CN111482767A - Manufacturing method of high-speed rotor - Google Patents
Manufacturing method of high-speed rotor Download PDFInfo
- Publication number
- CN111482767A CN111482767A CN202010233108.0A CN202010233108A CN111482767A CN 111482767 A CN111482767 A CN 111482767A CN 202010233108 A CN202010233108 A CN 202010233108A CN 111482767 A CN111482767 A CN 111482767A
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- Prior art keywords
- shaft
- rotor
- dynamic balance
- inner hole
- machining
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C3/00—Shafts; Axles; Cranks; Eccentrics
- F16C3/02—Shafts; Axles
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M1/00—Testing static or dynamic balance of machines or structures
- G01M1/14—Determining unbalance
- G01M1/16—Determining unbalance by oscillating or rotating the body to be tested
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/16—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields
Abstract
A manufacturing method of a high-speed rotor comprises a first shaft and a second shaft; the shaft comprises a first inner hole and a second inner hole with different apertures; the shaft II comprises a first shaft section and a second shaft section with different diameters; one end of the first shaft section of the second shaft penetrates through the second inner hole of the first shaft and is fixedly connected with one end of the first shaft. The manufacturing method comprises the following steps: respectively processing the first shaft and the second shaft to preset sizes; assembling and welding the first shaft and the second shaft to form a rotor; performing surface treatment on the assembled rotor and then performing finish machining to ensure that the roughness of the rotor surface is Ra0.05-0.2 and the coaxiality is 0.001-0.03 mm; finally, dynamic balance is carried out, and the dynamic balance grade reaches G0.4-2.5. The method can manufacture the high-speed rotor with high precision and high yield, and realizes full-automatic production.
Description
Technical Field
The invention relates to the field of high-speed rotating shaft processing and detection, in particular to the field of batch production processing and detection of special long and thin rotors of gas turbine or micro gas turbine generator rotors, electric turbochargers, ultrahigh-speed generators and the like, and particularly relates to a manufacturing method of a high-speed rotor.
Background
Generally, a high-speed rotor needs to be used with a non-contact bearing or a high-precision ball bearing, so the default application premise of the high-speed rotor is the high-precision rotor. In the high-speed rotor, the production, quality detection and consistency control of the high-speed shaft and the high-speed disk are always difficult, and the high-speed shaft is also a main technical obstacle for large-scale mass production of products using the high-speed shaft. In particular to a high-speed two-segment shaft and a high-speed three-segment shaft which need to be assembled with a magnetic core of a motor. Due to high precision requirement, high assembly difficulty and low yield of the high-speed shaft, the production cost of the common process is very high, wherein the cost of materials wasted by waste parts and the cost of working hours are taken as main points. Wherein the accuracy requirements include, but are not limited to, surface finish (especially in the context of using air bearings), case hardening, hot-set verticality of the disk, coaxiality of the shafts (especially for two-section shafts and three-section shafts), machining and precision assembly of the disk, thermal stress of the shrink-fit process, residual internal stress during machining, dynamic balance accuracy, and the like.
Usually, a shaft is processed on a tool once, the precision is relatively well guaranteed, but once repeated clamping and assembling are involved, the precision is easily out of tolerance, and particularly, the application scenes with thermal stress and internal stress are involved. In the process of hot sleeving a disc workpiece on a shaft after the disc workpiece is machined, the perpendicularity of the disc workpiece deviates about 0.1-1 degrees; the two sections of finish-machined shafts are subjected to heat treatment after friction welding or common welding, the coaxiality of the two sections of finish-machined shafts deviates by about 1 per mill to 1 percent, and if the two sections of finish-machined shafts are three sections of shafts, the tolerances are sequentially accumulated; the accumulated thermal stress in the hot sleeve process can generate about 1% of adverse effects on factors such as verticality, coaxiality and axial positioning after the workpiece is cooled; furthermore, the effect of welding and assembly on the amount of unbalance inside the rotor can limit the accuracy of the dynamic balance. Common surface treatments, especially repeated clamping processes, add up tolerances.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the defects of the prior art are overcome, and the manufacturing method of the high-speed rotor is provided, so that the high-speed rotor is manufactured efficiently, at low cost and in batch, and effective detection is implemented.
The technical solution of the invention is as follows: a manufacturing method of a high-speed rotor comprises a first shaft and a second shaft; the shaft comprises a first inner hole and a second inner hole with different apertures, the aperture of the first inner hole is smaller than that of the second inner hole, and a first bearing position is arranged on the outer circumference corresponding to the first inner hole; the shaft II comprises a first shaft section and a second shaft section with different diameters, and the diameter of the first shaft section is larger than that of the second shaft section; the first shaft section of the second shaft is provided with an inner hole; one end of the first shaft section of the second shaft penetrates through the second inner hole of the first shaft and is fixedly connected with one end of the first shaft, and a second bearing position is arranged on the outer circumference of the part, which is not inserted into the second inner hole, of the first shaft section of the second shaft; the rotating speed of the high-speed rotor is 150000rpm-160000 rpm;
the manufacturing method comprises the following steps:
s100, respectively machining the first shaft and the second shaft to preset sizes;
s200, assembling and welding:
inserting the first shaft section of the second shaft into a second inner hole of the first shaft, and welding matching surfaces of the first shaft and the second shaft;
s300, surface treatment:
the surface treatment time is 1-60 seconds, the online microwave surface treatment is completed, the thermal stress is released, and a rough finished piece is obtained after the rotor is cooled to room temperature and the stress is removed;
s400, fine machining: fine machining to rotor surface roughness Ra0.05-0.2 and coaxiality 0.001-0.03 mm;
s500, dynamic balance:
and (3) placing the finely processed rotor in dynamic balance equipment, carrying out dynamic balance by taking the first bearing position and/or the second bearing position as a reference, and removing the amount of the non-working surface of the rotor in the dynamic balance process to remove the unbalance amount so as to enable the dynamic balance grade to reach G0.4-2.5.
Further, the step S100 processes the first shaft and the second shaft to predetermined dimensions, respectively:
the first shaft machining step comprises the following steps:
SA110, performing stress relief on a bar used for machining the first shaft, and then roughly machining an outer circle, wherein a margin is reserved at the first bearing position, and the margin meets the requirement of subsequent combined machining;
SA120, finishing the other outer circles except the first bearing position to the size; under the auxiliary tool of the tool, finishing inner holes on two sides of the shaft to the size by using a boring mill; finishing the assembly end faces at the two ends to the size;
SA130, performing dynamic balance on the first shaft, wherein the dynamic balance position is at a second inner hole, the rotating speed of the dynamic balance is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5;
the step of processing the second shaft (2) comprises the following steps:
SB110, performing stress relief on a bar stock used for machining the second shaft, and then roughly machining an outer circle, wherein a second bearing position is provided with a margin, and the margin meets the requirement of subsequent combined machining;
SB120, finishing the other outer circles except the second bearing position to the size; machining an inner hole to the size; finishing the assembly end faces at the two ends to the size;
SB130, finishing the welding surface to the size;
SB140, single-piece dynamic balancing, wherein the second shaft is subjected to dynamic balancing, an inner hole is taken at the dynamic balancing position, the rotating speed of the dynamic balancing is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balancing grade reaches G0.4-2.5;
and/or
The step of finishing in step S400 includes:
s410, clamping: positioning and clamping by taking the excircle corresponding to the second inner hole of the first shaft as a clamping reference surface, and ensuring that the coaxiality of the clamping reference surface of the whole rotor and the first inner hole of the first shaft is kept at 0.001-0.03 mm;
s420, high-frequency wave finishing: using a clamping reference surface as a standard, and performing finish machining on a part with the distortion degree exceeding 0.1mm and the allowance exceeding 0.05mm by using a high-frequency wave surface treatment process, wherein in the high-frequency wave finish machining process, the allowance is reserved, and meets the requirement of subsequent combined machining; the removing part comprises a first bearing position, a second bearing position and a welding position; the frequency of the high-frequency wave is 0.1-1 MHz;
s430, hardening treatment: hardening the whole rotor;
s440, finishing: finely machining the second shaft section of the shaft to the size;
s450, integral finish machining: and removing the allowance to the size at one time by using a fine grinding process so that the surface roughness of the rotor is Ra0.05-0.2 and the coaxiality is 0.001-0.03 mm.
Furthermore, the high-speed rotor also comprises a motor magnetic core which is arranged in a second inner hole of the first shaft, and one end of a first shaft section of the second shaft penetrates through the second inner hole of the first shaft and is abutted against the motor magnetic core;
the step S100 processes the first shaft and the second shaft to predetermined dimensions, respectively:
the first shaft machining step comprises the following steps:
SA110, performing stress relief on a bar used for machining the first shaft, and then roughly machining an outer circle, wherein a margin is reserved at the first bearing position, and the margin meets the requirement of subsequent combined machining;
SA120, finishing the other outer circles except the first bearing position to the size; under the auxiliary tool of the tool, finishing inner holes on two sides of the shaft to the size by using a boring mill; finishing the assembly end faces at the two ends to the size;
SA130, performing dynamic balance on the first shaft, wherein the dynamic balance position is at a second inner hole, the dynamic balance rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5;
the second shaft machining step comprises the following steps:
SB110, performing stress relief on a bar stock used for machining the second shaft, and then roughly machining an outer circle, wherein a second bearing position is provided with a margin, and the margin meets the requirement of subsequent combined machining;
SB120, finishing the other outer circles except the second bearing position to the size; machining an inner hole to the size; finishing the assembly end faces at the two ends to the size;
SB130, finishing the welding surface to the size;
SB140, single-piece dynamic balancing, wherein the second shaft is subjected to dynamic balancing, an inner hole is taken at the dynamic balancing position, the dynamic balancing rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balancing grade reaches G0.4-2.5;
and/or
The assembling and welding step of step S200 includes:
s210, performing interference heat mounting on the finely processed motor magnetic core into a second inner hole of the first shaft; inserting the second first shaft section into the second inner hole to abut against the motor magnetic core;
s220, welding the matching surfaces of the first shaft and the second shaft by using a welding process;
and/or
The step of finishing in step S400 includes:
s410, clamping: positioning and clamping by taking the outer circle corresponding to the magnetic core of the motor as a clamping reference surface, and ensuring that the coaxiality of the clamping reference surface of the whole rotor and the inner hole at the right side of the shaft is kept at 0.001-0.03 mm;
s420, high-frequency wave finishing: using a clamping reference surface as a standard, and performing finish machining on a part with the distortion degree exceeding 0.1mm and the allowance exceeding 0.05mm by using a high-frequency wave surface treatment process, wherein in the high-frequency wave finish machining process, the allowance is reserved, and meets the requirement of subsequent combined machining; the removing part comprises a first bearing position, a second bearing position and a welding position; the frequency of the high-frequency wave is 0.1-1 MHz;
s430, hardening treatment: hardening the whole rotor;
s440, finishing: finely machining the second shaft section of the second shaft to the size;
s450, integral finish machining: and removing the allowance to the size at one time by using a fine grinding process so that the surface roughness of the rotor is Ra0.05-0.2 and the coaxiality is 0.001-0.03 mm.
Further, the high-speed rotor also comprises a thrust disc which is fixedly sleeved on one end side of the excircle corresponding to a second inner hole of the shaft;
the step S100 further includes machining the thrust disc to a predetermined size, including the steps of:
SC110, roughly machining a blank for machining the thrust disc after stress removal;
SC120, finish machining the inner hole of the thrust disc to the size, wherein the surface roughness of the finish machined inner hole is Ra0.2-Ra0.4, and the disc end surface of the thrust disc is provided with a margin which meets the requirement of subsequent combined machining;
SC130, single piece dynamic balance, the dynamic balance is carried out on the thrust disc, the outer circumference of the thrust disc is taken at the dynamic balance position, the rotating speed of the dynamic balance is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5;
the assembling and welding step in the step S200 includes:
s210, inserting the first shaft section of the second shaft into a second inner hole of the first shaft; sleeving the thrust disc on one end side of the excircle corresponding to the second inner hole of the shaft in an interference shrink fit mode, wherein the end side of the thrust disc is aligned with the end side of the excircle corresponding to the second inner hole of the shaft;
s220, respectively welding the matching surfaces of the thrust disc and the first shaft and the matching surfaces of the first shaft and the second shaft on the aligning sides of the thrust disc and one end of the first shaft by using a welding process;
the removing part in the step S420 comprises a first bearing position, a second bearing position, a welding position and an end face of the thrust disc;
the step S450 further includes making the perpendicularity of the thrust disc to the first shaft be 0.001-0.03 mm.
Further, the high-speed rotor also comprises a thrust disc which is fixedly sleeved on one end side of the excircle corresponding to a second inner hole of the shaft;
the step S100 further includes machining the thrust disc to a predetermined size, including the steps of:
SC110, roughly machining a blank for machining the thrust disc after stress removal;
SC120, finish machining the inner hole of the thrust disc to the size, wherein the surface roughness of the finish machined inner hole is Ra0.2-Ra0.4, and the disc end surface of the thrust disc is provided with a margin which meets the requirement of subsequent combined machining;
SC130, single piece dynamic balance, the dynamic balance is carried out on the thrust disc, the outer circumferential surface of the thrust disc is taken at the dynamic balance position, the dynamic balance rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5;
the assembling and welding step in the step S200 includes:
s210, performing interference heat mounting on the finely processed motor magnetic core into a second inner hole of the first shaft; inserting a first shaft section of a second shaft into a second inner hole of the first shaft to abut against the motor magnetic core; sleeving the thrust disc on one end side of the excircle corresponding to the second inner hole of the shaft in an interference shrink fit mode, wherein the end side of the thrust disc is aligned with the end side of the excircle corresponding to the second inner hole of the shaft;
s220, respectively welding the matching surfaces of the thrust disc and the first shaft and the matching surfaces of the first shaft and the second shaft on the aligning sides of the thrust disc and one end of the first shaft by using a welding process;
the removing part in the step S420 comprises a first bearing position, a second bearing position, a welding position and an end face of the thrust disc;
the step S450 also comprises that the perpendicularity of the thrust disc and the first shaft is 0.001-0.03 mm.
Further, the high-speed rotor also comprises a gas compressor, a turbine and a locking nut, wherein the gas compressor and the turbine are sequentially fixedly sleeved on the second shaft section of the second shaft and are fastened through the locking nut;
the step S500 of dynamic balancing includes the steps of:
s510, placing the rotor subjected to the step S400 in dynamic balance equipment, and performing dynamic balance by taking the first bearing position and/or the second bearing position as a reference, wherein in the dynamic balance process, the amount of a non-working surface of the rotor is removed to remove the unbalance amount, so that the dynamic balance grade reaches G0.4-2.5;
s520, sequentially and fixedly sleeving the gas compressor, the turbine and the locking nut after the single piece dynamic balance on the second shaft, and screwing by using a torque wrench; the dynamic balance grade of the single-piece dynamic balance compressor, the turbine and the locking nut reaches G0.4-2.5;
and S530, driving the rotor to rotate by using a motor or air blowing, carrying out dynamic balance by taking the first bearing position and/or the second bearing position as a reference, and removing the amount of the non-working surface of the rotor to remove the unbalance in the dynamic balance process so as to enable the dynamic balance grade to reach G0.4-2.5.
Further, the step S530 includes:
s531, driving the rotor to raise the speed to 8000-;
s532, driving the rotor to raise the speed to 20000-25000rpm by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to remove unbalance, and enabling the dynamic balance grade to reach G0.4-2.5;
s533, driving the rotor to increase the speed to 25000-;
s534, driving the rotor to increase the speed to 120000rpm by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to remove unbalance, and enabling the dynamic balance grade to reach G0.4-2.5;
and S535, driving the rotor to accelerate to full speed by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to remove unbalance, and enabling the dynamic balance grade to reach G0.4-2.5.
Further, the step S440 is to finish the workpiece by using a grinding process.
Further, the grinding process in step S450 adopts a special grinding wheel mold, the special grinding wheel mold is provided with an inner cavity, the shape and size of the inner wall of the inner cavity are the same as the designed shape and size of the rotor, and the rotor is placed in the special grinding wheel mold and is finely ground to the size of the rotor.
Further, after all finishing steps in steps S100-400, the rotor dimensions are checked.
Further, the dynamic balance level is selected to be G1.
Further, the amount of removing the non-working surface of the rotor in the step S500 adopts automatic laser derusting or a non-contact process of 0.1-1GHz high-frequency waves.
Further, when the motor magnetic core is arranged, in step S500, the motor is used to drive the rotor to rotate to perform a dynamic balance test, the stator of the motor is non-contact sleeved on the outer circle corresponding to the motor magnetic core, and the motor magnetic core is used as the rotor of the motor.
Further, in the dynamic balance equipment, the motor and/or the bearing used is the motor and/or the bearing originally assembled when the high-speed rotor works.
Further, the bearing is an air bearing.
Further, the non-working surface includes a first bore of the first shaft and a boss of the thrust disc.
Further, when the rotor is driven to rotate by air blowing, the air supply part blows the turbine to drive the rotor to rotate.
Furthermore, the non-working surface of the rotor comprises a first inner hole of the shaft, a boss of the thrust disc, a locking nut and a part of the shaft II, wherein the part penetrates out of the locking nut.
Further, a spacer ring for axial positioning is arranged between the gas compressor and the turbine, and the gas compressor, the spacer ring, the turbine and a locking nut are sequentially fixedly sleeved on the second shaft and are screwed by a torque wrench; the dynamic balance grade of the single-piece dynamic balance compressor, the spacer ring, the turbine and the locking nut reaches G0.4-2.5.
Further, the dynamic balance level is selected to be G1.
Compared with the prior art, the invention has the advantages that:
1. the high-speed rotor manufacturing method of the invention realizes the production with high precision and high yield by combining special processes such as rough machining, welding, hot sleeve assembly, heat treatment, finish machining, surface treatment, tooling, measurement, clamping control and the like in a specific mode, sequence and mode with process requirements.
2. The high-speed rotor manufacturing method of the invention can realize the yield of industrialized mass production, and the yield of conventional high-speed rotor production does not exceed 2/3.
3. The manufacturing method of the high-speed rotor has compact production links and improves the efficiency.
4. The high-speed rotor manufacturing method of the present invention has high reliability, and can surely obtain a workpiece meeting the technical requirements.
5. The manufacturing method of the high-speed rotor of the invention has lower production cost than the traditional method.
6. The high-speed rotor manufacturing method of the invention greatly reduces the precision requirement of equipment.
7. The high-speed rotor manufacturing method has extremely high automation degree which can reach 100 percent.
Drawings
Fig. 1 is a schematic structural view of a high-speed rotor of embodiment 1 of the invention;
fig. 2 is a schematic structural view of a high-speed rotor of embodiment 2 of the invention;
FIG. 3 is a schematic structural view of a high-speed rotor of embodiment 3 of the invention;
FIG. 4 is a schematic structural view of a high-speed rotor of embodiment 4 of the invention;
FIG. 5 is a schematic structural view of a high-speed rotor of embodiment 5 of the invention;
FIG. 6 is a schematic structural view of a high-speed rotor of embodiment 6 of the invention;
FIG. 7 is a schematic structural view of a high-speed rotor of embodiment 7 of the invention;
FIG. 8 is a schematic structural view of a high-speed rotor of embodiment 8 of the invention;
FIG. 9 is a schematic structural view of a first shaft of the present invention;
FIG. 10 is a schematic view of the structure of the second shaft of the present invention;
FIG. 11 is a schematic view of the thrust disc of the present invention;
FIG. 12 is a schematic view of an assembled structure corresponding to embodiments 1 and 3 of the present invention;
FIG. 13 is a schematic view showing the corresponding assembly structure of embodiments 2 and 4 of the present invention;
FIG. 14 is a schematic view of an assembled structure corresponding to embodiments 5 and 7 of the present invention;
FIG. 15 is a schematic view of an assembled structure corresponding to embodiments 6 and 8 of the present invention;
fig. 16 is a schematic view of a clamping structure corresponding to embodiments 1 and 3 of the invention;
fig. 17 is a schematic view of a clamping structure corresponding to embodiments 2 and 4 of the invention;
FIG. 18 is a schematic view of a clamping structure corresponding to embodiments 5 and 7 of the present invention;
fig. 19 is a schematic view of a clamping structure corresponding to embodiments 6 and 8 of the present invention.
Reference numerals:
1: a first shaft; 2: a second shaft; 3: a compressor; 4: a turbine; 5: locking the nut; 6: a motor magnetic core; 7: a thrust disc; 8: a first bearing position; 9: a second bearing position; 10: the balance; 11: welding a surface; 12: and (5) clamping the datum plane.
Detailed Description
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the invention and to simplify the description, and are not intended to indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and are therefore not to be considered limiting of the invention. Furthermore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
The invention relates to a structural form of 8 high-speed rotors with the rotating speed of 150000rpm-160000rpm, preferably 155000rpm, and the structural form of the 8 high-speed rotors is shown in figures 1-8.
Example 1
The high-speed rotor structure of embodiment 1 is shown in fig. 1, and includes a first shaft 1 and a second shaft 2; the first shaft 1 comprises a first inner hole and a second inner hole with different apertures, wherein the aperture of the first inner hole is smaller than that of the second inner hole, and a first bearing position 8 is arranged on the outer circumference corresponding to the first inner hole; the second shaft 2 comprises a first shaft section and a second shaft section which are different in diameter, and the diameter of the first shaft section is larger than that of the second shaft section; one end of the first shaft section of the second shaft 2 penetrates through the second inner hole of the first shaft 1 and is fixedly connected with one end of the first shaft 1, and a second bearing position 9 is arranged on the outer circumference of the part, which is not inserted into the second inner hole, of the first shaft section of the second shaft 2.
Preferably, the second shaft 2 is provided with an inner hole in the first shaft section to achieve light weight.
Preferably, the outer diameter of the portion of the first shaft section of the second shaft 2 inserted into the second inner bore of the first shaft 1 is larger than the outer diameter of the second bearing portion 9 not inserted into the outer circumference of the second inner bore of the first shaft 1.
Example 2
The high-speed rotor structure of embodiment 2 is shown in fig. 2, a motor magnetic core 6 is fixedly installed in a second inner hole of a first shaft 1 of the high-speed rotor, one end of a first shaft section of a second shaft 2 penetrates through the second inner hole of the first shaft 1 and abuts against the motor magnetic core 6, and other structures are the same as those of embodiment 1 and are not described again.
Example 3
The high-speed rotor structure of embodiment 3 is as shown in fig. 3, and on the basis of the structure of the high-speed rotor of embodiment 1, the high-speed rotor structure further comprises a compressor 3, a turbine 4 and a lock nut 5, wherein the compressor 3 and the turbine 4 are sequentially and fixedly sleeved on the second shaft section of the second shaft 2 and are fastened through the lock nut 5.
Preferably, a spacer ring (not shown) is provided between the compressor 3 and the turbine 4 to enhance the rigidity of the rotor.
Example 4
The high-speed rotor structure of embodiment 4 is shown in fig. 4, a motor core 6 is fixedly installed in a second inner hole of a first shaft 1 of the high-speed rotor, one end of a first shaft section of a second shaft 2 passes through the second inner hole of the first shaft 1 and abuts against the motor core 6, and other structures are the same as those in embodiment 3 and are not described again.
Example 5
The high-speed rotor structure of embodiment 5 is as shown in fig. 5, and on the basis of the structure of the high-speed rotor of embodiment 1, the high-speed rotor structure further includes a thrust disk 7 fixedly sleeved on one end side of an outer circle corresponding to the second inner hole of the first shaft 1. The sleeved position of the thrust disc 7 corresponds to the position of the first shaft section of the second shaft 2 inserted into the second inner hole part of the first shaft 1.
Example 6
The high-speed rotor structure of embodiment 6 is shown in fig. 6, a motor magnetic core 6 is fixedly installed in a second inner hole of a first shaft 1 of the high-speed rotor, one end of a first shaft section of a second shaft 2 passes through the second inner hole of the first shaft 1 and abuts against the motor magnetic core 6, and other structures are the same as those in embodiment 5 and are not described again.
Example 7
The high-speed rotor structure of embodiment 7 is as shown in fig. 7, and on the basis of the structure of the high-speed rotor of embodiment 5, the high-speed rotor structure further comprises a compressor 3, a turbine 4 and a lock nut 5, wherein the compressor 3 and the turbine 4 are sequentially and fixedly sleeved on the second shaft section of the second shaft 2 and are fastened through the lock nut 5.
Preferably, a spacer ring (not shown) is provided between the compressor 3 and the turbine 4 to enhance the rigidity of the rotor.
Example 8
The high-speed rotor structure of embodiment 8 is shown in fig. 8, a motor core 6 is fixedly installed in a second inner hole of a first shaft 1 of the high-speed rotor, one end of a first shaft section of a second shaft 2 passes through the second inner hole of the first shaft 1 and abuts against the motor core 6, and other structures are the same as those in embodiment 7 and are not described again.
The invention provides a method for processing the high-speed rotor, which comprises the following steps:
and S100, respectively machining the first shaft 1 and the second shaft 2.
As shown in fig. 9, fig. 9 is a schematic structural diagram of a shaft 1, and a processing method of the shaft 1 includes the following steps:
SA110, performing stress relief on a bar used for machining the first shaft 1, and then roughly machining an outer circle, wherein a margin is reserved at the first bearing position 8, and the margin meets the requirement of subsequent combined machining;
SA120, finishing the other outer circles except the first bearing position 8 to the size; under the auxiliary tool of the tool, finishing inner holes on two sides of the first shaft 1 to the size by using a boring mill; finishing the assembly end faces at the two ends to the size;
SA130, performing dynamic balance on the first shaft 1, wherein the dynamic balance position is at a second inner hole, the dynamic balance rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5, preferably G1.
As shown in fig. 10, fig. 10 is a schematic structural diagram of a second shaft 2, and the processing method of the second shaft 2 includes the following steps:
SB110, performing stress relief on a bar stock for processing the second shaft 2, and then roughly processing an outer circle, wherein a margin is reserved at the second bearing position 9, and the margin meets the requirement of subsequent combined processing;
SB120, finishing the other outer circles except the second bearing position 9 to the size; machining an inner hole to the size; finishing the assembly end faces at the two ends to the size;
SB130, finishing the welding surface 11 to the size;
SB140, single dynamic balance, the second shaft 2 is dynamically balanced, the inner hole is taken at the dynamic balance position, the dynamic balance rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5, preferably G1.
Further, step S100 further includes machining the thrust disk 7.
As shown in fig. 11, fig. 11 is a schematic structural diagram of a thrust disk, and a processing method of the thrust disk includes the following steps:
SC110, performing rough machining after the stress of the blank for machining the thrust disc 7 is removed;
SC120, finish machining the inner hole to the size, wherein the surface roughness of the finish machined inner hole is Ra0.2-Ra0.4, and a margin 10 (shown in figure 15) is reserved on the disc end surface of the thrust disc and meets the requirement of subsequent combined machining;
and the SC130 is used for carrying out dynamic balance on the thrust disc 7, the outer circumferential surface of the thrust disc is taken at the dynamic balance position, the dynamic balance rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5, preferably G1.
And S200, assembling and welding. Specifically, the method comprises the following steps:
s210, performing interference heat treatment on the finely processed motor magnetic core 6 in a second inner hole; inserting the second shaft 2 into the second inner hole to abut against the motor magnetic core 6; sleeving the thrust disc 7 on one end side of the excircle corresponding to the second inner hole of the first shaft 1 in an interference shrink fit mode, wherein the end side of the thrust disc 7 is aligned with the end side of the excircle corresponding to the second inner hole of the first shaft 1;
and S220, welding the matching surfaces of the thrust disc 7 and the shaft I1 and the matching surfaces of the shaft I1 and the shaft II 2, namely the welding surface 11 in the drawing 15, on the aligning sides of the thrust disc 7 and the shaft I1 respectively by using a welding process, preferably laser welding.
In step S200, fig. 12 is referred to for the drawings corresponding to embodiment 1 and embodiment 3, fig. 13 is referred to for the drawings corresponding to embodiment 2 and embodiment 4, fig. 14 is referred to for the drawings corresponding to embodiment 5 and embodiment 7, and fig. 15 is referred to for the drawings corresponding to embodiment 6 and embodiment 8.
S300, surface treatment
1-60 seconds, preferably 10 seconds, completing on-line (without installing and clamping a tool or taking a production line down) microwave surface treatment, releasing thermal stress, and obtaining a rough finished piece after the rotor is cooled to room temperature and destressed.
S400, finish machining
S410, clamping
And the outer circle corresponding to the motor magnetic core 6 (in the embodiment without the motor magnetic core 6, the second inner hole of the first shaft 1) is used as a clamping reference surface 12 for positioning and clamping, so that the coaxiality of the clamping reference surface 12 of the whole rotor and the inner hole on the right side of the first shaft 1 is kept between 0.001 and 0.03mm, and preferably 0.02 mm.
In step S400, fig. 16 for embodiments 1 and 3, fig. 17 for embodiments 2 and 4, fig. 18 for embodiments 5 and 7, and fig. 19 for embodiments 6 and 8 are shown.
S420, high-frequency wave finish machining
The rotor shown in fig. 16-19 is a rotor with microscopic distortions. And at the moment, a part with the distortion degree exceeding 0.1mm and the allowance exceeding 0.05mm is machined by using a high-frequency wave (0.1-1MHz) surface treatment process, the allowance is reserved in the high-frequency wave fine machining process, the allowance meets the subsequent combined machining requirement, the removed parts comprise a first bearing position 8, a second bearing position 9, a welding position, the end face of a thrust disc 7 and the like, and the machining precision and the surface roughness of the whole rotor are further improved.
S430, hardening treatment
The entire rotor is hardened to improve surface roughness and hardness and fatigue resistance of the entire rotor.
S440, finishing
And (3) finishing the second shaft section of the second shaft 2 to the size, and preferably adopting a grinding process.
S450, integral finish machining
And (3) removing the allowance to the size at one time by using a fine grinding process, ensuring that the surface roughness of the rotor is Ra0.05-0.2, the coaxiality is 0.001-0.03mm, and the verticality of the thrust disc 7 and the shaft I1 is 0.001-0.03 mm.
The fine grinding process adopts a special grinding wheel die, the special grinding wheel die is provided with an inner cavity, the shape and the size of the inner wall of the inner cavity are the same as the design appearance and the size of the rotor, the rotor after the step S440 is placed in the special grinding wheel die (the rotor is aligned and clamped on the fine grinding tool firstly and then is integrally placed in the special grinding wheel die), and the inner cavity of the special grinding wheel die finely grinds the rotor to the size.
Preferably, in steps S100-400, the finishing step, each piece is checked for size.
S500, dynamic balance
S510, placing the rotor subjected to the step S450 into dynamic balance equipment, performing dynamic balance by taking the first bearing position 8 and/or the second bearing position 9 as a reference, and removing the amount of a non-working surface of the rotor to remove the unbalance in the dynamic balance process to enable the dynamic balance grade to reach G0.4-2.5 dynamic balance precision, preferably G1.
Preferably, the amount of removing the non-working surface of the rotor is realized by using a non-contact process such as automatic laser derusting or 0.1-1GHz high-frequency waves.
Preferably, for the embodiment provided with the motor magnetic core 6, the motor is used to drive the rotor to rotate to perform a dynamic balance test, specifically, the stator of the motor is sleeved on the excircle corresponding to the motor magnetic core 6 in a non-contact manner, and the motor magnetic core 6 is used as the rotor of the motor.
Preferably, in the dynamic balancing device, the motor and/or the bearing used is a motor and/or a bearing originally assembled and matched when the rotor works. Further preferably, the bearing is an air bearing.
Preferably, the non-working surface includes, but is not limited to, the first bore of the first shaft 1, and the boss of the thrust disc 7.
S520, sequentially fixing and sleeving the compressor 3, the turbine 4 and the locking nut 5 which are subjected to dynamic balancing on the second shaft 2, and screwing by using a torque wrench; the dynamic balance grade of the single-piece dynamic balance compressor 3, the turbine 4 and the locking nut 5 reaches G0.4-2.5 dynamic balance precision, preferably G1.
And S530, driving the rotor to rotate by using a motor or air blowing, carrying out dynamic balance by taking the first bearing position 8 and/or the second bearing position 9 as a reference, and removing the amount of a non-working surface of the rotor in the dynamic balance process to remove unbalance, so that the dynamic balance grade reaches G0.4-2.5 dynamic balance precision, preferably G1.
Preferably, when the motor is used for driving the rotor to rotate, the stator of the motor is sleeved on the excircle corresponding to the motor magnetic core 6 in a non-contact manner, and the motor magnetic core 6 is used as the rotor of the motor.
Preferably, when the rotor is rotated by blowing gas, the gas supply unit blows the turbine 4 to rotate the rotor.
Preferably, the non-working surface of the rotor includes, but is not limited to, the first inner hole of the first shaft 1, the boss of the thrust disc 7, the lock nut 5, and the part of the second shaft 2 which penetrates through the lock nut 5.
Preferably, the amount of removing the non-working surface of the rotor is realized by using a non-contact process such as automatic laser derusting or 0.1-1GHz high-frequency waves.
Preferably, the pneumatic driving components are a compressor 3 and a turbine 4, and the compressor 3 and the turbine 4 are mounted on the rotor system from the right side and then locked by a locking nut 5. As shown in particular in fig. 5.
Preferably, a spacer ring (not shown in the figure) for axial positioning is arranged between the compressor 3 and the turbine 4, and the compressor 3, the spacer ring, the turbine 4 and the locking nut 5 are sequentially fixedly sleeved on the second shaft 2 and are screwed by a torque wrench; the dynamic balance grade of the single-piece dynamic balance compressor 3, the spacer ring, the turbine 4 and the locking nut 5 reaches G0.4-2.5 dynamic balance precision, preferably G1.
Preferably, in the dynamic balancing device, the motor and/or the bearing used is a motor and/or a bearing originally assembled and matched when the rotor works.
Preferably, a motor or air blowing is used for driving the rotor to rotate, dynamic balance is performed by taking the first bearing position 8 and/or the second bearing position 9 as a reference, in the dynamic balance process, the amount of a non-working surface of the rotor is removed to achieve unbalance removal, the dynamic balance grade reaches G0.4-2.5 dynamic balance precision, preferably G1, and the method comprises the following steps:
s531, driving the rotor to raise the speed to 8000-;
s532, driving the rotor to raise the speed to 20000-25000rpm by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to realize unbalance removal, and enabling the dynamic balance grade to reach G0.4-2.5 dynamic balance precision, preferably G1;
s533, driving the rotor to increase the speed to 25000-;
s534, driving the rotor to increase the speed to 120000rpm by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to realize unbalance removal, and enabling the dynamic balance grade to reach G0.4-2.5 dynamic balance precision, preferably G1;
and S535, driving the rotor to accelerate to full speed by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to remove unbalance, and enabling the dynamic balance grade to reach G0.4-2.5 dynamic balance precision, preferably G1.
In summary, the present invention provides a method for manufacturing a high-speed rotor, which includes a first shaft and a second shaft; the shaft comprises a first inner hole and a second inner hole with different apertures; the shaft II comprises a first shaft section and a second shaft section with different diameters; one end of the first shaft section of the second shaft penetrates through the second inner hole of the first shaft and is fixedly connected with one end of the first shaft. The manufacturing method comprises the following steps: respectively processing the first shaft and the second shaft to preset sizes; assembling and welding the first shaft and the second shaft to form a rotor; performing surface treatment on the assembled rotor and then performing finish machining to ensure that the roughness of the rotor surface is Ra0.05-0.2 and the coaxiality is 0.001-0.03 mm; and finally, performing dynamic balance, wherein the dynamic balance grade reaches G0.4-2.5. The method can manufacture the high-speed rotor with high precision and high yield, and realizes full-automatic production.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an illustrative embodiment," "an example," "a specific example," or "some examples" or the like mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
While embodiments of the invention have been shown and described, it will be understood by those of ordinary skill in the art that: various changes, modifications, substitutions and alterations can be made to the embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
Claims (20)
1. The manufacturing method of the high-speed rotor is characterized in that the high-speed rotor comprises a first shaft and a second shaft; the shaft comprises a first inner hole and a second inner hole with different apertures, the aperture of the first inner hole is smaller than that of the second inner hole, and a first bearing position is arranged on the outer circumference corresponding to the first inner hole; the shaft II comprises a first shaft section and a second shaft section with different diameters, and the diameter of the first shaft section is larger than that of the second shaft section; the first shaft section of the second shaft is provided with an inner hole; one end of the first shaft section of the second shaft penetrates through the second inner hole of the first shaft and is fixedly connected with one end of the first shaft, and a second bearing position is arranged on the outer circumference of the part, which is not inserted into the second inner hole, of the first shaft section of the second shaft; the rotating speed of the high-speed rotor is 150000rpm-160000 rpm;
the manufacturing method comprises the following steps:
s100, respectively machining the first shaft and the second shaft to preset sizes;
s200, assembling and welding:
inserting the first shaft section of the second shaft into a second inner hole of the first shaft, and welding matching surfaces of the first shaft and the second shaft;
s300, surface treatment:
the surface treatment time is 1-60 seconds, the online microwave surface treatment is completed, the thermal stress is released, and a rough finished piece is obtained after the rotor is cooled to room temperature and the stress is removed;
s400, fine machining: fine machining to rotor surface roughness Ra0.05-0.2 and coaxiality 0.001-0.03 mm;
s500, dynamic balance:
and (3) placing the finely processed rotor in dynamic balance equipment, carrying out dynamic balance by taking the first bearing position and/or the second bearing position as a reference, and removing the amount of the non-working surface of the rotor in the dynamic balance process to remove the unbalance amount so as to enable the dynamic balance grade to reach G0.4-2.5.
2. The method of manufacturing a high-speed rotor according to claim 1,
the step S100 processes the first shaft and the second shaft to predetermined dimensions, respectively:
the first shaft machining step comprises the following steps:
SA110, performing stress relief on a bar used for machining the first shaft, and then roughly machining an outer circle, wherein a margin is reserved at the first bearing position, and the margin meets the requirement of subsequent combined machining;
SA120, finishing the other outer circles except the first bearing position to the size; under the auxiliary tool of the tool, finishing inner holes on two sides of the shaft to the size by using a boring mill; finishing the assembly end faces at the two ends to the size;
SA130, performing dynamic balance on the first shaft, wherein the dynamic balance position is at a second inner hole, the rotating speed of the dynamic balance is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5;
the step of processing the second shaft (2) comprises the following steps:
SB110, performing stress relief on a bar stock used for machining the second shaft, and then roughly machining an outer circle, wherein a second bearing position is provided with a margin, and the margin meets the requirement of subsequent combined machining;
SB120, finishing the other outer circles except the second bearing position to the size; machining an inner hole to the size; finishing the assembly end faces at the two ends to the size;
SB130, finishing the welding surface to the size;
SB140, single-piece dynamic balancing, wherein the second shaft is subjected to dynamic balancing, an inner hole is taken at the dynamic balancing position, the rotating speed of the dynamic balancing is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balancing grade reaches G0.4-2.5;
and/or
The step of finishing in step S400 includes:
s410, clamping: positioning and clamping by taking the excircle corresponding to the second inner hole of the first shaft as a clamping reference surface, and ensuring that the coaxiality of the clamping reference surface of the whole rotor and the first inner hole of the first shaft is kept at 0.001-0.03 mm;
s420, high-frequency wave finishing: using a clamping reference surface as a standard, and performing finish machining on a part with the distortion degree exceeding 0.1mm and the allowance exceeding 0.05mm by using a high-frequency wave surface treatment process, wherein in the high-frequency wave finish machining process, the allowance is reserved, and meets the requirement of subsequent combined machining; the removing part comprises a first bearing position, a second bearing position and a welding position; the frequency of the high-frequency wave is 0.1-1 MHz;
s430, hardening treatment: hardening the whole rotor;
s440, finishing: finely machining the second shaft section of the shaft to the size;
s450, integral finish machining: and removing the allowance to the size at one time by using a fine grinding process so that the surface roughness of the rotor is Ra0.05-0.2 and the coaxiality is 0.001-0.03 mm.
3. The method for manufacturing a high-speed rotor according to claim 1, further comprising a motor magnetic core installed in the second inner hole of the first shaft, wherein one end of the first shaft section of the second shaft passes through the second inner hole of the first shaft and abuts against the motor magnetic core;
the step S100 processes the first shaft and the second shaft to predetermined dimensions, respectively:
the first shaft machining step comprises the following steps:
SA110, performing stress relief on a bar used for machining the first shaft, and then roughly machining an outer circle, wherein a margin is reserved at the first bearing position, and the margin meets the requirement of subsequent combined machining;
SA120, finishing the other outer circles except the first bearing position to the size; under the auxiliary tool of the tool, finishing inner holes on two sides of the shaft to the size by using a boring mill; finishing the assembly end faces at the two ends to the size;
SA130, performing dynamic balance on the first shaft, wherein the dynamic balance position is at a second inner hole, the dynamic balance rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5;
the second shaft machining step comprises the following steps:
SB110, performing stress relief on a bar stock used for machining the second shaft, and then roughly machining an outer circle, wherein a second bearing position is provided with a margin, and the margin meets the requirement of subsequent combined machining;
SB120, finishing the other outer circles except the second bearing position to the size; machining an inner hole to the size; finishing the assembly end faces at the two ends to the size;
SB130, finishing the welding surface to the size;
SB140, single-piece dynamic balancing, wherein the second shaft is subjected to dynamic balancing, an inner hole is taken at the dynamic balancing position, the dynamic balancing rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balancing grade reaches G0.4-2.5;
and/or
The assembling and welding step of step S200 includes:
s210, performing interference heat mounting on the finely processed motor magnetic core into a second inner hole of the first shaft; inserting the second first shaft section into the second inner hole to abut against the motor magnetic core;
s220, welding the matching surfaces of the first shaft and the second shaft by using a welding process;
and/or
The step of finishing in step S400 includes:
s410, clamping: positioning and clamping by taking the outer circle corresponding to the magnetic core of the motor as a clamping reference surface, and ensuring that the coaxiality of the clamping reference surface of the whole rotor and the inner hole at the right side of the shaft is kept at 0.001-0.03 mm;
s420, high-frequency wave finishing: using a clamping reference surface as a standard, and performing finish machining on a part with the distortion degree exceeding 0.1mm and the allowance exceeding 0.05mm by using a high-frequency wave surface treatment process, wherein in the high-frequency wave finish machining process, the allowance is reserved, and meets the requirement of subsequent combined machining; the removing part comprises a first bearing position, a second bearing position and a welding position; the frequency of the high-frequency wave is 0.1-1 MHz;
s430, hardening treatment: hardening the whole rotor;
s440, finishing: finely machining the second shaft section of the second shaft to the size;
s450, integral finish machining: and removing the allowance to the size at one time by using a fine grinding process so that the surface roughness of the rotor is Ra0.05-0.2 and the coaxiality is 0.001-0.03 mm.
4. The manufacturing method of the high-speed rotor according to claim 2, wherein the high-speed rotor further comprises a thrust disc fixedly sleeved on one end side of an outer circle corresponding to a second inner hole of the shaft;
the step S100 further includes machining the thrust disc to a predetermined size, including the steps of:
SC110, roughly machining a blank for machining the thrust disc after stress removal;
SC120, finish machining the inner hole of the thrust disc to the size, wherein the surface roughness of the finish machined inner hole is Ra0.2-Ra0.4, and the disc end surface of the thrust disc is provided with a margin which meets the requirement of subsequent combined machining;
SC130, single piece dynamic balance, the dynamic balance is carried out on the thrust disc, the outer circumference of the thrust disc is taken at the dynamic balance position, the rotating speed of the dynamic balance is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5;
the assembling and welding step in the step S200 includes:
s210, inserting the first shaft section of the second shaft into a second inner hole of the first shaft; sleeving the thrust disc on one end side of the excircle corresponding to the second inner hole of the shaft in an interference shrink fit mode, wherein the end side of the thrust disc is aligned with the end side of the excircle corresponding to the second inner hole of the shaft;
s220, respectively welding the matching surfaces of the thrust disc and the first shaft and the matching surfaces of the first shaft and the second shaft on the aligning sides of the thrust disc and one end of the first shaft by using a welding process;
the removing part in the step S420 comprises a first bearing position, a second bearing position, a welding position and an end face of the thrust disc;
the step S450 further includes making the perpendicularity of the thrust disc to the first shaft be 0.001-0.03 mm.
5. The manufacturing method of the high-speed rotor according to claim 3, wherein the high-speed rotor further comprises a thrust disc fixedly sleeved on one end side of an outer circle corresponding to a second inner hole of the shaft;
the step S100 further includes machining the thrust disc to a predetermined size, including the steps of:
SC110, roughly machining a blank for machining the thrust disc after stress removal;
SC120, finish machining the inner hole of the thrust disc to the size, wherein the surface roughness of the finish machined inner hole is Ra0.2-Ra0.4, and the disc end surface of the thrust disc is provided with a margin which meets the requirement of subsequent combined machining;
SC130, single piece dynamic balance, the dynamic balance is carried out on the thrust disc, the outer circumferential surface of the thrust disc is taken at the dynamic balance position, the dynamic balance rotating speed is lower than the first-order critical rotating speed of the high-speed rotor, and the dynamic balance grade reaches G0.4-2.5;
the assembling and welding step in the step S200 includes:
s210, performing interference heat mounting on the finely processed motor magnetic core into a second inner hole of the first shaft; inserting a first shaft section of a second shaft into a second inner hole of the first shaft to abut against the motor magnetic core; sleeving the thrust disc on one end side of the excircle corresponding to the second inner hole of the shaft in an interference shrink fit mode, wherein the end side of the thrust disc is aligned with the end side of the excircle corresponding to the second inner hole of the shaft;
s220, respectively welding the matching surfaces of the thrust disc and the first shaft and the matching surfaces of the first shaft and the second shaft on the aligning sides of the thrust disc and one end of the first shaft by using a welding process;
the removing part in the step S420 comprises a first bearing position, a second bearing position, a welding position and an end face of the thrust disc;
the step S450 also comprises that the perpendicularity of the thrust disc and the first shaft is 0.001-0.03 mm.
6. The manufacturing method of the high-speed rotor according to any one of claims 2 to 5, characterized by further comprising a gas compressor, a turbine and a lock nut, wherein the gas compressor and the turbine are fixedly sleeved on the second shaft section of the second shaft in sequence and are fastened through the lock nut;
the step S500 of dynamic balancing includes the steps of:
s510, placing the rotor subjected to the step S400 in dynamic balance equipment, and performing dynamic balance by taking the first bearing position and/or the second bearing position as a reference, wherein in the dynamic balance process, the amount of a non-working surface of the rotor is removed to remove the unbalance amount, so that the dynamic balance grade reaches G0.4-2.5;
s520, sequentially and fixedly sleeving the gas compressor, the turbine and the locking nut after the single piece dynamic balance on the second shaft, and screwing by using a torque wrench; the dynamic balance grade of the single-piece dynamic balance compressor, the turbine and the locking nut reaches G0.4-2.5;
and S530, driving the rotor to rotate by using a motor or air blowing, carrying out dynamic balance by taking the first bearing position and/or the second bearing position as a reference, and removing the amount of the non-working surface of the rotor to remove the unbalance in the dynamic balance process so as to enable the dynamic balance grade to reach G0.4-2.5.
7. The method of manufacturing a high-speed rotor according to claim 6, wherein the step S530 includes:
s531, driving the rotor to raise the speed to 8000-;
s532, driving the rotor to raise the speed to 20000-25000rpm by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to remove unbalance, and enabling the dynamic balance grade to reach G0.4-2.5;
s533, driving the rotor to increase the speed to 25000-;
s534, driving the rotor to increase the speed to 120000rpm by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to remove unbalance, and enabling the dynamic balance grade to reach G0.4-2.5;
and S535, driving the rotor to accelerate to full speed by using a motor or air blowing, detecting dynamic balance, removing the amount of the non-working surface of the rotor to remove unbalance, and enabling the dynamic balance grade to reach G0.4-2.5.
8. The method for manufacturing a high-speed rotor according to any one of claims 2 to 7, wherein the step S440 of finishing uses a grinding process.
9. The method for manufacturing a high-speed rotor according to any one of claims 2 to 7, wherein the grinding process in step S450 is performed by using a special grinding wheel mold, the special grinding wheel mold is provided with an inner cavity, the shape and the size of the inner wall of the inner cavity are the same as the designed shape and the size of the rotor, and the rotor is placed in the special grinding wheel mold and is finely ground to the size of the rotor.
10. The method for manufacturing a high-speed rotor according to any one of claims 1 to 7, wherein the rotor size is checked after all finishing steps in steps S100 to 400.
11. The method of manufacturing a high speed rotor according to any one of claims 1 to 7, wherein the dynamic balance class is selected as G1.
12. The method for manufacturing a high-speed rotor according to any one of claims 1 to 7, wherein the amount of removing the non-working surface of the rotor in the step S500 is performed by an automated laser derusting process or a non-contact process of 0.1 to 1GHz high-frequency waves.
13. The method for manufacturing a high-speed rotor according to any one of claims 1 to 7, wherein when a motor magnetic core is provided, in step S500, a dynamic balance test is performed by using a motor to drive the rotor to rotate, and a stator of the motor is non-contact sleeved on an outer circle corresponding to the motor magnetic core, wherein the motor magnetic core is used as a rotor of the motor.
14. A method of manufacturing a high speed rotor according to claim 13, wherein in the dynamic balancing apparatus, the motor and/or the bearing used is a motor and/or a bearing originally provided when the high speed rotor is in operation.
15. The method of manufacturing a high speed rotor according to claim 14, wherein the bearing is an air bearing.
16. A method of manufacturing a high speed rotor according to claim 5 or claim 6, wherein the non-working surfaces include the first bore of the first shaft and the land of the thrust disc.
17. The method of manufacturing a high-speed rotor according to claim 7, wherein when the rotor is rotated by blowing gas, a gas supply member blows the turbine to rotate the rotor.
18. The method of claim 7 wherein the non-working surface of the rotor includes a first bore of the shaft, the boss of the thrust disc, the lock nut, and a portion of the shaft extending through the lock nut.
19. The manufacturing method of the high-speed rotor according to claim 7, wherein a spacer ring for axial positioning is arranged between the compressor and the turbine, and the compressor, the spacer ring, the turbine and a locking nut are sequentially fixedly sleeved on the second shaft and screwed down by a torque wrench; the dynamic balance grade of the single-piece dynamic balance compressor, the spacer ring, the turbine and the locking nut reaches G0.4-2.5.
20. The method of manufacturing a high speed rotor according to claim 19, wherein the dynamic balance level is selected to be G1.
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| CN202010233108.0A CN111482767A (en) | 2020-03-29 | 2020-03-29 | Manufacturing method of high-speed rotor |
| PCT/CN2020/135906 WO2021196727A1 (en) | 2020-03-29 | 2020-12-11 | Manufacturing method for high-speed rotor |
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| CN202010233108.0A CN111482767A (en) | 2020-03-29 | 2020-03-29 | Manufacturing method of high-speed rotor |
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| DE102014209869B3 (en) * | 2014-05-23 | 2015-07-23 | Hirschvogel Umformtechnik Gmbh | Method for producing a shaft |
| CN107813106A (en) * | 2017-10-21 | 2018-03-20 | 王友宏 | The processing method of chemical centrifugal pump shaft |
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| CN110332214A (en) * | 2019-08-23 | 2019-10-15 | 宁波巨航冷挤科技有限公司 | A kind of motor shaft and its manufacturing process of the new-energy automobile high-speed driving based on light-weight design |
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| CN111482767A (en) * | 2020-03-29 | 2020-08-04 | 至玥腾风科技集团有限公司 | Manufacturing method of high-speed rotor |
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2020
- 2020-03-29 CN CN202010233108.0A patent/CN111482767A/en active Pending
- 2020-12-11 WO PCT/CN2020/135906 patent/WO2021196727A1/en active Application Filing
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