpendicularity defect of the stator 9, thus enabling auxiliary detection of perpendicularity.

[0030] Air is supplied to each detection column 12 through the air source device 2, and the gas flows out from the air outlet 122 at the top of the detection column 12. If the mounting surface of the stator 9 is flat, the air outlet 122 is completely sealed, and the gas cannot escape; if the mounting surface of the stator 9 is uneven, the gas flows out from the gap between the top surface of the detection column 12 and the mounting surface of the stator 9. The displacement sensor 4 detects the back pressure change at the air outlet 122 and converts the back pressure change into the corresponding displacement value output. Multiple detection columns 12 can simultaneously detect different positions of the stator 9, completing the detection of multiple positions at once, improving detection efficiency; compared with traditional plug gauge detection, this system avoids the subjective bias of manual operation, and can detect micron-level unevenness, with objective, reliable, and highly accurate detection results.

[0031] The pipeline 3 includes a main gas pipeline 31 connected to the gas source device 2 and multiple branch pipelines 32 connected to the main gas pipeline 31 and each air inlet 111 via a reversing valve 5. The displacement sensor 4 is installed on each branch pipeline 32. The reversing valve 5 is an electromagnetic reversing valve, which is electrically connected to the controller 6.

[0032] The reversing valve 5 can distribute a single compressed air source from the air source device 2 to multiple branch pipelines 32 connected to each detection column 12, and the on / off switching and control of each branch pipeline 32 can be realized through electrical signals.

[0033] In one embodiment, a controller 6 electrically connected to the reversing valve 5 and the displacement sensor 4 is also included. The controller 6 is a PLC controller or an industrial computer. The controller 6 can control the opening and closing of each air outlet of the reversing valve 5 to realize independent air supply control or synchronous air supply control of each branch pipeline 32, and collect the displacement value output by each displacement sensor 4. The displacement value is compared with the preset standard displacement threshold range for judgment, and the detection data is stored and analyzed.

[0034] In one embodiment, a positioning mechanism 7 is provided on the base 11 and the stator 9 to define the circumferential orientation of the stator 9; the positioning mechanism 7 includes a positioning platform 71 provided on the base 11 and a positioning groove 72 provided on the stator 9 that is adapted to the positioning platform 71.

[0035] With the positioning mechanism 7 in place, when the stator 9 is placed on the testing platform 1, the positioning platform 71 on the base 11 is embedded in the positioning groove 72 of the stator 9, which effectively restricts the circumferential movement of the stator 9. At the same time, it ensures that the stator 9 is placed in the same position each time it is tested, so that the top end face of each testing column 12 corresponds to the same circumferential position of the bottom mounting surface of the stator 9 each time, thus ensuring the comparability and consistency of the test data of each batch of stator 9.

[0036] The testing method of this invention begins with the operator placing the motor stator 9 to be tested above the testing platform 1, aligning the center through hole of the stator 9 with the guide post 13, and then slowly lowering it to fit the stator 9 onto the guide post 13, with the bottom mounting surface of the stator 9 resting on the top end face of the testing post 12. If the stator 9 cannot be smoothly fitted onto the guide post 13, it indicates a serious deviation in the verticality of the stator 9, and it can be directly judged as unqualified. Then, the stator 9 is lifted upwards and rotated so that the positioning groove 72 on the stator 9 aligns with the positioning platform 71 on the base 11 and is embedded therein, completing the circumferential positioning and ensuring that the top end face of each testing post 12 corresponds to the same circumferential position of the bottom mounting surface of the stator 9.

[0037] After placement, the gas source device 2 is activated, and the gas supply pressure is adjusted to the preset standard pressure value through the pressure regulating valve 8. Compressed gas flows through the main gas pipeline 31, the reversing valve 5, and the branch pipeline 32, entering the ventilation channel 121 inside the detection column 12 from the air inlet 111 on the base 11, and flowing out from the air outlet 122 at the top of the detection column 12. The controller 6 controls the reversing valve 5 to supply gas to each branch pipeline 32 sequentially for individual detection or to supply gas to multiple pipelines simultaneously for detection.

[0038] Displacement sensors 4 installed on each branch pipe 32 collect back pressure signals in each branch pipe 32 in real time. If the mounting surface of the stator 9 is flat and good at the position of the detection column 12, the vent 122 is completely sealed by the mounting surface of the stator 9, and the gas cannot escape. The displacement sensor 4 outputs a reference displacement value (close to zero). If the mounting surface of the stator 9 has a depression or bulge at the position of the detection column 12, there is a gap between the vent 122 and the mounting surface of the stator 9. The gas escapes from the gap between the top surface of the detection column 12 and the mounting surface of the stator 9. The back pressure at the nozzle of the displacement sensor 4 decreases accordingly. After detecting the change in back pressure at the vent 122, the displacement sensor 4 converts the back pressure change into a corresponding displacement value output. The displacement value represents the size of the gap between the top end face of the corresponding detection column 12 and the bottom mounting surface of the stator 9, that is, the degree of unevenness at that position.

[0039] The controller 6 receives the displacement values ​​output by each displacement sensor 4, controls the opening and closing of each branch pipe 32 of the reversing valve 5, records the detection data of each displacement value, and compares each displacement value with the preset standard displacement threshold range. If the displacement value exceeds the standard displacement threshold range, it is determined that there is an unevenness defect on the stator 9 mounting surface at the corresponding position of the detection column 12.

[0040] The controller 6 records the displacement detection data of each detection column 12 corresponding to the point. Through the map generation module built into the controller 6, the displacement value of each detection point is visualized and mapped with different colors according to the circumferential distribution position of each detection column 12 on the bottom mounting surface of the stator 9, generating a visual flatness distribution map of the bottom mounting surface of the stator 9. The flatness of each detection point is displayed in a graphical way, which makes it easy for operators to quickly identify the location and degree of defects.

[0041] The controller 6 performs statistical analysis on the detection data of all stators 9 in the same batch. When it is found that multiple stators 9 in the same batch continuously exceed the threshold displacement value at the corresponding detection point in the same circumference, the system issues an early warning, determines that there is an abnormality (such as wear or deformation) in the forming position of the mold that produced this batch of stators 9, and suggests that the mold be inspected and repaired to achieve traceability of production mold failure and improve the pass rate of subsequent production.

[0042] The above embodiments are illustrative of the present invention and are not intended to limit the present invention. Any simple modifications to the present invention are within the scope of protection of the present invention.

Claims

1. A horizontal plane detection system for the stator mounting position of a motor, characterized in that: The system includes a testing platform (1), a gas source device (2) that supplies compressed gas to the testing platform (1) through a pipeline (3), and a displacement sensor (4) installed on the pipeline (3) for detecting the flatness of the stator (9). The testing platform (1) includes a base (11), a number of testing columns (12) installed on the base (11) for supporting the bottom mounting surface of the stator (9), and a guide column (13) installed in the middle of the number of testing columns (12). The testing column (12) has an internal ventilation channel (121), and the top end face of the testing column (12) has an air outlet (122) communicating with the ventilation channel (121). The base (11) has a number of air inlets (111) that correspond one-to-one with the ventilation channels (121) of each testing column (12).

2. The horizontal plane detection system for the stator mounting position of a motor according to claim 1, characterized in that: The displacement sensor (4) is a pneumatic gap detection sensor.

3. The horizontal plane detection system for the stator mounting position of a motor according to claim 1, characterized in that: The pipeline (3) includes a main gas pipeline (31) connected to the gas source device (2) and multiple branch pipelines (32) connected to each air inlet (111) via a reversing valve (5) of the main gas pipeline (31). The displacement sensor (4) is installed on each branch pipeline (32).

4. The horizontal plane detection system for the stator mounting position of a motor according to claim 3, characterized in that: It also includes a controller (6) electrically connected to the reversing valve (5) and the displacement sensor (4). The controller (6) is used to control the opening and closing of each branch pipeline (32) and collect the displacement value output by each displacement sensor (4). Then, the displacement value is compared with the preset standard displacement threshold range to determine whether the flatness of the bottom mounting surface of the stator (9) at the corresponding position of each detection column (12) is qualified.

5. The horizontal plane detection system for the stator mounting position of a motor according to claim 1, characterized in that: It also includes a positioning mechanism (7) set on the base (11) and the stator (9) to limit the circumferential orientation of the stator (9).

6. The horizontal plane detection system for the stator mounting position of a motor according to claim 5, characterized in that: The positioning mechanism (7) includes a positioning platform (71) disposed on the base (11) and a positioning groove (72) disposed on the stator (9) that is adapted to the positioning platform (71).

7. The horizontal plane detection system for the stator mounting position of a motor according to claim 1, characterized in that: Several detection columns (12) are evenly distributed around the guide column (13), and the top end face of each detection column (12) is located in the same horizontal plane.

8. The horizontal plane detection system for the stator mounting position of a motor according to claim 3, characterized in that: The main gas pipeline (31) is equipped with a pressure regulating valve (8) for adjusting the gas pressure value of each gas inlet (111).

9. A method for detecting the horizontal plane of a motor stator mounting position, characterized in that, Includes the following steps: S1: Place the stator on the testing platform, so that the central through hole of the stator fits into the guide post, and place the bottom mounting surface of the stator on the top end face of multiple testing posts. The circumferential placement posture of the stator is defined by the positioning table on the base being embedded in the positioning groove of the stator. S2: Start the gas source device to allow compressed gas to enter the ventilation channel inside each detection column through the pipeline and flow out from the air outlet on the top end face of each detection column; S3: Displacement sensors installed on each pipeline collect back pressure signals in each air path in real time. The back pressure signals reflect the back pressure changes at the air holes caused by the deviation of the flatness of the stator bottom surface. The real-time collected back pressure signals are converted into corresponding displacement values ​​and output. The displacement values ​​represent the size of the gap between the top end face of the corresponding detection column and the bottom mounting surface of the stator. S4: Compare the displacement values ​​obtained in step S3 with the preset standard displacement threshold range. If any displacement value exceeds the threshold range, it is determined that there is a flatness defect at the corresponding position of the bottom mounting surface of the stator.

10. A method for detecting the horizontal plane of a motor stator mounting position according to claim 9, characterized in that: In step S2, the reversing valve is used to detect the individual gas supply to each branch pipeline sequentially or to detect the simultaneous gas supply to multiple pipelines.

Images