A cast aluminum rotor bar break testing device

Abstract

The utility model discloses a cast aluminium rotor broken strip testing arrangement belongs to testing technical field, including test platform, cast aluminium rotor broken strip testing arrangement still includes test subassembly and drive assembly, and test subassembly is located with drive assembly in test platform, and test platform includes workbench surface, and test subassembly and drive assembly are located workbench surface upper and lower two sides respectively, and test subassembly includes positioning subassembly, detection subassembly and clamping assembly, and the plane of clamping assembly is perpendicular to the plane of workbench surface, and rotor is located in clamping assembly, and detection subassembly is located one side of clamping assembly, and the plane of clamping assembly is perpendicular with the plane of positioning subassembly each other. The gravity direction is consistent with rotor axial direction through the vertical arrangement of clamping assembly in test platform, and rotor is naturally drooping under the action of gravity, and reduces the additional eccentricity or sway of the gravity, and compared with horizontal arrangement, can reduce the rotor unbalance influence of the factor such as installation, improves test stability.

Description

Technical Field

[0001] This utility model relates to the field of testing technology, and in particular to a test device for broken bars of cast aluminum rotor. Background Technology

[0002] During the production of cast aluminum rotors, various factors can lead to defects such as porosity, sand holes, residue, thin bars, broken bars, and undercasting. Motors using such rotors have lower load capacity than those with normal cast aluminum rotors, resulting in reduced motor efficiency. Current technology for addressing rotor bar breakage issues primarily utilizes horizontal rotor testing instruments. However, in environments with limited space, this design restricts layout flexibility. For large or heavy rotors, horizontal placement requires clamping and positioning using overhead cranes or other lifting equipment, which is relatively complex. Furthermore, the large lateral span makes precise alignment of the test position more difficult. Additionally, the rotor's own weight can cause uneven bearing stress, potentially leading to inconsistent bearing wear over prolonged testing, affecting rotor rotation accuracy and introducing testing errors. Summary of the Invention

[0003] In order to overcome the shortcomings of the existing technology, the purpose of this utility model is to realize a test device for broken bars of cast aluminum rotors that vertically arranges the clamping components in the test platform.

[0004] The objective of this utility model is achieved through the following technical solution: A test device for testing broken bars of cast aluminum rotors includes a test platform. The test device further includes a test component and a drive component. The test component and the drive component are located within the test platform. The test platform includes a worktable. The test component and the drive component are located on the upper and lower sides of the worktable, respectively. The test component includes a positioning component, a detection component, and a clamping component. The plane of the clamping component is perpendicular to the plane of the worktable. The rotor is located in the clamping component. The detection component is located on one side of the clamping component. The plane of the clamping component is perpendicular to the plane of the positioning component.

[0005] Preferably, the clamping assembly includes a base plate, a lower seat plate, a clamping guide rod, a clamping screw, a first handwheel, a clamping sliding block, a clamping fixing block, and a clamping locking block. The base plate is fixedly connected to the worktable surface, and the lower seat plate is fixedly connected to the worktable surface through the base plate. The clamping screw is fixedly connected to the first handwheel. The clamping sliding block, the sliding block, and the clamping fixing block are provided with through holes. The clamping guide rod is arranged parallel to the clamping screw and passes through the through holes, thereby realizing the vertical movement, positioning, and locking of the clamping assembly.

[0006] Preferably, the clamping assembly further includes a cylinder, a main drive shaft, a bearing cover, a first center, a second center, and a rotating shaft located between the first center and the second center. The cylinder is fixed to the clamping block, the second center is fixed to the main drive shaft, and the main drive shaft is connected to the base plate through the bearing cover.

[0007] Preferably, the test assembly further includes a dial located between the second tip and the bearing cap.

[0008] Preferably, the drive assembly includes a motor, a large synchronous pulley, a synchronous belt, a small synchronous pulley, and a speed measuring disc. The small synchronous pulley is connected to the output end of the motor, the large synchronous pulley is connected to the small synchronous pulley through the synchronous belt, and the speed measuring disc is coaxially connected to the large synchronous pulley.

[0009] Preferably, the cast aluminum rotor bar breakage testing device further includes a tensioning assembly, which includes a tensioning wheel, an adjusting plate, a tensioning guide rail, a tensioning top block, and a tensioning plate. The adjusting plate is connected to the tensioning wheel, the tensioning wheel abuts against the synchronous belt, and the tensioning top block cooperates with the tensioning plate to push the adjusting plate to slide linearly along the tensioning guide rail.

[0010] Preferably, the positioning component is located on one side of the clamping component and fixed on the base plate. The positioning component includes fixed blocks arranged symmetrically at intervals and a first guide rod and a lead screw passing through the fixed blocks. The positioning component also includes a second handwheel, a slider, and a second guide rod perpendicular to the slider. The second handwheel is fixedly connected to the lead screw.

[0011] Preferably, the positioning component further includes a scale, which is parallel to the first optical rod and fixed to the fixing block.

[0012] Preferably, the positioning component further includes a locking block located on the second optical rod.

[0013] Preferably, the test platform further includes a front panel, a display screen, and buttons, with the display screen located on the front panel and the buttons located on the workbench.

[0014] Compared with existing technologies, the cast aluminum rotor bar breakage testing device and machine tool of this invention have the following advantages: This application's cast aluminum rotor bar breakage testing device, by vertically arranging the clamping assembly within the testing platform with the direction of gravity aligned with the rotor's axis, allows the rotor to hang naturally under gravity, resulting in more stable contact with the clamping assembly and reducing additional eccentricity or swaying caused by gravity. Compared to a horizontal arrangement, this reduces the impact of rotor imbalance caused by installation and other factors, improving testing stability. The optocoupler moves synchronously with the large synchronous pulley, using the signal output from the optocoupler as the synchronization signal to ensure signal acquisition at specific rotor rotation positions. This ensures that the acquired magnetic field signal corresponds to the rotor's position, facilitating subsequent analysis of magnetic field signals at different positions and improving the accuracy and reliability of rotor bar breakage detection. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the cast aluminum rotor bar breakage testing device of this application; Figure 2 for Figure 1 Exploded view of the structure of the cast aluminum rotor bar breakage test device after removing the test platform; Figure 3 for Figure 1 A schematic diagram of the clamping component structure; Figure 4 This is a structural diagram of the drive assembly and the tensioning assembly; Figure 5 for Figure 1 A schematic diagram of the positioning component.

[0016] In the diagram: 100, Test platform; 101, Workbench; 102, Front panel; 103, Display screen; 104, Button assembly; 200, Test component; 201, Positioning component; 2011, Fixing block; 2012, First guide rod; 2013, Lead screw; 2014, Second handwheel; 2015, Slider; 2016, Second guide rod; 2017, Scale; 2018, Locking block; 202, Clamping component; 2021, Base plate; 2022, Lower base plate; 2023, Clamping guide rod; 2024, Clamping lead screw; 2025, First handwheel; 2026, Clamping... 2027. Sliding block; 2028. Pressing and fixing block; 2029. Pressing and locking block; 2030. Cylinder; 2031. Main drive shaft; 2032. Bearing cover; 2033. First center; 2034. Second center; 205. Dial; 300. Drive assembly; 301. Motor; 302. Large synchronous pulley; 303. Synchronous belt; 304. Small synchronous pulley; 305. Speed ​​measuring disc; 400. Tensioning assembly; 401. Tensioning wheel; 402. Adjusting plate; 403. Tensioning guide rail; 404. Tensioning top block; 405. Tensioning plate; 500. Optical coupler; 600. Baffle plate. Detailed Implementation

[0017] 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.

[0018] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or it can be fixed through another intermediate component. When a component is said to be "connected to" another component, it can be directly connected to the other component or it may be fixed through another intermediate component. When a component is said to be "set on" another component, it can be set directly on the other component or it may be set through another intermediate component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0020] Figures 1-5 This utility model discloses a test device for broken bars of cast aluminum rotor, comprising a test platform 100, a test component 200, and a drive component 300. The test component 200 and the drive component 300 are located within the test platform 100. The test platform 100 includes a worktable 101. The test component 200 and the drive component 300 are located on the upper and lower sides of the worktable 101, respectively. The test component 200 includes a positioning component 201, a detection component, and a clamping component 202. The plane of the clamping component 202 is perpendicular to the plane of the worktable 101. The rotor is located in the clamping component 202. The detection component is located on one side of the clamping component 202. The plane of the clamping component 202 is perpendicular to the plane of the positioning component 201.

[0021] Specifically, the detection component (not shown in the figure) is a Hall sensor.

[0022] In one embodiment of this application, the detection component is installed at the stator slot opening and can sensitively detect changes in the magnetic field generated during rotor rotation. When a bar breakage occurs in the rotor, the rotor current distribution changes, leading to an abnormal distribution of the air gap magnetic field. The Hall sensor installed near the stator slot opening can effectively capture this magnetic field change, thereby providing a basis for detecting rotor bar breakage faults.

[0023] The test platform 100 also includes a front panel 102, a display screen 103, and buttons 104. The display screen 103 is located on the front panel 102, and the buttons 104 are located on the work surface 101.

[0024] The positioning component 201 is located on one side of the clamping component 202 and fixed on the base plate 2021. The positioning component 201 includes fixed blocks 2011 arranged symmetrically at intervals, a first guide rod 2012 and a lead screw 2013 passing through the fixed blocks 2011. The positioning component 201 also includes a second handwheel 2014, a slider 2015 and a second guide rod 2016 perpendicular to the slider 2015. The second handwheel 2014 is fixedly connected to the lead screw 2013.

[0025] The positioning component 201 also includes a scale 2017, which is parallel to the first optical rod 2012 and fixed to the fixing block 2011. The positioning component 201 also includes a locking block 2018, which is located on the second optical rod 2016.

[0026] The clamping assembly 202 includes a base plate 2021, a lower seat plate 2022, a clamping rod 2023, a clamping screw 2024, a first handwheel 2025, a clamping sliding block 2026, a clamping fixing block 2027, and a clamping locking block 2028. The base plate 2021 is fixedly connected to the worktable surface 101, and the lower seat plate 2022 is fixedly connected to the worktable surface 101 through the base plate 2021. The clamping screw 2024 is fixedly connected to the first handwheel 2025. The clamping sliding block 2026 and the clamping fixing block 2027 are provided with through holes. The clamping rod 2023 is arranged parallel to the clamping screw 2024 and passes through the through holes, so as to realize the movement, positioning and locking of the clamping assembly 202 in the vertical direction.

[0027] The base plate 2021 is fixedly connected to the worktable 101, and the lower seat plate 2022 is fixed to the worktable 101 through the base plate 2021, which provides a stable installation foundation for the entire vertical motion mechanism.

[0028] Specifically, the clamping rods 2023 are arranged symmetrically.

[0029] Specifically, there are two clamping rods 2023.

[0030] The clamping rod 2023 serves as a guide, restricting components such as the clamping sliding block 2026 to move only along the direction (vertical) of the clamping rod 2023, ensuring the linearity and stability of the movement; the clamping screw 2024 is used to transmit power.

[0031] The clamping sliding block 2026 can slide on the clamping rod 2023 and the clamping screw 2024 to achieve vertical movement. The clamping fixing block 2027 is relatively fixed in position, serving as support and positioning, and also providing a position for the installation and fixing of components such as the clamping screw 2024.

[0032] After the pressing sliding block 2026 moves to the appropriate position, it is locked by the pressing locking block 2028 to prevent it from shifting during the test and to ensure stable pressing of components such as the rotor.

[0033] The clamping assembly 202 also includes a cylinder 2029, a main drive shaft 2030, a bearing cover 2031, a first tip 2032, a second tip 2033, and a rotating shaft located between the first tip 2032 and the second tip 2033. The cylinder 2029 is fixed on the clamping block 2027, and the second tip 2033 is fixed on the main drive shaft 2030. The main drive shaft 2030 is connected to the base plate 2021 through the bearing cover 2031.

[0034] The test assembly 200 also includes a dial 203, which is located between the second tip 2033 and the bearing cover 2031. By observing the relationship between the scale on the dial 203 and the corresponding position of the rotor error on the display, the location of the rotor quality problem can be determined relatively accurately.

[0035] The drive assembly 300 includes a motor 301, a large synchronous pulley 302, a synchronous belt 303, a small synchronous pulley 304, and a speed measuring disc 305. The small synchronous pulley 304 is connected to the output end of the motor 301 for transmission. The large synchronous pulley 302 is connected to the small synchronous pulley 304 through the synchronous belt 303. The speed measuring disc 305 is coaxially connected to the large synchronous pulley 302.

[0036] The aluminum rotor bar breakage test device also includes a tensioning assembly 400, which includes a tensioning wheel 401, an adjusting plate 402, a tensioning guide rail 403, a tensioning top block 404, and a tensioning plate 405. The adjusting plate 402 is connected to the tensioning wheel 401, and the tensioning wheel 401 abuts against the synchronous belt 303. The tensioning top block 404 and the tensioning plate 405 cooperate to push the adjusting plate 402 to slide linearly along the tensioning guide rail 403.

[0037] The cast aluminum rotor bar breakage testing device of this application also includes an optocoupler 500 and a baffle 600. The optocoupler 500 and baffle 600 are located on one side of the large synchronous pulley 302. The optocoupler 500 rotates together with the large synchronous pulley 302. When the baffle 600 passes the optocoupler 500, it blocks the optical path in the optocoupler 500, causing a change in the optocoupler's signal level. By measuring the frequency of the output signal of the optocoupler 500, the rotational speed of the large synchronous pulley 302 can be accurately calculated, thereby obtaining the rotor's rotational speed information. In rotor bar breakage testing, rotational speed is a crucial parameter; the characteristic signals generated by rotor bar breakage may differ at different rotational speeds. Therefore, accurate rotational speed measurement is essential for analyzing rotor bar breakage. Furthermore, when acquiring the magnetic field signal detected by the Hall sensor, the signal output by the optocoupler 500 is used as a synchronization signal to ensure signal acquisition at a specific rotational position of the rotor. This ensures that the acquired magnetic field signal corresponds to the rotor's position, facilitating subsequent analysis of magnetic field signals at different positions and improving the accuracy and reliability of rotor bar breakage detection.

[0038] In use, the cast aluminum rotor bar breakage testing device of this application places the cast aluminum rotor to be tested in the clamping assembly 202. By rotating the first handwheel 2025, the clamping screw 2024 is rotated, causing the clamping sliding block 2026 to slide on the clamping guide rod 2023 and the clamping screw 2024, adjusting its vertical position to stably clamp the rotor between the first center point 2032 and the second center point 2033. Then, the clamping locking block 2028 is used to lock it to prevent displacement during the test. According to the rotor size, the second handwheel 2014 of the positioning assembly 201 is rotated, and the screw 2013 rotates, causing the slider 2015 to move along the first guide rod 2012 and the second guide rod 2016. The position is observed through the scale 2017, and after adjusting to the appropriate position, it is locked with the locking block 2018. The tensioning assembly 400 is adjusted. If the synchronous belt 303 is loose, the tensioning top block 404 and the tensioning plate 405 are adjusted, pushing the adjusting plate 402 along the tensioning guide rail 403. Sliding causes the tensioning pulley 401 to press against the synchronous belt 303, ensuring normal transmission. The motor 301 of the drive assembly 300 is activated via the button 104 on the test platform 100. The motor 301 drives the small synchronous pulley 304 to rotate, which in turn drives the large synchronous pulley 302 to rotate via the synchronous belt 303, thus rotating the rotor. When the large synchronous pulley 302 rotates, the baffle 600 on it rotates with it, blocking the light path as it passes through the optocoupler 500, causing a change in the optocoupler 500's signal level. The frequency of the optocoupler 500's output signal is measured to calculate the speed of the large synchronous pulley 302 and the rotor. Simultaneously, using the optocoupler 500's output signal as a synchronization signal, the magnetic field signal detected by the Hall sensor installed near the stator slot is acquired, ensuring the magnetic field signal corresponds to the rotor position. The Hall sensor detects changes in the air gap magnetic field in real time as the rotor rotates. If a rotor bar breaks, the rotor current distribution changes, and the air gap magnetic field becomes abnormal. The Hall sensor captures this change and transmits it to the test device for analysis and processing. The location and condition of the broken rotor bar are determined by observing the relationship between the scale on dial 203 and the corresponding position of the rotor error on the display. The cast aluminum rotor broken bar testing device of this application, by vertically arranging the clamping assembly 202 within the testing platform 100 with the direction of gravity aligned with the rotor axis, allows the rotor to hang naturally under gravity, resulting in more stable contact with the clamping assembly 202 and reducing additional eccentricity or swaying caused by gravity. Compared to a horizontal arrangement, this reduces the impact of rotor imbalance caused by installation and other factors, improving test stability. The optocoupler 500 moves synchronously with the large synchronous pulley 302, using the signal output from the optocoupler 500 as the synchronization signal to ensure signal acquisition at specific rotational positions of the rotor. This ensures that the acquired magnetic field signal corresponds to the rotor's position, facilitating subsequent analysis of magnetic field signals at different positions and improving the accuracy and reliability of rotor broken bar detection.

[0039] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the utility model patent. It should be noted that for those skilled in the art, several modifications and improvements can be made without departing from the concept of this utility model. These are all equivalent modifications and improvements made to the above embodiments based on the essential technology of this utility model, and all of these fall within the protection scope of this utility model.

Claims

1. A test device for broken bars of a cast aluminum rotor, comprising a test platform, characterized in that: The cast aluminum rotor bar breakage testing device further includes a testing component and a driving component. The testing component and the driving component are located within the testing platform. The testing platform includes a worktable. The testing component and the driving component are located on the upper and lower sides of the worktable, respectively. The testing component includes a positioning component, a detection component, and a clamping component. The plane of the clamping component is perpendicular to the plane of the worktable. The rotor is located in the clamping component. The detection component is located on one side of the clamping component. The plane of the clamping component is perpendicular to the plane of the positioning component.

2. The cast aluminum rotor bar breakage testing device according to claim 1, characterized in that: The clamping assembly includes a base plate, a lower seat plate, a clamping guide rod, a clamping screw, a first handwheel, a clamping sliding block, a clamping fixing block, and a clamping locking block. The base plate is fixedly connected to the worktable surface, and the lower seat plate is fixedly connected to the worktable surface through the base plate. The clamping screw is fixedly connected to the first handwheel. The clamping sliding block, the sliding block, and the clamping fixing block are provided with through holes. The clamping guide rod is arranged parallel to the clamping screw and passes through the through holes, thereby realizing the vertical movement, positioning, and locking of the clamping assembly.

3. The cast aluminum rotor bar breakage testing device according to claim 2, characterized in that: The clamping assembly further includes a cylinder, a main drive shaft, a bearing cover, a first center, a second center, and a rotating shaft located between the first center and the second center. The cylinder is fixed to the clamping block, the second center is fixed to the main drive shaft, and the main drive shaft is connected to the base plate through the bearing cover.

4. The cast aluminum rotor bar breakage testing device according to claim 3, characterized in that: The test assembly also includes a dial located between the second tip and the bearing cap.

5. The cast aluminum rotor bar breakage testing device according to claim 2, characterized in that: The drive assembly includes a motor, a large synchronous pulley, a synchronous belt, a small synchronous pulley, and a speed measuring disc. The small synchronous pulley is connected to the output end of the motor. The large synchronous pulley is connected to the small synchronous pulley through the synchronous belt. The speed measuring disc is coaxially connected to the large synchronous pulley.

6. The cast aluminum rotor bar breakage testing device according to claim 5, characterized in that: The cast aluminum rotor bar breakage testing device also includes a tensioning assembly, which includes a tensioning wheel, an adjusting plate, a tensioning guide rail, a tensioning top block, and a tensioning plate. The adjusting plate is connected to the tensioning wheel, the tensioning wheel abuts against the synchronous belt, and the tensioning top block cooperates with the tensioning plate to push the adjusting plate to slide linearly along the tensioning guide rail.

7. The cast aluminum rotor bar breakage testing device according to claim 2, characterized in that: The positioning component is located on one side of the clamping component and fixed on the base plate. The positioning component includes fixed blocks arranged symmetrically at intervals, a first guide rod and a lead screw passing through the fixed blocks, and the positioning component also includes a second handwheel, a slider and a second guide rod perpendicular to the slider. The second handwheel is fixedly connected to the lead screw.

8. The cast aluminum rotor bar breakage testing device according to claim 7, characterized in that: The positioning component also includes a scale, which is parallel to the first optical rod and fixed to the fixing block.

9. The cast aluminum rotor bar breakage testing device according to claim 7, characterized in that: The positioning component also includes a locking block located on the second optical rod.

10. The test device for broken bars of a cast aluminum rotor according to claim 1, characterized in that: The testing platform also includes a front panel, a display screen, and buttons. The display screen is located on the front panel, and the buttons are located on the workbench.

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