JP2004222458A - Welding method for segment conductor and control method for welding quality of segment conductor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a welding method for segment conductors wherein a torch is moved to positions suitable for welding segment conductors for significantly reducing a poor weld. <P>SOLUTION: With respect to the end flat faces 14 and 24 of separate segment conductors 11 and 21 on one end side or the other end side, to be welded together by a torch, the following procedure is taken: the positions of their two vertexes which adjoin each other on the torch side but do not adjoin chamfered portions 15 and 25 are measured through image processing through four pairs of measuring windows W1, the measuring windows in each pair being orthogonal to each other. Thereby, the positions are determined as torch movement basic information. The torch is moved based on the torch movement basic information. Thus, the torch is moved to positions for suitable for welding the segment conductors 11 and 21. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a segment conductor welding method and a segment conductor welding quality control method for welding segment conductors in a segment conductor used in a motor of a hybrid vehicle, an electric vehicle, or the like.
[0002]
[Prior art]
Conventionally, in manufacturing a motor having a segment conductor as one of the constituent elements, for example, according to the following procedure / method, a plurality of segment conductors are assembled and then each segment conductor is welded to each other.
[0003]
That is, first, as shown in the plan view of FIG. 29, a stator core 101 (about 200 to 300 mm in diameter) in which a plurality of penetration grooves 102 are radially provided is prepared. Next, as shown in FIG. 30, both ends of a plurality of substantially U-shaped segment conductors 103 are inserted into and set in the respective penetration grooves 102 of the stator core 101. In addition, as shown in FIG. 31, both ends of a plurality of substantially U-shaped segment conductors 104 are inserted and set.
In this regard, FIG. 32 is a diagram showing a part of a state in which both ends of each of the segment conductors 103 and 104 are inserted and set in each of the penetration grooves 102 of the stator core 101. In FIG. 32, the segment conductor 104 is indicated by a two-dot chain line so that the segment conductors 103 and 104 can be distinguished.
[0004]
Thereafter, both ends of the plurality of segment conductors 103 and 104 set in the respective penetration grooves 102 of the stator core 101 are passed through the stator core 101 as shown in FIG. As shown in FIG. 34, both ends of each of the segment conductors 103 and 104 are bent at one end to one side in the circumferential direction of the stator core 101, and the other end is bent to the other side in the circumferential direction of the stator core 101. Further, at this time, the distal ends at one end and the other end of each of the segment conductors 103 and 104 are bent in the axial direction of the stator core 101 as shown in FIG. As a result, the tip ends of the segment conductors 103 and 104 assembled to the stator core 101 are radially arranged as shown in FIG. Note that FIG. 35 shows only the leading ends of the segment conductors 103 and 104, but the total number of leading ends of the segment conductors 103 and 104 is very large at "576".
[0005]
Next, the distal ends of the segment conductors 103 and 104 radially arranged are welded in pairs adjacent to each other in the radial direction of the stator core 101. Therefore, as shown in FIG. 36, the scheduled welding locations 105 are also arranged radially, and from a different point of view, the scheduled welding locations 105 extend over many concentric circles of the stator core 101. Will be located. In FIG. 36, the total number of the scheduled welding locations 105 reaches 288 (48 / round × 6 rounds).
[0006]
Therefore, in the prior art, in order to weld the tip of each of the segment conductors 103 and 104 at each to-be-welded portion 105, the to-be-welded portion 105 drawn by rotating the stator core 101 in which the plurality of segment conductors 103 and 104 are assembled. A continuous welding is performed by fixing the torch on the circular orbit and rotating the stator core 101 by a predetermined angle, and sequentially moving the welding scheduled portion 105 under the torch. Therefore, every time the continuous welding on one circumferential track is completed, the torch is fixed on the next circumferential track and continuous welding is performed, and if this is repeated, all the welding scheduled portions 105 are welded. be able to.
[0007]
Here, the welding scheduled portion 105 will be described. In the following, the segment conductors 103 and 104 at the scheduled welding location 105 will be described as “segment conductors 11 and 21 to be welded” regardless of which of the segment conductors 103 and 104.
As shown in FIGS. 25 and 26, in each of the scheduled welding locations 105, the bare conductors 12, 22 and the enamel covering parts 13, 23 are located at the same height in the segment conductors 11, 21 to be welded. In addition, when the flat end faces 14, 24 of the bare wire portions 12, 22 and the chamfered portions 15, 25 are located symmetrically, and when welding is performed, the gap between the segment conductors 11, 21 to be welded is set. The design is such that the torch 31 is located at the center and is assembled to the stator core 101.
Therefore, if the arc of the torch 31 is performed in the state shown in FIGS. 25 and 26, the quality of welding in the segment conductors 11 and 21 can be ensured.
[0008]
At this time, there is also a technique in which welding is performed while rocking the torch in order to prevent the welded portions from coming into contact with each other (for example, see Patent Document 1).
[0009]
[Patent Document 1]
JP-A-10-234160
[0010]
[Problems to be solved by the invention]
However, in a step before welding the segment conductors 11 and 21, one end of each of the segment conductors 103 and 104 is bent to one side in the circumferential direction of the stator core 101 as shown in FIG. Are bent in the circumferential direction of the stator core 101, and at this time, the distal ends of the segment conductors 103 and 104 are bent in the axial direction of the stator core 101 as shown in FIG.
[0011]
For this reason, in each of the welding scheduled portions 105, the segment conductors 11 and 21 to be welded are positioned vertically and horizontally as shown in FIG. 27, for example, depending on the variation in the material, the amount of springback, and other conditions. In many cases, the displacement occurs (see FIG. 25 and comparison), and as shown in FIG. 28, the displacement occurs due to torsion (see FIG. 26 and comparison).
[0012]
In the state shown in FIGS. 27 and 28, the distance from the welding target segment conductors 11 and 21 to the torch 31 becomes longer or shorter at the welding scheduled portion 105. It is also possible to fix the torch 31 on the circumferential orbit of 105 and rotate the stator core 101 having the plurality of segment conductors 103 and 104 by a predetermined angle at a predetermined angle to sequentially move the to-be-welded portion 105 below the torch 31. Or, even if the torch 31 is swung in addition to this, the welding is almost always defective.
[0013]
Therefore, the present invention has been made in view of the above points, and a method of welding a segment conductor in which a torch is moved to a position suitable for welding a segment conductor, thereby greatly reducing welding defects. Is to be provided as a first subject.
[0014]
Further, when the segment conductors 11 and 21 to be welded are welded to the respective welding scheduled locations 105, welding failure is detected as a part of quality control. Examples of the detection items for the places where welding is performed include, for example, non-welding or melting and melting, insufficient melting, gaps between the places where the segment conductors 11 and 21 are welded, and the presence or absence of foaming in the enamel coating portions 13 and 23. 36, there is a large number of scheduled welding spots 105, as shown in FIG. 36, so that the burden on the worker is large, and there is a variation in the judgment criteria, and the welding defect is overlooked. The fear is great.
[0015]
Therefore, the present invention has been made in view of the above-described points, and by performing image processing on a planar image of a welded portion, it is possible to accurately and accurately detect unwelded and fused portions of a welded portion and insufficient melting. A second object is to provide a method of controlling the welding quality of a segment conductor which can be easily performed.
[0016]
In addition, the present invention has been made in view of the above points, and a segment that can accurately and easily measure a gap between welding portions by performing image processing on a planar image of the welding portion. A third object is to provide a welding quality control method for a conductor.
[0017]
In addition, the present invention has been made in view of the above points, and by performing image processing on the image of the insulating covering portion of the segment conductor, it is possible to accurately detect the presence or absence of foaming of the insulating covering portion of the segment conductor. A fourth object is to provide a method for controlling the welding quality of a segment conductor which can be performed easily.
[0018]
[Means for Solving the Problems]
The invention according to claim 1, which has been made to solve the first problem, twists both ends of a plurality of substantially U-shaped segment conductors penetrating into a stator core in the circumferential direction of the stator core in opposite directions to be adjacent to each other. In a method of welding a segment conductor in which one end or the other end of a separate segment conductor is welded with a torch, one end or the other end of the separate segment conductor which is welded by the torch is used. For each of the tip planes, the positions of two vertices that are adjacent on the torch side but not adjacent to the chamfered part are determined as torch movement basic information by measuring by planar image processing, and the torch movement basic information is obtained. The torch is moved based on the following.
[0019]
The invention according to claim 2 is the segment conductor welding method according to claim 1, wherein, based on the torch movement basic information, one end side of another segment conductor which is welded by the torch or another. It is characterized in that a torch moving position having the same distance from each of the end planes on the end side to the torch is obtained, and the torch is moved to the torch moving position.
[0020]
In the method for welding a segment conductor according to the present invention having such features, both ends of a plurality of substantially U-shaped segment conductors each having a tip plane adjacent to a chamfer are formed to penetrate the stator core and extend in the circumferential direction of the stator core. The segments are twisted in opposite directions, and the end portions of one end or the other end of the separate segment conductors are welded with a torch after they are adjacent to each other. However, before welding with the torch, for each of the tip planes on one end side or the other end side of the separate segment conductors that are in a relationship to be welded with the torch, two pieces that are adjacent on the torch side and not adjacent to the chamfered part The positions of the vertices are determined by image processing in plan view as torch movement basic information, and the torch is moved based on the torch movement basic information.
[0021]
That is, in the segment conductor welding method of the present invention, before welding with the torch, each of the end planes on one end side or the other end side of the separate segment conductors that are welded with the torch are adjacent on the torch side. At the same time, the position of two vertices that are not adjacent to the chamfered part is measured by image processing in plan view to obtain as torch movement basic information, and the segment conductor is welded by moving the torch based on the torch movement basic information. Since the torch is moved to an appropriate position for performing the welding, it is possible to significantly reduce welding defects.
[0022]
In particular, in the segment conductor welding method of the present invention, for each of the tip planes on one end side or the other end side of the separate segment conductors that are welded by the torch, the two are adjacent on the torch side and adjacent to the chamfer. Since the positions of the two vertices that are not measured are determined by the image processing in plan view as the torch movement basic information, the torch is welded by the torch when the torch is moved based on the torch movement basic information. It is possible to reflect the direction of the tip plane on one end side or the other end side of the separate segment conductor, and to eliminate the adverse effect of the chamfered part in image processing in plan view.
[0023]
In addition, as an example of moving the torch based on the torch movement basic information, the torch movement basic information allows the torch to be welded by the torch from each of the end planes at one end or the other end of the separate segment conductor to the torch. A torch moving position having the same distance may be obtained, and the torch may be moved to this torch moving position.
[0024]
Further, the invention according to claim 3 made to solve the second problem is to twist both ends of a plurality of substantially U-shaped segment conductors penetrating into the stator core in opposite directions in the circumferential direction of the stator core, After welding the tip of one end side or the other end side of the separate segment conductors that have become adjacent to each other with a torch, the welding quality control method of the segment conductor that detects unwelded and melted and insufficient melting of the welding location is detected. There, a plane image is obtained by irradiating the welding point with direct illumination and indirect illumination, and based on a correlation value in the plane image, after detecting unwelding and melting of the welding point, the plane image is obtained. Detecting insufficient fusion of the welding location based on the area value in the above.
[0025]
That is, in the method for controlling the quality of welding of a segment conductor according to the present invention, a flat image is obtained by irradiating a welding location with direct illumination and indirect illumination, and based on a correlation value in the planar image, the welding location is not welded or melted. Is detected, based on the area value in the plane image, based on the area value in the weld, the insufficient fusion of the weld is detected.Thus, the image processing of the plane image of the weld is performed. The shortage can be accurately and easily detected.
[0026]
In particular, in the method for controlling the quality of welding of a segment conductor according to the present invention, a flat image is obtained by irradiating a welding location with direct illumination and indirect illumination, so that reflected light and the like are not affected by the shape of the welding location. A flat image free from the influence of the above can be obtained.
[0027]
In addition, when the welded part is insufficiently melted, unlike the case where the welded part is unwelded and separate, the welded part is integrated, so that the image is a flat image that is not affected by reflected light. Even if the process is performed, it is difficult to detect unwelded and melt-separated welds at the same time as detecting even insufficient fusion of the welded spots. Based on the correlation value in the image, it detects unwelded and unmelted portions of the welding location, and then detects insufficient fusion of the welding location based on the area value in the planar image. It is possible to detect unwelded parts, melting and melting, and insufficient melting.
[0028]
Further, the invention according to claim 4 made to solve the third problem is to twist both ends of a plurality of substantially U-shaped segment conductors penetrating into the stator core in opposite directions in the circumferential direction of the stator core, A segment conductor for measuring a gap between radially adjacent welded portions of the stator core after welding one end or the other end of a separate segment conductor that is radially adjacent to the stator core with a torch. A welding color quality control method, wherein a plane color image of the welding point is obtained, and a boundary of the welding point in the plane color image is detected by a logical sum of two or more colors, so that the stator core is radially adjacent to the stator core. It is characterized by measuring a gap between fitting welding points.
[0029]
That is, in the segment conductor welding quality control method of the present invention, a plane color image of a welding point is acquired, and a boundary of the welding point in the plane color image is detected by a logical sum of two or more colors, so that the stator core is radially oriented. Since the gap between the adjacent welding points is measured, the gap between the welding points can be accurately and easily measured by processing the planar image of the welding point.
[0030]
In particular, in the welding quality control method of the segment conductor of the present invention, the boundary of the welding point in the plane color image is detected by the logical sum of two or more colors. In this regard, in the plane color image, at least the welding point is detected. The light is projected in two colors, a bright part and a dark part, and the shadow appearing near the boundary of the welded part can be visually judged. Therefore, based on this judgment, two or more colors used for detecting the boundary of the welded part are used. The color can be specified accurately, which can help to improve the measurement accuracy of the gap between the welded portions.
[0031]
The invention according to claim 5, which is made to solve the fourth problem, twists both ends of a plurality of substantially U-shaped segment conductors penetrating into the stator core in the circumferential direction of the stator core in opposite directions. After welding the tip of one end side or the other end side of the separate segment conductor which became adjacent in the radial direction of the stator core with a torch, the segment conductor for detecting the presence or absence of foaming of the insulating coating portion of the segment conductor In the welding quality control method, obtaining an image of the insulating covering portion of the segment conductor, based on the area value of the glossy portion in the image, to detect the presence or absence of foaming of the insulating covering portion of the segment conductor, Features.
[0032]
That is, in the method for controlling the welding quality of the segment conductor of the present invention, an image of the insulating covering portion of the segment conductor is obtained, and the presence or absence of foaming of the insulating covering portion of the segment conductor is detected based on the area value of the glossy portion in the image. Therefore, by performing image processing on the image of the insulating covering portion of the segment conductor, it is possible to accurately and easily detect the presence or absence of foaming of the insulating covering portion of the segment conductor.
[0033]
In particular, in the segment conductor welding quality control method of the present invention, when acquiring an image of the insulating covering portion of the segment conductor, not only the foaming of the insulating covering portion of the segment conductor, but also the bending of the insulating covering portion of the segment conductor. Considering that the location and the location that is the boundary of the insulating coating also shine, the presence or absence of foaming in the insulating coating of the segment conductor is detected based on the area value of the glossy part in the image, so the detection accuracy has improved significantly. .
[0034]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present embodiment relates to a method for welding a segment conductor and a method for managing the quality of welding a segment conductor, which are performed on each of the scheduled welding locations 105 in FIG. 36 described in the section of “Prior Art”.
[0035]
First, a method for welding a segment conductor in the present embodiment will be described.
In the method for welding a segment conductor according to the present embodiment, as shown in FIG. 7, before each to-be-welded portion 105 is welded by torch 31 (see FIGS. 27 and 28), as shown in FIG. A planar image is obtained by indirect illumination by the camera 51 installed above the upper and lower surfaces 11 and 21.
FIG. 7 shows a state after the segment conductors 11 and 21 have been welded.
[0036]
Then, as shown in FIG. 1, four sets of a pair of measurement windows W1 orthogonal to each other are set in the acquired plane image. In this regard, in the segment conductor 11 to be welded, two sets of measurement windows W1 are set for three sides of the tip plane 14 that is not adjacent to the chamfered portion 15. Similarly, in the segment conductor 21 to be welded, two sets of measurement windows W1 are set for three sides of the tip plane 24 that is not adjacent to the chamfered portion 25.
[0037]
Then, as shown in FIG. 2, in the segment conductor 11 to be welded, three edges of the tip plane 14 that are not adjacent to the chamfered portion 15 are detected through the two sets of measurement windows W1. The positions of the two vertices P1 on the side facing the segment conductor 21 to be welded are measured. At this time, the direction of the tip plane 14 can be known from the measured positions of the two vertices P1. Similarly, in the segment conductor 21 to be welded, the edges of the three sides of the tip plane 24 that are not adjacent to the chamfered portion 25 are detected through the two sets of measurement windows W1, so that the segment conductor 21 to be welded is detected. The positions of two vertices P2 on the side facing segment conductor 11 are measured. At this time, the direction of the tip plane 24 can be known from the measured positions of the two vertices P2.
[0038]
Here, when the segment conductors 11 and 21 to be welded are three-dimensionally inclined, the measurement positions of the vertices P1 and P2 of the tip planes 14 and 24 of the segment conductors 11 and 21 to be welded are approximate values, The required accuracy of ± 0.1 is sufficiently satisfied by this method.
[0039]
Note that the side facing the segment conductor 11 to be welded and the side facing the segment conductor 21 to be welded are also the side of the torch 31 as can be seen from FIGS.
[0040]
Then, as shown in FIG. 3, in the segment conductor 11 to be welded, the center of gravity G1 of the tip plane 14 is obtained from the measured positions of the two vertices P1. Similarly, in the segment conductor 21 to be welded, the center of gravity G2 of the tip plane 24 is obtained from the measured positions of the two vertices P2. Here, the center of gravity G1, G2 of the tip planes 14, 24 can be obtained from the measured positions of the two vertices P1, P2, respectively, because the shapes and sizes of the tip planes 14, 24 are known in design. .
[0041]
Then, as shown in FIG. 4, an intersection G3 between the line connecting the two centers of gravity G1 and G2 and the circumferential orbit L of the torch 31 is determined, and the torch 31 is moved to the intersection G3. Here, the movement of the torch 31 is performed by a robot device (not shown).
Note that, as described in the section of “Prior Art”, the circumferential orbit L of the torch 31 is a torch viewed from the stator core 101 side when the stator core 101 on which the plurality of segment conductors 103 and 104 are assembled is rotated. Means 31 circumferential orbits.
[0042]
Then, for the segment conductor 11 to be welded, the distance between the two vertices P1 is calculated from the positions of the two vertices P1. At this time, since the distance between the two vertices P1 in the plane image becomes longer as the tip plane 14 is at a higher position, the height of the tip plane 14 is obtained based on the distance between the two vertices P1. Similarly, for the segment conductor 21 to be welded, the height of the tip plane 24 is determined based on the distance between the two vertices P2 calculated from the positions of the two vertices P2.
[0043]
The segment conductors 11 and 21 to be welded have a total number of “576” in the stator core 101 and are dense as shown in FIG. 35, so that all the segment conductors 11 and 21 are located from the side. It is difficult to image. In consideration of this situation, it is effective to obtain the heights of the tip end planes 14, 24 of the segment conductors 11, 21 to be welded from the plane images.
[0044]
Then, based on the height of the tip plane 14 and the height of the tip plane 24, as shown in FIG. 5, the distance a from the center of gravity G1 of the tip plane 14 of the segment conductor 11 to be welded to the torch 31, and the segment conductor to be welded. The distance b from the center of gravity G2 of the tip plane 24 of the torch 21 to the torch 31 is determined. Then, the torch 31 is moved in the radial direction of the stator core 101 so that the distance a is equal to the distance b, and as shown in FIG. 5, the torch 31 is moved from the center of gravity G1 of the distal end plane 14 of the segment conductor 11 to be welded. The distance to the torch 31 is set to “a ′”, and the distance from the center of gravity G2 of the tip plane 24 of the segment conductor 21 to be welded to the torch 31 is set to “b ′” (a ′ = b ′). Thereafter, in this state, the torch 31 is arced to weld the segment conductors 11 and 21 to be welded.
[0045]
Here, the optimal installation height of the camera 51 will be described. In the present embodiment, the width of a workpiece having a width of 4 mm is measured while changing the installation height of the camera 51 in order to prevent the planar image acquired by the camera 51 from being out of focus and inaccurate measurement. The experiment shown in FIG. 6 was able to be obtained. In FIG. 6, the horizontal axis indicates the installation height of the camera 51. In this regard, the value of the scale means the scale of the cage provided beside the camera 51, and the installation height of the camera 51. Is not an absolute value, but a relative installation height of the camera 51.
In addition, the installation height of the camera 51 is about 50 mm from the tip planes 14 and 24 of the segment conductors 11 and 21 to be welded.
[0046]
According to FIG. 6, when the installation height of the camera 51 is in the range of −6 to −2 on the scale of the cage provided beside the camera 51, it can be understood that the width of the work having a width of 4 mm can be accurately measured. Therefore, in the present embodiment, the installation height of the camera 51 is set to -4 corresponding to the center of the range A of -6 to -2 on the scale of the cage provided beside the camera 51, and the depth of focus can be deeply taken. I did it.
[0047]
Also, in the two-dimensional image acquired by the camera 51, as shown in FIGS. 1 to 3, four sets of a pair of measurement windows W1 orthogonal to each other are set. If the horizontal conductors are set on the basis of the vertical conductors, even if the welding target segment conductors 11 and 21 greatly vary, the welding target segment conductors 11 and 21 can be obtained via the four sets of measurement windows W1. Can be detected.
[0048]
In FIGS. 1 to 3, two sets of measurement windows W1 in the segment conductor 11 to be welded and two sets of measurement windows W1 in the segment conductor 21 to be welded do not overlap with each other. This is for the sake of simplicity for the sake of convenience, and in fact, it is often set to overlap. However, even if they are set to overlap, both sides of the segment conductors 11 and 21 to be welded must not be included in each measurement window W1.
[0049]
In addition, when detecting three edges of the tip planes 14 and 24 that are not adjacent to the chamfers 15 and 25 through the four measurement windows W1, the edges are directed from inside the tip planes 14 and 24 to the outside. If the portion where the gradation drop is large is detected, the edge detection accuracy is improved.
[0050]
As described in detail above, in the method of welding a segment conductor according to the present embodiment, a plurality of substantially U-shaped segment conductors 11 and 21 in which tip planes 14 and 24 adjacent to chamfers 15 and 25 are formed. 25 (see FIGS. 25 and 26), penetrate into the penetration groove 102 of the stator core 101 (see FIG. 33), and twist in opposite directions in the circumferential direction of the stator core 101. At this time, each segment conductor 11, 21 Are bent in the axial direction of the stator core 101 (see FIG. 34), and the end portions on one end side or the other end side of the separate segment conductors 11 and 21 are adjacent to each other (see FIG. 35), and then welded by the torch 31. (See FIGS. 25 and 26).
33 to 35, the segment conductors 11 and 21 are described as segment conductors 103 and 104.
[0051]
However, before welding with the torch 31, each of the tip planes 14 and 24 on one end side or the other end side of the separate segment conductors 11 and 21 that are welded by the torch 31 are adjacent to each other on the torch 31 side. At the same time, the positions P1 and P2 of two vertices that are not adjacent to the chamfers 15 and 25 are measured by image processing on a planar image acquired by the camera 51, thereby obtaining the torch movement basic information (see FIG. 2). ). Then, based on the torch movement basic information, the centers of gravity G1 and G2 of the tip planes 14 and 24 are obtained, and further, the intersection G3 between the line connecting the two centers of gravity G1 and G2 and the circumferential orbit L of the torch 31 is obtained. The torch 31 is moved to the intersection G3 (see FIG. 4). Further, a torch moving position in which the distances from the centers of gravity G1, G2 of the tip end planes 14, 24 to the torch 31 are equal is determined, and the torch 31 is moved to this torch moving position (see FIG. 5).
[0052]
That is, in the segment conductor welding method of the present embodiment, before welding with the torch 31, the tip planes 14, 14 on the one end side or the other end side of the separate segment conductors 11 and 21 which are in a relationship of being welded by the torch 31. For each of the torches 31, the positions of two vertices P 1 and P 2 that are adjacent to the torch 31 and are not adjacent to the chamfers 15 and 25 are measured by image processing in a plan view, thereby obtaining basic torch movement information. By moving the torch 31 on the basis of the movement basic information, the torch 31 is moved to a position suitable for welding the segment conductors 11 and 21, thereby significantly reducing welding defects.
[0053]
In particular, in the segment conductor welding method of the present embodiment, each of the tip planes 14 and 24 at one end side or the other end side of the separate segment conductors 11 and 21 which are welded by the torch 31 are connected to the torch 31 side. Since the positions of two vertices P1 and P2 adjacent to each other and not adjacent to the chamfers 15 and 25 are measured by image processing in plan view as torch movement basic information, from the torch movement basic information, It is possible to know the orientation of the tip planes 14, 24 on one end side or the other end side of the separate segment conductors 11, 21 which are in a relationship of being welded by the torch 31. Therefore, when the torch 31 is moved based on the torch movement basic information, the directions of the tip planes 14 and 24 on one end side or the other end side of the separate segment conductors 11 and 21 which are welded by the torch 31 are changed. Can be reflected. Further, in the two-dimensional image acquired by the camera 51, two sets of measurement windows W1, which are the basis of the image processing, are set for three sides of the tip planes 14, 24 which are not adjacent to the chamfered parts 15, 25, respectively. Therefore, when the torch 31 is moved based on the torch movement basic information, it is possible to eliminate the adverse effects of the chamfers 15 and 25 in the image processing in a plan view.
[0054]
In this regard, in the planar image obtained by the camera 51, as shown in FIG. 23, a measurement window W5 including the tip planes 14, 24 of the segment conductors 11, 21 is set, and the segment conductors 11, 21 are determined by pattern matching. When trying to measure the positions of the tip planes 14 and 24, the boundary between the tip planes 14 and 24 and the chamfers 15 and 25 in the segment conductors 11 and 21 is included in the measurement window W5. The positions of the planes 14 and 24 cannot be measured accurately.
[0055]
In the planar image acquired by the camera 51, as shown in FIG. 24, four sets of a pair of orthogonal measurement windows W6 are set, and a pair of diagonals of the tip planes 14, 24 in the segment conductors 11, 21 are set. When the positions of the tip planes 14, 24 of the segment conductors 11, 21 are measured after the positions of P1, P2 are obtained, the tip planes 14, 24 of the segment conductors 11, 21 are respectively measured in the two sets of measurement windows W6. Therefore, the position of the tip planes 14 and 24 of the segment conductors 11 and 21 cannot be accurately measured. In this case, even if the positions of the pair of diagonals P1 and P2 of the tip planes 14 and 24 in the segment conductors 11 and 21 are obtained, the orientation of the tip planes 14 and 24 of the segment conductors 11 and 21 can be known. Therefore, the position of the tip planes 14 and 24 of the segment conductors 11 and 21 cannot be accurately measured.
[0056]
Next, a method for controlling the welding quality of the segment conductor in the present embodiment will be described.
In the welding quality control method for the segment conductor according to the present embodiment, as shown in FIG. 7, after each of the scheduled welding locations 105 is welded by the torch 31 (see FIGS. 27 and 28), The planar image is acquired by the camera 51 installed above the segment conductors 11 and 21 of FIG. In addition, images are acquired by cameras 52 and 53 installed diagonally above the segment conductors 11 and 21 to be welded.
FIG. 7 shows a state after the segment conductors 11 and 21 have been welded, and the segment conductors 11 and 21 are integrated by a welding ball 41.
[0057]
FIG. 11 shows a planar image acquired by the camera 51 at this time. As shown in FIG. 11, in the present embodiment, three welding balls 41 arranged in the radial direction of stator core 101 are imaged in plane image V acquired by camera 51. Further, in the present embodiment, two cameras 51 are installed in the radial direction of the stator core 101, and two continuous planar images V are acquired as shown in FIG. The plane image V may not be continuous.
[0058]
Further, in the present embodiment, when acquiring a planar image with the camera 51, the welding ball 41 is irradiated with the direct illumination 54 and the indirect illumination 55 as shown in FIG. This is because when the welding ball 41 is illuminated only by the indirect illumination 55 because the welding ball 41 has an elliptical shape, the central portion 41A of the welding ball 41 becomes bright as shown on the left side of FIG. When a shadow is formed on the peripheral portion 41B of the ball 41 and the welding ball 41 is irradiated only with the direct illumination 54, as shown in the center of FIG. By illuminating the welding ball 41 with the direct illumination 54 and the indirect illumination 55 in consideration of the surrounding portion 41D becoming brighter, the entire 41E of the welding ball 41 is brightened as shown on the right side of FIG. is there.
[0059]
Then, in the present embodiment, for each of the welding balls 41 in the planar image V, an unwelded one, one that is melted, and one that is insufficiently melted as shown in FIG. 12 are detected. First, a correlation analysis with the master image shown on the left side of FIG. 12 is performed. FIG. 14 shows the result of the correlation analysis. In FIG. 14, “acceptable products” are indicated by thick lines, those that have not been welded or melted are indicated by thin lines, and those that are insufficiently melted are indicated by dotted lines. According to FIG. 14, when it is determined based on a certain correlation value, it is possible to determine all of the unwelded or melted ones (thin lines in FIG. 14) as “NG products”. (Thick line in FIG. 14) is determined as “NG product”, and most of the insufficiently melted product (dotted line in FIG. 14) is determined as “OK product”.
[0060]
Therefore, in the present embodiment, the area of the central part of the welding ball 41 is measured for a product determined as “NG product” in FIG. 14, and as shown in FIG. Detects those that are not welded or melted and are insufficiently melted. In FIG. 15, as in the case of FIG. 14, "acceptable products" are indicated by thick lines, those that are not welded or melted are indicated by thin lines, and those that are insufficiently melted are indicated by dotted lines. According to FIG. 15, when a judgment is made based on a certain threshold value, an unwelded or melted one (the thin line in FIG. 15) and an insufficiently melted one (the dotted line in FIG. 15) can be determined as “NG product”. Of course, in FIG. 15 as well, a very small part of the "acceptable product" (thick line in FIG. 14) is determined to be "NG product". Since the welding quality is improved, this erroneous determination hardly occurs.
[0061]
Further, in the present embodiment, the area of the central portion of the welding ball 41 is measured for a product determined as “OK product” in FIG. 14 and, as shown in FIG. Detect what is under melting. In FIG. 16, “passed products” are indicated by thick lines, and those that are insufficiently melted are indicated by dotted lines, as in the case of FIG. 14. According to FIG. 16, when judged with a certain threshold value, the one with insufficient melting (dotted line in FIG. 16) can be determined as “NG product”, and the “passed product” (thick line in FIG. 16) can be determined as “OK”. Article).
[0062]
In the area measurement of each welding ball 41 in the plane image V, as shown in FIG. 13, correction is performed so that a measurement window W2 for area measurement is set at the center of each welding ball 41. .
[0063]
Further, in the present embodiment, the height of each welding ball 41 in plane image V can be measured. Because, as shown in FIG. 17A, when the welding ball 41 is irradiated with the direct illumination 57, the welding ball 41 in the plane image V becomes as shown in FIG. 18A, and the central portion 41F of the welding ball 41 is obtained. 17B, the surrounding portion 41G of the welding ball 41 becomes brighter, and as shown in FIG. 17B, when the welding ball 41 is directly illuminated by the illumination 56, the welding ball 41 in the plane image V becomes the one shown in FIG. As shown in FIG. 17, the central portion 41I of the welding ball 41 becomes darker and the peripheral portion 41J of the welding ball 41 becomes brighter. In this regard, FIGS. 17 (a) and (b) and FIGS. As can be seen from the comparison, if the distance from the direct lighting 56, 57 to the welding ball 41 is different, the width of the peripheral portion 41I, 41J of the welding ball 41 is also different. If you know, directly Distance from light 56 and 57 to weld ball 41, because thus, it is possible to determine the height of the weld bead 41.
[0064]
However, in the present embodiment, the direct illuminations 56 and 57 use the direct illumination 54 shown in FIG. 9, and the relationship between the height of the welding ball 41 and the white width around the welding ball 41 at this time is shown in FIG. The height of the welding ball 41 is determined from the white width around the welding ball 41 based on the relationship shown in FIG. As can be seen from FIG. 19, no matter how the height of the welding ball 41 changes, the white width of the peripheral portion of the welding ball 41 should be within the range of about 0.6 to 1.5. Thus, the height of the welding ball 41 can be determined with high accuracy.
[0065]
As described in detail above, in the method for controlling the quality of welding of a segment conductor according to the present embodiment, the planar image V is obtained by irradiating the welding ball 41 with the direct illumination 54 and the indirect illumination 55 (see FIG. 11). In the plane image V, based on the correlation value with respect to the master image shown on the left side of FIG. 12, the non-welding and melting of the welding ball 41 are detected (see the thin line in FIG. 14). Thereafter, in the plane image V, based on the area value of the central portion of the welding ball 41, an insufficient melting of the welding ball 41 is detected from those determined as “NG products” in FIG. 14 (FIG. 15). Further, based on the area value of the central portion of the welding ball 41, the insufficient melting of the welding ball 41 is detected from those determined as “OK products” in FIG. 14 (dotted line in FIG. 16). reference). Therefore, by performing image processing on the planar image V of the welding ball 41, it is possible to accurately and easily detect whether the welding ball 41 is unwelded, melted, or melted insufficiently.
[0066]
In particular, in the method for controlling the welding quality of the segment conductor according to the present embodiment, since the planar image V is obtained by irradiating the welding ball 41 with the direct illumination 54 and the indirect illumination 55, the shape depends on the shape of the welding ball. Without this, it is possible to acquire a planar image V that is not affected by reflected light or the like (see FIGS. 9 and 10).
[0067]
Also, unlike the case where the welding ball 41 is insufficiently melted, unlike the case where the welding ball 41 is not welded or melted and separated, considering that the welding ball 41 is integrated (see FIG. 12), a flat surface free from the influence of reflected light or the like is obtained. Even if image processing is performed on the image V, it is difficult to detect unwelded and melted parts and detect insufficient melting at the same time in one plane image V. However, welding quality control of the segment conductor according to the present embodiment is difficult. In the method, unwelding and melting are detected based on the correlation value in the plane image V (see the thin line in FIG. 14), and then, insufficient melting of the welding ball 41 is detected based on the area value in the plane image V. Therefore (see dotted lines in FIGS. 15 and 16), it is possible to detect unwelded, melted, and insufficiently melted in one planar image V.
[0068]
In the present embodiment, the gap between the welding balls 41 is measured. For this purpose, the welding ball 41 is irradiated by the direct illumination 54 and the indirect illumination 55, a flat color image is acquired by the camera 51, and the gap B between the welding balls 41 is measured as shown in FIG. Here, the gap B between the welding balls 41 is the distance between the welding balls 41 arranged in the radial direction of the stator core 101.
[0069]
In the present embodiment, a measurement window W4 for measuring the gap B between the welding balls 41 is set in the planar color image acquired by the camera 51, as shown in FIG. At this time, each welding ball 41 is illuminated by the direct illumination 54 and the indirect illumination 55, and the whole becomes bright. However, since each welding ball 41 has an elliptical shape, a very small shadow is formed on the outline thereof. It is inevitable that a portion 41K is formed, and the reference value of the gap B between the welding balls 41 is as small as about 1 mm. Greatly affects the accuracy when measuring the gap B of
[0070]
Therefore, in the present embodiment, in the planar color image acquired as sampling by the camera 51, a color indicating a bright portion of the welding ball 41 and a color indicating a shadow portion 41K of the welding ball 41 correspond to each. The color designated by the color of the pixel and the color included in a certain range around the color indicating the bright part of the welding ball 41 or the color included in the certain range around the color indicating the shadow part 41K of the welding ball 41 The boundary of the welding ball 41 is detected by treating the pixel having the same as the one representing the welding ball 41. In this way, the shadow portion 41K of each welding ball 41 is not treated as a part of the gap B between each welding ball 41, which can contribute to improvement in measurement accuracy.
[0071]
As described above in detail, in the method for controlling the welding quality of the segment conductor according to the present embodiment, a plane color image of the welding ball 41 is obtained, and the boundary of the welding ball 41 in the plane color image is calculated by the logical sum of two or more colors. Since the gap B between the welding balls 41 adjacent in the radial direction of the stator core 101 is measured by the detection, the gap B between the welding balls 41 is measured by performing image processing on a plane image of the welding balls 41. Can be performed accurately and easily.
[0072]
In particular, in the method for controlling the welding quality of the segment conductor according to the present embodiment, in the flat color image, the color indicating the bright portion of the welding ball 41 and the color indicating the shadow portion 41K of the welding ball 41 correspond to each. The color designated by the color of the pixel and the color included in a certain range around the color indicating the bright part of the welding ball 41 or the color included in the certain range around the color indicating the shadow part 41K of the welding ball 41 The boundary of the welding ball 41 in the flat color image is detected by the logical sum of two or more colors, treating the pixel having the same as the one representing the welding ball 41. In this regard, in the plane color image, at least the welding ball 41 is projected in two colors of a bright portion and a dark portion, and a shadow portion 41K appearing near the boundary of the welding ball 41 can be determined by visual color. Based on the above, it is possible to accurately specify two or more colors to be used when detecting the boundary of the welding ball 41, which can help to improve the measurement accuracy of the gap B between the welding balls 41.
[0073]
Further, in the present embodiment, in order to confirm the insulation properties of the enamel covering portions 13 and 23 of the segment conductors 11 and 21, the segment conductors 11 and 21 are obtained from the images acquired by the cameras 52 and 53 shown in FIG. 7. The presence or absence of foaming of the enamel covering portions 13 and 23 is detected. For example, the image acquired by the camera 53 is as shown in FIG. 20, and the foam 13A of the enamel covering portion 13 of the segment conductor 11 can be detected.
[0074]
However, for that purpose, as shown in FIG. 20, in the image obtained by the camera 53, the enamel covering portion of the segment conductor 11 is avoided so as to avoid the boundary between the enamel covering portion 13 of the segment conductor 11 and the bare wire 21. 13, a detection window W3 is set. This is because, at the boundary, the portion 13C from which the enamel has been peeled off of the enamel coating portion 13 has gloss similarly to the foam 13A, and may be erroneously detected as the foam 13A. In addition, in the place where the enamel coating portion 13 is bent, it may be reflected as a glossy portion 13B in the same manner as the foam 13A. However, since the glossy portion 13B is larger than the foam 13A, Excluded by area filter.
[0075]
Note that the above-described image processing is also performed when foaming of the enamel covering portion 23 of the segment conductor 21 is detected from an image acquired by the camera 52.
[0076]
As described above in detail, in the method for controlling the welding quality of the segment conductor according to the present embodiment, the images of the enamel coating portions 13 and 23 of the segment conductors 11 and 21 are acquired by the cameras 52 and 53, and the glossy portions in the images are obtained. Since the presence or absence of the foam 13A of the enamel covering portions 13 and 23 of the segment conductors 11 and 21 is detected based on the area value of the segment conductors, the image of the enamel covering portions 13 and 23 of the segment conductors 11 and 21 is image-processed. This makes it possible to accurately and easily detect the presence or absence of the foam 13A or the like in the enamel covering portions 13 and 23 of the segment conductors 11 and 21.
[0077]
In particular, in the segment conductor welding quality control method of the present embodiment, when the images of the enamel coating portions 13 and 23 of the segment conductors 11 and 21 are acquired, the foaming of the insulating coating portions 13 and 23 of the segment conductors 11 and 21 is performed. In addition to 13A and the like, at the place where the enamel coating portion 13 is bent, it may be projected as a glossy portion 13B in the same manner as the foam 13A and the like, and the enamel coating portion 13 of the segment conductor 11 and the bare wire 21 Considering that the portion 13 of the enamel coating portion 13 from which the enamel has peeled shines at the boundary of (see FIG. 20), based on the area value of the glossy portion in the image, the enamel coating portions 13 and 23 of the segment conductors 11 and 21 are considered. Since the presence or absence of the foam 13A is detected, the detection accuracy is significantly improved.
[0078]
Finally, the sequence of each operation of the above-described embodiment will be described with reference to the flowchart of FIG. In the present embodiment, first, in S11, the positions of the segment conductors 11 and 21 to be welded are measured before the torch 31 (see FIGS. 27 and 28) is welded to each of the welding locations 105 by the torch 31 (see FIGS. 27 and 28). Then, the process proceeds to S12. In S12, it is determined whether the segment conductors 11 and 21 to be welded can be welded by the position correction of the torch 31. Here, when it is determined that the welding of the segment conductors 11 and 21 to be welded is not possible by the position correction of the torch 31 (S12: No), the process proceeds to S13, and the positions of the segment conductors 11 and 21 to be welded are determined. The correction is performed manually, and the process returns to S11. On the other hand, when it is determined that the segment conductors 11 and 21 to be welded can be welded by the position correction of the torch 31 (S12: Yes), the process proceeds to S14.
[0079]
In S14, after the position of the torch 31 is corrected, welding is continuously performed on each of the scheduled welding locations 105 on the same circumferential track. Further, similarly, welding is continuously performed on each of the scheduled welding locations 105 on the same circumferential track different from that described above.
At this time, if the height of the torch 31 is corrected in consideration of the height of the segment conductors 11 and 21 to be welded and the heat generation state thereof, the reduction of welding defects becomes more remarkable.
After performing the continuous welding in this way, the process proceeds to S15.
[0080]
At S15, unwelded and melted ones of the welding balls 41 are detected. Next, in S16, it is determined whether or not there is an "NG product" due to the unwelded or melted product. Here, when it is determined that there is an “NG product” due to an unwelded or melted product (S16: Yes), the process proceeds to S17, where it is determined that the product is not welded or melted. The welding is performed on the object one by one to correct it, and the process returns to S15. On the other hand, when it is determined that there is no “NG product” due to the unwelded or melted product (S16: No), the process proceeds to S18, where the welding balls 41 that are insufficiently melted are detected. I do.
[0081]
Next, in S19, it is determined whether or not there is an “NG product” due to the insufficient melting. Here, when it is determined that there is an “NG product” due to the insufficient melting (S19: Yes), the process proceeds to S20, and the one determined to be the insufficient melting is applied to a single shot. Correction is performed by performing welding, and the process returns to S18. On the other hand, when it is determined that there is no “NG product” due to insufficient melting (S19: No), the process proceeds to S21, and the gap B between the welding balls 41 is measured.
[0082]
Next, in S22, it is determined whether or not the gap B between the welding balls 41 has secured the reference value. Here, if there is a gap B between the welding balls 41 for which the reference value has not been secured (S22: No), the process proceeds to S23, and after the position of the welding balls 41 is adjusted with a jig at the corresponding location, the process proceeds to S21. Return to On the other hand, if it is determined that the gap B between all the welding balls 41 has secured the reference value (S22: Yes), the process proceeds to S24.
[0083]
Next, in S24, the presence or absence of foaming of the enamel coating portions 13, 23 of the segment conductors 11, 21 is detected, and the process proceeds to S25. In S25, it is determined whether there is no foaming of the enamel covering portions 13 and 23 of the segment conductors 11 and 21 or whether the enamel covering portions 13 and 23 of the segment conductors 11 and 21 can be repaired with the insulating paint even if there is foaming. Here, when it is determined that there is no foaming in the enamel covering portions 13 and 23 of the segment conductors 11 and 21, or even when there is foaming in the enamel covering portions 13 and 23 of the segment conductors 11 and 21, it can be repaired by insulating coating. If it is determined (S25: Yes), the process proceeds to S26, where the product is shipped. On the other hand, if it is determined that the enamel covering portions 13 and 23 of the segment conductors 11 and 21 have foaming and cannot be repaired by the insulation coating (S25: No), the process proceeds to S27 and is discarded.
[0084]
Note that the present invention is not limited to the above-described embodiment, and various changes can be made without departing from the gist of the present invention.
For example, in the present embodiment, the distance from the center of gravity G1, G2 of one of the end planes 14, 24 on the one end side or the other end side of the separate segment conductors 11, 21 to be welded by the torch 31 is different. The same torch movement position is obtained, and the torch 31 is moved to this torch movement position (see FIG. 5).
In this regard, the midpoint between the center of gravity G1 of the tip plane 14 of the segment conductor 11 to be welded and the center of gravity G2 of the tip plane 24 of the segment conductor 21 to be welded is simply obtained, and the torch 31 is moved to the midpoint. You may.
[0085]
【The invention's effect】
In the segment conductor welding method of the present invention, before welding with the torch, each of the end planes on one end side or the other end side of the separate segment conductors which are in a relationship to be welded with the torch, are adjacent on the torch side and face Welding the segment conductor by measuring the positions of two vertices that are not adjacent to the torch as basic torch movement information by measuring the image processing in a plan view, and moving the torch based on the torch movement basic information. Since the torch is moved to an appropriate position, it is possible to significantly reduce welding defects.
[0086]
In particular, in the segment conductor welding method of the present invention, for each of the tip planes on one end side or the other end side of the separate segment conductors that are welded by the torch, the two are adjacent on the torch side and adjacent to the chamfer. Since the positions of the two vertices that are not measured are determined by the image processing in plan view as the torch movement basic information, the torch is welded by the torch when the torch is moved based on the torch movement basic information. It is possible to reflect the direction of the tip plane on one end side or the other end side of the separate segment conductor, and to eliminate the adverse effect of the chamfered part in image processing in plan view.
[0087]
Further, in the method for controlling the quality of welding of a segment conductor according to the present invention, a flat image is obtained by irradiating a welding location with direct illumination and indirect illumination, and based on a correlation value in the flat image, unwelding and melting of the welding location are performed. Is detected, based on the area value in the plane image, based on the area value in the weld, the insufficient fusion of the weld is detected.Thus, the image processing of the plane image of the weld is performed. The shortage can be accurately and easily detected.
[0088]
In particular, in the method for controlling the quality of welding of a segment conductor according to the present invention, a flat image is obtained by irradiating a welding location with direct illumination and indirect illumination, so that reflected light and the like are not affected by the shape of the welding location. A flat image free from the influence of the above can be obtained.
[0089]
In addition, when the welded part is insufficiently melted, unlike the case where the welded part is unwelded and separate, the welded part is integrated, so that the image is a flat image that is not affected by reflected light. Even if the process is performed, it is difficult to detect unwelded and melt-separated welds at the same time as detecting even insufficient fusion of the welded spots. Based on the correlation value in the image, it detects unwelded and unmelted portions of the welding location, and then detects insufficient fusion of the welding location based on the area value in the planar image. It is possible to detect unwelded parts, melting and melting, and insufficient melting.
[0090]
In the welding quality control method for a segment conductor according to the present invention, a plane color image of a welding point is acquired, and a boundary of the welding point in the plane color image is detected by a logical sum of two or more colors, so that the stator core is radially oriented. Since the gap between the adjacent welding points is measured, the gap between the welding points can be accurately and easily measured by processing the planar image of the welding point.
[0091]
In particular, in the welding quality control method of the segment conductor of the present invention, the boundary of the welding point in the plane color image is detected by the logical sum of two or more colors. In this regard, in the plane color image, at least the welding point is detected. Since the image is projected in two colors, a bright part and a dark part, and the shadow appearing near the boundary of the welded portion can be visually judged, the two colors or more used when detecting the boundary of the welded portion are based on this judgment. The color can be specified accurately, which can help to improve the measurement accuracy of the gap between the welded portions.
[0092]
In the method for controlling the quality of welding of a segment conductor according to the present invention, an image of the insulating coating of the segment conductor is obtained, and the presence or absence of foaming of the insulating coating of the segment conductor is detected based on the area value of the glossy portion in the image. Therefore, by performing image processing on the image of the insulating covering portion of the segment conductor, it is possible to accurately and easily detect the presence or absence of foaming of the insulating covering portion of the segment conductor.
[0093]
In particular, in the segment conductor welding quality control method of the present invention, when acquiring an image of the insulating covering portion of the segment conductor, not only the foaming of the insulating covering portion of the segment conductor, but also the bending of the insulating covering portion of the segment conductor. Considering that the location and the location that is the boundary of the insulating coating also shine, the presence or absence of foaming in the insulating coating of the segment conductor is detected based on the area value of the glossy part in the image, so the detection accuracy has improved significantly. .
[Brief description of the drawings]
FIG. 1 is a diagram showing a state when four sets of a pair of mutually orthogonal measurement windows are set with respect to a plane image obtained by imaging a segment conductor to be welded in an embodiment of the present invention.
FIG. 2 shows an embodiment of the present invention, in which a position of two vertexes (ones facing each other) of each segment conductor is measured via a measurement window on a plane image obtained by capturing a segment conductor to be welded. FIG.
FIG. 3 is a conceptual diagram when a position of a center of gravity of each segment conductor is determined via positions of two vertexes (ones on opposite sides) of a segment conductor to be welded in one embodiment of the present invention.
FIG. 4 is a conceptual diagram when a temporary movement point of a torch is obtained via a position of a center of gravity of a segment conductor to be welded in one embodiment of the present invention.
FIG. 5 is a conceptual diagram when the torch is moved to a position where the distance from the tip plane of the segment conductor to be welded to the torch is equal in one embodiment of the present invention.
FIG. 6 is a graph showing a result of an experiment for measuring the width of a work having a width of 4 mm while changing the installation height of a camera in one embodiment of the present invention.
FIG. 7 is a diagram showing a camera installation state in one embodiment of the present invention.
FIG. 8 is a flowchart of an embodiment of the present invention.
FIG. 9 is a conceptual diagram when capturing a welding ball in a planar image using direct illumination or indirect illumination in one embodiment of the present invention.
FIG. 10 is a diagram illustrating light and shade generated in a welding ball captured in a plane image when a plane image is acquired using direct illumination or indirect illumination in one embodiment of the present invention.
FIG. 11 is a diagram showing a positional relationship between planar images obtained by imaging a welding ball with two cameras in one embodiment of the present invention.
FIG. 12 is a diagram showing an example of a master image when performing a correlation analysis of each welding ball in a planar image and an example of unwelding, melting, and insufficient melting in one embodiment of the present invention.
FIG. 13 is a diagram showing a measurement window that is position-corrected for measuring the area of each welding ball in a planar image in one embodiment of the present invention.
FIG. 14 is a diagram showing a result of performing a correlation analysis of each welding ball in a planar image in one embodiment of the present invention.
FIG. 15 shows a result of discriminating a welding ball that is insufficiently melted based on the area of the central portion of the welding ball, as compared with the welding ball determined as “NG product” in the correlation analysis of each welding ball in the plane image in the embodiment of the present invention. FIG.
FIG. 16 shows a result of discriminating a welding ball that is insufficiently melted based on the area of a central portion of a welding ball, as compared with a welding ball that is determined to be “OK product” in a correlation analysis of each welding ball in a planar image in one embodiment of the present invention. FIG.
FIG. 17 is a diagram showing a positional relationship between a camera and a welding ball in order to explain that the height can be obtained from a welding ball captured in a planar image in one embodiment of the present invention. It is.
FIG. 18 is a view showing that the height of the welding ball can be obtained from the welding ball captured in the planar image according to the embodiment of the present invention. It is a figure showing that width of a bright surrounding part changes.
FIG. 19 is a view showing the relationship between the height of a welding ball and the width of a bright surrounding portion of the welding ball in order to explain that the height of the welding ball can be determined from a welding ball captured in a planar image in one embodiment of the present invention. It is a figure showing a relation.
FIG. 20 is a diagram showing a window set on an image for detecting the presence or absence of foaming of the enamel covering portion of the segment conductor in one embodiment of the present invention.
FIG. 21 is a diagram showing a gap between welding balls arranged in a radial direction of a stator core in one embodiment of the present invention.
FIG. 22 is a diagram showing a window set on a plane image for measuring a gap between welding balls arranged in a radial direction of a stator core in one embodiment of the present invention.
FIG. 23 is a diagram showing an example of a window set to a plane image of a segment conductor to be welded for comparison with an embodiment of the present invention.
FIG. 24 is a diagram showing an example of a window set in a plane image obtained by capturing a segment conductor to be welded for comparison with the embodiment of the present invention.
FIG. 25 is a front view showing an ideal positional relationship between a segment conductor and a torch to be welded;
FIG. 26 is a plan view showing an ideal positional relationship between a segment conductor and a torch to be welded;
FIG. 27 is a front view showing an example of a realistic positional relationship between a segment conductor and a torch to be welded;
FIG. 28 is a plan view showing an example of a realistic positional relationship between a segment conductor and a torch to be welded.
FIG. 29 is a plan view of a stator core.
FIG. 30 is a perspective view when both ends of the segment conductor are inserted into the penetration grooves of the stator core.
FIG. 31 is a perspective view when both ends of the segment conductor are inserted into the penetration grooves of the stator core.
FIG. 32 is a perspective view when both ends of the segment conductor are inserted into the penetration grooves of the stator core.
FIG. 33 is a perspective view when both ends of the segment conductor penetrate into the penetration grooves of the stator core.
FIG. 34 is a perspective view when both ends of a segment conductor penetrating into a penetration groove of a stator core are twisted.
FIG. 35 is a diagram showing only a front end plane of a segment conductor disposed on the back side of the stator core by twisting both ends of the segment conductor penetrating the penetration groove of the stator core.
FIG. 36 is a view showing a portion to be welded provided on the back side of the stator core by twisting both ends of the segment conductor penetrating into the penetration groove of the stator core.
[Explanation of symbols]
11,21,103,104 segment conductor
31 Torch
41 welding ball
54,56,57 direct lighting
55 Indirect lighting
101 Stator core
105 welding spot
B Gap between welding balls adjacent in the radial direction of the stator core
P1, P2 Two vertices adjacent on the torch side of the tip plane of the segment conductor
V Planar image obtained by direct and indirect illumination

Claims (5)

Both ends of a plurality of substantially U-shaped segment conductors penetrating into the stator core are twisted in opposite directions in the circumferential direction of the stator core, and the ends on one end side or the other end side of the separate segment conductors adjacent to each other are torched. In the welding method of the segment conductor to be welded by
For each of the tip planes at one end or the other end of the separate segment conductors that are welded by the torch, the positions of two vertices that are adjacent on the torch side but not adjacent to the chamfered part are viewed in plan. A method for welding segment conductors, characterized in that the torch is moved based on the torch movement basic information by measuring as torch movement basic information by performing measurement by image processing according to (1). It is a welding method of the segment conductor of Claim 1, Comprising:
Based on the torch movement basic information, a torch movement position in which the distance from each of the end planes at one end or the other end of the separate segment conductors which are welded by the torch to the torch is equal is determined. Moving the torch to a position. Both ends of a plurality of substantially U-shaped segment conductors penetrating into the stator core are twisted in opposite directions in the circumferential direction of the stator core, and the ends on one end side or the other end side of the separate segment conductors adjacent to each other are torched. After welding in, the welding quality control method of the segment conductor to detect the unwelded and melted part of the welding point, insufficient melting,
Obtaining a planar image by irradiating the welding location with direct illumination and indirect illumination, and based on the correlation value in the planar image, detecting non-welding and melting of the welding location, and then calculating the area value in the planar image. A welding quality control method for a segment conductor, which detects a lack of melting at the welding location based on the method. One end or the other end of a separate segment conductor which is formed by twisting both ends of a plurality of substantially U-shaped segment conductors penetrating into the stator core in the circumferential direction of the stator core in opposite directions to each other and radially adjacent to the stator core. After welding the tip of the side with a torch, the welding quality control method of the segment conductor to measure the gap between the welding spots adjacent in the radial direction of the stator core,
Obtaining a plane color image of the welding portion, and detecting a boundary between the welding portions in the plane color image by a logical sum of two or more colors, thereby measuring a gap between welding portions adjacent in the radial direction of the stator core. And a method for controlling the welding quality of the segment conductor. One end or the other end of a separate segment conductor which is formed by twisting both ends of a plurality of substantially U-shaped segment conductors penetrating into the stator core in the circumferential direction of the stator core in opposite directions to each other and radially adjacent to the stator core. After welding the tip of the side with a torch, the welding quality control method of the segment conductor to detect the presence or absence of foaming of the insulating covering portion of the segment conductor,
Acquiring an image of the insulating covering portion of the segment conductor, and detecting the presence or absence of foaming of the insulating covering portion of the segment conductor based on the area value of the glossy portion in the image, the welding quality of the segment conductor. Management method.

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