CN112072810A - Copper-aluminum composite rotor, aluminum casting mold and manufacturing method thereof - Google Patents
Copper-aluminum composite rotor, aluminum casting mold and manufacturing method thereof Download PDFInfo
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- CN112072810A CN112072810A CN202010866807.9A CN202010866807A CN112072810A CN 112072810 A CN112072810 A CN 112072810A CN 202010866807 A CN202010866807 A CN 202010866807A CN 112072810 A CN112072810 A CN 112072810A
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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
- H02K1/26—Rotor cores with slots for windings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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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
- H02K15/0012—Manufacturing cage rotors
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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
- H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K17/00—Asynchronous induction motors; Asynchronous induction generators
- H02K17/02—Asynchronous induction motors
- H02K17/16—Asynchronous induction motors having rotors with internally short-circuited windings, e.g. cage rotors
- H02K17/165—Asynchronous induction motors having rotors with internally short-circuited windings, e.g. cage rotors characterised by the squirrel-cage or other short-circuited windings
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/02—Windings characterised by the conductor material
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Induction Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The invention discloses a copper-aluminum composite rotor, a cast aluminum mould and a manufacturing method thereof, wherein the copper-aluminum composite rotor comprises: the iron core is provided with a shaft hole and a plurality of slots; the copper conducting bars are inserted into the slots one by one, two ends of each copper conducting bar protrude out of the slots, and the side walls of the copper conducting bars are tightly connected with the side walls of the slots; the aluminum guide bars are correspondingly inserted into the slots one by one, and the aluminum guide bars wrap the peripheries of the copper guide bars and are tightly connected with the inner side walls of the slots; the two aluminum short-circuit rings are respectively arranged at two ends of the iron core, a plurality of through holes corresponding to the slots one by one are formed in the aluminum short-circuit rings, and the two end parts of the copper conducting bar respectively penetrate through the through holes of one aluminum short-circuit ring to form outward convex parts; the two aluminum short-circuit rings and the aluminum guide strips are integrally formed by die casting. The copper-aluminum composite rotor can improve the running state of the motor, prolong the service life of the motor, meet the running requirement of a high-performance motor, and has high production efficiency and low manufacturing cost.
Description
Technical Field
The invention relates to a copper-aluminum composite rotor, a cast aluminum mold and a manufacturing method thereof.
Background
The electric spindle is a core functional component of an industrial main machine numerical control machine tool, and along with the development of the numerical control machine tool in the direction of increasingly powerful functions, increasingly wide processing range and increasingly higher precision, the performance requirements on the electric spindle are gradually improved, wherein only one mode of meeting the requirement of the numerical control machine tool on the wide processing range is that the electric spindle has to have a wide working range, namely, the driving motor for the electric spindle has to have a wide speed regulation range and green and efficient operation characteristics.
The high-speed direct drive is an important way for improving the power density of a motor, saving the production materials of the motor and meeting the special limit of certain occasions on the volume and the size of the motor, and the three-phase asynchronous motor is a driving motor type which is widely applied in the field of a current electric spindle due to the obvious characteristics of simple structure, firmness, durability, convenient control and the like, can realize smooth speed regulation by changing the operating frequency of the motor through a frequency converter, enables the motor to execute constant-torque operation below a rated rotating speed and execute constant-power operation above the rated rotating speed, and can also carry a high-precision position sensor to realize precise speed control and precise stop positioning functions.
In order to pursue the operating efficiency of the asynchronous motor, the current mainstream rotor form of the electric spindle for driving the asynchronous motor mainly uses a copper rotor, and the manufacturing process of the electric spindle is generally completed by adopting a medium-frequency brazing process. Although the intermediate frequency brazing process of the copper rotor is perfected, the welding quality is relatively stable, and the operation effect of the copper rotor motor is relatively ideal, the preparation work time is long, the welding process is complex, high-value precious metal materials are more, automatic production is difficult to form, the defect of high cost of the welded copper rotor is particularly obvious, and the application and popularization of the copper rotor are severely limited. In order to overcome the obvious defect of the asynchronous motor with the copper rotor, a hot tide for manufacturing the copper rotor by adopting a copper casting process has been raised at home and abroad, and unfortunately, the hot tide is finally limited by the immaturity of the copper casting process and has no obvious effect, so that the asynchronous motor with the cast copper rotor, especially the asynchronous motor with the cast pure copper rotor, is still fresh at present.
Disclosure of Invention
An object of the application is to provide a copper-aluminum composite rotor, which can solve the problems of immature process of the existing cast copper rotor, low production efficiency of the brazed copper rotor and high manufacturing cost, and can meet the requirement of high-performance motor operation. Another objective of the present application is to provide an aluminum casting mold for manufacturing the aluminum bars and the aluminum short-circuit rings of the above copper-aluminum composite rotor, and a manufacturing method for manufacturing the above copper-aluminum composite rotor.
The purpose of the application is realized by the following technical scheme:
a copper-aluminum composite rotor is characterized by comprising:
the iron core comprises a plurality of laminated rotor punching sheets, the iron core is provided with a shaft hole penetrating through two ends of the iron core and a plurality of slots, and the slots are annularly arranged on the periphery of the shaft hole;
one of the copper conducting bars is correspondingly inserted into each slot, two ends of each copper conducting bar protrude out of the slots, and the side walls of the copper conducting bars are tightly connected with the side walls of the slots;
one of the aluminum guide strips is correspondingly inserted into each slot, and the aluminum guide strips wrap the periphery of the copper guide strips and are tightly connected with the inner side walls of the slots; and
the two aluminum short-circuit rings are respectively arranged at two ends of the iron core, a plurality of through holes corresponding to the slots one by one are formed in the aluminum short-circuit rings, and the two end parts of the copper conducting bar respectively penetrate through the through holes of one aluminum short-circuit ring to form outer convex parts;
the two aluminum short circuit rings and the plurality of aluminum guide strips are integrally formed by die casting.
In the above copper-aluminum composite rotor, optionally, each aluminum conducting bar includes two aluminum bar separated pieces, and the two aluminum bar separated pieces are respectively disposed on the inner and outer sides of the copper conducting bar.
In the above copper-aluminum composite rotor, optionally, the cross section of the copper bar is trapezoidal, and the cross section of the aluminum bar splitting member is semicircular.
In the above copper-aluminum composite rotor, optionally, a ratio range of a cross-sectional area of each copper bar to a cross-sectional area of each aluminum bar is 1: (0.5-2).
In the above copper-aluminum composite rotor, optionally, the periphery of the copper conducting bar is provided with a plurality of clamping grooves, and the aluminum conducting bar and/or the aluminum short circuit ring are provided with positioning protrusions which are positioned in cooperation with the clamping grooves.
In the above copper-aluminum composite rotor, optionally, each of the slots is provided at a position where both ends of the copper bar protrude from the iron core, and the positioning protrusion is provided on the aluminum short circuit ring.
In the above copper-aluminum composite rotor, optionally, outer edges of both ends of the copper bar are provided with chamfers.
The utility model provides a cast aluminium mould for cast above-mentioned copper aluminium composite rotor's aluminium conducting bar and aluminium short circuit ring, it includes: positioning fixture, static mould and moving mould; the positioning jig includes:
the shaft core is inserted into the shaft hole of the iron core;
the first positioning die is sleeved outside the shaft core and is arranged at the first end part of the iron core, a plurality of first positioning grooves used for being matched and positioned with the outer convex parts at one end of each copper bar are formed in the first positioning die, and a first annular cavity used for communicating each slot and forming one aluminum short circuit ring is formed in the first positioning die;
the second positioning die is sleeved outside the shaft core and is arranged at the second end part of the iron core, and a plurality of second positioning grooves used for being matched and positioned with the outer convex parts at the other ends of the copper bars are formed in the second positioning die;
the second positioning die is accommodated in the static die, a second annular cavity for communicating the slots and forming another aluminum short circuit ring is defined between the second positioning die and the static die, and a pouring port communicated with the second annular cavity is formed in the static die;
the first positioning die is accommodated in the movable die, a cavity matched with the periphery of the iron core is formed in the movable die, and the movable die is provided with a first demolding ejection core which is connected through a spring and used for being abutted to the second positioning die in a matched mode and a second demolding ejection core which is connected through a spring and used for being abutted to the first positioning groove in a matched mode.
In the above aluminum casting mold, optionally, positioning pins are connected between the second positioning die and the stationary die and are distributed at intervals along the circumferential direction.
A manufacturing method of a copper-aluminum composite rotor comprises the following steps:
laminating a plurality of rotor punching sheets into an iron core, and respectively inserting copper conducting bars into slots of the iron core;
inserting a shaft core into a shaft hole of an iron core, respectively inserting an outer convex part at one end of each copper conducting bar into each first positioning groove of a first positioning die, and respectively inserting an outer convex part at the other end of each copper conducting bar into each second positioning groove of a second positioning die, so as to respectively install the first positioning die and the second positioning die at two ends of the iron core, and forming a pre-assembly body;
after the movable die is in a die opening state relative to the static die, the preassembly body is installed in a cavity of the movable die;
after the movable mold is closed relative to the static mold, aluminum liquid is injected from a pouring gate of the static mold through pressure and flows into the first annular cavity, each slot and the second annular cavity respectively, so that the copper-aluminum composite rotor is formed;
when the movable mold opens relative to the static mold, the separation between the second positioning mold and the copper-aluminum composite rotor, the separation between the first positioning mold and the copper-aluminum composite rotor and the separation between the copper-aluminum composite rotor and the movable mold are respectively realized through the first demolding top core and the second demolding top core.
According to the copper-aluminum composite rotor, the cast-aluminum mold and the manufacturing method thereof, the squirrel cage bars comprise the copper guide bars and the aluminum guide bars, so that the resistivity of the squirrel cage bars is greatly improved relative to the cast-aluminum rotor, and therefore the running efficiency of a motor is improved; in addition, the copper conducting bar is served as by the copper bar of prefabricated shaping, and aluminium conducting bar and short-circuit ring are solidified and formed by aluminium liquid after pouring into, and copper conducting bar and rotor core are cladding and fixed after solidifying by aluminium liquid finally, and this kind of copper aluminium composite rotor not only can satisfy the operation demand of high performance motor, and for present cast copper rotor and cast aluminium rotor, production efficiency increases substantially, and low in manufacturing cost.
Drawings
The present application is described in further detail below in connection with the accompanying drawings and preferred embodiments, but those skilled in the art will appreciate that the drawings are only drawn for the purpose of explaining the preferred embodiments, and therefore should not be taken as limiting the scope of the present application. Furthermore, unless specifically stated otherwise, the drawings are intended to be conceptual in nature or configuration of the described objects and may contain exaggerated displays and are not necessarily drawn to scale.
FIG. 1 is a longitudinal cross-sectional view of one embodiment of a copper aluminum composite rotor of the present application;
FIG. 2 is an enlarged schematic view of part A of FIG. 1;
FIG. 3 is a transverse cross-sectional view of the copper aluminum composite rotor of the embodiment shown in FIG. 1;
FIG. 4 is a schematic structural diagram of a copper bar of the copper-aluminum composite rotor of the embodiment shown in FIG. 1;
FIG. 5 is a schematic structural diagram of an aluminum conducting bar and an aluminum short-circuit ring of the copper-aluminum composite rotor of the embodiment shown in FIG. 1;
FIG. 6 is a schematic structural view of an embodiment of a cast aluminum mold of the present application;
FIG. 7 is a longitudinal cross-sectional view of a first positioning die of the cast aluminum mold of FIG. 6;
FIG. 8 is a right side view of the first positioning die of FIG. 7;
FIG. 9 is a longitudinal cross-sectional view of a second positioning die of the cast aluminum die of FIG. 6;
FIG. 10 is a right side view of the second positioning die of FIG. 9;
fig. 11 is a schematic structural diagram of an assembly in a method for manufacturing a copper-aluminum composite rotor according to an embodiment of the present application.
In the figure:
10. a copper-aluminum composite rotor; 11. an iron core; 111. a shaft hole; 112. a slot; 12. a copper conducting bar; 121. an outer convex portion; 122. a card slot; 123. chamfering; 13. an aluminum conducting bar; 131. separating the aluminum strips into pieces; 14. an aluminum short circuit ring; 141. a via hole; 142. positioning the projection;
20. casting an aluminum mold; 21. positioning a clamp; 211. a shaft core; 212. a first positioning die; 2121. a first positioning groove; 2122. a first annular cavity; 213. a second positioning die; 2131. a second positioning groove; 22. static molding; 221. a pouring gate; 23. a second annular cavity; 24. moving the mold; 241. a cavity; 25. a spring; 26. a first demold core; 27. a second demolded core; 28. positioning pins;
30. pre-assembly.
Detailed Description
Hereinafter, preferred embodiments of the present application will be described in detail with reference to the accompanying drawings. Those skilled in the art will appreciate that the descriptions are illustrative only, exemplary, and should not be construed as limiting the scope of the application.
First, it should be noted that the orientations of top, bottom, upward, downward, and the like referred to herein are defined with respect to the orientation in the respective drawings, are relative concepts, and thus can be changed according to different positions and different practical states in which they are located. These and other orientations, therefore, should not be used in a limiting sense.
It should be noted that the term "comprising" does not exclude other elements or steps and the "a" or "an" does not exclude a plurality.
Furthermore, it should be further noted that any single technical feature described or implied in the embodiments herein, or any single technical feature shown or implied in the figures, can still be combined between these technical features (or their equivalents) to obtain other embodiments of the present application not directly mentioned herein.
It will be further understood that the terms "first," "second," and the like, are used herein to describe various information and should not be limited to these terms, which are used merely to distinguish one type of information from another. For example, "first" information may also be referred to as "second" information, and similarly, "second" information may also be referred to as "first" information, without departing from the scope of the present application.
It should be noted that in different drawings, the same reference numerals indicate the same or substantially the same components.
As shown in fig. 1 to 5, a first aspect of the embodiment of the present invention provides a copper-aluminum composite rotor 10, which includes: the structure comprises an iron core 11, a plurality of copper conducting bars 12, a plurality of aluminum conducting bars 13 and two aluminum short-circuit rings 14; the iron core 11 comprises a plurality of rotor punching sheets which are arranged in a laminated mode, the iron core 11 is provided with a shaft hole 111 and a plurality of slots 112, the shaft hole 111 and the slots 112 penetrate through two ends of the iron core 11, the slots 112 are annularly arranged on the periphery of the shaft hole 111, a plurality of copper guide bars 12 are correspondingly inserted into the slots 112 one by one, two ends of each copper guide bar 12 protrude out of the slots 112, the side walls of the copper guide bars 12 are tightly connected with the side walls of the slots 112, a plurality of aluminum guide bars 13 are correspondingly inserted into the slots 112 one by one, the aluminum guide bars 13 wrap the periphery of the copper guide bars 12 and are tightly connected with the inner side walls of the slots 112, two aluminum short circuit rings 14 are respectively arranged at two ends of the iron core 11, a plurality of through holes 141 corresponding to the slots 112 one by one are arranged on the aluminum short circuit rings 14, and; wherein, two aluminium short circuit rings 14 and a plurality of aluminium conducting bars 13 adopt integrative die-casting shaping.
Based on the technical scheme, the copper-aluminum composite rotor 10 is light in overall weight, low in rotational inertia and large in starting torque, so that the dynamic response of the motor can be quicker, and the copper-aluminum composite rotor 10 skillfully combines the respective advantages of a cast aluminum rotor and a welded copper rotor, so that on one hand, the resistivity of the squirrel cage bar is greatly improved relative to the cast aluminum rotor by adding a copper section bar in the squirrel cage bar, thereby improving the running efficiency of the motor, and on the other hand, the temperature rise of the copper-aluminum composite rotor 10 is effectively improved due to the fact that the heat conductivity coefficient of aluminum is far higher than that of a copper guide bar 12, thereby improving the running state of the motor, prolonging the service life of the motor, and being suitable for high-speed and; in addition, the aluminum conducting bars 13 and the aluminum short circuit ring 14 are integrally formed by die casting, so that the welding process of the aluminum short circuit ring 14 is fundamentally cancelled, the adverse effect caused by welding of the rotor short circuit ring is avoided, the production efficiency is greatly improved, and the manufacturing cost is low.
Specifically, as shown in fig. 3, each aluminum conducting bar 13 includes two aluminum bar separated pieces 131, the two aluminum bar separated pieces 131 are respectively disposed on the inner and outer sides of the copper conducting bar 12, the cross section of the copper conducting bar 12 is trapezoidal, the cross section of the aluminum bar separated piece 131 is semicircular, and the shape of the slot 112 is adapted to the copper conducting bar 12 and the aluminum bar separated pieces 131; by configuring the shape and size of the slots 112 and the distribution of the copper bars 12 and the aluminum bars 13 as described above, the magnetic path characteristics of the rotor can be optimized to obtain the best rotor impedance performance, thereby obtaining the best motor performance, and in particular providing an effective path for accommodating the contradiction between the efficiency and the power factor of the motor.
Specifically, the cross section of the copper bar 12 is an isosceles trapezoid, two bottom edges of the copper bar extend along the circumferential direction of the iron core 11, and the bottom edge is located outside the upper edge as viewed along the radial direction, as shown in fig. 3.
In addition, in the embodiment, the rotor resistance can be adjusted by adjusting the ratio of copper to aluminum in the conducting bars, so that the performance of the motor is further optimized; preferably, the ratio of the cross-sectional area of each copper bar 12 to the cross-sectional area of each aluminum bar 13 is in the range of 1: (0.5-2), and the cross section shapes of the copper conducting bar 12 and the aluminum conducting bar 13 are matched, so that the optimal rotor impedance performance and the motor performance are optimized.
In this embodiment, in order to connect the copper conducting bar 12, the aluminum conducting bar 13, and the aluminum short-circuit ring 14 together, a plurality of slots 122 are formed on the periphery of the copper conducting bar 12, during the die-casting of the aluminum conducting bar 13 and the aluminum short-circuit ring 14, the aluminum liquid can enter the slots 122, after the aluminum liquid is solidified, positioning protrusions 142 closely connected to the slots 122 are disposed on the aluminum conducting bar 13 or the aluminum short-circuit ring 14 to form a limiting mechanism, so as to prevent the copper conducting bar 12 from loosening or displacing, as shown in fig. 2 and 4.
For example, as shown in fig. 1 and fig. 2, each of the slots 122 is opened at a position where both ends of the copper bar 12 protrude out of the iron core 11, and the positioning protrusion 142 is disposed on the aluminum short-circuit ring 14, so that the connection reliability between the aluminum short-circuit ring 14 and the copper bar 12 can be ensured.
Illustratively, the locking grooves 122 are ring-shaped around the outer circumference of the copper bars 12, and a plurality of ring-shaped locking grooves 122 are axially spaced at both ends of each copper bar 12, and as shown in fig. 4, the positioning protrusions 142 are ring-shaped to fit the locking grooves 122.
In addition, as shown in fig. 4, in the present embodiment, the outer edges of both ends of the copper bar 12 are set to be chamfers 123; before the aluminum conducting bar 13 and the aluminum short-circuit ring 14 are die-cast, the iron core 11 and the copper conducting bar 12 need to be fixed, at this time, the outward protruding parts 121 at the two ends of the copper conducting bar 12 play a limiting role, and the chamfer 123 mainly plays a guiding role, so that the copper conducting bar 12 can smoothly enter the limiting position corresponding to the casting mold.
A second aspect of the embodiment of the present invention provides a cast aluminum mold 20, which is used for casting an aluminum conducting bar 13 and an aluminum short-circuit ring 14 in a copper-aluminum composite rotor 10 according to the first aspect of the present invention, specifically, as shown in fig. 6 to 10, the cast aluminum mold 20 includes a positioning fixture 21, a stationary mold 22 and a movable mold 24, the positioning fixture 21 includes a shaft core 211, a first positioning mold 212 and a second positioning mold 213, and the stationary mold 22 and the movable mold 24 are respectively used for being mounted on an upper die base and a lower die base.
Specifically, the shaft core 211 is configured to be inserted into the shaft hole 111 of the iron core 11, the first positioning mold 212 is sleeved outside the shaft core 211 and configured to be installed at a first end portion of the iron core 11, the first positioning mold 212 is provided with a plurality of first positioning grooves 2121 configured to be matched and positioned with the outer protrusions 121 at one end of each copper bar, and the first positioning mold 212 is provided with a first annular cavity 2122 configured to be communicated with each slot 112 and to form one of the aluminum short-circuit rings 14, as shown in fig. 7 and 8 in particular, the second positioning mold 213 is sleeved outside the shaft core 211 and configured to be installed at a second end portion of the iron core 11, the second positioning mold 213 is provided with a plurality of second positioning grooves 2131 configured to be matched and positioned with the outer protrusions 121 at the other end of each copper bar, the second positioning mold 213 is accommodated on the stationary mold 22, a second annular cavity 23 configured to be communicated with each slot 112 and to form another aluminum short-circuit ring 14 is defined between the second positioning mold 213 and, as shown in fig. 6, 9 and 10, the stationary mold 22 is provided with a sprue gate 221 communicating with the second annular cavity 23, the first positioning mold 212 is accommodated in the movable mold 24, the movable mold 24 is provided with a cavity 241 matching with the outer periphery of the iron core 11, and the movable mold 24 is provided with a first mold release top core 26 connected by a spring 25 and adapted to be abutted against the second positioning mold 213 in a fitting manner, and a second mold release top core 27 connected by a spring 25 and adapted to be abutted against the first positioning groove 2121 in a fitting manner.
In this embodiment, in order to facilitate the demolding, the inner sidewall of the first positioning die 212 for defining the first annular cavity 2122, the inner sidewall of the second positioning die 213 for defining the second annular cavity 23, and the inner sidewall of the stationary die 22 for defining the second annular cavity 23 each have a draft angle.
In this embodiment, the steps of manufacturing the copper-aluminum composite rotor 10 by using the cast-aluminum mold 20 include:
firstly, laminating a plurality of rotor punching sheets into an iron core 11, and respectively inserting copper conducting bars 12 into each slot 112 of the iron core 11;
then, the shaft core 211 is inserted into the shaft hole 111 of the iron core 11, the outer protrusion 121 at one end of each copper bar 12 is respectively inserted into each first positioning groove 2121 of the first positioning die 212, and the outer protrusion 121 at the other end of each copper bar 12 is respectively inserted into each second positioning groove 2131 of the second positioning die 213, so as to respectively mount the first positioning die 212 and the second positioning die 213 at two ends of the iron core 11, thereby forming the pre-assembly body 30, as shown in fig. 11;
after the static die 22 and the movable die 24 which are arranged on the upper die base and the lower die base are installed and debugged, when the movable die 24 is in a die opening state relative to the static die 22, the preassembly 30 is arranged in a die cavity 241 of the movable die 24;
after the movable mold 24 is closed relative to the stationary mold 22, ensuring that the first positioning mold 212 is accommodated in the movable mold 24 and the second positioning mold 213 is accommodated in the stationary mold 22, injecting aluminum liquid from a pouring port 221 of the stationary mold 22 through pressure, wherein the aluminum liquid flows into the first annular cavity 2122, each slot 112 and the second annular cavity 23 respectively, and forming the copper-aluminum composite rotor 10 after the aluminum liquid is solidified;
and finally, opening the movable die 24 relative to the stationary die 22, and at first, demolding between the second positioning die 213 and the copper-aluminum composite rotor 10 is realized by the first demolding top core 26 through the elastic force of the spring 25, and with further opening the die, demolding between the first positioning die 212 and the copper-aluminum composite rotor 10 and demolding between the copper-aluminum composite rotor 10 and the movable die 24 are sequentially realized by the second demolding top core 27 through the elastic force, so that the manufacturing of the copper-aluminum composite rotor 10 is completed.
In addition, in order to prevent the preassembly 30 from rotating in the cavity 241 during the die casting process, positioning pins 28 are connected between the second positioning die 213 and the stationary die 22 and are distributed at intervals along the circumferential direction, and the circumferential rotation of the preassembly 30 can be limited by the positioning pins 28.
To sum up, according to the copper-aluminum composite rotor, the cast-aluminum mold and the manufacturing method thereof, the squirrel cage bar comprises the copper guide bar and the aluminum guide bar, so that the resistivity of the squirrel cage bar is greatly improved relative to the cast-aluminum rotor, the running efficiency of the motor is improved, and the temperature rise of the copper-aluminum composite rotor is effectively improved due to the fact that the heat conductivity coefficient of aluminum is far higher than that of the copper guide bar, so that the running state of the motor can be improved, and the service life of the motor is prolonged; in addition, the copper conducting bar is served as by the copper bar of prefabricated shaping, and aluminium conducting bar and short-circuit ring are solidified and formed by aluminium liquid after pouring into, and copper conducting bar and rotor core are cladding and fixed after solidifying by aluminium liquid finally, and this kind of copper aluminium composite rotor not only can satisfy the operation demand of high performance motor, and for present cast copper rotor and cast aluminium rotor, production efficiency increases substantially, and low in manufacturing cost.
This written description discloses the application with reference to the drawings, and also enables one skilled in the art to practice the application, including making and using any devices or systems, using suitable materials, and using any incorporated methods. The scope of the present application is defined by the claims and includes other examples that occur to those skilled in the art. Such other examples are to be considered within the scope of the claims as long as they include structural elements that do not differ from the literal language of the claims, or that they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Claims (10)
1. A copper-aluminum composite rotor is characterized by comprising:
the iron core comprises a plurality of laminated rotor punching sheets, the iron core is provided with a shaft hole penetrating through two ends of the iron core and a plurality of slots, and the slots are annularly arranged on the periphery of the shaft hole;
one of the copper conducting bars is correspondingly inserted into each slot, two ends of each copper conducting bar protrude out of the slots, and the side walls of the copper conducting bars are tightly connected with the side walls of the slots;
one of the aluminum guide strips is correspondingly inserted into each slot, and the aluminum guide strips wrap the periphery of the copper guide strips and are tightly connected with the inner side walls of the slots; and
the two aluminum short-circuit rings are respectively arranged at two ends of the iron core, a plurality of through holes corresponding to the slots one by one are formed in the aluminum short-circuit rings, and the two end parts of the copper conducting bar respectively penetrate through the through holes of one aluminum short-circuit ring to form outer convex parts;
the two aluminum short circuit rings and the plurality of aluminum guide strips are integrally formed by die casting.
2. The copper-aluminum composite rotor according to claim 1, wherein each aluminum bar comprises two aluminum bar sub-members, the two aluminum bar sub-members being respectively disposed on inner and outer sides of the copper bar.
3. The copper-aluminum composite rotor as in claim 1, wherein the copper bars are trapezoidal in cross-section and the aluminum bar segments are semi-circular in cross-section.
4. The copper-aluminum composite rotor of claim 3, wherein a ratio of a cross-sectional area of each of the copper bars to a cross-sectional area of each of the aluminum bars ranges from 1: (0.5-2).
5. The copper-aluminum composite rotor as claimed in claim 1, wherein the copper bars are provided with a plurality of slots at the periphery thereof, and the aluminum bars and/or the aluminum short circuit rings are provided with positioning protrusions which are positioned in cooperation with the slots.
6. The copper-aluminum composite rotor as claimed in claim 5, wherein each of the slots is opened at a position where both ends of the copper bar protrude from the iron core, and the positioning protrusion is provided on the aluminum short circuit ring.
7. The copper-aluminum composite rotor according to claim 1, wherein outer edges of both ends of the copper bar are provided with chamfers.
8. An aluminum casting mold for casting the aluminum conducting bars and the aluminum short circuit rings of the copper-aluminum composite rotor as claimed in any one of claims 1 to 7, comprising: positioning fixture, static mould and moving mould; the positioning jig includes:
the shaft core is inserted into the shaft hole of the iron core;
the first positioning die is sleeved outside the shaft core and is arranged at the first end part of the iron core, a plurality of first positioning grooves used for being matched and positioned with the outer convex parts at one end of each copper bar are formed in the first positioning die, and a first annular cavity used for communicating each slot and forming one aluminum short circuit ring is formed in the first positioning die;
the second positioning die is sleeved outside the shaft core and is arranged at the second end part of the iron core, and a plurality of second positioning grooves used for being matched and positioned with the outer convex parts at the other ends of the copper bars are formed in the second positioning die;
the second positioning die is accommodated in the static die, a second annular cavity for communicating the slots and forming another aluminum short circuit ring is defined between the second positioning die and the static die, and a pouring port communicated with the second annular cavity is formed in the static die;
the first positioning die is accommodated in the movable die, a cavity matched with the periphery of the iron core is formed in the movable die, and the movable die is provided with a first demolding ejection core which is connected through a spring and used for being abutted to the second positioning die in a matched mode and a second demolding ejection core which is connected through a spring and used for being abutted to the first positioning groove in a matched mode.
9. The cast aluminum mold of claim 8, wherein positioning pins are connected between the second positioning die and the stationary die and are distributed at intervals along the circumferential direction.
10. A manufacturing method of a copper-aluminum composite rotor is characterized by comprising the following steps:
laminating a plurality of rotor punching sheets into an iron core, and respectively inserting copper conducting bars into slots of the iron core;
inserting a shaft core into a shaft hole of an iron core, respectively inserting an outer convex part at one end of each copper conducting bar into each first positioning groove of a first positioning die, and respectively inserting an outer convex part at the other end of each copper conducting bar into each second positioning groove of a second positioning die, so as to respectively install the first positioning die and the second positioning die at two ends of the iron core, and forming a pre-assembly body;
when the movable die is in a die opening state relative to the static die, the preassembly body is installed in a cavity of the movable die;
after the movable mold is closed relative to the static mold, aluminum liquid is injected from a pouring gate of the static mold through pressure and flows into the first annular cavity, each slot and the second annular cavity respectively, so that the copper-aluminum composite rotor is formed;
and the movable die is opened relative to the static die, and the separation between the second positioning die and the copper-aluminum composite rotor, the separation between the first positioning die and the copper-aluminum composite rotor and the separation between the copper-aluminum composite rotor and the movable die are respectively realized through the first demolding top core and the second demolding top core.
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| CN115395554A (en) * | 2022-04-22 | 2022-11-25 | 深圳市金典电子科技有限公司 | Solar energy and commercial power complementary power generation system and control method |
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