CN113414491A - Hairpin motor stator copper wire visual identification method and welding process - Google Patents
Hairpin motor stator copper wire visual identification method and welding process Download PDFInfo
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- CN113414491A CN113414491A CN202110811441.XA CN202110811441A CN113414491A CN 113414491 A CN113414491 A CN 113414491A CN 202110811441 A CN202110811441 A CN 202110811441A CN 113414491 A CN113414491 A CN 113414491A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
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Abstract
The invention discloses a hairpin motor stator copper wire visual identification method, which comprises the following steps: s1, acquiring original pictures of the end faces of all pins of the stator copper wire by using an industrial camera; s2, calibrating the center points of the end faces of all the pins of the stator copper wire, and fitting the center points of the end faces of the two pins to be welded into a straight line through a wiring tool and recording the straight line as L1; s3, calibrating two adjacent sides of a joint seam of the end surfaces of two pins to be welded, and respectively fitting into two straight lines which are respectively marked as L2 and L3; s4, respectively fitting the intersection points of the straight line L1 and the straight line L2 and the intersection points of the straight line L3, respectively marking as A, B, and calculating the length and the coordinates of the weld joint of the end faces of the two pins to be welded according to the distance between A, B two points; s5, generating welding tracks of the end faces of all the pins of the stator copper wire according to the welding seam coordinates of the end faces of all the pins calculated in S4; the invention can complete the identification of all welding spot positions in the required beat, avoids the conditions of deviation and omission of welding spots and solves the problem of poor real-time identification effect of the welding spot positions.
Description
Technical Field
The invention belongs to the technical field of production of hairpin motor stator copper wires, and relates to a hairpin motor stator copper wire visual identification method and a welding process.
Background
The Hairpin permanent magnet synchronous motor (hair pin motor) is gradually applied to the domestic driving motor market in a large scale, and compared with the traditional winding type motor, the hair pin permanent magnet synchronous motor has the advantage that the volume of the motor is smaller under the same power due to the characteristic that a stator copper wire of the hair pin motor is flat, and is the development direction of the next generation of new energy automobile driving motor. However, due to the complex manufacturing process, the number of manufacturers capable of mass production in the Chinese market is small at present, and particularly, the number of the hair-clamping motors with more than 8 layers belongs to high-end products in China and even in the whole world. The hairpin motor stators with more than 8 layers are provided with hundreds of welding spots, the identification of all welding positions is required to be completed in a required beat, the identification result cannot be deviated or omitted, the positions of all single welding spots on each stator are different due to the elastic deformation of copper wires, the high requirement is provided for the real-time identification of the welding positions, the welding efficiency is low, and therefore the hairpin motor stator copper wire visual identification method and the welding process are provided.
Disclosure of Invention
Aiming at the problems, the invention provides a hairpin motor stator copper wire visual identification method and a welding process, which well solve the problems of deviation and omission in welding spot identification, poor real-time identification effect and low welding efficiency in the prior art.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows: a hairpin motor stator copper wire visual identification method comprises the following steps:
s1, acquiring original pictures of the end faces of all pins of the stator copper wire by using an industrial camera;
s2, calibrating the center points of the end faces of all pins of the stator copper wire in the original picture, and fitting the center points of the end faces of the two pins contacting to-be-welded into a straight line through a wiring tool, and marking as L1;
s3, calibrating two adjacent sides of a joint seam of the end faces of two pins to be welded in the original picture, and respectively fitting into two straight lines which are respectively marked as L2 and L3;
s4, respectively fitting the intersection points of the straight line L1, the straight line L2 and the straight line L3, respectively marking as A, B, and calculating the length and the coordinate of the weld joint of the end faces of the two pins to be welded according to the distance between A, B two points;
and S5, generating welding tracks of all the pin end faces of the stator copper wire according to the welding seam coordinates of all the pin end faces calculated in the S4.
Further, in the step S2, a spot tool is used to calibrate the center points of the end faces of all the pins of the stator copper wire.
Further, in step S3, a CogFindLineTool is used, and a gray threshold range is set to calibrate two adjacent sides of the joint seam of the end surfaces of the two pins to be welded.
Further, the step S4 further includes the following steps:
s41, finding out the pixel coordinates (X) of the point A and the point B by adopting a CogIntersectLineLineTool tool1，Y1)、(X2，Y2) And the angle θ between the line L1 and the line L2 or the line L3;
s42, and then according to the pixel coordinate (X) in step S411，Y1)、(X2，Y2) Calculating the length L of the welding seam and the coordinates (X, Y) of the welding seam of the end surfaces of the two pins by the included angle theta and the following formula;
coordinate of welding point is X ═ X1+X2)/2；Y＝(Y1+Y2)/2；
The length of the weld joint is
Further, in the step S5, a two-dimensional arc tool is used to generate the welding tracks of the end faces of all the pins of the stator copper wire.
Further, in step S41, a cogintersectlinetool is used to calculate the distance between point a and point B for determining the size and offset of the weld.
The invention also provides a welding process of the stator copper wire of the hairpin motor, which is characterized in that the stator copper wire pin end face is welded by using the hairpin motor stator copper wire visual identification method, and the welding process comprises the following steps:
t1, clamping and positioning the stator copper wire to be welded by a tool;
t2, identifying welding tracks of all pin end faces of the stator copper wire by adopting the hairpin motor stator copper wire visual identification method;
and T3, welding all welding points on the welding track by using a servo laser welding device.
Further, the trajectory of the laser welding on each welding point in the step T3 is an ellipse.
Compared with the prior art, the invention has the following beneficial effects:
according to the visual identification method for the stator copper wire of the hairpin motor, the weld coordinates and the weld lengths of the end faces of all pins of the stator copper wire can be calculated, the identification of all welding spot positions can be completed in required beats, the situations of deviation and omission of welding spots are avoided, and the problem of poor real-time identification effect of the welding spot positions is solved.
According to the welding process of the hairpin motor stator copper wire, all welding point positions can be identified in required beats, all welding points are welded in sequence according to the generated welding tracks, and the welding process is high in welding efficiency and process stability.
Drawings
FIG. 1 is a schematic diagram of a hairpin machine stator copper wire visual identification method of the invention;
FIG. 2 is a diagram of the effect of the hairpin motor stator copper wire after being identified by the visual identification method of the invention;
FIG. 3 is a welding point welding track diagram in the hairpin motor stator copper wire welding process.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, the method for visually identifying the stator copper wire of the hairpin machine according to the invention comprises the following steps:
s1, acquiring original pictures of the end faces of all pins of the stator copper wire by using an industrial camera;
s2, calibrating the central points of the end faces of all pins of the stator copper wire in the original picture by using a spot tool in Cognex Vision Pro software, and fitting the central points of the end faces of the two pins contacting to-be-welded into a straight line by using a connecting line tool, wherein the straight line is marked as L1;
s3, calibrating two adjacent sides of a joint seam of end faces of two pins to be welded in an original picture by adopting a CogFindLineTool tool and setting a gray threshold range, and respectively fitting into two straight lines which are respectively marked as L2 and L3; setting the gray threshold range as 220-255; the brightness of the light reflected by the end face of the normal copper wire pin is very strong, namely the gray value is very large and is close to 255, and the area outside the end face of the pin is darker and is generally lower than 220;
s4, respectively fitting the intersection points of the straight line L1, the straight line L2 and the straight line L3, respectively marking as A, B, and calculating the length and the coordinate of the weld joint of the end faces of the two pins to be welded according to the distance between A, B two points;
and S5, generating welding tracks of all the pin end faces of the stator copper wire according to the welding seam coordinates of all the pin end faces calculated in the S4.
When the technical scheme is used, the visual identification method for the stator copper wire of the hairpin motor can calculate the weld coordinates and the weld lengths of the end faces of all pins of the stator copper wire, can complete the identification of the positions of all welding points in required beats, avoids the occurrence of deviation and omission of the welding points, and solves the problem of poor real-time identification effect of the positions of the welding points.
In this embodiment, the step S4 further includes the following steps:
s41, finding out the pixel coordinates (X) of the point A and the point B by adopting a CogIntersectLineLineTool tool1，Y1)、(X2，Y2) And the angle θ between the line L1 and the line L2 or the line L3;
s42, and then according to the pixel coordinate (X) in step S411，Y1)、(X2，Y2) Calculating the length L of the welding seam and the coordinates (X, Y) of the welding seam of the end surfaces of the two pins by the included angle theta and the following formula;
coordinate of welding point is X ═ X1+X2)/2；Y＝(Y1+Y2)/2；
The length of the weld joint is
And meanwhile, a CogIntersectLineLineTool tool is adopted to calculate the distance between the point A and the point B so as to judge the size and the offset of the welding line, for the pin with a larger welding line and without the welding line, the coordinate point of the pin is directly eliminated, the coordinate point of the normal welding line is directly collected, the welding track generated by the normal welding point can be directly welded, the welding point with the larger welding line and without the welding line needs to be checked and corrected, the identification accuracy is improved, and the deviation is avoided.
In this embodiment, in step S5, a two-dimensional arc tool is used to generate welding tracks of end faces of all pins of the stator copper wire.
The invention also provides a welding process of the stator copper wire of the hairpin motor, which utilizes the stator copper wire vision identification method of the hairpin motor to weld the end surface of the pin of the stator copper wire and comprises the following steps:
t1, clamping and positioning the stator copper wire to be welded by a tool;
t2, identifying welding tracks of all pin end faces of the stator copper wire by adopting the hairpin motor stator copper wire visual identification method;
and T3, welding all welding points on the welding track by using a servo laser welding device.
Preferably, a galvanometer is installed in the servo laser welding equipment, the galvanometer and the welding track are combined to calibrate the operation area, and a laser welding head in the servo laser welding equipment is controlled by a servo motor to move to the left position of each welding point in the welding track to weld the end faces of the copper wire pins; specifically, the welding track at each welding point is elliptical, and the elliptical welding track is adopted to enable the copper bodies at the periphery and four corners of the end face of each pin to be just dissolved in the welding line, so that the copper bodies are not excessively welded to the outside of each pin, and welding spots are round and full; high welding efficiency and high process stability.
Although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that various changes in the embodiments and/or modifications of the invention can be made, and equivalents and modifications of some features of the invention can be made without departing from the spirit and scope of the invention.
Claims (8)
1. A hairpin machine stator copper wire visual identification method is characterized by comprising the following steps:
s1, acquiring original pictures of the end faces of all pins of the stator copper wire by using an industrial camera;
s2, calibrating the center points of the end faces of all pins of the stator copper wire in the original picture, and fitting the center points of the end faces of the two pins contacting to-be-welded into a straight line through a wiring tool, and marking as L1;
s3, calibrating two adjacent sides of a joint seam of the end faces of two pins to be welded in the original picture, and respectively fitting into two straight lines which are respectively marked as L2 and L3;
s4, respectively fitting the intersection points of the straight line L1, the straight line L2 and the straight line L3, respectively marking as A, B, and calculating the length and the coordinate of the weld joint of the end faces of the two pins to be welded according to the distance between A, B two points;
and S5, generating welding tracks of all the pin end faces of the stator copper wire according to the welding seam coordinates of all the pin end faces calculated in the S4.
2. The method for visually identifying stator copper wires of a hairpin machine according to claim 1, wherein a spot tool is used to calibrate the center points of all pin end faces of stator copper wires in step S2.
3. The method for visually recognizing the stator copper wire of the hairpin motor according to claim 1, wherein in step S3, a CogFindLineTool is used, and a gray threshold range is set to calibrate the adjacent two sides of the joint seam of the end faces of the two pins to be welded.
4. The method for visually identifying hairpin motor stator copper wires as claimed in claim 1, wherein said step S4 further comprises the steps of:
s41, finding out the pixel coordinates (X) of the point A and the point B by adopting a CogIntersectLineLineTool tool1，Y1)、(X2，Y2) And the angle θ between the line L1 and the line L2 or the line L3;
s42, and then according to the pixel coordinate (X) in step S411，Y1)、(X2，Y2) Calculating the length L of the welding seam and the coordinates (X, Y) of the welding seam of the end surfaces of the two pins by the included angle theta and the following formula;
coordinate of welding point is X ═ X1+X2)/2；Y＝(Y1+Y2)/2；
The length of the weld joint is
5. The method for visually recognizing stator copper wires of a hairpin machine according to claim 1, wherein in step S5, welding tracks of all pin end faces of stator copper wires are generated by using a two-dimensional arc tool.
6. The method as claimed in claim 4, wherein in step S41, a CogIntersectLineLineTool tool is used to calculate the distance between point A and point B for determining the size and offset of the weld.
7. A hairpin machine stator copper wire welding process is characterized in that the stator copper wire pin end face is welded by the hairpin machine stator copper wire visual identification method of any one of claims 1 to 6, and the process comprises the following steps:
t1, clamping and positioning the stator copper wire to be welded by a tool;
t2, identifying welding tracks of all pin end faces of the stator copper wire by adopting the hairpin motor stator copper wire visual identification method;
and T3, welding all welding points on the welding track by using a servo laser welding device.
8. The hairpin stator copper wire welding process of claim 7 wherein the trajectory of the laser weld at each weld point in the step T3 is elliptical.
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| CN202110811441.XA CN113414491B (en) | 2021-07-16 | 2021-07-16 | Visual identification method and welding process for stator copper wires of hairpin motor |
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| CN202110811441.XA CN113414491B (en) | 2021-07-16 | 2021-07-16 | Visual identification method and welding process for stator copper wires of hairpin motor |
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| CN113414491B CN113414491B (en) | 2023-07-14 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN118196067A (en) * | 2023-05-05 | 2024-06-14 | 苏州卡门哈斯激光技术有限责任公司 | Visual positioning detection method for welding flat copper wire motor |
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| EP0584859A1 (en) * | 1992-08-10 | 1994-03-02 | Koninklijke Philips Electronics N.V. | Discharge lamps with composite electrodes and method of installation of these electrodes in the lamps |
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| CN101249587A (en) * | 2008-04-07 | 2008-08-27 | 北京工业大学 | Device for reducing 1420 aluminum lithium alloy laser beam welding air holes |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN118196067A (en) * | 2023-05-05 | 2024-06-14 | 苏州卡门哈斯激光技术有限责任公司 | Visual positioning detection method for welding flat copper wire motor |
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