换向器滚压加工过程检测系统研究

    As an integral part of some mechanical devices, commutator is mainly used in motors, starters and other equipments. The machining accuracy of commutator significantly affects the performance of these devices, especially in some special areas. The first step of the commutator machining process is to roll the plate work piece to form a round ring, and form a gap between both ends of the contact area. The size of the gap will directly determine the performance of the commutator, so it is necessary to detect the gap.The detection of the gap of commutator is detection of the displacement. There are a variety of methods to detect displacement, and the principles are also different. So far, the parts processing detection has been researched at home and abroad, which also made some results can be learned. However, due to the different of parts and processing conditions, the specific requirements of parts and factors to be considered are different. Therefore, it is necessary for the specific technical requirements of certain key components to do specific studies to determine what kind of detection method. According to the requirements of commutator rolling machining forming, a variety of detection methods and sensors were compared. During forming process, the eddy current sensing method was put forward to detect the contact gap of commutator, and the piezoelectric force sensing measurement was used to detect the force change. Two kinds of information were fused to constitute the detection system. Two kinds of signals complement each other to make up the insufficiency of sole signal, and the system’s accuracy and the reliability were enhanced.In this paper, the performance of eddy current sensor was studied, the experiments were designed, and the feasibility of using the eddy current sensor was validated through the experimental data. A dynamometer which used to detect the roller pressure was designed and calibrated, some important parameters such as the non-linear error, the repeatability error and the horizontal interference were got, and the results met the standards. In addition, this paper researched on the factors that affected detection system and experimental verification, and took appropriate measures to reduce or eliminate the influences. Through the analysis of experimental data, when the work piece qualified was obtained and verified by simulation experiment.