Rotor defect detection equipment

Abstract

The utility model relates to rotor defect detection equipment, it includes XYZ translation mechanism, bearing mechanism and phase control ultrasonic probe, wherein the phase control ultrasonic probe is coupled with the XYZ translation mechanism and carries out translation along mutually perpendicular X direction, Y direction and Z direction by means of the XYZ translation mechanism, the bearing mechanism includes the bearing platform that is used for placing the rotor to be detected, the phase-controlled ultrasonic probe is provided with an arc-shaped end face, the arc-shaped end face is matched with the peripheral face of a rotor to be detected, and a plurality of wafers are arranged on the arc-shaped end face so as to emit ultrasonic waves to the rotor to be detected. The rotor defect detection equipment can realize detection and identification of internal defects of the rotor with relatively high precision and efficiency.

Description

Technical Field

[0001] The utility model relates to the field of motors, and in particular to a detection device for detecting rotor defects. Background Art

[0002] As a crucial component of electric motors, the rotor places high demands on safety, requiring high-precision inspection for internal defects. For example, in squirrel-cage cast rotors, defects such as cracked end rings, internal shrinkage, or porosity can occur in the end rings. In the conductor bars, defects such as porosity or shrinkage within the bars, or broken or thin bars within the slots can also occur. These defects can lead to increased rotor resistance, increased losses, reduced efficiency, decreased starting and minimum torque, increased slip, and elevated temperature rise.

[0003] In view of this, a variety of detection methods for rotor defects are known from the prior art, such as the use of X-rays or CT to detect end ring defects, the use of broken bar detectors to detect conductor bar defects, and physical end sectioning and rotor conductor bar beveling detection methods. Here, through the X-ray or CT detection methods, the power cannot penetrate the rotor core, so that the internal defects of the conductor bar cannot be detected. CT detection of the end ring takes a long time and there is a risk of radiation during use. The broken bar detector based on electromagnetic induction is easily affected by factors such as the environmental magnetic field, installation distance and radial runout of the cast rotor, and has certain defects in detection accuracy. The physical end sectioning and rotor conductor bar beveling detection methods require the destruction of the structure of the cast rotor, which will affect the production process and increase cost investment.

[0004] It should be noted that the content introduced here only provides background information related to the present disclosure and does not necessarily belong to the prior art. Utility Model Content

[0005] According to different aspects, the present invention aims to provide an improved rotor defect detection device, which can solve or alleviate one or more of the above-mentioned problems.

[0006] In addition, the present invention is also intended to solve or alleviate other technical problems existing in the prior art.

[0007] Specifically, the rotor defect detection equipment according to the present invention includes an XYZ translation mechanism, a supporting mechanism and a phased ultrasonic probe, wherein the phased ultrasonic probe is coupled to the XYZ translation mechanism and is translated along the X, Y and Z directions perpendicular to each other with the help of the XYZ translation mechanism, and the supporting mechanism includes a supporting platform for placing the rotor to be tested, wherein the phased ultrasonic probe has an arc-shaped end face, which is adapted to the outer peripheral surface of the rotor to be tested and a plurality of chips are arranged on the arc-shaped end face to transmit ultrasonic waves to the rotor to be tested.

[0008] Optionally, an actuator is also coupled to the phased-control ultrasonic probe, which is used to drive the phased-control ultrasonic probe to rotate around the Z direction, wherein the actuator includes a motor and a ball joint coupled thereto to drive the phased-control ultrasonic probe to rotate around the Z direction, or the actuator includes a horizontal rotating slide and a manual joystick.

[0009] Optionally, the carrying mechanism further includes a roller and an actuating device located on the carrying platform, wherein the rotor to be tested is placed on the roller with its axis parallel to the axis of the roller, and the actuating device drives the roller to rotate around its own axis to drive the rotor to be tested to rotate around its own axis.

[0010] Optionally, a pair of rollers spaced apart from each other and parallel to each other are provided on the supporting platform, wherein the rotor to be tested is supported on the rollers with its outer circumferential surface.

[0011] Optionally, the actuating device for the roller includes a motor, a transmission belt coupled to the output end of the motor, and a synchronous pulley coupled to the transmission belt, wherein the synchronous pulley is fixed to the end of the roller to drive the roller to rotate around its own axis.

[0012] Optionally, the apparatus further comprises a box in which a medium capable of conducting ultrasound waves is accommodated, wherein the rotor to be measured is immersed in the medium in an assembled state.

[0013] Optionally, a protective chain for storing the wiring harness is further included, wherein the protective chain extends outside along a frame of the rotor defect detection device, and the XYZ translation mechanism and the supporting mechanism are fixed on the frame.

[0014] Optionally, the XYZ translation mechanism includes an X-axis translation device having an X-axis motor and a belt transmission mechanism, a Y-axis translation device having a Y-axis motor and a Y-axis lead screw, and a Z-axis translation device having a Z-axis motor and a Z-axis lead screw, wherein the Y-axis translation device and the Z-axis translation device are supported on the frame by means of a support plate, and the support plate is motion-coupled with the X-axis translation device.

[0015] Optionally, the X-axis translation device further includes a guide rail fixed on the frame, and one side of the support plate is coupled to the transmission belt of the belt transmission mechanism of the X-axis translation device, wherein the support plate is pulled by the transmission belt to translate on the guide rail.

[0016] The rotor defect detection device according to the present disclosure can detect and identify internal defects of the rotor with high accuracy and efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above and other features of the present invention will become apparent with reference to the accompanying drawings, in which:

[0018] Figure 1 An embodiment of a rotor defect detection device according to the present invention is shown;

[0019] Figure 2 Shows the case where the box is removed. Figure 1 Rotor defect detection equipment;

[0020] Figure 3 Shown separately according to Figure 1 The bearing mechanism of the rotor defect detection equipment;

[0021] Figure 4 Schematically shows the Figure 1 XYZ translation mechanism of rotor defect detection equipment;

[0022] Figure 5 A configuration scheme of the rotor to be measured and the phased ultrasonic probe is shown;

[0023] Figure 6 Shown according to Figure 5 sectional view of . DETAILED DESCRIPTION

[0024] It is easy to understand that according to the technical solution of the present invention, without changing the essential spirit of the present invention, a person skilled in the art can propose a variety of interchangeable structural methods and implementation methods. Therefore, the following specific embodiments and drawings are only illustrative of the technical solution of the present invention and should not be regarded as the entire present invention or as a limitation or restriction of the technical solution of the present invention.

[0025] The terms "up," "down," "left," "right," "front," "back," "front," "back," "top," and "bottom" mentioned or potentially mentioned in this specification are defined relative to the structures shown in the accompanying drawings. They are relative concepts and may vary depending on their location or usage. Therefore, these or other directional terms should not be interpreted as restrictive. In addition, the terms "first," "second," "third," and similar expressions are used only for descriptive and distinguishing purposes and should not be understood to indicate or imply the relative importance of the corresponding components.

[0026] refer to Figure 1 and Figure 2 , which shows an embodiment of a rotor defect detection device 100 according to the present invention as a whole, which includes a frame 110 used as a mounting carrier, on which an XYZ translation mechanism 120 (which is Figure 4), and a supporting mechanism 130 (which is shown in detail in the figure) is provided in the space surrounded by the frame. Figure 3 The XYZ translation mechanism 120 is coupled to the phased ultrasonic probe 140 to cause the phased ultrasonic probe to translate along the mutually perpendicular X, Y, and Z directions. Figure 4 , which can be understood by analogy with a commonly used spatial coordinate system. The X and Y directions lie in the horizontal plane, while the Z direction is the vertical direction. The support mechanism 130 includes a support platform 131, which is used to place and secure the rotor 200 under test. During the test process, the phased ultrasonic probe 140 is moved to a preset position via the XYZ translation mechanism 120, then transmits ultrasonic waves toward the rotor 200 under test. Ultrasonic imaging is used to detect and identify internal defects in the rotor 200 under test.

[0027] By applying phased ultrasonic equipment to the internal defect detection of motor rotors, on the one hand, it does not require damage to the rotor and is harmless to the human body, and on the other hand, it can also ensure detection accuracy and efficiency.

[0028] In another embodiment (not shown), the frame 110 used as a mounting support is not mandatory. For example, the supporting mechanism 130 and the box 150 (described later) can be placed on a flat surface or a base, and the XYZ translation mechanism 120 and the phased ultrasonic probe 140 coupled thereto can be fixed in a suspended manner.

[0029] Here, in order to better adapt to the rotor to be measured, the phased ultrasonic probe 140 has an arc-shaped end surface adapted to the outer circumference of the rotor to be measured, and a plurality of or a specified number of wafers are regularly arranged on the arc-shaped end surface. Figure 5 and Figure 6 As shown, when the rotor 200 to be tested is cylindrical, the arcuate end surface can be a circular segment. During the testing process, the arcuate end surface transmits ultrasonic waves to the rotor to be tested when it is at a preset distance from the outer circumference of the rotor to be tested.

[0030] In a specific embodiment, the phased ultrasonic probe 140 is configured to have an operating frequency of 10 MHz, 128 elements divided into multiple rows, an element spacing of 0.4 mm, an element width of 4 mm, and a longitudinal wave incident scanning method with a deflection angle of 0°. During the detection process, the operating parameters of the phased ultrasonic probe 140 can be configured as follows: gain of 27 dB, acoustic path range of 34.65 mm, longitudinal wave speed of 6300 m / s, incident angle of 0°, probe delay of 10-20 μs, suppression of 0, thickness of 50 mm; excitation mode of PE (pulse echo), pulse width of 50.00 ns, excitation level of 115 V, repetition frequency of 41 Hz; 1st element excitation, 16 elements excited, focal depth of 25 mm; filter state of bandpass, low-pass filter multiple of 16 MHz, high-pass filter multiple of 5 MHz, waveform mode of full wave. It should be noted that this embodiment is intended to present relevant parameter configurations and is not restrictive. The above configurations and chip arrangements can be adjusted and set according to specific detection tests.

[0031] The phased ultrasonic probe 140 emits ultrasonic waves toward the rotor 200 under test using an arc-shaped excitation pattern. By utilizing the acoustic impedance variations between the rotor's core and aluminum / copper interfaces, the aluminum / copper interfaces and air interfaces, and the core and air interfaces, internal defects in the bars and end rings can be identified, enabling quality assessment of the rotor under test. This is particularly advantageous for cast motor rotors.

[0032] Next, according to Figure 1 、 Figure 2 ,and Figure 4 The XYZ translation mechanism 120 is described in detail. The Y-direction translation of the XYZ translation mechanism is achieved by means of a screw drive (i.e., a Y-direction translation device), which includes a Y-direction motor 121 and a Y-direction screw 122. Specifically, the Y-direction motor 121 is fixed to the support plate 123 by means of screws, and the Y-direction screw 122 is fixed to the support plate 123 by means of a sliding bearing and a bearing seat, wherein the support plate is movably supported on the frame 110, specifically, movably supported on a pair of guide rails on the frame 110. A Y-direction guide rail 124 extending along the Y-direction is also provided on the support plate 123, which is in motion coupling with the horizontal top plate of the bracket 125. Specifically, the slider located at the lower part of the top plate and the Y-direction guide rail 124 are in motion coupling. Here, the Y-axis lead screw 122 converts the rotational motion of the Y-axis motor 121 into translational motion, and drives the bracket 125 to translate on the Y-axis guide rail 124, so that the phased ultrasonic probe 140 fixed on the side plate extending along the Z-axis of the bracket 125 can translate along the Y-axis together.

[0033] Then, the X-direction translation of the XYZ translation mechanism 120 and the phased ultrasonic probe 140 is realized by the X-direction motor and the belt transmission mechanism (i.e., the X-direction translation device). Specifically, the X-direction motor 126 is fixed to the frame 110 and its output end is connected to the transmission belt of the belt transmission mechanism (see Figure 4 The transmission belt is kinetically coupled to one side of the support plate 123, thereby pulling the support plate for translation along a guide rail (a pair of guide rails disposed on opposite sides of the frame in the drawings). The guide rail is disposed on the frame 110 and extends substantially parallel to the side edges of the support plate 123. The traction of the transmission belt causes the support plate 123, the bracket 125 disposed thereon, and the phased-control ultrasound probe 140 coupled thereto to translate along the X-axis.

[0034] The Z-direction translation of the XYZ translation mechanism 120 is also achieved by means of a screw drive (i.e., a Z-direction translation device), and includes a Z-direction motor 127 and a Z-direction screw 128. The Z-direction motor 127 can be fixed to the support plate 123 by means of screws, and the Z-direction screw 128 extends along the Z-direction and is fixed to the bracket 125. A belt transmission mechanism is also provided between the output end of the Z-direction motor 127 and the Z-direction screw 128 to transmit the rotational motion of the Z-direction motor to the Z-direction screw. Figure 4 As shown in FIG, a transmission belt is arranged on the horizontal top plate of the bracket 125 to transmit the rotational motion of the output end of the Z-direction motor to the input end of the Z-direction lead screw.

[0035] In an optional embodiment, a protective chain 111 is provided on the frame to contain the wiring harness. This ensures the safety of the wiring harness while also preventing interference with the movement of the XYZ translation mechanism 120. Specifically, the protective chain can extend along the outside of the frame 110 and can be fixed directly to the frame 110 or to an outer edge of the frame 110.

[0036] In an optional embodiment, in addition to the translational mobility of the phased-control ultrasonic probe along the X, Y, and Z directions, it also has rotational motion about the Z direction (that is, in the XY plane perpendicular to the Z direction) to enable detection of rotors with different sizes and different guide bar forms (e.g., straight slots, skewed slots, irregular slots). This is achieved by an actuator 170 located at the phased-control ultrasonic probe. As shown in the figure, the actuator may include a horizontal rotation slide and a manual joystick, wherein the phased-control ultrasonic probe connected thereto is adjusted by rotating the manual joystick and then adjusting the horizontal rotation slide.

[0037] It is also possible that the actuating device for realizing the rotational movement about the Z direction includes a motor and a ball joint coupled thereto.

[0038] Next, refer to Figure 2 and Figure 3 The supporting mechanism 130 for placing the rotor under test in the rotor defect detection equipment is described in detail. To achieve overall inspection of the rotor under test, the supporting mechanism 130 should also enable the rotor under test to rotate. Specifically, a roller 132 is provided on the supporting platform 131, on which the rotor under test 200 is placed with its axis parallel to the axis of the roller 132. The roller 132 is driven by a dedicated actuator of the supporting mechanism 130 to rotate about its own axis, thereby driving the rotor under test 200 to rotate about its own axis. Taking the embodiment shown in the figure as an example, when inspecting a straight-slot rotor, the phased ultrasonic probe is moved in the X-direction by the XYZ translation mechanism to cover the entire length of the guide bar in the axial direction and the internal defect detection of the end ring at the end. On the other hand, the rotation of the rotor under test about its own axis covers the internal defect detection of the rotor under test in the circumferential direction, thereby achieving comprehensive and accurate defect detection without damaging the rotor structure.

[0039] In an optional embodiment, a pair of spaced-apart and parallel rollers are provided on the support platform 131 , and each roller is rotated synchronously by a dedicated actuating device to drive the rotor to be tested supported on the roller by its outer circumference to rotate around its own axis.

[0040] Here, the following optional implementations are given for the actuating device for the carrier platform, such as Figure 3 As shown in FIG, it includes a motor 133, a transmission belt 134, a synchronous pulley 135, and a tensioning pulley 136. The synchronous pulley 135 is fixed to the end of a drum 132, wherein the drum is fixed to the support platform 131 via a support so that it can rotate about its own axis. One end of the transmission belt 134 is coupled to the output end of the motor 133 and is also coupled to the synchronous pulley 135 on the drum 132. The actuator can be held by a vertical bracket substantially perpendicular to the support platform 131 to fully utilize the space within the frame 110 and avoid motion interference with the XYZ translation mechanism 120.

[0041] In another optional embodiment, the rotor defect detection apparatus further includes a housing 150 for containing an ultrasonically conductive medium, which can be water or oil. Specifically, the medium can have an additional rust-resistant function, such as rust-resistant oil. The medium within housing 150 is circulated by an external source and, in particular, filtered using a filtration device. The rotor 200 to be tested and the operating phased ultrasonic probe 140 are inserted below the surface of the medium. By submerging the rotor to be tested in the medium, the influence of external factors on ultrasonic imaging can be avoided and the disadvantage of poor wedge adaptability can be improved.

[0042] In addition, it is also feasible that, in the test preparation stage, the medium in the box can be coated on the rotor to be tested, which can also avoid the influence of external factors on ultrasonic imaging.

[0043] Furthermore, a calibration block 160 is provided within the housing 150 near the support platform 131 of the support mechanism 130 to facilitate calibration of the phased ultrasonic probe 140 prior to testing. Specifically, the phased ultrasonic testing process for a rotor under test can be performed as follows: first, the linearity of the phased array equipment is verified; the operability of the wafer of the phased ultrasonic probe is confirmed; the rotor under test is placed in the housing and submerged in the medium; the phased ultrasonic system is calibrated, including time base calibration, sensitivity calibration, and wedge delay calibration; and the relevant motion actuators of the rotor defect detection equipment are controlled to automatically move to comprehensively identify internal defects in the rotor under test.

[0044] It should be understood that all the above preferred embodiments are illustrative rather than restrictive, and various modifications or variations made by those skilled in the art to the above-described specific embodiments under the concept of the present invention should be within the legal protection scope of the present invention.

Claims

1. A rotor defect detection device, characterized in that: The apparatus comprises an XYZ translation mechanism, a supporting mechanism, and a phased ultrasonic probe, wherein the phased ultrasonic probe is coupled to the XYZ translation mechanism and is translated along mutually perpendicular X, Y, and Z directions by means of the XYZ translation mechanism. The supporting mechanism comprises a supporting platform for placing a rotor to be measured. The phased ultrasonic probe has an arc-shaped end face, which is adapted to the outer circumferential surface of the rotor to be measured and has a plurality of wafers arranged on the arc-shaped end face to transmit ultrasonic waves to the rotor to be measured.

2. The rotor defect detection device according to claim 1, characterized in that: An actuating device is also coupled to the phased-control ultrasonic probe, which is used to drive the phased-control ultrasonic probe to rotate around the Z direction, wherein the actuating device includes a motor and a ball joint coupled thereto, or the actuating device includes a horizontal rotating slide and a manual joystick.

3. The rotor defect detection device according to claim 1, characterized in that: The carrying mechanism also includes a roller and an actuating device located on the carrying platform, wherein the rotor to be tested is placed on the roller with its axis parallel to the axis of the roller, and the actuating device drives the roller to rotate around its own axis, thereby driving the rotor to be tested to rotate around its own axis.

4. The rotor defect detection device according to claim 3, characterized in that: A pair of rollers spaced apart from each other and parallel to each other are provided on the supporting platform, wherein the rotor to be tested is supported on the rollers with its outer circumferential surface.

5. The rotor defect detection device according to claim 3, characterized in that: The actuating device for the roller includes a motor, a transmission belt coupled to an output end of the motor, and a synchronous pulley coupled to the transmission belt, wherein the synchronous pulley is fixed to an end of the roller to drive the roller to rotate around its own axis.

6. The rotor defect detection device according to claim 1, characterized in that: The invention also comprises a box in which a medium capable of conducting ultrasound waves is accommodated, wherein the rotor to be measured is immersed in the medium in an assembled state.

7. The rotor defect detection device according to claim 1, characterized in that: It also includes a protection chain for storing the wire harness therein, wherein the protection chain extends outside along the frame of the rotor defect detection equipment, and the XYZ translation mechanism and the supporting mechanism are fixed on the frame.

8. The rotor defect detection device according to claim 7, characterized in that: The XYZ translation mechanism includes an X-axis translation device having an X-axis motor and a belt transmission mechanism, a Y-axis translation device having a Y-axis motor and a Y-axis lead screw, and a Z-axis translation device having a Z-axis motor and a Z-axis lead screw, wherein the Y-axis translation device and the Z-axis translation device are supported on the frame by means of a support plate, and the support plate is motion-coupled with the X-axis translation device.

9. The rotor defect detection device according to claim 8, characterized in that: The X-direction translation device also includes a guide rail fixed on the frame, and one side of the support plate is coupled to the transmission belt of the belt transmission mechanism of the X-direction translation device, wherein the support plate is pulled by the transmission belt to translate on the guide rail.

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