CN111524681B - Magnetizing method of permanent magnet and manufacturing method of high-speed rotor - Google Patents
Magnetizing method of permanent magnet and manufacturing method of high-speed rotor Download PDFInfo
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- CN111524681B CN111524681B CN202010233104.2A CN202010233104A CN111524681B CN 111524681 B CN111524681 B CN 111524681B CN 202010233104 A CN202010233104 A CN 202010233104A CN 111524681 B CN111524681 B CN 111524681B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F13/00—Apparatus or processes for magnetising or demagnetising
- H01F13/003—Methods and devices for magnetising permanent magnets
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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
- H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
Abstract
A permanent magnet magnetizing method and a manufacturing method of a high-speed rotor are provided, the magnetizing method eliminates the deviation of the magnetizing direction of a permanent magnet by detecting the included angle between the magnetizing direction of a permanent magnet blank and the geometric axial direction of the permanent magnet blank and processing the magnetizing direction of the permanent magnet blank to be parallel to the geometric axial direction, the permanent magnet obtained by the method is used as a magnetic core of a motor to be applied to the high-speed rotor, the magnetizing method of the permanent magnet is used as a part of steps in the manufacturing method of the high-speed rotor, and the manufactured high-speed rotor has the performance of high precision and high yield.
Description
Technical Field
The invention relates to the field of processing and manufacturing of permanent magnets, in particular to a magnetizing method of a permanent magnet and a manufacturing method of a high-speed rotor.
Background
As the permanent magnet is more and more widely used, particularly in the case of being used in high-precision magnetoelectric equipment, not only the characteristics of the permanent magnet, such as magnetic energy product, remanence, coercive force, temperature coefficient and the like, need to be concerned, but also the error between the actual magnetizing direction of the permanent magnet and the geometric axial direction of the permanent magnet, namely the magnetizing angle deviation shape, is taken as an important index, the performance of high-precision magnetoelectric equipment can be influenced to a greater extent, the existence of magnetizing angle deviation can cause the asymmetry of the system, to some extent, eccentricity, if used on a rotor, can lead to poor rotor dynamics, when the rotor rotates at high speed, large unbalanced force can be generated, the energy loss and the vibration of the rotor are increased, the stability of the equipment is influenced, when the magnetic material is used for high-precision magnetic equipment, the precision and the performance of the equipment are influenced, and the existence of magnetizing angle deviation seriously restricts the discovery of the precision magnetic equipment. In addition, at present, no mature scheme is available in the industry for ensuring the magnetizing angle of the permanent magnet. In the prior art, qualified products are screened according to the performance of the products after the products are adapted. However, the method is time-consuming and labor-consuming, and has low yield and high production cost.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the defects of the prior art are overcome, the permanent magnet magnetizing method and the manufacturing method of the high-speed rotor are provided, the deviation of the magnetizing angle of the permanent magnet is controlled in the permanent magnet production and manufacturing stage, and the cost waste caused by later screening is avoided.
The technical solution of the invention is as follows: a method for magnetizing a permanent magnet comprises the following steps:
s100, manufacturing a permanent magnet blank, and reserving a preset machining allowance for the blank;
s200, magnetizing the permanent magnet blank;
s300, detecting an included angle theta between the magnetizing direction of the permanent magnet blank and the geometric axial direction of the permanent magnet blank;
s400, finishing the permanent magnet blank by taking the detected magnetizing direction as an axial direction according to the included angle theta to obtain a permanent magnet with a preset size, and enabling the magnetizing direction of the permanent magnet to be parallel to the geometric axial direction of the permanent magnet.
Further, the step of S300 detecting an included angle θ between the magnetizing direction of the permanent magnet blank and the geometric axial direction of the permanent magnet blank includes:
s310, fixing the permanent magnet blank;
s320, manufacturing a magnetic pointer by using a magnetic conductive material, fixing the pointer near the geometric center of the permanent magnet blank, and enabling the pointer to freely rotate, wherein the direction of the pointer when the pointer stops is the magnetic field direction of the permanent magnet blank;
s330, calibrating the magnetic field direction.
Further, a manufacturing method of a high-speed rotor comprises a first shaft, a second shaft and a motor magnetic core; 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; the motor magnetic core is arranged in the second inner hole of the first shaft, and one end of the 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; 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 processing a first shaft, a second shaft and a motor magnetic core to preset sizes; the motor magnetic core is processed by the magnetizing method of the permanent magnet;
s200, assembling and welding:
s210, the manufactured motor magnetic core is subjected to interference heat loading 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;
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, in step S100:
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;
further, 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 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;
further, the assembling and welding step in 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;
further, the removing part in the step S420 includes a first bearing position, a second bearing position, a welding position, and an end surface 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 dynamic balance level is selected to be G1.
Compared with the prior art, the invention has the advantages that:
the technical scheme of the invention has the following beneficial technical effects:
1. the permanent magnet magnetizing method detects the magnetizing direction of the permanent magnet, and performs finish machining on the permanent magnet blank according to the magnetizing direction of the permanent magnet to eliminate the deviation of the magnetizing direction of the permanent magnet.
2. The high-speed rotor manufacturing method of the invention combines 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, thereby realizing the high-precision and high-yield production of the high-speed rotor.
Drawings
FIG. 1 is a schematic structural view of a permanent magnet blank of the present invention with the magnetization direction thereof at an angle to the axial direction;
FIG. 2 is a schematic view of the present invention in a configuration for processing a permanent magnet blank according to a magnetizing direction;
fig. 3 is a schematic structural view of a high-speed rotor of embodiment 1 of the invention;
FIG. 4 is a schematic structural view of a high-speed rotor of embodiment 2 of the invention;
FIG. 5 is a schematic structural view of a high-speed rotor of embodiment 3 of the invention;
FIG. 6 is a schematic structural view of a high-speed rotor of embodiment 4 of the invention;
FIG. 7 is a schematic structural view of a first shaft of the present invention;
FIG. 8 is a schematic view of the structure of the second shaft of the present invention;
FIG. 9 is a schematic view of the thrust disc of the present invention;
FIG. 10 is a schematic view of an assembled structure corresponding to embodiments 1 and 2 of the present invention;
FIG. 11 is a schematic view of an assembled structure corresponding to embodiments 3 and 4 of the present invention;
fig. 12 is a schematic view of a clamping structure corresponding to embodiments 1 and 2 of the invention;
fig. 13 is a schematic view of a clamping structure corresponding to embodiments 3 and 4 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.
A first aspect of the present invention provides a method for magnetizing a permanent magnet, as specifically shown in fig. 1 and 2:
the method comprises the following steps:
s100, manufacturing a permanent magnet blank, and reserving a preset machining allowance for the blank.
And S200, magnetizing the permanent magnet blank.
And S300, detecting an included angle theta between the magnetizing direction of the permanent magnet blank and the geometric axial direction of the permanent magnet blank.
Specifically, step S300 includes the following steps:
s310, fixing the permanent magnet blank;
s320, manufacturing a magnetic pointer by using a magnetic conductive material, fixing the pointer near the geometric center of the permanent magnet blank, and enabling the pointer to freely rotate, wherein the direction of the pointer when the pointer stops is the magnetic field direction of the permanent magnet blank;
s330, calibrating the magnetic field direction.
S400, finishing the permanent magnet blank by taking the detected magnetizing direction as an axial direction according to the included angle theta to obtain a permanent magnet with a preset size, and enabling the magnetizing direction of the permanent magnet to be parallel to the geometric axial direction of the permanent magnet.
The permanent magnet obtained by the permanent magnet magnetizing method eliminates the deviation between the magnetizing direction and the axial direction.
A second aspect of the present invention provides a method of manufacturing a high speed rotor having a rotational speed of 150000rpm to 160000rpm, preferably 155000rpm, in the form of the structure shown in fig. 1 to 4.
Example 1
The high-speed rotor structure of embodiment 1 is shown in fig. 3, 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; 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 to be abutted against the motor magnetic core 6 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 hole of the first shaft 1 is larger than the outer diameter of the portion of the second bearing 9 not inserted into the outer circumference of the second inner hole of the first shaft 1.
Example 2
The high-speed rotor structure of embodiment 2 is as shown in fig. 4, 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 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 3
The high-speed rotor structure of embodiment 3 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 4
The high-speed rotor structure of embodiment 4 is shown in fig. 6, and on the basis of the structure of the high-speed rotor of embodiment 3, 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 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.
The method for manufacturing the high-speed rotor specifically comprises the following steps:
s100', respectively processing the first shaft 1, the second shaft 2 and the motor magnetic core 6, wherein the motor magnetic core 6 is obtained by the permanent magnet magnetizing method.
As shown in fig. 7, fig. 7 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. 8, fig. 8 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, the step S100' further includes machining the thrust disc 7.
As shown in fig. 9, fig. 9 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 an inner hole to the size, wherein the surface roughness of the finish machined inner hole is Ra0.2-Ra0.4, and a margin 10 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', the finely processed motor magnetic core 6 is subjected to interference heat filling into 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;
s220', the mating surfaces of the thrust disk 7 and the shaft one 1, and the mating surfaces of the shaft one 1 and the shaft two 2, i.e., the weld surface 11 in fig. 11, are welded, respectively, on the alignment sides of the thrust disk 7 and the shaft one 1 using a welding process, preferably laser welding.
In step S200', fig. 10 is referred to for the drawings corresponding to embodiment 1 and embodiment 2, and fig. 11 is referred to for the drawings corresponding to embodiment 3 and embodiment 4.
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', fine 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. 12 is referred to for the drawings corresponding to embodiment 1 and embodiment 2, and fig. 13 is referred to for the drawings corresponding to embodiment 3 and embodiment 4.
S420' high-frequency wave finish machining
The rotor shown in fig. 12-13 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 the step S100 '-400', the finishing step, each piece check size.
S500', dynamic balance
S510 ', the rotor which is processed by the step S450' is placed in dynamic balance equipment, dynamic balance is carried out 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 the non-working surface of the rotor is removed to remove the unbalance amount, and the dynamic balance grade reaches 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, the motor is used for driving 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', the gas compressor 3, the turbine 4 and the locking nut 5 which are subjected to dynamic balancing are sequentially fixedly sleeved on the second shaft 2 and are screwed down by 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', a motor or air blowing is used for driving the rotor to rotate, dynamic balance is carried out by taking the first bearing position 8 and/or the second bearing position 9 as a reference, the amount of the non-working surface of the rotor is removed in the dynamic balance process so as to remove the unbalance, and 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. 6.
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 accelerate 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 the dynamic balance, removing the amount of the non-working surface of the rotor to remove the unbalance amount, 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 summary, the present invention provides a method for magnetizing a permanent magnet and a method for manufacturing a high-speed rotor, in which an included angle between a magnetizing direction of a permanent magnet blank and a geometric axial direction of the permanent magnet blank is detected, and the magnetizing direction is processed to be parallel to the geometric axial direction, so as to eliminate a deviation of the magnetizing direction of the permanent magnet, and the permanent magnet obtained by the method is applied to the high-speed rotor as a magnetic core of a motor.
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 (9)
1. The manufacturing method of the high-speed rotor is characterized in that the high-speed rotor comprises a first shaft, a second shaft and a motor magnetic core; 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; the motor magnetic core is arranged in the second inner hole of the first shaft, and one end of the 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; 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 processing a first shaft, a second shaft and a motor magnetic core to preset sizes; the motor magnetic core is processed by a magnetizing method of a permanent magnet;
s110, manufacturing a permanent magnet blank, and reserving a preset machining allowance for the blank;
s120, magnetizing the permanent magnet blank;
s130, detecting an included angle theta between the magnetizing direction of the permanent magnet blank and the geometric axial direction of the permanent magnet blank;
s140, finishing the permanent magnet blank by taking the detected magnetizing direction as an axial direction according to the included angle theta to obtain a permanent magnet with a preset size, and enabling the magnetizing direction of the permanent magnet to be parallel to the geometric axial direction of the permanent magnet;
s200, assembling and welding:
s210, the manufactured motor magnetic core is subjected to interference heat loading 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;
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 for manufacturing a high-speed rotor according to claim 1, wherein the step S130 of detecting an included angle θ between a magnetizing direction of the permanent magnet blank and a geometric axial direction of the permanent magnet blank includes:
s131, fixing the permanent magnet blank;
s132, manufacturing a magnetic pointer by using a magnetic conductive material, fixing the pointer near the geometric center of the permanent magnet blank, and enabling the pointer to freely rotate, wherein the direction of the pointer when the pointer stops is the magnetic field direction of the permanent magnet blank;
s133, calibrating the magnetic field direction.
3. The method for manufacturing a high-speed rotor according to claim 1, wherein in step S100:
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 dynamic balance, to axle two carry out dynamic balance, the hole is got to the dynamic balance position, the dynamic balance rotational speed is less than the first order critical speed of high speed rotor, and the dynamic balance grade reaches G0.4-2.5.
4. The method of manufacturing a high-speed rotor according to claim 1 or 3,
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.
5. The manufacturing method of the high-speed rotor according to claim 4, 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;
and SC120, finishing 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;
6. the method of manufacturing a high-speed rotor according to claim 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; and sleeving the thrust disc on one end side of the excircle corresponding to the first second inner hole of the shaft in an interference hot-fitting manner, wherein the end side of the thrust disc is aligned with the end side of the excircle corresponding to the first 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;
7. the method of manufacturing a high-speed rotor according to claim 6,
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.
8. The manufacturing method of the high-speed rotor according to claim 7, 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.
9. The method of manufacturing a high-speed rotor according to claim 8, 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.
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| CN202010233104.2A CN111524681B (en) | 2020-03-29 | 2020-03-29 | Magnetizing method of permanent magnet and manufacturing method of high-speed rotor |
| PCT/CN2020/135907 WO2021196728A1 (en) | 2020-03-29 | 2020-12-11 | Magnetizing method for permanent magnet and manufacturing method for high-speed rotor |
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| CN202010233104.2A CN111524681B (en) | 2020-03-29 | 2020-03-29 | Magnetizing method of permanent magnet and manufacturing method of high-speed rotor |
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| CN111524681B (en) * | 2020-03-29 | 2021-07-27 | 靳普 | Magnetizing method of permanent magnet and manufacturing method of high-speed rotor |
| CN113972798B (en) * | 2021-11-19 | 2023-02-21 | 珠海格力智能装备有限公司 | Rotor positioning device and rotor magnetizing equipment |
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