CN113414491B - Visual identification method and welding process for stator copper wires of hairpin motor - Google Patents
Visual identification method and welding process for stator copper wires of hairpin motor Download PDFInfo
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- CN113414491B CN113414491B CN202110811441.XA CN202110811441A CN113414491B CN 113414491 B CN113414491 B CN 113414491B CN 202110811441 A CN202110811441 A CN 202110811441A CN 113414491 B CN113414491 B CN 113414491B
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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 visual identification method for a stator copper wire of a hairpin motor, which comprises the following steps: s1, acquiring original pictures of all pin end faces of a stator copper wire by an industrial camera; s2, calibrating center points of all pin end faces of the stator copper wire, and fitting the center points of the two pin end faces to be welded into a straight line through a connecting tool, and marking the straight line as L1; s3, calibrating adjacent two sides of a joint seam of the end surfaces of the two pins to be welded, respectively fitting two straight lines, and respectively marking the straight lines as L2 and L3; s4, fitting intersection points of the straight line L1, the straight line L2 and the straight line L3 respectively, marking as A, B respectively, and calculating weld joint lengths and weld joint coordinates of the end faces of the two pins to be welded according to the distance between A, B points; s5, generating welding tracks of all pin end faces of the stator copper wire according to the welding line coordinates of all pin end faces calculated in the S4; the invention can complete the recognition of all welding spot positions in the required beat, avoids the situations of deviation and omission of welding spots, and solves the problem of poor real-time recognition effect of the welding spot positions.
Description
Technical Field
The invention belongs to the technical field of production of stator copper wires of a hairpin motor, and relates to a visual identification method and a welding process of the stator copper wires of the hairpin motor.
Background
The hair permanent magnet synchronous motor (Hairpin motor) is gradually applied in large scale in domestic driving motor market, compared with the traditional wound motor, the Hairpin motor stator copper wire is flat, and the motor volume can be smaller under the same power, so that the hair motor stator copper wire is the development direction of the next generation new energy automobile driving motor. However, because of the complex manufacturing process, the manufacturers capable of mass production in China at present, especially more than 8 layers of hairpin motors, belong to high-end products in China and even worldwide. The stator of the hairpin motor above 8 layers is provided with hundreds of welding spots, all welding positions need to be identified within the required beat, deviation and omission cannot occur in the identification result, the positions of all single welding spots on each stator are different due to elastic deformation of copper wires, high requirements are provided for real-time identification of the welding positions, and the welding efficiency is low, so that the visual identification method and the welding process for the copper wires of the stator of the hairpin motor are provided.
Disclosure of Invention
Aiming at the problems, the invention provides a visual identification method and a welding process for a stator copper wire of a hairpin motor, which well solve the problems of deviation and omission of welding spot identification, poor real-time identification effect and low welding efficiency in the prior art.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows: a visual identification method for stator copper wires of a hairpin motor comprises the following steps:
s1, acquiring original pictures of all pin end faces of a stator copper wire by an industrial camera;
s2, calibrating the center points of all pin end faces of the stator copper wire in the original picture, fitting the center points of the two pin end faces which are contacted with the to-be-welded into a straight line through a connecting 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 an original picture, respectively fitting into two straight lines, and respectively marking as L2 and L3;
s4, fitting intersection points of the straight line L1, the straight line L2 and the straight line L3 respectively, marking as A, B respectively, and calculating weld joint lengths and weld joint coordinates of the end faces of the two pins to be welded according to the distance between the A, B two points;
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 mark the center points of all the pin end faces of the stator copper wire.
Further, in the step S3, a cog findlinetool is used, and a gray threshold range is set to demarcate two adjacent sides of the joint seam between the two pin end surfaces to be soldered.
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 CogInterrectLineLineTool tool 1 ，Y 1 )、(X 2 ，Y 2 ) And an angle θ between the straight line L1 and the straight line L2 or the straight line L3;
s42, then according to the pixel coordinates (X in step S41 1 ，Y 1 )、(X 2 ，Y 2 ) Calculating the weld joint length L and the weld joint coordinates (X, Y) of the end surfaces of the two pins according to the included angle theta and the following formula;
the welding spot coordinates are x= (X) 1 +X 2 )/2；Y＝(Y 1 +Y 2 )/2；
The length of the welding line is
Further, in the step S5, a two-dimensional arc tool is used to generate welding tracks of all pin end surfaces of the stator copper wire.
Further, in the step S41, the distance between the point a and the point B is calculated by using the cgintellect linetool to determine the size and the offset of the weld.
The invention also provides a card-issuing motor stator copper wire welding process, which is characterized by utilizing the card-issuing motor stator copper wire visual identification method to weld the end face of a stator copper wire pin, and comprising the following steps:
t1, tightly positioning a to-be-welded stator copper wire by using a tooling clamp;
t2, recognizing welding tracks of all pin end faces of the stator copper wire by adopting the hairpin motor stator copper wire visual recognition method;
and T3, welding all welding spots on the welding track by adopting servo laser welding equipment.
Further, the track of the laser welding on each welding spot in the step T3 is elliptical.
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 joint coordinates and the weld joint lengths of all pin end faces of the stator copper wire can be calculated, identification of all welding spot positions can be completed in a required beat, the situation that welding spots are deviated and omitted is avoided, and the problem that the real-time identification effect of the welding spot positions is poor is solved.
According to the card-issuing motor stator copper wire welding process, the positions of all welding spots can be identified in the required beat, all the welding spots are welded in sequence according to the generated welding track, the welding efficiency is high, and the process stability is high.
Drawings
FIG. 1 is a schematic diagram of a method for visually identifying a stator copper wire of a hairpin motor according to the invention;
fig. 2 is an effect diagram after the identification of the stator copper wire of the hairpin motor according to the visual identification method of the invention;
fig. 3 is a diagram of welding track of welding points in the process of welding the stator copper wires of the hairpin motor of the invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
As shown in fig. 1, the visual identification method for the stator copper wire of the hairpin motor provided by the invention comprises the following steps:
s1, acquiring original pictures of all pin end faces of a stator copper wire by an industrial camera;
s2, marking the center points of all pin end surfaces of the stator copper wire in the original picture by adopting a spot tool in Cognex Vision Pro software, fitting the center points of the two pin end surfaces which are contacted with the to-be-welded into a straight line by adopting a connecting tool, and marking the straight line as L1;
s3, adopting a CogFindLineTool tool, setting a gray threshold range to calibrate adjacent two sides of a joint seam of two pin end surfaces to be welded in an original picture, respectively fitting into two straight lines, and respectively marking as L2 and L3; setting the gray threshold range to 220-255; the normal reflection brightness of the copper wire pin end surface is strong, namely the gray value is large and is close to 255, and the area outside the pin end surface is darker and is generally lower than 220;
s4, fitting intersection points of the straight line L1, the straight line L2 and the straight line L3 respectively, marking as A, B respectively, and calculating weld joint lengths and weld joint coordinates of the end faces of the two pins to be welded according to the distance between the A, B two points;
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 of the stator copper wire of the hairpin motor can calculate the weld joint coordinates and the weld joint lengths of all pin end surfaces of the stator copper wire, can finish 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.
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 CogInterrectLineLineTool tool 1 ，Y 1 )、(X 2 ，Y 2 ) And an angle θ between the straight line L1 and the straight line L2 or the straight line L3;
s42, then according to the pixel coordinates (X in step S41 1 ，Y 1 )、(X 2 ，Y 2 ) Calculating the weld joint length L and the weld joint coordinates (X, Y) of the end surfaces of the two pins according to the included angle theta and the following formula;
the welding spot coordinates are x= (X) 1 +X 2 )/2；Y＝(Y 1 +Y 2 )/2；
The length of the welding line is
Meanwhile, the CogInterrectLineLineTool 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, the coordinate points of the welding line are directly removed for the pins with larger welding line and without welding line, the coordinate points of the normal welding line are directly collected, the welding track can be directly generated for the normal welding line to be welded, the welding line with larger welding line and without welding line needs to be checked and corrected, the accuracy of identification 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 all pin end surfaces of the stator copper wire.
The invention also provides a card-issuing motor stator copper wire welding process, which utilizes the card-issuing motor stator copper wire visual identification method to weld the end face of a stator copper wire pin, and comprises the following steps:
t1, tightly positioning a to-be-welded stator copper wire by using a tooling clamp;
t2, recognizing welding tracks of all pin end faces of the stator copper wire by adopting the hairpin motor stator copper wire visual recognition method;
and T3, welding all welding spots on the welding track by adopting servo laser welding equipment.
Preferably, a vibrating mirror is arranged in the servo laser welding equipment, the operation area is calibrated by combining the vibrating mirror and the welding track, and a laser welding head in the servo laser welding equipment is controlled to move to the left position of each welding spot in the welding track by using a servo motor to weld the end face of a copper wire pin; specifically, the welding track at each welding point is elliptical, and the elliptical welding track is adopted so that the periphery of the end face of the pin and the copper bodies at four corners can be just dissolved into the welding line, the welding is not excessively performed on the outside of the pin, and the welding points are round and full; the welding efficiency is high, and the process stability is high.
Although the present invention has been described with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications may be made to the embodiments described, or equivalents may be substituted for elements thereof, and any modifications, equivalents, improvements and changes may be made without departing from the spirit and principles of the present invention.
Claims (1)
1. The process for welding the stator copper wire of the hairpin motor is characterized by comprising the following steps of:
t1, tightly positioning a to-be-welded stator copper wire by using a tooling clamp;
t2, recognizing welding tracks of all pin end faces of the stator copper wire by adopting a hairpin motor stator copper wire visual recognition method; the visual identification method for the stator copper wires of the hairpin motor comprises the following steps:
s1, acquiring original pictures of all pin end faces of a stator copper wire by an industrial camera;
s2, calibrating the center points of all pin end faces of the stator copper wire in the original picture, fitting the center points of the two pin end faces which are contacted with the to-be-welded into a straight line through a connecting 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 an original picture, respectively fitting into two straight lines, and respectively marking as L2 and L3;
s4, fitting intersection points of the straight line L1, the straight line L2 and the straight line L3 respectively, marking as A, B respectively, and calculating weld joint lengths and weld joint coordinates of the end faces of the two pins to be welded according to the distance between the A, B two points;
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;
in the step S2, a spot tool is adopted to mark the center points of all pin end faces of the stator copper wire;
in the step S3, a CogFindLineTool tool is adopted, and a gray threshold range is set to demarcate two adjacent sides of a joint seam of the two pin end surfaces to be welded;
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 CogInterrectLineLineTool tool 1 ，Y 1 ）、（X 2 ，Y 2 ) And an angle θ between the straight line L1 and the straight line L2 or the straight line L3;
s42, then according to the pixel coordinates (X in step S41 1 ，Y 1 ）、（X 2 ，Y 2 ) Calculating the weld joint length L and the weld joint coordinates (X, Y) of the end surfaces of the two pins according to the included angle theta and the following formula;
weld coordinates are x= (X) 1 +X 2 ）/2；Y=（Y 1 +Y 2 ）/2；
Weld length l=sinθ ×
；
In the step S5, welding tracks of all pin end surfaces of the stator copper wire are generated by adopting a two-dimensional arc tool;
in the step S41, a cog inter-electrode linetool is used to calculate the distance between the point a and the point B, so as to determine the size and the offset of the weld;
t3, adopting servo laser welding equipment to weld all welding spots on welding tracks of all pin end faces of the generated stator copper wire; and the welding track of the laser welding on each welding spot 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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| CN113414491B true CN113414491B (en) | 2023-07-14 |
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| CA2103692A1 (en) * | 1992-08-10 | 1994-02-11 | David R. Woodward | Method of installation of composite electrodes in discharge lamps |
| JP5002329B2 (en) * | 2007-02-21 | 2012-08-15 | 株式会社新川 | Semiconductor device and wire bonding method |
| 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 |
| CN102179598B (en) * | 2011-03-31 | 2013-05-01 | 中国科学院自动化研究所 | Method and device for centering initial welding positions of flat narrow welding lines and tracking welding lines |
| CN111322954B (en) * | 2020-03-19 | 2021-07-27 | 北京神工科技有限公司 | Assembly tool pose measuring method and device, storage medium and electronic equipment |
| CN112621034A (en) * | 2020-12-10 | 2021-04-09 | 北京博清科技有限公司 | Welding gun positioning method, device, equipment and storage medium |
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