CN102510141A - Amorphous, microcrystalline or nano-crystalline alloy stator iron core for axial magnetic flux motor and manufacture method for stator iron core - Google Patents
Amorphous, microcrystalline or nano-crystalline alloy stator iron core for axial magnetic flux motor and manufacture method for stator iron core Download PDFInfo
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Abstract
The invention discloses an amorphous, microcrystalline or nano-crystalline alloy stator iron core for an axial magnetic flux motor and a manufacture method for the stator iron core. The manufacture method includes the steps: firstly, rolling and cutting a coiled amorphous, microcrystalline or nano-crystalline alloy wide band into an alloy strip coil (6) which is twice as high as that of the finished iron core, then uniformly punching a plurality of strip slots (17) in the middle of the alloy strip coil at intervals with the same equipment, performing insulation coating treatment and further coiling the alloy strip coil on an inner core (24) of the iron core, wherein the strip slots (17) are as same as open slots (26) in width, and the length of each strip slot (17) is twice of the depth of each open slot (26); next, adding an iron core outer-circumference protecting layer on the outer circumference face of the coiled alloy strip coil, then transversely halving the alloy strip coil into two identical alloy iron cores along the axial perpendicular plane of the alloy strip coil; and finally, carrying out high-temperature annealing treatment on the iron cores formed by processing. The stator iron cores prepared by the method are more excellent in performance, and particularly applicable to a high-speed motor, a high-power density motor and a high-torque density motor.
Description
Technical field
The invention belongs to the magnetic circuit part field of motor; Be specifically related to a kind of axial-flux electric machine with amorphous, crystallite or nanocrystalline alloy stator iron core and manufacturing approach thereof, this kind stator core especially is fit to be applied in and requires energy-efficient high rotating speed, high power density and high torque density electrical machine.
Background technology
Motor is the highest electric equipment of power consumption in the world, improve electric efficiency to energy-saving and emission-reduction, alleviate energy shortage and environmental pollution all is significant.At present, the raising of electric efficiency receives the great attention of countries in the world.The plurality of applications field not only requires motor to have high efficiency, also will have characteristics such as high power density, high torque density or high rotating speed, such as electric automobile, Aero-Space, high speed compressor or the like.The silicon steel core that conventional motors is used has been difficult to satisfy more and more harsher performance requirement.Because the non-crystaline amorphous metal soft magnetic material has low-loss, high magnetic permeability, high strength and characteristic such as corrosion-resistant, the research that is applied to electric machine iron core with its alternative silicon steel receives the great attention of a lot of countries in recent years.
At first have a look radial flux (perhaps claiming radial air gap) amorphous electric machine iron core and progress.The disclosed amorphous metal stator core of in June, 1998 U.S. Honeywell WO99/66624 of house journal is that the band with different length is superimposed as and carries out hot curing after arc or the C shape and handle to form and have the toothed stator iron core to internal diameter direction.2004 HIT (Hitachi) patent of invention US6737951B1 disclosed method be to handle with carrying out hot curing after the amorphous band stack; Cut into the polyhedron amorphous block that one side even two sides have arch surface again, then these amorphous blocks are arranged the complete stator core of formation again.All there is air gap in the amorphous alloy iron core that these two kinds of methods are made in jointing positions, has influenced the performance of iron core to a certain extent.The patent WO2004/070740 of U.S. Metglas Inc in 2004 discloses the method that photoetching etching legal system is equipped with the amorphous stator core, and this method complex process, efficient are low, are not suitable for producing in batches.The patent of invention CN101286676A of Antai Science and Technology Co., Ltd in 2008 discloses a kind of first hot curing and has handled the amorphous block method of the making stator core of integral cutting moulding again of making; For the radial flux amorphous iron core that processability is outstanding has been established technical foundation, but make the restriction that the size of iron core has been received the amorphous alloy strips width.Shenzhen Huarenxing Technology Co., Ltd. has proposed to use the method for the means making large scale radial flux amorphous alloy iron core that splices in patent CN101882816A.
Because amorphous alloy strips is the continuous thin-band material with constant width; The watt level of motor does not receive the restriction of amorphous alloy strips width basically when making the axial-flux electric machine stator core; And the utilance of material exceeds several times than making the radial magnetic field electric machine iron core; Add axial-flux electric machine and have power density and torque density height, the axial distance weak point is beneficial to advantages such as motor radiating, has more advantage so non-crystaline amorphous metal is made the motor in axial magnetic field stator core.The patent US005731649A of U.S. LE company in 1998 discloses and has used the amorphous block of reeling to constitute electric machine iron core, uses direct amorphous cylinder of reeling to cause vortex current looping circuit as the tooth of iron core stator core, and iron loss is very big.Disclose in patent US7018498B2 up to LE company in 2006 and a kind ofly to have produced annular non-crystaline amorphous metal block earlier, milled out the method for the processing amorphous alloy stator iron core of axial teeth groove structure again.This method can be produced high performance axial magnetic flux amorphous alloy stator iron core.But, because non-crystaline amorphous metal becomes very crisp through heat treatment after, when especially carrying out the Milling Process of the intensive amorphous alloy iron core of teeth groove, tooth portion takes place easily come off or damage, cause the rate of finished products reduction.And Milling Process will cause the iron core decreased performance at the inner gravitation of introducing of amorphous alloy stator iron core.The manufacture method of a kind of axial-flux electric machine with amorphous alloy iron core also disclosed among the patent CN101741153A of Hitachi Ind Equipment Sys of Amada Co., Ltd.; At first produce annular non-crystal block with the mode of resin casting mold; Then cut out a plurality of shapes bar-shaped non-crystal block identical, re-use discoid iron core holding member these bar-shaped non-crystal blocks are combined into amorphous alloy stator iron core with size.The amorphous alloy iron core that this method is made is made up of a plurality of little amorphous blocks, and there is air gap in core interior, but also needs to use the iron core holding member to be grouped together complex procedures to the amorphous iron core block that separates.
Problems such as in sum, still there is complex process in existing technology of making the non-crystaline amorphous metal electric machine iron core, cost is high, rate of finished products is low and performance is undesirable.
In view of the characteristics that amorphous alloy strips be fit to be made the axial-flux electric machine stator core, this patent provides a kind of processing method of making high-performance axial magnetic flux amorphous motor stator core.
Summary of the invention
The object of the present invention is to provide a kind of axial-flux electric machine with amorphous, crystallite or nanocrystalline alloy stator iron core and manufacturing approach thereof; This method cost is low, production efficiency is high and rate of finished products is high; And the performance of amorphous, crystallite or nanocrystalline alloy stator iron core through this method manufacturing is excellent more, and it is neatly smooth to have excellent soft magnet performance and outward appearance.
In order to achieve the above object, the invention provides following technical scheme:
A kind of axial-flux electric machine is with the manufacturing approach of amorphous, crystallite or nanocrystalline alloy stator iron core, and this stator core is a torus, and a plurality of radial opening grooves 26 are arranged on the annular end face, and wherein, method comprises following steps:
(1) use the roller shear device, amorphous, crystallite or the nanometer crystal alloy broadband of rolling are rolled up along the alloy strip steel rolled stock that belt length direction roller shear becomes to have fixed width, said fixed width is the twice of finished product iron core height;
(2) alloy strip steel rolled stock of said fixing width is provided on the passive rotation roller 5; Handle as follows successively: 1. jet-bedding is handled; Stamp out the trough of belt 17 on the vertical alloy strip steel rolled stock length direction continuously at said alloy strip steel rolled stock middle part, its width and open slot 26 width equate, length is the twice of open slot 26 degree of depth; 2. being coated with insulating barrier handles; 3. coiling processing is wound on alloy strip steel rolled stock on the iron core inner core 24 that has inner core groove 4, and said trough of belt 17 is corresponding with inner core groove 4 positions, is equivalent to the alloy strip steel rolled stock volume 25 with bathtub construction 15 of two axial magnetic flux iron core teeth portions to buckle thereby form; Said rotation roller 5 carries out intermittent synchronously rotation with iron core inner core 24 by 23 controls of a high precision numerical control dividing head;
(3) in step (2); When alloy strip steel rolled stock volume 25 coilings with bathtub construction 15 reach required external diameter; On the strip coil periphery, add one deck and the cylindrical protective layer that said periphery has identical bathtub construction, to vertical plane its five equilibrium crosscut is become amorphous, crystallite or the nanocrystalline alloy stator iron core 28 that two shapes are identical with size and have axial teeth groove structure along the alloy strip steel rolled stock spool again;
(4) amorphous that step (3) is obtained, crystallite or nanocrystalline alloy stator iron core 28 carry out annealing in process.
Described amorphous, crystallite or nanometer crystal alloy broadband material chosen from Fe base, iron are Ni-based, cobalt base amorphous, crystallite and nanometer crystal alloy strip.
The material of said iron core inner core 24 and cylindrical protective layer is selected from silicon steel, magnetism-free stainless steel, iron, aluminium, copper, titanium and alloy thereof, pottery, organic siliconresin, nylon, carbon fiber.
In the coiling processing of said step (2); Control the iron core inner cores through high precision numerical control dividing head 23 and realize intermittent rotation as follows: high precision numerical control dividing head 23 drives iron core inner cores 24 interval t rotation at regular intervals once; The anglec of rotation is θ=360 °/n; Wherein n is the quantity of the axial tooth 27 or the open slot 26 of amorphous, crystallite or nanocrystalline alloy stator iron core; The distance that while iron core inner core 24 drive alloy strip steel rolled stocks are advanced forward is s=π * r* θ/180, and in the dead time t after iron core heart 24 rotation θ angles, accomplishes a jet-bedding just and handle.
During said jet-bedding was handled, drift that uses and the gap between the jet-bedding were 1/10～1/2 of amorphous alloy strips gross thickness.
In said jet-bedding was handled, the trough of belt 17 on the said alloy strip steel rolled stock can be rectangle, ellipse or other arbitrary shapes, and the shape of inner core groove 4 is identical on the shape of said trough of belt 17 and the said iron core inner core 24.
The band number of plies≤10 of said alloy strip steel rolled stock volume layer.
Said trough of belt 17 is positioned at alloy strip steel rolled stock inside, is closed figures, and quantity >=1 of said trough of belt 17 on vertical band length direction.
The center line of said trough of belt 17 all points to the central axis of amorphous, crystallite or nanocrystalline alloy stator iron core 28, and the shape of trough of belt 17 and size do not increase with said amorphous, crystallite or nanocrystalline alloy stator iron core radius and change; Yet said tooth 16 can broaden along with the increase of said amorphous, crystallite or nanocrystalline alloy stator iron core radius gradually.
In said step (2), 1. jet-bedding is handled with the order that 2. is coated with the insulating barrier processing and can be exchanged.
Said step (4) is under the protective atmosphere of nitrogen or argon gas, to carry out.
Said step (4) is to accomplish adding under the condition in magnetic field, and magnetic field intensity is 2-40mT, and magnetic direction is along circumferencial direction unshakable in one's determination.
Insulating coating liquid is selected from a kind of in solution, colloidal sol or the suspension-turbid liquid of tetraethoxysilane, waterglass, MgO fine powder, SiO2 fine powder or insulating ceramics fine powder.
Carry out resin hot curing processing to handle back amorphous, crystallite or nanocrystalline alloy stator iron core 28 through said step (4).
The dipping lacquer process was carried out under vacuum during said resin hot curing was handled.
A kind of axial-flux electric machine is with amorphous, crystallite or nanocrystalline alloy stator iron core; This stator core is a torus; A plurality of radial opening grooves are arranged on the annular end face; Wherein the horizontal five equilibrium of stator core base substrate that obtained through roller shear, jet-bedding, coating, coiling and annealing in process by alloy strip steel rolled stock of this stator core is cut into two identical stator cores and forms, and this stator core base substrate comprises iron core inner core 24, is wound on alloy strip steel rolled stock with bathtub construction and cylindrical protective layer on the iron core inner core 24;
Wherein: iron core inner core 24 is made up of with cylinder 2 a pair of annular collet 1, and n inner core groove 4 uniformly distributing at the stack shell middle part of cylinder 2; The trough of belt 17 that a plurality of vertical alloy strip steel rolled stock length directions are arranged on the alloy strip steel rolled stock of reeling, the twice that width all equates with open slot, length is the open slot degree of depth of inner core groove 4 and trough of belt 17;
In the winding process, the trough of belt 17 on the said alloy strip steel rolled stock with bathtub construction is corresponding with inner core groove 4 positions on the iron core inner core 24, is equivalent to the alloy strip steel rolled stock volume 25 with bathtub construction 15 of two axial magnetic flux iron core teeth portions to buckle thereby form;
The periphery of cylindrical protective layer has the groove identical with trough of belt 17.
Trough of belt 17 on the said alloy strip steel rolled stock can be rectangle, ellipse or other arbitrary shapes, and the shape of inner core groove 4 is identical on the shape of said trough of belt 17 and the said iron core inner core 24.
The present invention compares with the technology of preparing of existing axial magnetic flux amorphous, crystallite or nanocrystalline alloy stator iron core and has the following advantages:
What (1) the present invention prepared amorphous, crystallite or the employing of nanocrystalline alloy stator iron core is the method for reeling behind the jet-bedding; Avoided alloy material because the problem that is difficult to process complicated bathtub construction that thin, crisp and hard characteristic causes, reduced to a great extent axial amorphous, crystallite or nanocrystalline alloy stator iron core production cost, improved production efficiency and iron core rate of finished products;
(2) preparation method of amorphous according to the invention, crystallite or nanocrystalline alloy stator iron core can save resin hot curing forming processes, and then can shorten production procedure, saving production cost, can also make production process environmental protection and energy saving more;
(3) preparation method of amorphous according to the invention, crystallite or nanocrystalline alloy stator iron core has used iron core inner core and periphery protective layer that the axial magnetic flux alloy-iron core is carried out mechanical fixation and protection; Replace resin hot curing bonding forming in the past; Improved the stability of amorphous, crystallite or nanocrystalline iron core, avoided because of ftractureing, fall problems such as tooth because of the bonding not firm iron core that causes between alloy thin band layer and the layer;
(4) can not use binding agent to carry out interlayer bonding for the preparation method of amorphous according to the invention, crystallite or nanocrystalline alloy stator iron core, and then can avoid because the introducing of bonding stress causes the problem of the decline of alloy-iron core soft magnet performance;
(5) hot curing that the preparation method carried out of amorphous according to the invention, crystallite or nanocrystalline alloy stator iron core is handled after jet-bedding and coiling and molding; So the stress that jet-bedding and coiling operation are introduced can be eliminated through annealing, and then the excellent soft magnet performance of amorphous, crystallite or nanometer crystal alloy material can farthest be kept in iron core;
(6) loss of amorphous of the present invention, crystallite or nanocrystalline alloy stator iron core is far below the silicon steel stator core; Magnetic permeability is far above silicon steel core; So use the motor of described amorphous, crystallite or nanocrystalline alloy stator iron core to have low temperature rise, high efficiency advantage, it is more obvious especially to be applied to pot motor, high power density and high torque density electrical machine effect.
Description of drawings
Fig. 1 is the sketch map of amorphous alloy stator iron core inner core according to the invention;
Fig. 2 is the sketch map of jet-bedding, coating and coiling and molding process in the amorphous alloy stator iron core manufacture process according to the invention;
Fig. 3 is the schematic appearance of the amorphous alloy stator iron core of employing manufacturing approach manufacturing of the present invention;
Fig. 4 carries out the sketch map of the amorphous alloy stator iron core of annealing in process for the frock jig preparation of packing into according to the invention;
Fig. 5 for dissimilar axial magnetic flux stator core when magnetic flux density is 0.6T; Core loss is with the curve chart of frequency change; Wherein, The 1 expression trade mark is the axial magnetic flux stator core of the silicon steel sheet making of DR255 among the figure, the axial magnetic flux amorphous alloy stator iron core that does not use the resin hot curing to handle of 2 expression the present invention preparations, the axial magnetic flux amorphous alloy stator iron core that the use resin hot curing that 3 expression the present invention prepare is handled;
Fig. 6 for dissimilar axial magnetic flux stator core when magnetic flux density is 1.0T; Core loss is with the curve chart of frequency change; Wherein, The 1 expression trade mark is the axial magnetic flux stator core of the silicon steel sheet making of DR255 among the figure, the axial magnetic flux amorphous alloy stator iron core that does not use the resin hot curing to handle of 2 expression the present invention preparations, the axial magnetic flux amorphous alloy stator iron core that the use resin hot curing that 3 expression the present invention prepare is handled.
Reference numeral
1 annular collet, 2 cylinders
3 inner core teeth, 4 inner core grooves
5 rotation rollers, 6 amorphous alloy strips volume
7 first backing rolls, 8 first registration rollers
Platform in 9 second registration rollers 10
11 mesopores 12 are presented a theatrical performance as the last item on a programme
14 trash receptacle in 13
15 bathtub constructions, 16 teeth
17 troughs of belt, 18 second backing rolls
19 coating ponds 20 the 3rd backing roll
21 coating liquid 22 are scraped the liquid plate
23 high precision numerical control dividing heads, 24 iron core inner cores
25 have the alloy strip steel rolled stock volume of bathtub construction
26 open slots, 27 axial tooths
28 amorphous, crystallite or nanocrystalline alloy stator iron core
29 square plates, 30 long screws
The 31 circular inner tubes of a tyre
Embodiment
Because adopting preparation method of the present invention to prepare axial-flux electric machine is identical with the method for amorphous, crystallite or nanocrystalline alloy stator iron core; Only need replace corresponding material; And select different parameter according to the performance of different materials; Can prepare the alloy stator core of amorphous, crystallite or different materials such as nanocrystalline, therefore, be example with the preparation amorphous alloy stator iron core only below; In conjunction with accompanying drawing and embodiment, specific embodiments of the invention describes in further detail.
Preparation in accordance with the present invention; The first step is to use the cutter sweep of routines such as amorphous alloy strips roller shear equipment that the non-crystaline amorphous metal broadband of rolling is vertically cut along the belt length direction; To form the amorphous alloy strips volume of preset width, wherein preset width is the prefabricated twice of making the amorphous alloy stator iron core height.The amorphous alloy strips volume can be the individual layer strip coil, also can be multiple strip coil, and the general band number of plies generally is not more than 10 layers.The amorphous alloy strips and the method for producing this kind alloy strip steel rolled stock are not done special restriction.
Second step was that iron core inner core 24 as shown in Figure 1 is installed on the device of making axial magnetic flux amorphous alloy iron core as shown in Figure 2, by the 23 control rotations of high precision numerical control dividing head.The amorphous alloy strips that roller shear in the first step is obtained having preset width carries out jet-bedding, is coated with insulating barrier and coiling processing.Wherein, The lamination coefficient of the amorphous alloy strips in the amorphous alloy iron core can be realized control through the size of the tension stress on the amorphous alloy strips in the adjustment winding process; Pulling force more greatly then lamination coefficient is high more, and this kind amorphous alloy iron core lamination coefficient generally is controlled between 0.75～0.90.Iron core inner core 24 is that the silicon steel plate of 0.5mm is processed by thickness, drives through high precision numerical control dividing head 23 and can realize rotating at any angle.High precision numerical control dividing head 23 is once rotation of t drive iron core inner core 24 realizations at interval at regular intervals; Anglec of rotation θ=360 °/n; Wherein n represents the quantity of the tooth or the trough of belt of amorphous alloy stator iron core, and meanwhile to drive the distance that amorphous alloy strips advance forward be s=π * r* θ/180 for iron core inner core 24; Notching device is accomplished a jet-bedding processing in the dead time t after each rotation θ angle.Amorphous alloy iron core carried out the rotation of θ angle next time after jet-bedding was finished dealing with under the drive of high precision numerical control dividing head 23; Carry out jet-bedding subsequently again and handle, so the repeatable operation amorphous alloy strips that will have a bathtub construction be wound on form on the iron core inner core 24 be equivalent to that two axial magnetic flux iron core teeth portion make-ups link together have a bathtub construction alloy strip steel rolled stock volume 25.
The shape of trough of belt can be rectangle, ellipse etc., and the groove on the inner core should be consistent with trough of belt, and the groove when trough of belt is rectangle on the inner core also is rectangle, and the groove when trough of belt is oval on the inner core is also for oval.
The 3rd step was to reel when reaching certain size when the external diameter with bathtub construction alloy strip steel rolled stock volume 25, take off from winding apparatus, and use welding perhaps methods such as rivet on its periphery, add the cylindrical protective layer that one deck and periphery have identical bathtub construction.Then, its five equilibrium crosscut is become two identical amorphous alloy stator iron cores of shape and size with axial teeth groove structure along the axial vertical plane of strip coil, as shown in Figure 3.
The 4th step was that the amorphous alloy stator iron core of making in the last step is carried out annealing in process.The purpose of annealing is to remove the volatilizable composition in the coating liquid and eliminate the stress that jet-bedding is operated and winding process is introduced in amorphous alloy iron core inside, further improves the soft magnet performance of amorphous alloy iron core.Annealing schedule is following, at first is warming up to 100-150 ℃ from room temperature, is incubated 1-3 hour; Continue again to be warming up between 300-560 ℃, be incubated 0-5 hour; Take out iron core after being cooled to room temperature then.Said annealing in process needs in protective atmospheres such as nitrogen or argon gas, accomplish, and also can be simultaneously accomplishes adding under the condition in magnetic field.
So far, axial-flux electric machine is used the amorphous alloy stator iron core completion of processing.Can also be according to practical application request, the amorphous alloy stator iron core through annealing in process of method for preparing to be carried out the resin hot curing handle, this step is inessential operation optionally.If it but is not very high that the amorphous alloy iron core that this method is made is used in that magnetic flux density to stator core requires, but the requirement for restriction of noise very Gao Shixu is carried out this step processing.Amorphous alloy iron core is immersed in the epoxy resin, can fully be immersed in amorphous alloy stator iron core inside in order to make epoxy resin, the dipping lacquer process can be carried out under vacuum environment.After treating that epoxy resin fully is immersed in the amorphous alloy iron core, the taking-up iron core is put into baking oven and is carried out the hot curing processing.
The band name composition of making the axial magnetic flux amorphous alloy stator iron core is Fe
80Si
9B
11(at.%), thickness is 30 ± 1 μ m, and width is 140mm, surfacing.The external diameter of waiting to make amorphous alloy stator iron core is 180mm, internal diameter 100mm, and high 40mm, groove depth 30mm, teeth groove quantity is 30.At first using roller shear equipment to become width to be the amorphous alloy strips of 80mm volume the amorphous alloy strips roller shear, is that the amorphous alloy strips of 80mm carries out secondary and reels that to form the 2 heavy amorphous alloy thin roll coil of strips for use with width again.Used thickness is that the silicon steel sheet of 0.5mm is made into iron core inner core as shown in Figure 1; The iron core inner core is that 180mm, internal diameter are that annular collet 1 and the internal diameter of 100mm is that 100mm, height are that the cylinder 2 of 80mm is formed by external diameter; Distributing uniformly at the stack shell of cylinder 2 middle part 30 inner core teeth 3 and 30 inner core grooves 4, wherein the width of inner core groove 4 is 0.50mm, length is 60mm.In addition; The cylindrical protective layer that is added on the amorphous alloy strips volume periphery also is made by the silicon steel sheet of 0.50mm; For external diameter is 180mm, high be the cylinder of 80mm, cylinder 2 stack shells middle part also is uniform-distribution with the identical rectangular channel of cylinder size and dimension of 30 and iron core inner core 24.
The jet-bedding of axial magnetic flux amorphous alloy stator iron core, coating and operating winding process are as shown in Figure 2; Be that the 2 heavy amorphous alloy strips of 80mm are wrapped on the rotation roller 5 at first with width; Get into towards platform 10 to first, second registration roller 8,9 through first backing roll 7; On platform 10, going out grooved after second backing roll 18 and the 3rd backing roll 20 get into dip-coating insulation coating liquid in the coating liquid 21; Remove excess coating liquid through scraping liquid plate 22, be wound at last and form alloy strip steel rolled stock volume 25 on the iron core inner core 24 by high precision numerical control dividing head 23 driven rotary with bathtub construction.
Wherein, the material in coating pond 19 is PVC, and coating liquid 21 wherein is the mixed liquor of nitric acid of deionized water and 0.001% (wt.) of alcohol, 2% (Wt.%) of positive silicic acid second vinegar, 88% (wt.%) of 9.999% (wt.%).
High precision numerical control dividing head 23 drives iron core inner core 24 whenever at a distance from rotation in 1 second once; The anglec of rotation is θ=360 °/30=12 °; Wherein 30 is teeth groove numbers of iron core, and meanwhile to drive the distance that amorphous alloy strips advance forward be s=π * r*12/180 (mm) for iron core inner core 24.In 1 second dead time after 12 ° of each rotations, presenting a theatrical performance as the last item on a programme 12 is pressed in amorphous alloy strips on platform 10, and drift 13 sweeps away rapidly, and the non-crystaline amorphous metal waste material falls into trash receptacle 14 from punching 11; Then drift 13 12 lifts with presenting a theatrical performance as the last item on a programme successively; Having accomplished a jet-bedding this moment handles; The bathtub construction of going out 15 comprises the tooth 16 and trough of belt 17 of the amorphous alloy stator iron core of manufacturing, and high precision numerical control dividing head 23 drive iron core inner cores 24 rotate 12 ° more then, begin jet-bedding, operating winding next time; Along with the increase of radius unshakable in one's determination, rotate distance that amorphous alloy strips advances also along with becoming big at every turn.So the repeatable operation amorphous alloy strips that will have a bathtub construction be wound on form on the iron core inner core 24 be equivalent to that two axial magnetic flux iron core teeth portion make-ups link together have a bathtub construction alloy strip steel rolled stock volume 25.
, takes off on together with iron core inner core 24 slave units the amorphous alloy strips volume external diameter that has bathtub construction when reaching 179mm; The cylindrical protective layer is welded on the periphery of amorphous alloy strips volume, to vertical plane its five equilibrium crosscut is become two identical amorphous alloy stator iron cores of shape and size with axial teeth groove structure along the amorphous alloy strips spool again.So far, accomplish the machine-shaping operation of axial magnetic flux amorphous alloy stator iron core, produced the amorphous alloy stator iron core that has open slot 26 and axial tooth 27 as shown in Figure 3.
At last amorphous alloy stator iron core is carried out The high temperature anneal.For fear of amorphous alloy stator iron core thermal deformation taking place in high-temperature annealing process, needs to use magnetism-free stainless steel frock jig as shown in Figure 4 that amorphous alloy stator iron core is carried out the deformation protection.The main body of frock jig is the square plate 29 that two thickness are 30mm, and it is processed by magnetism-free stainless steel, and dull and stereotyped four jiaos are equipped with long screw 30 respectively, can protect through the deformation to both ends of the surface about the amorphous alloy stator iron core in the fastening realization annealing process of screw.The center of two square plates 27 up and down all have with amorphous alloy stator iron core in the circular hole of circle measure-alike (diameter 100mm).Circular hole through square plate is inserted into the circular inner tube of a tyre 31 in the amorphous alloy stator iron core, prevents that the inside circle of amorphous alloy stator iron core from deformation radially taking place.Described The high temperature anneal is under nitrogen protection, adds along carrying out under the condition in iron core circumferencial direction magnetic field, and concrete technology is following:
1) adding one at the axial centre place of said amorphous alloy stator iron core can alive copper rod, and with the earthenware insulation, the whole then electric furnace of putting into nitrogen protection under carries out the heating anneal processing between copper rod and the amorphous alloy stator iron core;
Add the D.C. magnetic field that intensity is 20mT when 2) being warming up to 300 ℃, be warmed up to 390 ℃ with identical heating rate again with the rate of heat addition of 60 ℃/min;
3) keep magnetic field constant, at 380 ℃ of insulation 90min; Remove magnetic field when 4) being cooled to 300 ℃ with the speed of 40 ℃/min then, take out amorphous alloy stator iron core after being cooled to room temperature with identical cooling rate again.
The roller shear of amorphous alloy strips, jet-bedding, coating, coiling and annealing in process technology equal and embodiment 1 is identical.Exactly the amorphous alloy stator iron core of making among the embodiment 1 being carried out a resin hot curing again handles.Concrete technology is following: amorphous alloy stator iron core is soaked in the epoxy resin in the stainless steel tank of people, and put into vacuum tank together with dip tank and be evacuated to below the 1Pa, kept 30 minutes in this vacuum degree.Then lay down vacuum environment, take out amorphous alloy iron core and put into baking oven and carry out hot curing at 170 ℃ and handle, be incubated and turn off the baking oven power supply after 4 hours and naturally cool to room temperature by amorphous alloy stator iron core.So far, the axial magnetic flux amorphous alloy stator iron core of handling through the resin hot curing completes.
Use the trade mark to make the silicon steel core with the amorphous alloy stator iron core same size as the silicon steel sheet (thickness 0.35mm) of DR255; And with the axial magnetic flux amorphous alloy stator iron core that does not use the resin hot curing to handle; And the axial magnetic flux amorphous alloy stator iron core that uses the resin hot curing to handle has carried out the performance parameter contrast; Dc magnetic can be seen table 1, and core loss is seen Fig. 5 and Fig. 6 with the change curve of frequency.
Data among contrast table 1, Fig. 5 and Fig. 6 are found; The axial magnetic flux amorphous alloy stator iron core magnetic permeability that does not use resin hot curing processing of method for preparing is far above silicon steel core; Magnetic flux density just can reach 1.12T when excitation intensity was 100A/m, was more than 2 times of silicon steel core under the identical excitation intensity; And the loss of amorphous alloy iron core is very low, frequency range when 50-1000Hz loss value all less than 1/7 of silicon steel core.It is thus clear that the amorphous alloy stator iron core excellent in soft magnetic properties that this method is made, advantage will be more obvious when especially under high frequency, being applied to electric machine iron core.It can also be seen that from the data of table 1, Fig. 5 and Fig. 6 the amorphous alloy stator iron core soft magnet performance of handling through the resin hot curing has decline slightly than the amorphous alloy stator iron core of handling without the resin hot curing; But its advantage is that the noise of amorphous alloy stator iron core is significantly reduced, but also can improve the mechanical stability of amorphous alloy iron core.
The dc magnetic contrast of the amorphous alloy stator iron core that table 1 trade mark is the silicon steel stator core of DR255, handle without hot curing, the amorphous alloy stator iron core handled through hot curing.
Claims (17)
1. an axial-flux electric machine is with the manufacturing approach of amorphous, crystallite or nanocrystalline alloy stator iron core, and this stator core is a torus, and a plurality of radial opening grooves (26) are arranged on the annular end face, and it is characterized in that: this method comprises following steps:
(1) use the roller shear device, amorphous, crystallite or the nanometer crystal alloy broadband of rolling are rolled up along the alloy strip steel rolled stock that belt length direction roller shear becomes to have fixed width, said fixed width is the twice of finished product iron core height;
(2) alloy strip steel rolled stock of said fixing width is provided on the passive rotation roller (5); Handle as follows successively: 1. jet-bedding is handled; Stamp out the trough of belt (17) on the vertical alloy strip steel rolled stock length direction continuously at said alloy strip steel rolled stock middle part, its width and open slot (26) width equates, length is the twice of open slot (26) degree of depth; 2. being coated with insulating barrier handles; 3. coiling processing; Alloy strip steel rolled stock is wound on the iron core inner core (24) that has inner core groove (4); And said trough of belt (17) is corresponding with inner core groove (4) position, is equivalent to the alloy strip steel rolled stock volume (25) with bathtub construction (15) of two axial magnetic flux iron core teeth portions to buckle thereby form; Said rotation roller (5) and iron core inner core (24) carry out intermittent synchronously rotation by a high precision numerical control dividing head (23) control;
(3) in step (2); When alloy strip steel rolled stock volume (25) coiling with bathtub construction (15) reaches required external diameter; On the strip coil periphery, add one deck and the cylindrical protective layer that said periphery has identical bathtub construction, to vertical plane its five equilibrium crosscut is become amorphous, crystallite or the nanocrystalline alloy stator iron core (28) that two shapes are identical with size and have axial teeth groove structure along the alloy strip steel rolled stock spool again;
(4) amorphous that step (3) is obtained, crystallite or nanocrystalline alloy stator iron core (28) carry out annealing in process.
2. the method described in claim 1 is characterized in that: described amorphous, crystallite or nanometer crystal alloy broadband material chosen from Fe base, iron are Ni-based, cobalt base amorphous, crystallite and nanometer crystal alloy strip.
3. the method described in claim 1, it is characterized in that: the material of said iron core inner core (24) and cylindrical protective layer is selected from silicon steel, magnetism-free stainless steel, iron, aluminium, copper, titanium and alloy thereof, pottery, organic siliconresin, nylon, carbon fiber.
4. the method described in claim 1; It is characterized in that: in the coiling processing of said step (2); Control the iron core inner core through high precision numerical control dividing head (23) and realize intermittent rotation as follows: high precision numerical control dividing head (23) drives iron core inner core (24) interval t rotation at regular intervals once; The anglec of rotation is θ=360 °/n, and wherein n is the quantity of the axial tooth (27) or the open slot (26) of amorphous, crystallite or nanocrystalline alloy stator iron core, and to drive the distance that alloy strip steel rolled stock advances forward be s=π * r* θ/180 to iron core inner core (24) simultaneously; And in the dead time t after iron core heart (24) rotation θ angle, accomplish a jet-bedding just and handle.
5. the method described in claim 1 is characterized in that: during said jet-bedding was handled, drift that uses and the gap between the jet-bedding were 1/10～1/2 of amorphous alloy strips gross thickness.
6. the method described in claim 1; It is characterized in that: in said jet-bedding is handled; Trough of belt on the said alloy strip steel rolled stock (17) can be rectangle, ellipse or other arbitrary shapes, and the shape of said trough of belt (17) is identical with the shape of the last inner core groove (4) of said iron core inner core (24).
7. the method described in claim 1 is characterized in that: the band number of plies≤10 of said alloy strip steel rolled stock volume layer.
8. the method described in claim 1, it is characterized in that: said trough of belt (17) is positioned at alloy strip steel rolled stock inside, is closed figures, and quantity >=1 of said trough of belt (17) on vertical band length direction.
9. the method described in claim 1; It is characterized in that: the center line of said trough of belt (17) all points to the central axis of amorphous, crystallite or nanocrystalline alloy stator iron core (28), and the shape of trough of belt (17) and size do not increase with said amorphous, crystallite or nanocrystalline alloy stator iron core radius and change; Yet said tooth (16) can broaden along with the increase of said amorphous, crystallite or nanocrystalline alloy stator iron core radius gradually.
10. the method described in claim 1 is characterized in that: in said step (2), 1. jet-bedding is handled and 2. is coated with the order that insulating barrier handles and can exchanges.
11. the method described in claim 1 is characterized in that: said step (4) is under the protective atmosphere of nitrogen or argon gas, to carry out.
12. the method described in claim 1 is characterized in that: said step (4) is to accomplish adding under the condition in magnetic field, and magnetic field intensity is 2-40mT, and magnetic direction is along circumferencial direction unshakable in one's determination.
13. the method described in claim 1 is characterized in that: insulating coating liquid is selected from a kind of in solution, colloidal sol or the suspension-turbid liquid of tetraethoxysilane, waterglass, MgO fine powder, SiO2 fine powder or insulating ceramics fine powder.
14. the method described in claim 1 is characterized in that: carry out resin hot curing processing to handle back amorphous, crystallite or nanocrystalline alloy stator iron core (28) through said step (4).
15. the method described in claim 14 is characterized in that: the dipping lacquer process was carried out under vacuum during said resin hot curing was handled.
16. the axial-flux electric machine of the method for claim 1 preparation is with amorphous, crystallite or nanocrystalline alloy stator iron core; This stator core is a torus; A plurality of radial opening grooves are arranged on the annular end face; It is characterized in that: the horizontal five equilibrium of stator core base substrate that this stator core is obtained through roller shear, jet-bedding, coating, coiling and annealing in process by alloy strip steel rolled stock is cut into two identical stator cores and forms; This stator core base substrate comprises iron core inner core (24), is wound on alloy strip steel rolled stock with bathtub construction and cylindrical protective layer on the iron core inner core (24);
Wherein: iron core inner core (24) is made up of a pair of annular collet (1) and cylinder (2), and n inner core groove (4) uniformly distributing at the stack shell middle part of cylinder (2); The trough of belt (17) that a plurality of vertical alloy strip steel rolled stock length directions are arranged on the alloy strip steel rolled stock of reeling, the twice that width all equates with open slot, length is the open slot degree of depth of inner core groove (4) and trough of belt (17);
In the winding process; Trough of belt (17) on the said alloy strip steel rolled stock with bathtub construction is corresponding with inner core groove (4) position on the iron core inner core (24), is equivalent to the alloy strip steel rolled stock volume (25) with bathtub construction (15) of two axial magnetic flux iron core teeth portions to buckle thereby form;
The periphery of cylindrical protective layer has and the identical groove of trough of belt (17).
17. like the said stator core of claim 16, it is characterized in that: the trough of belt on the said alloy strip steel rolled stock (17) can be rectangle, ellipse or other arbitrary shapes, and the shape of said trough of belt (17) is identical with the shape of the last inner core groove (4) of said iron core inner core (24).
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