CN111525753A - Manufacturing process of braking magnetic pole for linear eddy current braking device - Google Patents
Manufacturing process of braking magnetic pole for linear eddy current braking device Download PDFInfo
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- CN111525753A CN111525753A CN202010396823.6A CN202010396823A CN111525753A CN 111525753 A CN111525753 A CN 111525753A CN 202010396823 A CN202010396823 A CN 202010396823A CN 111525753 A CN111525753 A CN 111525753A
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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
- H02K49/00—Dynamo-electric clutches; Dynamo-electric brakes
- H02K49/02—Dynamo-electric clutches; Dynamo-electric brakes of the asynchronous induction type
- H02K49/04—Dynamo-electric clutches; Dynamo-electric brakes of the asynchronous induction type of the eddy-current hysteresis type
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
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- Insulation, Fastening Of Motor, Generator Windings (AREA)
Abstract
The invention discloses a manufacturing process of a braking magnetic pole for a linear eddy current braking device, which comprises the following steps: arranging a thermal shrinkage bandage in a groove at the periphery of the iron core; an insulating layer is bound on the periphery of the iron core, so that the thermal shrinkage binding belt is limited in the groove of the iron core; winding a coil outside the insulating layer; a supporting layer is arranged on the periphery of the coil, and a welding interface of the thermal shrinkage binding tape is welded and is transferred into a groove of the iron core; performing thermal shrinkage on the fixing ribbon, fixing the coil, the insulating layer and the supporting layer together and keeping the coil, the insulating layer and the supporting layer at the periphery of the iron core; a binding post is arranged on one side of the coil, and the end part of a cable of the coil is electrically connected with the binding post through a crimping terminal; and putting the product into a glue pouring mold for vacuum glue pouring and curing. The invention places and fixes the ribbon in the rectangular groove at the periphery of the iron core, so that the aluminum flat wire has more winding space, the slot fullness rate is improved, the ampere-turn number is increased, and the braking force is increased by 0.2%. The brake magnetic pole manufactured by the method can meet the requirements of a new generation of magnetic suspension train.
Description
Technical Field
The invention belongs to the technical field of rail vehicle braking systems, and particularly relates to a manufacturing process of a braking magnetic pole suitable for a magnetic suspension train.
Background
The existing magnetic suspension train mostly adopts a linear eddy current brake device to carry out emergency braking. The linear eddy current braking technology is characterized in that eddy current is generated on a side guide rail by utilizing a magnetic field generated by electrifying a braking magnetic pole under a high-speed condition, the magnetic field generated by the eddy current is mutually interacted and attracted with an original magnetic field according to Maxwell's law and Lenz's law, so that braking force is generated, and the braking force is finally transmitted to a vehicle bogie through a braking magnetic pole iron core, a magnetic yoke and a pull rod assembly, so that vehicle braking is realized.
The highest speed per hour of the Shanghai magnetic suspension train is 500km/h, the linear eddy current brake device used on the train uses magnetic poles, and the rated magnetomotive force of a single magnetic pole is 20.4 kA. Because space and weight are more strict, the magnetomotive force required to be generated is larger, and the problems of large manufacturing difficulty, high manufacturing cost, large difficulty of winding process and welding process and the like exist in the prior art of adopting the aluminum film winding coil.
The highest running speed of the new generation of magnetic suspension train is 600km/h, and the magnetomotive force required to be provided by the braking magnetic pole is calculated to be as high as 21.7kA according to the deceleration requirement. That is, the ampere-turns increase by 6.4%. Therefore, increasing the ampere-turns (increasing the slot fill factor) is a technical and technological challenge given the constant excitation current and given the space and weight limitations of existing pole structures. From the aspects of technical realization possibility and process guarantee feasibility, two technical schemes can be selected:
film aluminum wire winding coil technology: on the basis of the existing scheme, the number of turns is increased, and the sectional area of the aluminum film is reduced, so that the current density of the aluminum wire is increased, the coil is easily burnt out, the brake failure is caused, and the consequence is serious. The reduction of the thickness of the insulating diaphragm can also increase the slot filling rate, but the thickness of the current diaphragm is equal to that of a paint film of an enameled wire, and the reduction of the thickness can hardly ensure the insulating strength, thereby easily causing short circuit failure. The aluminum film wire winding coil technology has great challenges in increasing the slot filling rate and the ampere-turns, both in the technical realization possibility and in the process guarantee feasibility.
The aluminum flat wire winding coil technology comprises the following steps: firstly, the aluminum flat wire winding coil technology is a mature technology in industry, and both process feasibility and product reliability are guaranteed; secondly, through optimizing the cooperation to iron core geometry and pyrocondensation ribbon, increase the flat line winding space of aluminium, improve the groove full rate and ampere turns, reach the performance data requirement. This is the technical problem to be solved by the present invention.
Disclosure of Invention
The present invention is to overcome the above disadvantages of the prior art and to provide a manufacturing process of a brake magnetic pole for a linear eddy current brake.
In order to solve the technical problems, the invention provides a manufacturing process of a braking magnetic pole for a linear eddy current braking device, wherein the braking magnetic pole structure comprises an iron core, an insulating layer, a coil, a supporting layer, a fixing bandage, a binding post and a packaging layer, a plurality of grooves in the axial direction are arranged at intervals on the periphery of the iron core, and the manufacturing process comprises the following steps:
step 1, arranging a fixing ribbon in a groove at the periphery of an iron core, wherein the fixing ribbon is a heat-shrinkable ribbon;
and 7, putting the product into a glue pouring mold for vacuum glue pouring and curing.
The magnetic pole structure manufactured by the invention mainly comprises an epoxy resin packaging layer, a glass fiber net, an insulating adhesive tape, a thermal shrinkage band, an iron core, a coil assembly and a binding post. The iron core is low-carbon steel with good magnetic conductivity, has good magnetic conductivity and high strength, and mainly has the functions of conducting a magnetic circuit and transmitting braking force; the insulating tape mainly plays a role in electrical isolation and mechanical isolation between the iron core and the enameled wire; the coil assembly is an excitation part and generates strong magnetomotive force after being electrified; the wiring terminal is an electrical interface and introduces external energy into the coil assembly; the coil and the supporting layer (glass fiber net) are subjected to thermal shrinkage fastening by the thermal shrinkage band, so that the frameless coil is prevented from loosening; the addition of the support layer (glass fiber net) can further enhance the mechanical strength of the packaging layer; the epoxy resin packaging layer is an insulating glue layer, on one hand, the mechanical strength in a packaging area is increased, and on the other hand, the insulating and moisture-proof effects are achieved.
The invention places the fixing band in the rectangular groove at the periphery of the iron core, and the welding interface of the heat-shrinkable band is placed in the rectangular groove of the iron core, so that the aluminum flat wire has more winding space, the slot filling rate is improved, and the ampere-turns number is increased. Through finite element electromagnetic simulation calculation, the ampere-turn number of the rectangular groove of the iron core can be increased by 4% and the braking force can be increased by 0.4%. And the reduction of the braking force caused by the reduction of the cross-sectional area of the core due to the grooves is only 0.2%. Overall, the net increase in braking force is 0.2%. That is, the invention improves the optimization of the rectangular groove and the packaging layer of the iron core under the condition of ensuring that the braking performance of the coil is slightly increased, so that the packaging difficulty is reduced, the packaging strength is improved, and the consistency and the reliability of the product are improved.
Because the existing magnetic pole structure adopts an aluminum enameled wire, the binding post is made of brass, the mutual welding ratio of the aluminum enameled wire and the binding post is poor, and the production progress and the welding strength of a product are seriously influenced. The invention designs an outlet structure form, which better avoids the above problems, and uses a crimping terminal which is easy to be welded with copper and has good conductivity to crimp on the enameled wire after depainting, so that the lead and the crimping terminal are rigidly combined, and then the crimping terminal is welded with a binding post, thereby ensuring the integrity of the circuit. Due to the good weldability between the crimp terminal (made of copper material, such as H59, H62, etc.) and copper, the mechanical strength of the final weld is very strong.
The magnetic pole structure is particularly suitable for being applied to a linear eddy current braking device of a magnetic suspension train.
Under the condition of not changing the size of the original magnetic pole product, the rated power of the magnetic pole can reach 3.2KW, the magnetomotive force can reach 21.7kA, the heat-resisting temperature is not less than F level (155 ℃), the IP level meets IP67, the insulation and voltage resistance meets AC2.4kV (1 kHz) strength lasting for 1min, and the weight is not more than 24 kg. Can meet the requirements of the new generation of magnetic suspension train on the brake magnetic pole.
Drawings
Fig. 1 is a side view of a brake pole.
Fig. 2 is a top view of the brake pole.
Fig. 3 is a sectional view a-a of fig. 2.
Fig. 4 is an enlarged upper view of fig. 3.
Fig. 5 is a schematic diagram of the line-out structure of the brake pole.
Fig. 6(a) - (d) are schematic diagrams of the studs of the brake pole.
FIG. 7 is a view of the location of the weld interface before and after heat shrinking of the brake pole cross section heat shrink wrap.
FIG. 8 is a graph of brake pole braking force versus ampere-turns.
Fig. 9 is a schematic view of a heat shrink wrap and core arrangement.
Fig. 10 is a schematic view of vacuum potting.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention.
As shown in fig. 1 to 4, the magnetic pole structure to be manufactured by the present invention is a braking magnetic pole structure suitable for a linear eddy current braking device of a magnetic levitation train, and the size of the magnetic pole structure is as follows: 382.5mm in length, 167mm in width and 93.5mm in height. The brake magnetic pole mainly comprises an iron core 5, an insulating tape 3, a coil 6, a thermal shrinkage band 4, a glass fiber net 2, an epoxy resin packaging layer 1 and a binding post 7.
The iron core 5 is made of low-carbon steel with good magnetic permeability and high strength, and is used for conducting a magnetic circuit and transmitting braking force. Under the condition of meeting the magnetic flux requirement, the chamfer angle of the iron core 5 is not less than 28mm, the condition that the enameled wire protrudes at the junction of the chamfer angle and the straight edge can be prevented, on one hand, the enameled wire is prevented from being easily damaged due to local stress, and on the other hand, the size of the coil is prevented from exceeding the design requirement. The upper part and the lower part of the periphery of the iron core are respectively provided with a circle of concave steps, and the cable of the coil is wound on the periphery of the area between the two steps. The size of the concave step is about 2mm in width and 4mm in height, a certain space is reserved in the step, and after epoxy resin is cured in the space, the displacement of the coil assembly in the axial direction is hindered to a certain extent. In this embodiment, the periphery of the iron core 5 is provided with 8 axial (vertical) grooves 51 at intervals, and the grooves 51 are used for accommodating the thermal shrinkage bandage 4. The cross-section of the groove 51 is rectangular, but it may be semicircular or semi-elliptical.
The insulating tape 3 is wrapped around the core 5 (the area between the two steps) to isolate the coil 4 from the core 5, and to limit the heat shrinkable tape 4 in the groove 51 of the core 5. In this example, a glass fiber tape was used as the insulating tape.
The coil 6 is wound on the periphery of the insulating tape 3 by adopting an aluminum enameled wire and is used for generating magnetomotive force after being electrified.
Heat-shrinkable bands 4 are provided at intervals along the periphery of the core 5 for tightening the coil 6 and fixing and holding the coil 6, the insulating tape 3 and the glass fiber net 2 together at the periphery of the core 5. In this example, heat shrinkable tapes 4 are fixed around the core 5 at intervals by means of the insulating tape 3, and then the coil 6 is wound. This facilitates the fixing of the heat-shrinkable band 4 and the winding of the coil 6. The thickness of the thermal shrinkage band is recommended to be not less than 0.3mm in consideration of size limitation, strength and the like, the thickness of the thermal shrinkage band is 0.6mm, the width of the thermal shrinkage band is 12mm, and in order to accommodate the thermal shrinkage band and a welding interface of the thermal shrinkage band, the width of the groove 51 of the iron core 5 is 13mm, and the depth of the groove is 1 mm. In this embodiment, the welding interface 41 of the heat-shrinkable band 4 is lap-welded on the outside of the coil as shown in fig. 7 (a), and then the heat-shrinkable band 4 is rotated to move the welding interface 41 into the groove of the core 5, and then heat-shrinkable is performed again as shown in fig. 7 (c). Therefore, the winding space of the coil is increased, and the ampere turns can be increased by 4%. Of course, it is also possible to directly perform the heat shrinkage if the welding interface is not moved into the groove of the core 5, as shown in fig. 7 (b). Fig. 7 (c) is a further optimized scheme.
The basic principle of the invention is to determine the implementation scheme according to the relationship between the magnetic pole braking force and ampere-turns calculated by the electromagnetic theory. As can be seen from fig. 8, the relationship between the ampere-turn rating of the magnetic pole and the braking force rating is in a magnetic saturation state. The ampere turn is increased by 30 percent, and the braking force is increased by about 4 percent; the ampere-turns number is reduced by 30%, and the braking force is reduced by about 6%. By adopting the scheme of the invention, the ampere-turn number of the coil of the braking magnetic pole structure is increased by 4%, and the braking force can be increased by 0.4%. And the reduction of the braking force due to the reduction of the core cross-sectional area due to the grooves 51 is only 0.2%. Overall, the net increase in braking force is 0.2%. For the existing products, the net increase of 0.2% of the braking force is a very big breakthrough.
The terminal 7 and the cable end of the coil 6 are electrically connected by a crimp terminal 8, and the epoxy resin encapsulation layer 1 fixes the terminal 7 to the coil 6. In this example, the cable end of the coil 6 is depainted and then crimped to the crimp terminal 8. As shown in fig. 5 and 6, the bottom of the terminal 7 is provided with a rectangular groove 71, the crimp terminal 8 is partially clamped into the rectangular groove 71 and is welded and fixed (B in fig. 5 is a welded part), and the cable end of the coil 6 near the crimp terminal 8 is wrapped with a heat-shrinkable sleeve 9. The periphery of the cylinder of the binding post 7 is provided with at least one spline groove 72 which is mutually embedded and contacted with the packaging layer 1, thereby improving the packaging strength.
Epoxy encapsulation layer 1 wraps up outside magnetic pole structure for seal coil 6 and fasten it outside the iron core, the minimum thickness of epoxy layer should be not less than 1 mm. And encapsulating the product by using the epoxy resin encapsulating layer 1 to fix the coil 6 and the binding post 7. And the mechanical strength in the packaging area is increased, and the effects of insulation and moisture resistance are achieved.
The manufacturing process of the brake magnetic pole for the linear eddy current brake device comprises the following steps:
step 1, arranging a thermal contraction band 4 in a groove 51 along the periphery of an iron core 5, as shown in fig. 9;
and 4, arranging the glass fiber net 2 on the periphery of the coil 6, and welding and fixing a welding interface 41 of the ribbon 4. As a priority, the heat-shrinkable band is rotated and moved, so that the welding interface 41 is placed in the groove 51 of the iron core 5;
and 7, as shown in fig. 10, placing the magnetic pole structure into a glue pouring mold 11, placing the glue pouring mold into a vacuum box 13, and performing vacuum glue pouring, wherein the glue pouring port 12 is located at the bottom of the glue pouring mold 11. In this embodiment, utilize epoxy glue to encapsulate the product, make coil 6 and terminal 7 obtain fixedly to increase the mechanical strength in the encapsulation area, played insulating and dampproofing effect. After the glue filling, the glue filling mould is placed in a constant temperature box for solidification, and solidification is carried out by stages according to the solidification requirement of the epoxy resin glue: 6h, 80-2 h, 90-2 h, 100-8 h and 130 ℃, cooling and demoulding after solidification is finished.
And 8, opening the mold, checking the appearance of the magnetic pole, trimming the part with burrs, and measuring whether the resistance of the coil is consistent with that before packaging.
The innovation points of the invention are as follows:
1. the winding is carried out by using the aluminum enameled wire, so that the independent control requirement on the insulating film is saved, the folding condition after the aluminum film and the insulating film are changed does not exist, the cost and the winding process difficulty are greatly reduced, and the consistency and the reliability of the coil manufacture are improved;
2. a heat-shrinkable ribbon is placed in a rectangular groove on the periphery of the iron core, so that the space is optimally utilized, the groove fullness rate is increased, the ampere-turn number is increased, and the performance of the brake is improved;
3. after the coil is wound, the thermal shrinkage band is welded by hot melting, and the welding interface is moved into the rectangular groove of the iron core, so that the space is optimally utilized, and the fixing strength of the thermal shrinkage band is increased. Meanwhile, the cracking caused by the heating of the welding interface of the thermal shrinkage binding tape during packaging is avoided, and the consistency and reliability of the product are improved.
4. The coil is heated and fastened by heating the heat-shrinkable binding tape, so that the coil without the framework is not loose.
5. The optimized method reduces the welding position from 4 to 2 and increases the welding strength and the welding reliability by crimping a metal material (such as copper) which is easy to weld with copper on an enameled wire and then directly welding the enameled wire with a binding post. The rectangular interface of binding post bottom is favorable to increasing welding strength, and the peripheral spline groove of binding post is favorable to increasing the connection and the joint of binding post and encapsulated layer, increases the mechanical strength of binding post, improves maintenance convenience and product uniformity.
6. And the epoxy resin is used for vacuum packaging, so that the air gap content in the product is greatly reduced, and the heat-conducting property and the insulating property of the final product are improved.
In addition to the above embodiments, the present invention may have other embodiments. All technical solutions formed by adopting equivalent substitutions or equivalent transformations fall within the protection scope of the claims of the present invention.
Claims (8)
1. Linear eddy current arresting gear is with manufacturing process of braking magnetic pole, braking magnetic pole structure includes iron core (5), insulating layer (3), coil (6), supporting layer (2), fixed ribbon (4), terminal (7) and encapsulated layer (1), the peripheral interval of iron core (5) is equipped with slot (51) of a plurality of axial directions, manufacturing process includes following step:
step 1, arranging a fixing bandage (4) in a groove (51) on the periphery of an iron core (5), wherein the fixing bandage (4) is a heat-shrinkable bandage;
step 2, binding an insulating layer (3) on the periphery of the iron core (5) to enable the fixing binding belt (4) to be limited in a groove (51) of the iron core (5);
step 3, winding a coil (6) outside the insulating layer (3);
step 4, arranging a support layer (2) on the periphery of the coil (6), and welding and fixing a welding interface (41) of the binding belt (4);
step 5, performing thermal shrinkage on the fixing bandage (4), fixing the coil (6), the insulating layer (3) and the supporting layer (2) together and keeping the coil, the insulating layer and the supporting layer at the periphery of the iron core (5);
step 6, placing a binding post (7) on one side of the coil (6), and electrically connecting the end part of the cable of the coil (6) with the binding post (7) through a crimping terminal (8);
and 7, putting the product into a glue pouring mold for vacuum glue pouring and curing.
2. The process for manufacturing a brake pole for a linear eddy current brake apparatus according to claim 1, wherein: in the step 4, after the welding interface (41) of the welding fixing tie (4) is welded, the welding fixing tie (4) is rotated to place the welding interface (41) in the groove (51) of the iron core (5), and then the step 5 is executed.
3. The process for manufacturing a brake pole for a linear eddy current brake apparatus according to claim 1, wherein: the bottom of the binding post (7) is provided with a rectangular groove (71), and the crimping terminal (8) is partially embedded into the rectangular groove (71) at the bottom of the binding post (7) and is welded and fixed.
4. The process for manufacturing a brake pole for a linear eddy current brake apparatus according to claim 1, wherein: and the cable end part of the coil (6) close to the crimping terminal (8) is wrapped by a heat-shrinkable sleeve (9).
5. The process for manufacturing a brake pole for a linear eddy current brake apparatus according to claim 1, wherein: the periphery of the cylinder of the binding post (7) is provided with at least one spline groove (72) which is embedded and contacted with the packaging layer (1).
6. A process for manufacturing a magnetic pole structure according to claim 1, wherein: and 7, packaging the product by using epoxy resin glue, placing the glue filling mold in a constant temperature box for curing after the glue filling, curing according to the curing requirement of the epoxy resin glue, and cooling and demolding after the curing is finished.
7. The process for manufacturing a brake pole for a linear eddy current brake apparatus according to claim 1, wherein: step 8, opening the mould, checking the appearance of the magnetic pole, trimming the part with burrs, measuring the resistance of the coil and confirming the consistency with the resistance before packaging.
8. The process for manufacturing a brake pole for a linear eddy current brake apparatus according to claim 1, wherein: the insulating layer (3) is an insulating tape, and the supporting layer (2) is a glass fiber net.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010396823.6A CN111525753B (en) | 2020-05-12 | 2020-05-12 | Manufacturing process of braking magnetic pole for linear eddy current braking device |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010396823.6A CN111525753B (en) | 2020-05-12 | 2020-05-12 | Manufacturing process of braking magnetic pole for linear eddy current braking device |
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| CN111525753B CN111525753B (en) | 2022-07-29 |
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| CN201910730U (en) * | 2010-12-21 | 2011-07-27 | 泰乐玛汽车制动系统（上海）有限公司 | Coil structure of retarder |
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