CN112350532A

CN112350532A - Production process of anti-fatigue V3 motor

Info

Publication number: CN112350532A
Application number: CN202011435453.9A
Authority: CN
Inventors: 唐辉; 宋新华; 汪风珍
Original assignee: Zhangjiajie Institute of Aeronautical Engineering
Current assignee: Zhangjiajie Institute of Aeronautical Engineering
Priority date: 2020-12-10
Filing date: 2020-12-10
Publication date: 2021-02-09
Anticipated expiration: 2040-12-10
Also published as: CN112350532B

Abstract

The fatigue-resistant V3 motor production process comprises the steps of controlling the thickness and the copper content of enameled wires in incoming products, visually observing the uniformity of four walls of a casting, detecting the inner diameter of a stator by a cross reading method, detecting the total length and the bearing position precision of a main shaft, and preventing equal angle distribution when end cover lugs are designed, controlling a hydraulic valve method by two hands during processing, adjusting the installation angle of a small sliding plate by 1-1.5 degrees, then screwing a handle of the small sliding plate to adjust the processing allowance, positioning a motor by the motor, positioning the front end and the rear end, and carrying out standardized operation of the whole process flow from raw material entering a factory to product leaving the factory, so that the buzzing sound and the vibration of the main shaft of the motor are reduced, the service life of the motor is prolonged, or the noise of the motor during operation is reduced, and the fatigue-resistant V3 motor production process can be used for high-grade household products, High-end machine tools provide high-performance motors, thereby also reducing environmental pollution.

Description

Production process of anti-fatigue V3 motor

Technical Field

The application belongs to motors, and particularly relates to a production process of an anti-fatigue V3 motor.

Background

The applicant searches with 'motor and anti-fatigue' and 'motor and anti-fatigue' without finding patent application or granted patent directly related to anti-fatigue in the motor manufacturing process, the rotation error of the motor on the market is between 0.05mm and 0.07mm through field measurement, the rotation error of the low-price motor of part of small factories is larger, the motor is taken as an important power device, the high-end product of the motor is monopolized by foreign manufacturers, on the aspect of the motor of medical equipment, household articles and household appliances, on one hand, the pursuit in silence is realized, on the other hand, part of the medical equipment is sensitive to rotating speed and vibration, the rotation error of the motor is required to be smaller and better for the products, the rotation error of the motor is related to various factors, resonance, assembly error, post-assembly treatment, sand-founding process, motor shape design and machining process, particularly, metal fatigue is easily caused by resonance, which is directly shown in that a motor spindle has buzzing sound, the spindle is in a hand feeling and jumps, the resonance causes assembly damage of the spindle and a bearing, so that the overall performance of the motor is rapidly reduced, the motor cannot be used, or the noise is high, the motor spindle and the bearing are jammed or loosened in serious cases, the motor is burnt, the resonance is often caused by various factors, the appearance design, the high-speed starting of load and poor assembly easily cause resonance, the process management and control of each link of product production are enhanced by improving the introduction channel of raw materials of the motor, the occurrence of resonance can be reduced, the metal fatigue is reduced, the effective service time of the motor is prolonged, or the noise generated during the operation of the motor is reduced, and the motor is more suitable for various high-end applications.

From the price, the price of a common 1.5KW single-phase alternating current motor or a three-phase alternating current motor is generally about 400 plus 500 yuan, the price of a V3 motor is more than thousand yuan, and manufacturers are few, however, the inventor has tried in a motor factory, and from the processing technology, the processing technology of the motor is different from that of the common motor, the high-end motor supports a frequency converter and also supports the use in a non-frequency converter environment, most of users developed by the high-end motor manufacturer are foreign clients, therefore, 220/380V three-phase alternating current or 380/660V three-phase alternating current is often synchronously supported, but the configurations are obviously not particularly suitable for domestic users, and the price of a final product is raised.

From the perspective of environmental protection, casting technology is needed in the production process of the motor, and the production of steel products is a high-energy-consumption industry, so that the service life of the product is prolonged, and the environmental pollution can be indirectly reduced.

Disclosure of Invention

The technical problems to be solved are as follows:

1) the factors of resonance caused by the appearance on the product design need to be solved, so that metal fatigue is prevented;

2) the factors causing resonance when the raw materials are introduced need to be solved, so that metal fatigue is prevented;

3) the problem of overall performance of a product after assembly needs to be solved, the rotation error is reduced as much as possible, and the larger the rotation error is, the more easily resonance is caused, and metal fatigue is caused;

4) the test method comprises the steps of parameter detection and delivery test after product assembly, including rotation error test, temperature rise test, noise ear test, power error test and the like.

The technical scheme is as follows:

the production process of the V3 motor comprises the following steps, and the numbering of the steps is irrelevant to the sequence in the production process:

1) measuring the diameter of the enameled wire: the diameter of the enameled wire needs to be measured by a micrometer with the measurement precision of 0.001 mm;

2) measuring the copper purity, namely measuring the resistance value of the enameled wire with a certain length by using a resistance measurement method under the condition of room temperature of 20 degrees, and when the resistance value is more than a certain value, indicating that the copper content of the enameled wire is insufficient;

3) detecting the casting, namely visually detecting the casting, wherein the four walls of the casting are uniformly used as a motor shell and a motor end cover of the V3 motor, and the rest of the casting are selected as the motor shell and the motor end cover of the common motor;

4) detecting the inner diameter of the stator, wherein an inner micrometer is adopted for detecting the inner diameter of the stator, a cross measurement method is adopted for measuring, the reading is carried out by adopting a cross reading method, the cross reading method means that a value taking point of two times of reading is close to 90 degrees, after one end of the inner micrometer is fixed, the other end of the inner micrometer moves slowly, the maximum value is read, the average value of the two times of reading is the inner diameter of the stator, the stator which cannot be used as a V3 motor is provided with the difference value of the two times of reading being more than 0.03mm, and the stator which cannot be used as a V3 motor is provided with the difference value of the two times of reading being more than plus or minus 0.03mm, and similarly, the two parameters of a V;

5) detecting a main shaft, wherein the main shaft is mainly used for detecting the total length and the bearing position, the error of the total length is not more than 2mm, and the bearing position needs to be more than 0.005mm-0.015mm of the inner diameter of a bearing;

6) detecting a rotor, namely detecting the outer diameter of a rotor feeding part without detecting the outer diameter, measuring the outer diameter of the rotor after the rotor is machined, and making a V3 motor when the outer diameter is within plus or minus 0.03mm of a standard value, wherein the rest is used as a common motor;

7) the ears of the end cover are arranged in an angle, the ears of the end cover are divided into three ears and four ears, and the ears 8 cannot be distributed at equal angles no matter the three-ear end cover or the four-ear end cover is adopted;

8) the size of the bearing position of the end cover is limited during processing, the bearing position is processed, the size of the bearing position is A-0.005mm to A-0.015mm, A is the outer diameter of an outer ring, and the bearing position refers to the position of the end cover where a bearing is installed;

9) after the rotor is machined, the rotor is placed on a detection table, a line is drawn on the end face of the rotor, the detection motor is used for driving the rotor to rotate, then a detection belt is loosened, after the motor stops rotating freely, the line drawing position is observed, after several detections and the line drawing position is uncertain, the unbalance parameter of the rotor meets the standard, after the rotor is calibrated, the unbalance phenomenon is changed at the cast aluminum parts at two ends through manual drilling, and the V3 motor needs to select a rotor with the calibrated hole depth smaller than 0.3mm and the calibrated hole not larger than one;

10) the bearing is selected, the motor is required to reach the V3 grade, the bearing utilizes manual detection, visual detection and sound detection, the balls and the inner and outer rings are not blocked when the bearing with good quality rotates, the inner and outer rings cannot have slight looseness when the inner and outer rings are shaken, after the bearing rotates, the visual detection and the manual detection pass, the sound detection is carried out, the bearing is placed at the ear, the bearing rotates and listens sound, and the motor of the V3 motor needs the rotor with uniform rotating speed and cannot have slight abnormal sound;

11) rolling to enhance surface hardness, rolling by using a hard alloy hob, grasping the force, adding rolling oil, rolling for 2-3 times, stopping rolling after a measurement result is within a tolerance range, and wiping off the rolling oil after rolling;

12) the hydraulic control valve is screwed up and loosened by two hands, one hand is used for holding the control valve, the other hand is used for slightly beating the wrist of the hand for holding the control valve, the force is well mastered, and the method is required to be adopted by a boring machine and a single-energy machine;

13) the lathe is used for processing high-precision parts, the central line of a small sliding plate and a main shaft of the lathe is adjusted to be an angle of 1-1.5 degrees, and a handle of the small sliding plate is screwed when precision machining is needed, so that the high-precision parts can be obtained;

14) the motor fan is characterized in that a small metal shockproof ball which is identical in mass and shape and is embedded into each fan blade is added at the front end of each fan blade of the motor fan;

15) after the assembly, after the motor is partially assembled, the post-treatment is carried out on a lathe, the post-treatment is carried out by adopting a fixture motor to position 2, a rear end to position 3 and a front end to position 5, the rear end to position 3 and the front end to position 5 have the same structure and are only different in installation position, the post-treatment is arranged at the turning front end of the rear end, so the post-treatment is called front end positioning, when the front end thimble 2 is machined by using a round steel, after the front end thimble 2 is clamped by using a three-jaw chuck, the thimble part is machined, the angle of the machined thimble is required to be 60 degrees and is the same as the angle of a central hole of a main shaft of the motor, after the machining is finished, the motor positioning 2, the front end positioning 5 and/or the rear end positioning 3 are/is/are installed into the position corresponding to the main shaft of the motor, the motor is hoisted onto the lathe, after parameters are, the front-end thimble 2 needs on-site turning before each processing, cannot be replaced by a purchased dead thimble, and cannot be used for multiple times.

The motor positioning comprises a threaded hole 21, a circular ring 22 and a stop lever A23, wherein the threaded hole 21 is arranged above the circular ring 22, and the stop lever A23 forms a 90-degree angle with the circular ring 22.

The front end positioning device 5 comprises a screw A51, a screw B52, a stop lever B53, a screw C55 and a positioning support 56, wherein the positioning support 56 is provided with a circular ring, a threaded hole is formed in the circular ring and used for mounting the screw A51, the positioning support 56 is provided with a moving groove, the moving groove is used for placing two screws C55, two screws C (55) are used for connecting the stop lever B53, the stop lever B53 is moved by loosening the two screws C55 so as to adapt to processing of motors with different sizes, and a threaded hole is formed in the stop lever B53 and used for mounting the screw B52.

Has the advantages that: the production process of the fatigue-resistant V3 motor reduces the buzzing sound and the vibration of the main shaft of the motor, prolongs the service life of the motor, or reduces the noise of the motor during operation by the standardized operation of the whole process flow from the raw material entering factory to the product leaving factory, and can provide a high-performance motor for high-grade household products, medical instruments and high-end machine tools, thereby reducing the environmental pollution.

Drawings

FIG. 1 is a schematic view of lathe turning at the time of post-processing;

FIG. 2 is a schematic view of a motor positioning structure;

FIG. 3 is a schematic view of a front or rear positioning structure;

FIG. 4 is a schematic view of a four-lug end cap construction;

FIG. 5 is a schematic view of a three-lug end cap construction;

figure 6 is a schematic view of a motor fan blade configuration,

in the figure, 1 is a three-jaw chuck, 2 is a motor positioning, 3 is a rear end positioning, 4 is a motor, 5 is a front end positioning, 6 is a tailstock thimble, 7 is a front end thimble, 8 is an ear, 9 is a metal vibration-proof ball, 21 is a screw hole, 22 is a ring, 23 is a stopper a, 51 is a screw a, 52 is a screw B, 53 is a stopper B, 54 is a moving groove, 55 is a screw C, and 56 is a positioning bracket.

Detailed Description

The applicant describes embodiments of the present application with reference to the accompanying drawings.

Feeding detection:

1. and (3) measuring the diameter of the enameled wire by using a micrometer with the measurement precision of 0.001 mm.

2. The copper purity of the enameled wire is measured, a factory cannot directly measure the copper purity of the enameled wire, a resistance measurement method is used, namely the resistance value of the enameled wire with a certain length is measured at the room temperature of 20 degrees, and when the resistance value is larger than a certain value, the copper content of the enameled wire is not enough.

3. The detection of the casting is generally visual inspection, the motor shell and the motor end cover which are used as the V3 motor are uniformly arranged on four walls, and the motor shell and the motor end cover which are left to be used as the common motor are selected.

4. The inner diameter of the stator is detected by an inner diameter micrometer, it should be noted that, because the inner diameter of the stator is 0.5mm larger than the outer diameter of the rotor, the requirement of a common motor on the parameters is not strict, however, the V3 motor needs to be limited within plus or minus 0.02mm of standard parameters, and the cross reading method is adopted for reading, wherein the cross reading method means that the value taking points of two times of reading are close to 90 degrees, after one end of the inner diameter micrometer is fixed, the other end moves slowly, the maximum value is read, the average value of the two times of reading is the inner diameter of the stator, the difference value of the two times of reading exceeds 0.03mm and cannot be used as the stator of the V3 motor, the roundness of the stator proves that the inner diameter does not reach the standard, for example, the inner diameter of the stator of a certain type of motor is 100mm plus or minus 0, however, the V3 motor needs to be strictly executed to 0.03mm, that is, two tests with 99.97mm and 99.98mm are qualified, and 100.02mm and 99.98mm are not qualified.

5. The main shaft detection mainly detects the total length and the bearing position, the error of the total length is not more than 2mm, the bearing position needs to be larger than 0.005mm-0.015mm of the inner diameter of the bearing, for example, a 6206 bearing is adopted by a motor, the diameter of the bearing position is 30.005mm-30.015mm, the diameter of the bearing position is too small, the bearing position is easy to loosen, a series of problems are caused, the diameter of the bearing position is too large, the friction force between the inner ring and the outer ring of the bearing and a ball is increased sharply, the bearing is easy to heat and wear, the service life of the bearing is short, and the main shaft vibration is easy to cause during high-speed rotation.

6. In the detection of the rotor, a machining allowance of 0.2-0.5mm is reserved for the rotor, so the rotor is not detected generally, but the difference of the actual machining allowance of the rotor is relatively large, for a common motor, the maximum allowable error value of the rotor is allowed to be 0.1mm, the error value required by a V3 motor is within 0.03mm, after the rotor is machined, the outer diameter of the rotor is measured, the rotor is used as the V3 motor within plus or minus 0.03mm of a standard value, and the rest is used as the common motor.

The lugs of the end cover are arranged in an angle mode, the lugs of the end cover are divided into three lugs and four lugs, no matter the three lugs and the four lugs are used for the end cover, the three lugs or the four lugs are not distributed in an equal angle mode, for the four lug end cover, on one hand, resonance is prevented after assembly of a product, on the other hand, machining is facilitated, as the four lug end cover is machined through a lathe, machining is convenient through a three-jaw chuck, when the three-jaw chuck is machined, the four lug end cover in an equal angle mode is difficult to clamp, on the other hand, resonance is prevented after assembly of the product, and as the lugs are distributed in an equal angle mode, resonance is easy to cause, particularly, when the end cover runs at a high speed, metal fatigue is easy to cause due to resonance, or fatigue is.

The size of the bearing position of the end cover is limited during processing, the bearing position is processed, the size is between A-0.005mm and A-0.015mm, A is the outer diameter of the outer ring,

the calibration of the rotor is selected, after the rotor is machined, the rotor is placed on a detection table, a line is drawn on the end face of the rotor, the rotor is driven to rotate by a detection motor, then a detection belt is loosened, after the motor stops rotating freely, the line drawing position is observed, after several detections, the line drawing position is uncertain, the rotor is in a heavier state, otherwise, the rotor is heavier, the overweight refers to that a certain rotor is heavier, the generation reason is that a hollow groove is generated during aluminum casting or the sizes of aluminum casting grooves are different, after the general rotor is calibrated, the overweight phenomenon needs to be changed on the aluminum casting parts at two ends through manual drilling, the V3 motor needs to select a rotor with shallow calibration holes after calibration and the calibration holes cannot be more than one rotor, otherwise, the final detection is difficult to pass.

The selection of bearing, the motor is to reach V3 grade, the selection of bearing is an important ring, the bearing utilizes manual detection, ball and interior outer lane do not have the stuck phenomenon when the bearing of high quality is rotatory, when interior outer lane is rocked, can not have slight pine sensation, after rotating, place at the ear limit, the rotational speed is even, the bearing is in the transportation, all probably cause the damage in the installation, can not use, the V3 motor requires very badly to the detection of bearing, except limiting the brand, still detect at any time in the installation, the unqualified product of bearing roughly will account for half, the unqualified product of bearing just can only use as ordinary motor.

The hydraulic control valve is screwed and unscrewed, the strength is difficult to control when the hydraulic control valve is screwed and unscrewed by one hand, the control valve is held by one hand, the wrist of the hand holding the control valve is slightly beaten by the other hand, the strength is well controlled, a boring machine and a single-function machine can process high-precision parts by adopting the method.

The lathe is used for processing high-precision parts, the central line of a small sliding plate and a main shaft of the lathe is adjusted to be at an angle of 1-1.5 degrees, and the handle of the small sliding plate is screwed when precision machining is needed, so that the high-precision parts can be obtained.

The rolling enhances the surface hardness, a certain bearing position is 30.024mm after measurement and exceeds the upper limit of the bearing position of 30.015mm, and the bearing position is directly used as an unqualified product, so that the rolling is carried out by using a hard alloy hob, the strength is mastered, rolling oil is added, the rolling is carried out for 2-3 times, and the measurement result is about 30.010. After rolling, rolling oil is wiped off, otherwise, the bearing and the main shaft are easy to slip after installation, and the product is damaged.

The anti-vibration motor fan has the advantages that the anti-vibration motor fan is provided with a small thickened area at the front end of the dragonfly wing, so that the dragonfly wing is prevented from vibrating in the flying process through the small thickened area, and the improved airplane does not have the problem in the aspect, therefore, a small metal shockproof ball is added at the front end of the fan blade of the motor fan, the fan blade of the motor fan is prevented from vibrating in high-speed operation, the main shaft is easy to vibrate after the vibration occurs, the noise is too large, and the anti-vibration motor fan does not accord with the relevant standard of a V3 motor.

After assembly, after the motor is assembled, the post-processing is carried out by adopting a clamp motor positioning 2, a rear end clamp 3 and a front end clamp 5, it needs to be noted that the rear end positioning 3 and the front end positioning 5 have the same structure and are only different in installation position, and are installed at the turning front end of the rear end, so the front end positioning is called, only the step is carried out, namely, the subsequent connection and installation with a load are carried out, namely, the accuracy of connecting the load is improved, the motor positioning comprises a threaded hole 21, a circular ring 22 and a stop lever A23, the threaded hole 21 is arranged on the circular ring 22, the stop lever A23 and the circular ring 22 form a 90 degree angle, before turning, the circular ring 22 is sleeved on a motor spindle, a screw rod is inserted into the threaded hole 21, the screw rod is abutted against a pin groove of the motor spindle, and the stop lever A23 is installed towards a three-jaw chuck position and drives the motor to be positioned and rotated, the motor positioning drives the motor spindle to rotate, the front end positioning 5 comprises a screw A51, a screw B52, a stop lever B53, a screw C55 and a positioning support 56, the positioning support 56 is provided with a circular ring, a threaded hole is formed in the circular ring and used for installing the screw A51, the positioning support 56 is provided with a moving groove which is used for placing two screws C55, two screws C55 are used for connecting the stop lever B53, the stop lever B53 is moved by loosening the two screws C55 so as to adapt to the processing of motors with different sizes, the stop lever B53 is provided with a threaded hole and used for installing the screw B52, the motor is provided with a plurality of grooves by screwing the screw B52 to a motor shell, the stop lever B53 and the motor shell are connected together to rotate, a front end thimble is clamped by a three-jaw chuck firstly, then a front end thimble is processed, note that the front end thimble needs to be made of 45# steel, and the angle is ensured to be 30 degrees during processing, namely the thimble angle is 60 degrees, after the machining is finished, a dead thimble is installed on the tailstock, the motor to be machined is installed on a lathe, the lathe is adjusted, the motor is positioned, the front end of the motor is positioned, the rear end of the motor is positioned and adjusted, the motor main shaft and the three-jaw chuck are positioned in the motor positioning mode, when the three-jaw chuck rotates, the main shaft synchronously rotates, and the machining is started.

After the completion of the processing, the motor fan and the fan cover are mounted and then packaged, and these operations are not related to the V3 motor and are only briefly described.

Claims

1. A production process of an anti-fatigue V3 motor is characterized by comprising the following steps:

7) the ears of the end cover are arranged in an angle mode, the ears of the end cover are divided into three ears and four ears, and the ears (8) cannot be distributed at equal angles no matter the three-ear end cover or the four-ear end cover is adopted;

14) the motor fan is characterized in that a small metal shockproof ball (9) which is identical in mass and shape and is embedded into each fan blade is added at the front end of each fan blade of the motor fan;

15) after the assembly, after the motor is partially assembled, after the post-treatment is carried out on a lathe, the post-treatment adopts clamp motor positioning (2), rear end positioning (3), front end positioning (5) and rear end positioning (3), the structure of the front end positioning (5) is the same, only the mounting positions are different, the front end is arranged at the turning front end of the rear end, so the front end positioning is called, during the processing, a round steel is used as a front end thimble (2), after the front end thimble (2) is clamped by a three-jaw chuck, the thimble part is processed, the angle of the processed thimble is required to be 60 degrees and is the same as the angle of a central hole of a motor main shaft, after the processing is finished, the motor positioning (2), the front end positioning (5) and/or the rear end positioning (3) are/is arranged in the position corresponding to the motor main shaft, the motor is hoisted to the lathe, after the parameters are, the end cover of the motor is machined, after machining is finished, the accuracy and the roundness of a machined part can meet the standard, the front-end ejector pin (2) needs to be turned on site before machining every time, and cannot be replaced by a purchased dead ejector pin or used for multiple times.

2. The process for producing a fatigue-resistant V3 motor according to claim 1, wherein:

the motor positioning device is characterized in that the motor positioning device comprises a threaded hole (21), a circular ring (22) and a stop lever A (23), the threaded hole (21) is arranged on the circular ring (22), and the stop lever A (23) and the circular ring (22) form an angle of 90 degrees.

3. The process for producing a fatigue-resistant V3 motor according to claim 1, wherein:

front end location (5) by screw rod A (51), screw rod B (52), pin B (53), screw rod C (55), locating support (56) are constituteed, locating support (56) have the ring, threaded hole is used for installing screw rod A (51) on the ring, locating support (56) have the shifting chute, two screw rod C (55) are put into to the shifting chute, two screw rod C (55) are used for connecting pin B (53), through loosening two screw rod C (55), thereby move pin B (53), in order to adapt to the processing of the not motor of equidimension, threaded hole is gone up in pin B (53), be used for installing screw rod B (52).