An automatic photoelectric welding device

Abstract

This utility model belongs to the field of DC motor commutator welding technology, and discloses a photoelectric automatic welding device. It includes a main unit for rotating and spot welding a DC motor commutator, and a lifting component located in the middle of the main unit for vertically moving and supporting the welding of the DC motor commutator. A calibration component for detecting the circumferential position of the DC motor commutator is located on the side of the main unit. The lifting component includes a support block with a positioning groove at the top and an electric push rod at the bottom. The calibration component includes a fixed base with a cantilever rod on one side. An adjustment mechanism for adjusting the detection position is mounted on the cantilever rod, and a photoelectric sensor is installed at the end of the adjustment mechanism. This photoelectric automatic welding device uses a photoelectric sensing-main unit control closed-loop system to automatically complete the entire process of rotor clamping, angle calibration, welding head lifting and lowering, and multi-angle continuous welding. Manual intervention is only required for loading and unloading, significantly improving efficiency.

Description

Technical Field

[0001] This utility model belongs to the field of DC motor commutator welding technology, and in particular relates to a photoelectric automatic welding device. Background Technology

[0002] After the rotor winding of a DC motor is completed, commutator welding is a crucial process to ensure stable motor performance. This step directly affects current conduction efficiency, mechanical reliability, and long-term service life, and its importance is reflected in the following three dimensions: 1. Ensuring the reliability of electrical connections: The rotor winding is connected to the external circuit through the commutator, and the welding quality determines the contact resistance. Insufficient welding can lead to localized high resistance, resulting in increased temperature rise, which can reduce motor efficiency or even cause insulation aging or short circuits. The application of silver-based solder or high-frequency welding processes can effectively reduce contact resistance to below 5mΩ, ensuring stable current transmission. 2. Meeting the rigidity requirements of mechanical strength: The rotor is subjected to both centrifugal force and electromagnetic force during high-speed rotation. Unwelded commutator copper busbars and mica sheets may loosen due to vibration, leading to winding breakage or commutator detachment. Welding, through metallurgical bonding between metal atoms, solidifies the copper busbars and mica sheets into a single unit, achieving a tensile strength of over 120MPa, significantly improving structural stability. 3. A critical aspect of thermal management: The heat dissipation performance of the commutator welding area directly affects the motor's temperature rise. High-quality welding processes create uniform heat conduction channels, preventing localized overheating. For example, when using flame brazing, it is necessary to control the solder flow rate to ensure the absence of porosity defects, thereby improving heat diffusion efficiency.

[0003] Comparing with Chinese Patent CN105811673A, which discloses an automatic welding machine, the machine includes a main frame. The main frame houses a welding machine, a rotary motor, a main shaft, a secondary shaft, two coaxial three-jaw chucks for clamping the rotor shaft, and a downward-pressing welding structure for driving the welding machine up and down. The welding machine includes a body and a welding head. A clamping welding section is formed between the two three-jaw chucks. One three-jaw chuck is coaxially connected to the main shaft, and the other is coaxially connected to the secondary shaft. Both the main and secondary shafts rotate with the main frame. The main shaft can be driven to rotate by the rotary motor, which is a servo motor. The structure is reasonable and can weld the commutator's connecting feet and the rotor winding leads wound around the connecting feet, effectively removing varnish, creating conductivity, and enhancing connection stability and reliability.

[0004] However, the aforementioned patent requires manually aligning one corner of the commutator with the welding head, which can easily lead to visual operation errors and poor welding. It also increases the difficulty of operation, increases the labor intensity of operators, and seriously affects the efficiency and quality of mass production. Therefore, a new device needs to be designed. Utility Model Content

[0005] The purpose of this invention is to provide an automatic photoelectric welding device to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, this utility model provides the following technical solution:

[0007] An automatic photoelectric welding device includes a main assembly for rotating and spot welding a DC motor commutator, and a support assembly disposed in the middle of the main assembly for vertically moving to assist in welding the DC motor commutator. A calibration assembly for detecting the circumferential position of the DC motor commutator is disposed on the side of the main assembly. The support assembly includes a support block with a positioning groove at its top and an electric push rod at its bottom. Two limiting mechanisms for restricting vertical movement are symmetrically disposed on both sides of the support block. The calibration assembly includes a fixed base with a cantilever rod on one side. An adjustment mechanism for adjusting the detection position is disposed on the cantilever rod, and a photoelectric sensor is mounted at the end of the adjustment mechanism.

[0008] Furthermore: the host component includes a host body, a rotating clamping head is provided on the host body, a pneumatic lifting seat is provided above the rotating clamping head, and a welding head is provided below the pneumatic lifting seat.

[0009] Furthermore: an clearance groove is provided below the welding head, and the rotating clamping head is a cylindrical multi-lobed clamping structure.

[0010] Furthermore: the limiting mechanism includes two limiting sliders and a limiting frame symmetrically arranged on both sides of the supporting block, and a limiting groove is vertically arranged in the limiting frame, and the limiting slider slides along the limiting groove.

[0011] Furthermore: the cross-sectional shape of the limiting slider and the limiting groove is T-shaped, and the positioning groove is V-shaped.

[0012] Furthermore: the adjustment mechanism includes an adjustment frame that is slidably connected to the cantilever rod, a positioning support rod is slidably installed in the middle of the adjustment frame, and a first locking pin and a second locking pin are respectively installed on the upper and lower parts of the adjustment frame.

[0013] Furthermore, both the cantilever rod and the positioning support rod are cylindrical rods.

[0014] Compared with existing technologies, the beneficial effects are:

[0015] 1. It adopts a photoelectric induction-host control closed-loop system to automatically complete the entire process of rotor clamping, angle calibration, welding head lifting and lowering, and multi-hook angle continuous welding. Manual intervention is only required for loading and unloading, which greatly improves welding efficiency. It is especially suitable for the mass production of micro motor commutators. While ensuring a welding yield of ≥99.5%, the welding cycle of a single piece can be controlled within 8 seconds, resulting in significant comprehensive benefits.

[0016] 2. The photoelectric sensor head of the calibration component collects the circumferential position information of the rotor body in real time. Combined with the multi-lobed clamping structure of the rotating clamping head and the coordinated control of the main body, the precise positioning of the commutator hook angle (error ≤ 0.1mm) is achieved, avoiding the problems of false welding or mis-welding caused by the deviation of traditional manual alignment.

[0017] 3. The T-shaped limiting slider of the lifting component cooperates with the slide groove and the V-shaped positioning groove for double guidance, ensuring that the rotor does not wobble in the vertical direction during the welding process. At the same time, the electric push rod dynamically supports and offsets the welding pressure to prevent the thin-walled commutator from deforming.

[0018] 4. The three-dimensional adjustable structure of the cantilever rod-adjustment frame of the calibration component can adapt to the detection requirements of different rotor models, and the changeover adjustment time is shortened to within 2 minutes. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the photoelectric automatic welding device described in this utility model;

[0020] Figure 2 This is a schematic diagram of the main unit component of the photoelectric automatic welding device described in this utility model;

[0021] Figure 3 This is a schematic diagram of the lifting component of the photoelectric automatic welding device described in this utility model;

[0022] Figure 4 This is a right perspective view of the lifting component of the photoelectric automatic welding device described in this utility model;

[0023] Figure 5 This is a schematic diagram of the calibration component of the photoelectric automatic welding device described in this utility model;

[0024] Figure 6 This is a right view of the calibration component of the photoelectric automatic welding device described in this utility model.

[0025] In the attached drawings, the following are the reference numerals: 101, main body; 102, pneumatic lifting seat; 103, welding head; 104, rotating clamping head; 105, clearance groove; 201, limiting frame; 202, support block; 203, positioning groove; 204, limiting slide groove; 205, limiting slider; 206, electric push rod; 301, fixed seat; 302, cantilever rod; 303, adjusting frame; 304, positioning support rod; 305, photoelectric sensor head; 306, first locking pin; 307, second locking pin; 4, rotor body. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0027] Please see Figures 1-6 An automatic photoelectric welding device includes a main unit for rotating and spot welding a DC motor commutator, a support component disposed in the middle of the main unit for moving up and down to assist in welding the DC motor commutator, and a calibration component disposed on the side of the main unit for detecting the circumferential position of the DC motor commutator.

[0028] In this embodiment: the host component includes a host body 101, a rotating clamping head 104 is provided on the host body 101, a pneumatic lifting seat 102 is provided above the rotating clamping head 104, and a welding head 103 is provided below the pneumatic lifting seat 102; a clearance groove 105 is provided below the welding head 103; the rotating clamping head 104 is a cylindrical multi-lobed clamping structure; during preparation, the rotor body 4 is inserted into the rotating clamping head 104 and clamped and fixed for welding; during welding, the photoelectric sensor head 305 collects the rotor body 4 The circumferential position information is transmitted to the main body 101. The main body 101 first controls the rotating clamping head 104 to clamp the rotor body 4 and rotate it so that one hook of the commutator on the rotor body 4 is aligned with the welding head 103. Then, the main body 101 controls the pneumatic lifting seat 102 to move the welding head 103 back and forth to weld the hook of the commutator. At the same time, the main body 101 controls the rotating clamping head 104 to clamp the rotor body 4 and rotate it by a set rotation angle to accurately position and weld the hooks of the other commutators.

[0029] In this embodiment: the lifting component includes a support block 202, a positioning groove 203 is provided on the top of the support block 202, an electric push rod 206 is provided on the bottom of the support block 202, and two limiting mechanisms for limiting the vertical movement direction are symmetrically arranged on both sides of the support block 202; the limiting mechanism includes two limiting sliders 205 and a limiting frame 201 symmetrically arranged on both sides of the support block 202, a limiting groove 204 is vertically arranged in the limiting frame 201, and the limiting sliders 205 slide along the limiting grooves 204; the cross-sectional shape of the limiting sliders 205 and the limiting grooves 204 are both T-shaped, and the positioning groove 203 is V-shaped; when ready, the electric push rod 206 extends to push the support block 202 up, and the rotor body 4 is positioned by the positioning groove 203, and the limiting sliders 205 move along the limiting grooves 204 in the middle of the limiting frame 201 to ensure the stability of the vertical movement of the support block 202;

[0030] In this embodiment: the calibration component includes a fixed base 301, a cantilever rod 302 is provided on one side of the fixed base 301, an adjustment mechanism for adjusting the detection position is provided on the cantilever rod 302, and a photoelectric sensor head 305 is installed at the end of the adjustment mechanism; the adjustment mechanism includes an adjustment frame 303 slidably connected to the cantilever rod 302, a positioning support rod 304 is slidably installed in the middle of the adjustment frame 303, and a first locking pin 306 and a second locking pin 307 are respectively installed at the top and bottom of the adjustment frame 303; both the cantilever rod 302 and the positioning support rod 304... Cylindrical rods are used; during preparation, slide along the cantilever rod 302 on the fixed base 301 and rotate the adjusting frame 303 so that the positioning support rod 304 on the adjusting frame 303 is aligned with the rotor body 4. Then tighten the first locking pin 306, and slide the positioning support rod 304 under the support of the adjusting frame 303 so that the photoelectric sensor head 305 at the end of the positioning support rod 304 is close to the rotor body 4 to a suitable gap to complete the adjustment. During welding, the photoelectric sensor head 305 transmits the collected circumferential position information of the rotor body 4 to the main body 101.

[0031] Working principle: During preparation, the rotor body 4 is first inserted into the rotating clamping head 104 and clamped and fixed. The electric push rod 206 in the middle clearance groove 105 of the main body 101 then extends and pushes the support block 202 to rise. The rotor body 4 is positioned by the positioning groove 203. The limiting slider 205 moves along the limiting slide groove 204 in the middle of the limiting frame 201 to ensure the stability of the support block 202 moving up and down. Then, it slides along the cantilever rod 302 on the fixed seat 301 and rotates the adjusting frame 303 so that the positioning support rod 304 on the adjusting frame 303 is aligned with the rotor body 4. Then, the first locking nail 306 is tightened. Then, under the support of the adjusting frame 303, the positioning support rod 304 is slid so that the photoelectric sensor head 305 at the end of the positioning support rod 304 approaches the rotor body 4 to a suitable gap to complete the adjustment.

[0032] During welding, the photoelectric sensor head 305 transmits the collected circumferential position information of the rotor body 4 to the main body 101. The main body 101 first controls the rotating clamping head 104 to clamp the rotor body 4 and rotate it so that one hook of the commutator on the rotor body 4 is aligned with the welding head 103. Then, the main body 101 controls the pneumatic lifting seat 102 to move the welding head 103 up and down to weld the hook of the commutator. At the same time, the main body 101 controls the rotating clamping head 104 to clamp the rotor body 4 and rotate it by a set rotation angle to accurately position and weld the hooks of the other commutators. After welding is completed, the rotor body 4 is removed and replaced with another rotor body 4, and automatic calibration welding can be performed continuously.

[0033] Although embodiments of the present 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 present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A photoelectric automatic welding device, comprising a main unit for rotating and spot welding a DC motor commutator, characterized in that: It also includes a lifting component in the middle of the main unit for moving up and down to assist in welding the DC motor commutator, and a calibration component on the side of the main unit for detecting the circumferential position of the DC motor commutator. The lifting assembly includes a support block (202), the top of the support block (202) is provided with a positioning groove (203), the bottom of the support block (202) is provided with an electric push rod (206), and two limiting mechanisms for limiting the vertical movement direction are symmetrically arranged on both sides of the support block (202). The calibration assembly includes a fixed base (301), a cantilever rod (302) is provided on one side of the fixed base (301), an adjustment mechanism for adjusting the detection position is provided on the cantilever rod (302), and a photoelectric sensor head (305) is installed at the end of the adjustment mechanism.

2. The photoelectric automatic welding device according to claim 1, characterized in that: The host component includes a host body (101), a rotating clamping head (104) is provided on the host body (101), a pneumatic lifting seat (102) is provided above the rotating clamping head (104), and a welding head (103) is provided below the pneumatic lifting seat (102).

3. The photoelectric automatic welding device according to claim 2, characterized in that: The welding head (103) is provided with a clearance groove (105) below it, and the rotating clamping head (104) is a cylindrical multi-lobed clamping structure.

4. The photoelectric automatic welding device according to claim 1, characterized in that: The limiting mechanism includes two limiting sliders (205) and a limiting frame (201) symmetrically arranged on both sides of the supporting block (202). A limiting groove (204) is vertically arranged inside the limiting frame (201), and the limiting sliders (205) slide along the limiting groove (204).

5. The photoelectric automatic welding device according to claim 4, characterized in that: The limiting slider (205) and the limiting groove (204) are both T-shaped, and the positioning groove (203) is V-shaped.

6. The photoelectric automatic welding device according to claim 1, characterized in that: The adjustment mechanism includes an adjustment frame (303) that is slidably connected to the cantilever rod (302). A positioning support rod (304) is slidably installed in the middle of the adjustment frame (303). A first locking pin (306) and a second locking pin (307) are respectively installed on the upper and lower parts of the adjustment frame (303).

7. The photoelectric automatic welding device according to claim 6, characterized in that: Both the cantilever rod (302) and the positioning support rod (304) are cylindrical rods.

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