Disclosure of Invention
The application provides a manufacturing method of a stator framework, which has few welding steps and can effectively improve the production efficiency of the stator framework.
The application provides a manufacturing method of a stator framework, which comprises the following steps:
102, manufacturing a bottom wall member and manufacturing a side wall member of an integrally formed structure by adopting an extrusion forming process, wherein the side wall member comprises an inner ring wall, a middle ring wall, an outer ring wall, M circumferentially spaced first partition walls, M circumferentially spaced second partition walls and N circumferentially spaced third partition walls, the inner ring wall, the middle ring wall and the M first partition walls construct M first regions which are sequentially arranged along the circumferential direction, the middle ring wall, the outer ring wall and the M second partition walls construct M second regions which are sequentially arranged along the circumferential direction, the M first regions correspond to the M second regions, the N third partition walls are arranged in the M second regions and divide the M second regions into P sub-regions which are sequentially arranged along the circumferential direction, the bottom wall member comprises a first through hole and P second through holes, the P second through holes are circumferentially arranged outside the first through holes in an enclosing manner;
Step 106, fixing the bottom wall member on the first side of the side wall member, wherein a shaft hole is formed inside the first through hole and the inner annular wall, P second through holes correspond to P sub-regions, and an annular wall is formed inside the corresponding sub-region by the hole wall of each second through hole;
wherein M is a positive integer not less than 2, N is a positive integer not less than M, and P is a positive integer not less than 2M.
In an exemplary embodiment, in step 102, an extrusion process is used to fabricate an aluminum alloy substrate into a sidewall member profile of an integrally formed structure, and the sidewall member is cut out from the sidewall member profile.
In an exemplary embodiment, the aluminum alloy substrate is a 3-series aluminum alloy substrate.
In an exemplary embodiment, in step 106, the bottom wall member and the side wall member are welded using a brazing process.
In an exemplary embodiment, the brazing process includes: forming a solder plating layer on the side wall member; assembling the side wall member and the bottom wall member together and within a brazing operation apparatus, the side wall member being above the bottom wall member; melting the solder plating on the side wall member in the heating zone of the brazing work apparatus, the melted and flowing solder filling the gap between the side wall member and the bottom wall member under gravity and capillary action; and cooling and solidifying the brazing filler metal filled in the gap between the side wall member and the bottom wall member in a cooling area of the brazing operation equipment to form a brazing layer.
In an exemplary embodiment, between the step 102 and the step 106, the manufacturing method further includes: 104, arranging first liquid passing holes at the positions corresponding to the sub-areas on the middle annular wall, and arranging second liquid passing holes at the positions corresponding to the sub-areas on the outer annular wall
In an exemplary embodiment, in the step 104, a plurality of positioning protrusions are formed at circumferential intervals on one end of the outer annular wall facing the first side of the side wall member by forming a plurality of notches at circumferential intervals, and a plurality of positioning holes are formed at circumferential intervals on the edge of the bottom wall member; in step 106, a plurality of positioning protrusions are inserted into the plurality of positioning holes.
In an exemplary embodiment, in the step 102, the sidewall member further includes M transition connection sections, M second partition walls are connected to the outer annular wall through M transition connection sections, and the thickness of the transition connection sections is greater than that of the second partition walls.
In an exemplary embodiment, in step 104, a threaded hole is formed in an end wall of the transition joint section facing the second side of the sidewall member.
In an exemplary embodiment, in step 102, the bottom wall member is formed using a stamping process and a shaping process.
In an exemplary embodiment, M is equal to N, P is equal to 2M, M first partition walls and M second partition walls are in one-to-one correspondence in a radial direction, and N third partition walls are arranged in M second regions in one-to-one correspondence.
Compared with the prior art, the manufacturing method of the stator framework has the advantages that the side wall component is of the integrally formed structure manufactured by adopting the extrusion forming process, the manufacturing process is simple, welding is not needed, the bottom wall component is fixed on the first side of the side wall component, and therefore the manufactured stator framework is simple in process and higher in production efficiency.
Additional features and advantages of the application will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the application. Other advantages of the present application may be realized and attained by the instrumentalities and combinations particularly pointed out in the specification and the drawings.
Drawings
The accompanying drawings are included to provide an understanding of the present disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the examples serve to explain the principles of the disclosure and not to limit the disclosure.
Fig. 1 is a schematic perspective view of a stator assembly according to an embodiment of the present invention;
FIG. 2 is an exploded view of the stator assembly of FIG. 1;
FIG. 3 is a schematic perspective view of the stator frame of FIG. 1;
FIG. 4 is an exploded view of the stator frame of FIG. 1;
FIG. 5 is a cross-sectional view of a portion of the bottom wall member and the side wall member of FIG. 1 prior to brazing;
FIG. 6 is a cross-sectional view of the bottom wall member and the side wall member of FIG. 1 after brazing;
fig. 7 is a schematic perspective view of a stator frame profile according to an embodiment of the present application;
fig. 8 is a flowchart of a method for manufacturing a stator frame according to an embodiment of the present application.
Wherein, the correspondence between the reference numbers and the part names in fig. 1 to 7 is:
10 stator frame, 100 bottom wall component, 110 first through hole, 120 second through hole, 121 annular wall, 130 positioning hole, 200 side wall component, 210 inner annular wall, 220 middle annular wall, 221 first liquid passing hole, 230 outer annular wall, 231 second liquid passing hole, 232 positioning protrusion, 240 first partition wall, 250 second partition wall, 260 third partition wall, 270 first region, 280 second region, 281 sub-region, 290 transition connecting section, 291 screw hole, 300 brazing filler metal coating, 400 brazing layer, 500 bracket component, 510 third through hole, 520 fourth through hole, 600 side wall component profile, 700 stator winding.
Detailed Description
The present embodiments are described herein, but are by way of illustration rather than limitation, and the objects, aspects and advantages of the present invention will become more apparent from the following detailed description of the embodiments of the invention when taken in conjunction with the accompanying drawings. It should be noted that the embodiments and features of the embodiments in the present application may be arbitrarily combined with each other without conflict.
The present application provides a method for manufacturing a stator frame 10, as shown in fig. 3 to 8, including:
102, manufacturing a bottom wall member 100 and manufacturing a side wall member 200 of an integrally formed structure by using an extrusion forming process, wherein the side wall member 200 comprises an inner ring wall 210, a middle ring wall 220, an outer ring wall 230, M first partition walls 240 spaced in the circumferential direction (namely the circumferential direction of the stator framework 10), M second partition walls 250 spaced in the circumferential direction and N third partition walls 260 spaced in the circumferential direction, the inner ring wall 210, the middle ring wall 220 and the M first partition walls 240 form M first areas 270 sequentially arranged in the circumferential direction, the middle ring wall 220, the outer ring wall 230 and the M second partition walls 250 form M second areas 280 sequentially arranged in the circumferential direction, the M first areas 270 correspond to the M second areas 280, the N third partition walls 260 are arranged in the M second areas 280 and divide the M second areas 280 into P sub-areas 281 sequentially arranged in the circumferential direction, the bottom wall member 100 comprises a first through hole 110 and P second through holes 120, the P second through holes 120 are circumferentially arranged around the first through hole 110;
Step 106, fixing the bottom wall member 100 on the first side of the side wall member 200, wherein the first through hole 110 and the inner annular wall 210 form a shaft hole, the P second through holes 120 correspond to the P sub-areas 281, and the hole wall of each second through hole 120 forms an annular wall 121 inside the corresponding sub-area 281;
wherein M is a positive integer not less than 2, N is a positive integer not less than M, and P is a positive integer not less than 2M.
According to the manufacturing method of the stator framework 10, the side wall component 200 is of an integrally formed structure manufactured through an extrusion forming process, the manufacturing process is simple, welding is not needed, the bottom wall component 100 is fixed to the first side of the side wall component 200, the number of parts in the manufacturing process of the stator framework 10 is reduced to two, meanwhile, welding work in the manufacturing process of the side wall component 200 is omitted, the production efficiency is greatly improved, the production cost is reduced, the manufactured stator framework 10 is simple in process, and the production efficiency is higher.
In an exemplary embodiment, the manufacturing method further includes: 104, forming first liquid passing holes 221 in positions, corresponding to the sub-areas 281, on the middle ring wall 220, and forming second liquid passing holes 231 in positions, corresponding to the sub-areas 281, on the outer ring wall 230;
As shown in fig. 3 and 4, each of the second regions 280 includes a plurality of sub-regions 281, a portion of the first liquid passing holes 221 of the sub-regions 281 is a liquid inlet hole, another portion of the first liquid passing holes is a liquid outlet hole, a portion of the second liquid passing holes 231 of the sub-regions 281 is a liquid inlet hole, another portion of the second liquid passing holes is a liquid outlet hole, and each of the sub-regions 281 has at least one liquid inlet hole and one liquid outlet hole, so as to ensure that there are serial flow paths in the sub-regions 281 of each of the second regions 280, so that adjacent regions can be connected in serial, and the cooling effect of the stator frame 10 using oil cooling is better.
In an exemplary embodiment, as shown in fig. 7, in step 102, an extrusion process is used to fabricate an aluminum alloy substrate (or other equivalent substrate) into a sidewall member profile 600 of an integrally formed structure, and the sidewall member 200 is cut out of the sidewall member profile 600.
The aluminum base material has good plasticity, and is more beneficial to extrusion forming to manufacture the side wall member section bar 600; in addition, the aluminum base material has good corrosion resistance and good welding performance, and the side wall member 200 and the bottom wall member 100 can be hermetically connected in a welding mode, so that the process is simple.
In one embodiment, the aluminum alloy substrate is a 3-series aluminum alloy substrate or other equivalent substrate.
In an exemplary embodiment, as shown in fig. 5 and 6, in step 106, the bottom wall member 100 and the side wall member 200 are welded using a brazing process.
The bottom wall component 100 and the side wall component 200 are welded by adopting a brazing process, and the process of directly melting a base material is not adopted for welding, compared with the process of melting the base material, the brazing process can reduce the deformation of the bottom wall component 100 and the side wall component 200 in the welding connection process, ensure that the size of the manufactured stator framework 10 is more accurate, and the advantage of the brazing process is more obvious for a complex thin-wall structure.
In one example, as shown in fig. 5 and 6, the brazing process includes: putting the side wall member 200 into an electroplating tank to plate a solder plating layer 300; then, the side wall member 200 is taken out, and the side wall member 200 and the bottom wall member 100 are assembled together by the tooling jig, and the assembled side wall member 200 and the bottom wall member 100 are placed in the brazing work equipment such that the side wall member 200 is above the bottom wall member 100:
the assembled side wall member 200 and bottom wall member 100 enter the heating zone of the brazing operation equipment, the brazing filler metal plating layer 300 on the side wall member 200 is melted in the heating zone of the brazing operation equipment, and the melted brazing filler metal flows under the action of gravity and capillary action to fill the gap between the side wall member 200 and the bottom wall member 100;
The assembled side wall component 200 and the bottom wall component 100 enter a cooling area of the brazing operation equipment, and the brazing filler metal filled in the gap between the side wall component 200 and the bottom wall component 100 is cooled and solidified in the cooling area of the brazing operation equipment to form a brazing layer 400, so that the side wall component 200 and the bottom wall component 100 are connected in a sealing and welding mode;
the assembled side wall member 200 and bottom wall member 100 are taken out of the brazing operation equipment, the tooling fixture is disassembled, and the stator frame 10 is inspected, that is, whether the dimensional parameters and the profile tolerance of the formed stator frame 10 meet the design requirements is inspected.
In an exemplary embodiment, as shown in fig. 4, in step 104, a plurality of positioning protrusions 232 are formed at intervals in the circumferential direction by forming a plurality of notches at an end of the outer annular wall 230 facing the first side of the side wall member 200 at intervals in the circumferential direction, and a plurality of positioning holes 130 are formed at intervals in the circumferential direction at the edge of the bottom wall member 100; in step 106, the plurality of positioning protrusions 232 are inserted into the plurality of positioning holes 130. During the soldering process, the melted solder will fill the gap between the positioning protrusion 232 and the positioning hole 130, and the formed soldering layer 400 will simultaneously seal the gap between the positioning protrusion 232 and the positioning hole 130.
The cut sidewall member 200 has a margin of no more than 10mm for subsequent machining of the positioning projections 232 and the like. The positioning protrusions 232 are inserted into the positioning holes 130 in a one-to-one correspondence manner, so as to position the relative positions of the side wall member 200 and the bottom wall member 100, and ensure that the position tolerances of the P second through holes 120 and the P sub-regions 281 are not changed after the side wall member 200 and the bottom wall member 100 are welded and connected in a sealing manner.
The plurality of positioning protrusions 232 and the plurality of positioning holes 130 can be arranged into 2 groups, 3 groups, 6 groups or 10 groups, etc., all of which can achieve the purpose of the present application, and the purpose of the present application does not depart from the design concept of the present invention, and therefore, the present application shall not be repeated herein, and all shall fall within the protection scope of the present application.
In an exemplary embodiment, as shown in fig. 3 and 4, in step 102, the sidewall member 200 further includes M transition connection sections 290, the M second partition walls 250 are connected with the outer annular wall 230 by the M transition connection sections 290, and the thickness of the transition connection sections 290 is greater than that of the second partition walls 250; in step 104, a threaded hole 291 is formed in an end wall of the transitional coupling segment 290 facing the second side of the sidewall member 200 (the threaded hole 291 faces away from the bottom wall member 100). The bracket member 500 comprises a third through hole 510 and P fourth through holes 520, a screw is screwed into the screw hole 291 through the bracket member 500 to assemble the bracket member 500 and the stator frame 10 together, the stator winding is located in the P sub-regions 281, and is fixed to the fourth through hole 520 on the bracket member 500 and the second through hole 120 on the bottom wall member 100 through sealing at both axial ends (in sealing fit with the annular wall 221 formed by the hole wall of the second through hole 120 and the annular wall formed by the hole wall of the fourth through hole 520) to form a stator assembly, and the shaft hole also comprises the third through hole 510. The fit tolerance between the hole wall of the second through hole 120 and the stator winding 700 and the fit tolerance between the hole wall of the fourth through hole 520 and the stator winding 700 are set to be 0.05-0.1 mm, and the stator winding 700 is in sealing fit with the support member 500 and the bottom wall member 100.
In an exemplary embodiment, the bottom wall member 100 is formed 102 using a stamping process and a swaging process, the stamping process including punch stripping and fine blanking of the profile. After the bottom wall member 100 is shaped to the contour by the shaping process, each positioning hole 130 is processed.
In one embodiment, as shown in fig. 3 and 4, M is equal to N, P is equal to 2M, M first partition walls 240 and M second partition walls 250 are in one-to-one correspondence in the radial direction (such that the first regions 270 and the second regions 280 are in one-to-one correspondence in the radial direction), and N third partition walls 260 are arranged in one-to-one correspondence in the M second regions 280.
M may be 2, 3, 4, 6, 8, or 10, etc., N may be a non-integer multiple of M, and the number of the third partition walls 260 in each second sub-region 281 is not completely the same, so that the purpose of the present application can be achieved. All fall within the scope of protection of the present application.
To sum up, the manufacturing method of the stator framework provided by the application has the advantages that the side wall component is of the integrally formed structure manufactured by adopting the extrusion forming process, the manufacturing process is simple, welding is not needed, the bottom wall component is fixed on the first side of the side wall component, the manufacturing process of the stator framework is simple, and the production efficiency is higher.
In the description of the present invention, it should be noted that the terms "upper", "lower", "one side", "the other side", "one end", "the other end", "side", "opposite", "four corners", "periphery", "mouth" structure ", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplification of the description, but do not indicate or imply that the structures referred to have specific orientations, are configured in specific orientations, and operations, and thus, are not to be construed as limiting the present invention.
In the description of the embodiments of the present invention, unless otherwise explicitly specified or limited, the terms "connected," "directly connected," "indirectly connected," "fixedly connected," "mounted," and "mounted" are to be construed broadly and may be, for example, fixedly connected, detachably connected, or integrally connected; the terms "mounted," "connected," and "fixedly connected" may refer to a direct connection, an indirect connection through intervening media, and a connection between two elements. The specific meanings of the above terms in the present invention can be understood in a specific case to those of ordinary skill in the art.
Although the embodiments of the present invention have been described above, the above description is only for the purpose of understanding the present invention, and is not intended to limit the present invention. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.