CN102331434A - Failure analysis method for fracture of motor rotor enameled wire in automobile electronics - Google Patents
Failure analysis method for fracture of motor rotor enameled wire in automobile electronics Download PDFInfo
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- CN102331434A CN102331434A CN201110242114A CN201110242114A CN102331434A CN 102331434 A CN102331434 A CN 102331434A CN 201110242114 A CN201110242114 A CN 201110242114A CN 201110242114 A CN201110242114 A CN 201110242114A CN 102331434 A CN102331434 A CN 102331434A
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Abstract
The invention provides a failure analysis method for fracture of a motor rotor enameled wire in automobile electronics. The failure analysis method comprises the following steps of: A, observing a metal fracture surface of the fracture of an enameled wire sample needing subjecting to failure analysis by using a scanning electron microscopy, and analyzing possible failure reasons; B, analyzing elements on the surface of the enameled wire sample by using an X-ray feature particle energy spectrometer, and acquiring the possible failure reasons by comparing with enameled wire material design specifications; C, making a metallographic sample of the enameled wire sample; D, observing the made metallographic sample by using the scanning electron microscope, and inspecting whether the enameled wire sample meets indexes in design specification requirements or not; and E, analyzing the failure reasons and failure mechanisms of the enameled wire sample by synthesizing a conclusion obtained from the steps. The method has simple and clear steps and is easy to operate. According to the method, the failure reasons for the fracture of the motor rotor enameled wire are effectively analyzed, the improvement on wire enameled production process is promoted, and the product quality is improved.
Description
Technical field
The present invention relates to a kind of failure analysis method, particularly a kind of failure analysis method to motor rotor enameled wire in the automotive electronics.
Background technology
Automotive electronics is the general name of car body electronic control device for vehicle and vehicular automotive electronic control device.Automotive electronics is broadly divided into: infosystem, running gear control system, power train control system, body control system and safety control system etc.The most important effect of automotive electronics is security, the comfortableness, economical and recreational that improves automobile.The electric-control system of forming with sensor, microprocessor, actuator, dozens of even up to a hundred electronic devices and components and parts thereof.Wherein sensor is widely used in each vitals in the automotive electronics as a kind of sensitive device.
Motor is the equipment that converts electric energy to mechanical energy; It is to utilize hot-wire coil phenomenon of stressed rotation in magnetic field to process; Be distributed in each user place; Motor is by using the power supply difference to be divided into direct current motor and AC motor, and the motor major part in the electric system is an AC motor, can be synchronous motor or asynchronous machine.And the motor that in automotive electronics, uses mainly is made up of stator and rotor.Electrified wire stressed travel direction in magnetic field is relevant with the magnetic induction line direction with direction of current.The motor principle of work be magnetic field to the stressed effect of electric current, motor is rotated, thereby realizes the conversion of electric energy to mechanical energy.
The rotor of motor is the rotary part in the motor, and rotor is divided into two kinds of internal rotor rotating manner and outer rotor rotating manners.The internal rotor rotating manner is that the core body in the middle of the motor is a rotary body, and output torque is perhaps taken in energy.The outer rotor rotating manner is a rotary body with the motor ectosome promptly, and different modes has made things convenient for the application of various occasions.
For the conversion of this electric energy of realizing motor rotor to mechanical energy; Generally can twine electromagnetic wire according to certain rules on the rotor; So-called electromagnetic wire is meant a kind of electric wire with insulation course, and it is to realize the electromagnetism transformation of energy with winding configuration, is called winding wire again.
Enameled wire is a principal item of winding wire, is made up of conductor and insulation course two parts, and bare wire is behind annealing softening, and experience is repeatedly painted again; Cure and form, but will produce both conformance with standard requirements, the product of meeting customer need again also is not easy, and it receives raw material quality; Technological parameter, production equipment, factor affecting such as environment; Therefore, the mass property of various enameled wires has nothing in common with each other, but all possess mechanical property, chemical property, electrical property and thermal behavior four big performances.Press the conductor material branch: copper cash, aluminum steel and alloy wire.Therefore, when fracture takes place the enameled wire of the winding of motor rotor, how to carry out failure analysis fast and effectively and become the major issue that automotive electronics quality analysis field need solve.
Summary of the invention
Carry out failure analysis problem fast and effectively for how solving for the motor enameled wire fracture, the present invention provides following technical scheme:
Motor rotor enameled wire FRACTURE FAILURE ANALYSIS method in a kind of automotive electronics may further comprise the steps:
A, use scanning electron microscope are observed the metal fracture that needs carry out the enameled wire breakage place of failure analysis, analyze possible failure cause;
B, use X ray characteristic particle energy spectrometer are analyzed the element of enameled wire sample surfaces, through contrast enameled wire lead material design specification book, analyze possible failure cause;
The microsection sample of C, making enameled wire sample;
D, the microsection sample that uses sem observation to make check whether the enameled wire sample meets the index of design specifications claim;
The conclusion that E, comprehensive above step obtain, the failure cause and the failure mechanism thereof of analysis enameled wire sample.
As a kind of preferred version of the present invention, sem observation microsection sample is for observing diameter, the thickness of enameled wire and the homogeneity of enameled wire of enameled wire sample interior lead among the said step D.
As another kind of preferred version of the present invention, in the said steps A enameled wire sample is carried out using the mode of eye-observation that the enameled wire sample is carried out preliminary outward appearance observation before the sem observation, analyze possible failure cause.
The present invention has following advantage: the inventive method step is simple clear easy to operate, and effectively the failure cause to the fracture of motor rotor enameled wire carries out detailed and reliable analysis, can effectively promote the improvement of motor rotor Production of Enamel Wires technology, improves the quality of products.
Description of drawings
Fig. 1 sample fracture scanning electron microscope diagram sheet;
The fibrous ductile fracture of Fig. 2 sample fracture district picture;
Fig. 3 sample fracture energy spectrum analysis zone index map;
Fig. 4 partly carries out the ability spectrogram that energy spectrum analysis obtains for energy spectrometer to the square frame among Fig. 3.
Embodiment
Do to set forth in detail in the face of this process implementing example down, thereby protection scope of the present invention is made more explicit defining so that advantage of the present invention and characteristic can be easier to it will be appreciated by those skilled in the art that.
Present embodiment is used for the failure analysis that engine cooling is carried out with the unusual fracture failure of motor rotor enameled wire of fan to certain.This motor is used for the heating radiator electronic fan, and serviceability temperature is 800～1200 ℃.3 in inefficacy motor sample is provided in the present embodiment altogether, and the enameled wire of its cleaved is totally 6 places, and each inefficacy motor respectively has the enameled wire fracture of 2 places, and common feature all is to break at the motor front end, i.e. the same side of winding spot welding place.
Enameled wire working environment: U=12V; Maximum current I max=11A; Temperature T max=1200 ℃.
The concrete analysis step of this enforcement row is following:
A, carry out preliminary observation through the enameled wire sample to 3 inefficacies, find a common ground: the breakaway poing of enameled wire sample all is positioned at the same side of spot welding place metal fixture section; Use scanning electron microscope that the metal fracture that needs carry out the enameled wire breakage place of failure analysis is observed; As shown in Figure 1, finding has the shear fracture pattern in the fracture, and large-area dimple shape ductile fracture district is also arranged simultaneously; The fracture macro morphology is fibrous; As shown in Figure 2, can analyze, fibrous ductile fracture district is actually constriction up to the result who ruptures fully;
B, use X ray characteristic particle energy spectrometer are analyzed the element of enameled wire sample surfaces; Like Fig. 3 and shown in Figure 4; Can find out that from EDAX results table one fibrous ductile fracture fracture oxygen level is high, be the result owing to continuous oxidation in the fusing constriction process; So the ductile fracture of this fibrous ductile fracture fracture is actually constantly the fuse result of constriction process of enameled wire, rather than because exist other to cause cold short or hot-short abnormal elements;
Table one energy spectrometer analysis result
| Element | Weight％ | Atomic％ |
| O?K | 2.61 | 6.08 |
| Cu?K | 97.39 | 93.92 |
| Totals | 100 | 100 |
[0028]The microsection sample of C, making enameled wire sample;
D, the microsection sample that uses sem observation to make; Discovery enameled wire sample does not rupture as yet and by a side at the position of metal fixture covering the vestige of being sheared by the metal fixture burr is always arranged, and fracture also all is to rupture from a side that is sheared;
Exotic materials is carried out cross-section analysis by the burr cutting out section, and minimum diameter is 569um, has surpassed the standard of " the weld enameled wire allows 15%～30% distortion ", does not meet designing requirement.
E, deducibility goes out following common ground from above fracture data:
1: the shear fracture that the inefficacy fracture all has part metals anchor clamps burr to shear.
2: the inefficacy fracture all has large-area fibrous ductile fracture fracture (the process result of constriction).
3: seeing that from EDAX results fibrous ductile fracture fracture oxygen level is high, is the result owing to continuous oxidation in the fusing process, so the ductile fracture of this fibrous ductile fracture fracture is actually the result of the continuous fusing process of enameled wire.
Thereby draw the failure mechanism of motor rotor enameled wire:
Step1: enameled wire with metal fixture ERW process in, welding gear spot welding metal fixture and by the enameled wire of its covering;
Step2: metal fixture is closed, and the anchor clamps burr are sheared the copper wires of enameled wire, and enameled wire is produced certain mechanical damage;
Step3: owing to shear, the cross section diminishes, and it is big that current density becomes, and enameled wire heats up, and lacquer is burnt black; Because taking place, the enameled wire of fracture is positioned at the coiling reference position simultaneously, so the tension of tension has the contribution effect to follow-up ductile fracture;
Step4: the cross section current density is big, and wire rod more is prone to fusing, and the cross section is littler;
Step5: the cross section is littler, and current density is bigger, and wire rod more is prone to fusing, so get into vicious cycle, the centrifugal force when wherein promoting tension and the motor rotor high speed rotating of the reference position that winds the line in addition of plasticity necking rupture certainly;
Step6: become in current density under the centrifugal force acting in conjunction of tension and high speed rotating of big, coiling reference position, opened by necking rupture fully until wire rod, and the constantly oxidation in big electric current scorification process of the oxygen content of breakpoint fracture, so oxygen content is higher.
Judging manufacturer that this kind inefficacy is actually motor rotor soon through this scheme damages at the first lap coiling tension of enameled wire winding process and machinery in the enameled wire welding technology in advance; Caused enameled wire in the client use; Because the effective conductive area that has tension and cause owing to the preparatory damage of machinery reduces; Make current density increase, and the influences such as centrifugal force during rotation, the beginning ductile fracture ruptures up to final constriction fully.
The above; Be merely one of embodiment of the present invention; But protection scope of the present invention is not limited thereto; Any those of ordinary skill in the art are in the technical scope that the present invention disclosed, and variation or the replacement that can expect without creative work all should be encompassed within protection scope of the present invention.Therefore, protection scope of the present invention should be as the criterion with the protection domain that claims were limited.
Claims (3)
1. motor rotor enameled wire FRACTURE FAILURE ANALYSIS method in the automotive electronics, it is characterized in that: this method may further comprise the steps:
A, use scanning electron microscope are observed the metal fracture that needs carry out the enameled wire breakage place of failure analysis, analyze possible failure cause;
B, use X ray characteristic particle energy spectrometer are analyzed the element of enameled wire sample surfaces, through contrast enameled wire lead material design specification book, analyze possible failure cause;
The microsection sample of C, making enameled wire sample;
D, the microsection sample that uses sem observation to make check whether the enameled wire sample meets the index of design specifications claim;
The conclusion that E, comprehensive above step obtain, the failure cause and the failure mechanism thereof of analysis enameled wire sample.
2. motor rotor enameled wire FRACTURE FAILURE ANALYSIS method in a kind of automotive electronics according to claim 1 is characterized in that: sem observation microsection sample is for observing diameter, the thickness of enameled wire and the homogeneity of enameled wire of enameled wire sample interior lead among the said step D.
3. motor rotor enameled wire FRACTURE FAILURE ANALYSIS method in a kind of automotive electronics according to claim 1; It is characterized in that: in the said steps A enameled wire sample is carried out using the mode of eye-observation that the enameled wire sample is carried out preliminary outward appearance observation before the sem observation, analyze possible failure cause.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201110242114A CN102331434A (en) | 2011-08-23 | 2011-08-23 | Failure analysis method for fracture of motor rotor enameled wire in automobile electronics |
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| CN201110242114A CN102331434A (en) | 2011-08-23 | 2011-08-23 | Failure analysis method for fracture of motor rotor enameled wire in automobile electronics |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105866120A (en) * | 2016-03-24 | 2016-08-17 | 山东省分析测试中心 | Failure analysis method for suspended structural member of subway power supply network and application thereof |
| CN107703001A (en) * | 2017-10-16 | 2018-02-16 | 国网吉林省电力有限公司电力科学研究院 | The method of testing of operational factor during a kind of power transmission and transforming equipment copper conductor fracture |
| CN108535304A (en) * | 2018-04-27 | 2018-09-14 | 暨南大学 | Macroscopical metallographic detection method of fatiguability break bolt |
| CN114578014A (en) * | 2022-02-08 | 2022-06-03 | 复旦大学 | Comprehensive analysis method for abnormal failure of copper-based pin type radiator chemical plating part |
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2011
- 2011-08-23 CN CN201110242114A patent/CN102331434A/en active Pending
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| 于力等: "发电机定子导线断裂失效分析", 《腐蚀科学与防护技术》 * |
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105866120A (en) * | 2016-03-24 | 2016-08-17 | 山东省分析测试中心 | Failure analysis method for suspended structural member of subway power supply network and application thereof |
| CN107703001A (en) * | 2017-10-16 | 2018-02-16 | 国网吉林省电力有限公司电力科学研究院 | The method of testing of operational factor during a kind of power transmission and transforming equipment copper conductor fracture |
| CN108535304A (en) * | 2018-04-27 | 2018-09-14 | 暨南大学 | Macroscopical metallographic detection method of fatiguability break bolt |
| CN108535304B (en) * | 2018-04-27 | 2020-06-30 | 暨南大学 | Macroscopic metallographic detection method for bolts easy to fatigue fracture |
| CN114578014A (en) * | 2022-02-08 | 2022-06-03 | 复旦大学 | Comprehensive analysis method for abnormal failure of copper-based pin type radiator chemical plating part |
| CN114578014B (en) * | 2022-02-08 | 2023-12-22 | 复旦大学 | Comprehensive analysis method for abnormal failure of copper-based needle-type radiator chemical plating part |
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Application publication date: 20120125 |