CN116404827A - Integrated forming process of split rotor core - Google Patents
Integrated forming process of split rotor core Download PDFInfo
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- CN116404827A CN116404827A CN202310381365.2A CN202310381365A CN116404827A CN 116404827 A CN116404827 A CN 116404827A CN 202310381365 A CN202310381365 A CN 202310381365A CN 116404827 A CN116404827 A CN 116404827A
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- 238000000034 method Methods 0.000 title claims abstract description 55
- 230000008569 process Effects 0.000 title claims abstract description 44
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 140
- 239000000853 adhesive Substances 0.000 claims abstract description 92
- 230000001070 adhesive effect Effects 0.000 claims abstract description 92
- 229910000976 Electrical steel Inorganic materials 0.000 claims abstract description 43
- 238000010030 laminating Methods 0.000 claims abstract description 31
- 238000004519 manufacturing process Methods 0.000 claims abstract description 26
- 230000007246 mechanism Effects 0.000 claims abstract description 10
- 238000013461 design Methods 0.000 claims abstract description 9
- 239000003054 catalyst Substances 0.000 claims abstract description 7
- 238000002474 experimental method Methods 0.000 claims abstract description 4
- 238000005507 spraying Methods 0.000 claims description 124
- 238000001514 detection method Methods 0.000 claims description 55
- 239000003292 glue Substances 0.000 claims description 51
- 239000003795 chemical substances by application Substances 0.000 claims description 16
- 230000002950 deficient Effects 0.000 claims description 14
- 238000000465 moulding Methods 0.000 claims description 12
- 238000003825 pressing Methods 0.000 claims description 12
- 238000003475 lamination Methods 0.000 claims description 10
- 238000011084 recovery Methods 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 9
- 238000007711 solidification Methods 0.000 claims description 9
- 230000008023 solidification Effects 0.000 claims description 9
- 230000000694 effects Effects 0.000 claims description 7
- 238000012423 maintenance Methods 0.000 claims description 7
- 238000012544 monitoring process Methods 0.000 claims description 7
- 230000009471 action Effects 0.000 claims description 6
- 238000012858 packaging process Methods 0.000 claims description 6
- 238000005516 engineering process Methods 0.000 claims description 5
- 238000005070 sampling Methods 0.000 claims description 5
- 239000012790 adhesive layer Substances 0.000 claims description 3
- 238000006555 catalytic reaction Methods 0.000 claims description 3
- 230000007547 defect Effects 0.000 claims description 3
- 239000007921 spray Substances 0.000 claims description 3
- 238000010330 laser marking Methods 0.000 claims description 2
- 238000012797 qualification Methods 0.000 claims description 2
- 238000004080 punching Methods 0.000 description 7
- 229910052742 iron Inorganic materials 0.000 description 5
- 230000002349 favourable effect Effects 0.000 description 3
- 230000004907 flux Effects 0.000 description 3
- 239000010410 layer Substances 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 238000005457 optimization Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000001737 promoting effect Effects 0.000 description 2
- 238000005303 weighing Methods 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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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
-
- 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
-
- 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
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The invention relates to the field of integrated forming of rotor cores, and discloses an integrated forming process of split rotor cores, which comprises the following forming steps: s1, firstly, manufacturing a proper stamping die according to a predesigned rotor iron core shape, mounting the stamping die after the experiment is qualified on a machine, then preparing a silicon steel sheet blank with proper size, stamping the silicon steel sheet into an iron core blank through a stamping machine, wherein the die adopts a blanking and laminating integrated design, blanking and laminating are simultaneously carried out, a laminating process adopts a mechanically-automatic rotary laminating mechanism, the silicon steel blank is conveyed to the middle of a stamping die for blanking, and an adhesive catalyst are sprayed on the surface of the blank. According to the split type rotor core integrated forming process, the die is designed in a blanking and laminating integrated mode, blanking and laminating are carried out simultaneously, and a mechanical automatic rotary laminating mechanism is adopted in the laminating process, so that the production efficiency of the core is improved, and the manufacturing cost is saved.
Description
Technical Field
The invention relates to the field of integrated forming of rotor cores, in particular to an integrated forming process of split rotor cores.
Background
The rotor and the stator are the most important two structures in the motor; the rotor generally comprises a rotor core and rotor windings, wherein the rotor core is formed by laminating rotor silicon steel sheets, and the rotor windings are arranged on the rotor core; however, the rotor silicon steel sheets are laminated and then are required to be fixed to form a complete rotor iron core, and the lamination uniformity of the rotor silicon steel sheets and the fixation firmness of the rotor silicon steel sheets can influence the overall performance of the rotor, so that the simple lamination fixation is not suitable for motors with higher requirements on use scenes, the stability is poor, vibration is large when the motor is used, noise is high, gaps are formed between the silicon steel sheets, the motor is fixed only by two ends, the connection strength is low, the motor is safe when in use, the defective rate is high when in production, the loss cost is high, and mass production of production enterprises is not facilitated.
Disclosure of Invention
The invention mainly aims to provide an integrated forming process of a split rotor core, which can effectively solve the problems in the background technology.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
an integrated forming process of a split rotor core comprises the following forming steps:
s1, firstly, manufacturing a proper stamping die according to a predesigned rotor core shape, mounting the stamping die subjected to experiment qualification on a machine, preparing a silicon steel sheet blank with proper size, stamping the silicon steel sheet into a core blank through a stamping machine, adopting a blanking and laminating integrated design for the die, carrying out blanking and laminating simultaneously, adopting a mechanical automatic rotary laminating mechanism for the laminating process, conveying the silicon steel blank to the middle of a stamping die for blanking, spraying an adhesive and a bonding catalyst on the surface of the blank, enabling the adhesive to be quickly solidified through contact between the catalyst and the adhesive, forming a rotor core, stopping spraying the adhesive after the number of the rotor core reaches a preset number, and transporting the rotor core from the stamping die one by one through a transporting device;
s2, spraying adhesive on the inner wall of a central hole and the surface with a groove body structure after blanking a sheet of the rotor core, adopting a glue spraying bonding mode between the silicon steel sheet and the silicon steel sheet, arranging an accelerator spraying station outside a die, spraying a quick curing accelerator on the blank from an accelerator spraying port before the blank enters a blanking die through a transported wheel, and arranging a rotor core spraying station in the die;
s3, spraying points of the quick curing accelerator are uniformly distributed in a round shape, spraying stations of the quick curing accelerator can be arranged at any position before a rotor core adhesive spraying station, the quick curing of the adhesive can be guaranteed by reasonably selecting the spraying stations according to the design requirement of a die, the spraying stations of the adhesive in a blanking die are generally arranged at the previous station of blanking, the spraying ports adopt an integral structure with a plurality of adhesive spraying channels, and the adhesive is sprayed to all the adhesive points on a sheet under the action of applied pressure;
s4, the bonding glue spraying modes of the rotor iron core and the stator iron core can be divided into 2 modes of inner ring spraying and outer ring spraying, each adhesive spraying mode comprises a plurality of glue spraying points, the specific glue spraying point number is determined according to the groove-shaped number of the iron core, the glue spraying points are reasonably arranged, the glue spraying area on the iron core is ensured to be sufficient, meanwhile, glue overflow during lamination is avoided, 2 modes of an inner spraying ring and an outer spraying ring are arranged at a quick curing agent spraying station, each curing agent spraying mode also comprises a plurality of spraying points, the number of quick curing accelerator spraying points and the number of adhesive spraying points can be equal, the positions are in a corresponding relation, all quick curing accelerator points sprayed are in full contact and are fully mixed when all adhesive points sprayed are laminated, and quick curing of the adhesive is realized;
s5, taking the outer edge of a blanked rotor groove body as the appearance characteristic of a blanked rotor iron core sheet, blanking the rotor iron core into a guide channel through blanking the outer contour of the rotor, fixing the rotor iron core with the previously blanked rotor iron core to form an iron core finished product, forming a round hole site on a strip, taking the round hole site as a preformed hole of the blanked stator iron core sheet in the blanking process, fully mixing and solidifying a quick solidification promoter among sheets with an adhesive to realize tight combination among iron core sheets, and in the blanking process, enabling each iron core sheet in the channel to be mutually adhered more firmly through downward stamping force and upward lifting action of a supporting hydraulic cylinder at the bottom of the iron core blanking guide channel to form a semi-finished iron core strip;
s6, after the strip pressing is finished, taking the manufactured semi-finished iron core out of the equipment through a mechanical arm, vertically placing the semi-finished iron core on a conveyor belt, transferring the semi-finished rotor iron core to a dimension detection procedure through the conveyor belt, measuring the height diameter and the inner diameter of a shaft hole of the rotor iron core through an infrared laser detector, uploading monitoring data to a main control chip for data comparison, transferring the rotor iron core to an industrial detection camera for image comparison detection after the detection data are qualified, monitoring whether the semi-finished iron core has a shape defect through an image comparison technology, and if the dimension detection and the shape detection are all passed, continuing to work through the conveyor belt, and transferring the rotor iron core to a next rotor shaft entering procedure;
s7, when the semi-finished rotor core is conveyed to the front of the rotor shaft inserting machine through the conveying belt, the rotor core can be clamped through the mechanical arm, the rotor core is vertically placed below the shaft inserting opening, the rotor rotating shaft can be inserted into the shaft hole in the middle of the rotor core through the rotor shaft inserting machine, after the rotor shaft inserting machine finishes the shaft inserting of the rotor core, the mechanical arm transfers the rotor core to the rotating shaft positioning machine, the iron core is placed on the positioning table through the mechanical arm, then the hydraulic rods on the upper portion and the lower portion of the iron core are synchronously started, the rotating shaft is positioned through centering clamping, after the rotating shaft positioning is finished, the fixing rings are sleeved on two sides of the rotating shaft through the small mechanical arm, quick adhesive is smeared on one side close to the fixing rings, then the fixing rings are pressurized through the pressurizing sleeves on two sides, after the quick adhesive is solidified, the complete fixation of the iron core and the rotating shaft can be completed through the fixing rings, and after the rotor shaft inserting is completed, the rotor core is conveyed to a manual detection and packaging process through the mechanical arm and the conveying belt.
Preferably, the quick curing accelerator and the glue spraying mechanism in the step S3 should have the functions of timely glue delivery, accurate glue delivery, adjustable glue delivery quantity and glue delivery speed, and complete the on-off of glue delivery, and in addition, various factors such as economical efficiency and manufacturability of manufacture should be considered.
Preferably, in the step S6, if the rotor core does not pass through the detection procedure, the rotor core is taken down by the mechanical arm and placed into the feed-back box, the recovery detection is waited for manually, if the detection can be carried out, the maintenance is carried out, the step S6 is put into the process again, and if the detection does not have the maintenance condition, the rotor core is split and recovered.
Preferably, in the step S7, after the rotor core enters the manual detection and packaging process, a worker performs random sampling detection (10 samples are randomly extracted from every 100 cores for detection) on each batch of cores, packages and stores the batch of rotor cores after no defective products are detected, and performs all detection on the batch of cores if defective products (less than 2 samples) occur in the sampling detection; if more defective products (more than or equal to 3) are detected, all the rotor cores in the batch and the front and back three batches are detected.
Preferably, in the step S2, the glue spraying position of the accelerator spraying station is located below the blank, so that the male die does not need to be unset, when the blank reaches the adhesive spraying station, the adhesive spraying opening sprays adhesive at a specific position of the blanking sheet, and the quick curing accelerator is sprayed on the blank to utilize the catalysis effect of the quick curing accelerator on the adhesive, so that the effect of quick curing of the adhesive structure is obtained, and the efficiency of the finished product of the iron core is improved.
Preferably, in the step S5, since the thickness of the iron core is increased when each piece of blanking sheet is blanked, in order to make the strip material smoothly transported to the next station in the blanking process, the back pressure exists on the supporting hydraulic cylinder, and when each piece of blanking sheet is blanked, the hydraulic cylinder correspondingly descends by the distance of the thickness of one piece of iron core, so that the pressing force of bonding each time is unchanged.
Preferably, in the step S4, the glue spraying amount of each adhesive spraying station needs to be determined by punching the size of the sheet, and in order to obtain the iron core structure with reliable adhesion, the diameter of the glue drop is generally smaller than 1 mm, and the inner spraying and the outer spraying modes are both feasible, and specifically need to be selected according to actual requirements.
Preferably, in the step S5, after the silicon steel sheet is discharged, when the stacking is waiting for pressing, the height of the strip to be pressed is detected by an infrared laser detector, if the height is too high, a corresponding number of silicon steel sheets are taken down, if the height is too low, a corresponding number of silicon steel sheets are added, after the height reaches the standard, the silicon steel sheet strip is weighted by a weight measuring instrument, whether the weight reaches the specified weight is detected, if the weight reaches the specified weight, the pressing is continued, and if the weight does not reach or exceed the specified weight, the strip is marked by laser after the pressing.
Preferably, after the laser marked rotor core enters step S7, the marked rotor core may be identified by an industrial inspection camera in the inspection process, and removed by a mechanical arm, and placed in a recovery box for waiting for recovery.
Preferably, in the step S2, the thickness of the glue layer between the silicon steel sheets is not more than 0.003mm.
Compared with the prior art, the invention has the following beneficial effects:
1. the punching and laminating integrated design is adopted through the die, the punching and laminating are carried out simultaneously, the laminating process adopts a mechanical automatic rotary laminating mechanism, the production efficiency of the iron core is improved, the manufacturing cost is saved, and when the punching sheet is formed, adhesive is sprayed on the inner wall of the central shaft hole of the rotor iron core and the surface of the rotor iron core with a groove body structure, the silicon steel sheet and the silicon steel sheet are bonded by adopting a bonding mode of spraying glue, compared with the traditional welding and riveting connection mode, the efficiency of a motor finished product can be improved by connecting the motor iron core through the bonding mode, the generated noise, vibration and acoustic vibration roughness are small, the integral bonding strength of the rotor iron core is high, the durability is better, the iron loss is reduced, the magnetic flux density is increased, meanwhile, the integrated forming of iron core strip materials can be realized, and the process time cost is greatly reduced.
2. The quantity of the spraying points of the quick curing accelerator and the quantity of the spraying points of the adhesive are changed, so that all sprayed points of the quick curing accelerator and all sprayed points of the adhesive are completely contacted and fully mixed when the sprayed points of the adhesive are overlapped, the quick curing of the adhesive is realized, or redundant points of the adhesive are not combined with the quick curing accelerator and are directly contacted with the iron core blanking sheet, the adhesive which is not combined with the quick curing accelerator is cured under the natural condition after blanking, overlapping and discharging of the stamping sheet, the quick curing and the natural curing of the curing agent are realized under the room temperature condition, the curing connection strength between each iron core sheet layer is effectively increased, the integral structural strength of the iron core is improved, and the reliable guarantee is provided for the motor iron core when the motor iron core is used.
3. Through setting up multichannel detection process and can all monitor at every step of rotor core preparation, can find out the problem reason in the first time that goes wrong to can effectively reduce further loss, be favorable to rotor core preparation technology's optimization work, promote market competition, the mass production of convenient production type enterprise, in time retrieve the defective article of detecting simultaneously can effectively stop the damage, avoid the defective article further to flow down, be favorable to promoting rotor core's final yield.
Drawings
Fig. 1 is a process flow diagram of an integrated molding process of a split rotor core according to the present invention.
Detailed Description
The invention is further described in connection with the following detailed description, in order to make the technical means, the creation characteristics, the achievement of the purpose and the effect of the invention easy to understand.
As shown in fig. 1, an integrated molding process of a split rotor core includes the following molding steps:
s1, firstly, a proper stamping die is manufactured according to the shape of a rotor iron core designed in advance, the stamping die after the experiment is qualified is mounted on a machine, then a silicon steel sheet blank with proper size is prepared, the silicon steel sheet is stamped into an iron core blank through a stamping machine, the die is in a blanking and laminating integrated design, blanking and laminating are carried out simultaneously, a mechanical automatic rotary laminating mechanism is adopted in the laminating process, the production efficiency of the iron core is improved, the manufacturing cost is saved, the silicon steel blank is conveyed to the middle of a stamping die for blanking, an adhesive and an adhesive catalyst are sprayed on the surface of the blank, the adhesive is quickly solidified through contact of the catalyst and the adhesive, the rotor iron core is formed, the adhesive spraying is stopped after the number of the rotor iron core reaches the preset number, and the rotor iron core is transported out from the stamping die one by one through a transportation device;
s2, after the rotor iron core blanking sheet is formed, adhesive needs to be sprayed on the inner wall of a central hole and the surface with a groove body structure, compared with the traditional welding and riveting connection mode, the efficiency of a motor finished product can be improved by connecting a motor iron core through the adhesive bonding mode, the generated noise, vibration and acoustic vibration roughness are small, the overall bonding strength of the rotor iron core is high, the durability is better, the iron loss is reduced, the magnetic flux density is increased, an accelerator spraying station is arranged outside a die, a quick curing accelerator is sprayed on a blank from an accelerator spraying port before the blank enters a blanking die through a transported wheel, and the rotor iron core spraying station is arranged in the die;
s3, spraying points of the quick curing accelerator are uniformly distributed in a round shape, spraying stations can be arranged at any position before a rotor core adhesive spraying station, the spraying stations are reasonably selected according to the design requirement of a die, the quick curing of the adhesive can be realized, the spraying stations of the adhesive in a blanking die are generally arranged at the previous station of blanking and blanking, the positions are the best spraying stations for the lamination and fixation of blanking sheets through multiple tests, waste caused by the fact that the adhesive is cured and failed in advance in the blanking process can be effectively avoided, the higher the requirement of the premature spraying adhesive on the environmental temperature is, the manufacturing cost is increased, the whole structure with a plurality of adhesive spraying channels is adopted for the spraying ports, the adhesive is sprayed on each adhesive point on the sheet under the action of the applied pressure, the production efficiency can be effectively improved, and the production period can be shortened;
s4, the bonding glue spraying mode of the rotor iron core and the stator iron core can be divided into 2 modes of inner ring spraying and outer ring spraying, each adhesive spraying mode comprises a plurality of glue spraying points, the specific glue spraying point number is determined according to the groove-shaped number of the iron core, the glue spraying points are reasonably arranged, the glue spraying area on the iron core is ensured to be sufficient, meanwhile, glue overflowing during lamination is avoided, an inner spraying ring and an outer spraying ring 2 mode are arranged at a quick curing agent spraying station, each curing agent spraying mode also comprises a plurality of spraying points, the number of the quick curing agent spraying points and the number of the adhesive spraying points can be equal, the positions are in a corresponding relation, all the sprayed quick curing agent points are fully contacted and fully mixed when laminated, the quick curing of the adhesive is realized, the quantity of the glue spraying points can be more than that of the quick curing agent spraying points, the redundant adhesive points are not combined with the quick curing agent, but are directly contacted with the iron core, the quick curing agent blanking agent is not combined with the iron core, the adhesive blanking agent is enabled to be reliably contacted with the iron core, the adhesive blanking agent is enabled to be cured under the conditions of natural lamination, the natural curing condition is realized, and the strength of the iron core is improved, and the strength is naturally cured when the iron core is laminated, and the strength is naturally cured;
s5, taking the outer edge of a blanked rotor groove body as the appearance characteristic of a blanked rotor iron core sheet, blanking the rotor iron core into a guide channel through blanking the outer contour of the rotor, fixing the rotor iron core with the previously blanked rotor iron core to form an iron core finished product, forming a round hole site on a strip, taking the round hole site as a preformed hole of the blanked stator iron core sheet in the blanking process, fully mixing and solidifying a quick solidification promoter among sheets with an adhesive to realize tight combination among iron core sheets, and in the blanking process, enabling each iron core sheet in the channel to be mutually adhered more firmly through downward stamping force and upward lifting action of a supporting hydraulic cylinder at the bottom of the iron core blanking guide channel to form a semi-finished iron core strip;
s6, after the strip pressing is finished, taking the manufactured semi-finished iron core out of the equipment through a mechanical arm, vertically placing the semi-finished iron core on a conveyor belt, transferring the semi-finished rotor iron core to a dimension detection procedure through the conveyor belt, measuring the height diameter and the inner diameter of a shaft hole of the rotor iron core through an infrared laser detector, uploading monitoring data to a main control chip for data comparison, transferring the rotor iron core to an industrial detection camera for image comparison detection after the detection data are qualified, monitoring whether the semi-finished iron core has a shape defect through an image comparison technology, and if the dimension detection and the shape detection are all passed, continuing to work through the conveyor belt, and transferring the rotor iron core to a next rotor shaft entering procedure;
s7, when the semi-finished rotor core is conveyed to the front of the rotor shaft inserting machine through the conveying belt, the rotor core can be clamped through the mechanical arm, the rotor core is vertically placed below the shaft inserting opening, the rotor rotating shaft can be inserted into the shaft hole in the middle of the rotor core through the rotor shaft inserting machine, after the rotor shaft inserting machine finishes the shaft inserting of the rotor core, the mechanical arm transfers the rotor core to the rotating shaft positioning machine, the iron core is placed on the positioning table through the mechanical arm, then the hydraulic rods on the upper portion and the lower portion of the iron core are synchronously started, the rotating shaft is positioned through centering clamping, after the rotating shaft positioning is finished, the fixing rings are sleeved on two sides of the rotating shaft through the small mechanical arm, quick adhesive is smeared on one side close to the fixing rings, then the fixing rings are pressurized through the pressurizing sleeves on two sides, after the quick adhesive is solidified, the complete fixation of the iron core and the rotating shaft can be completed through the fixing rings, and after the rotor shaft inserting is completed, the rotor core is conveyed to a manual detection and packaging process through the mechanical arm and the conveying belt.
In the step S3, the quick curing accelerator and the glue spraying mechanism have the functions of timely glue delivery, accurate glue quantity, adjustable glue quantity and glue delivery speed and capability of completing glue delivery, and in addition, various factors such as economy and manufacturability of manufacturing are considered.
And S6, if the rotor core does not pass through the detection procedure, the rotor core is taken down by the mechanical arm and placed into the feed box, the recovery detection is waited for manually, if the maintenance can be carried out through detection, the rotor core is put into the step S7 again after the maintenance is carried out, and if the maintenance condition is not met through detection, the rotor core is split and recovered.
S7, after the rotor iron cores enter a manual detection and packaging process, workers randomly sample and detect each batch of iron cores (10 iron cores are randomly extracted for detection every 100 iron cores), package and warehouse-in the batch of rotor iron cores after detection and no defective products are detected, and if defective products (less than 2 iron cores) appear in the sampling detection, all the iron cores in the batch are detected; if more defective products (more than or equal to 3) are detected, all the rotor cores in the batch and the front and back three batches are detected.
In the step S2, the glue spraying position of the accelerator spraying station is positioned below the blank, so that the male die does not need to be unset, when the blank reaches the adhesive spraying station, the adhesive spraying opening sprays adhesive at the specific position of the blanking sheet, and the quick curing accelerator is sprayed on the blank to obtain the effect of quick curing the adhesive structure by utilizing the catalysis effect of the quick curing accelerator on the adhesive, so that the finished product efficiency of the iron core is improved.
In the step S5, the thickness of the iron core is increased when each piece of blanking sheet is blanked, so that the strip material is smoothly conveyed to the next station in the blanking process, the back pressure exists on the supporting hydraulic cylinder, and when one piece of blanking sheet is added each time, the hydraulic cylinder correspondingly descends by the distance of the thickness of one piece of iron core, so that the pressing force of bonding each time is unchanged.
In the step S4, the glue spraying amount of each adhesive spraying station is determined by the size of a blanking sheet, the diameter of a common glue drop is smaller than 1 mm for obtaining a core structure with reliable bonding, and the inner spraying mode and the outer spraying mode are selected to be feasible, and the selection is specifically required according to actual requirements.
And S5, after the silicon steel sheets are discharged, when the stacked materials are waiting to be pressed, carrying out height detection on the strips to be pressed through an infrared laser detector, taking down the silicon steel sheets with corresponding quantity if the height is too high, adding the silicon steel sheets with corresponding quantity if the height is too low, weighing the silicon steel sheet strips through a weighing instrument after the height reaches the standard, detecting whether the weight of the silicon steel sheets reaches the specified weight, continuing to press if the weight reaches the specified weight, and carrying out laser marking on the strips after the pressing if the weight does not reach or exceed the specified weight.
After the laser marked rotor core enters the step S7, the marked rotor core can be identified by an industrial detection camera in the detection process, and is taken down by a mechanical arm and put into a recovery box to wait for recovery.
In the S2 step, the thickness of the adhesive layer between the silicon steel sheets is not more than 0.003mm, the lamination coefficient is an important index for representing the lamination process level of the silicon steel sheets of the iron core, the thickness of the adhesive layer can influence the lamination coefficient, the iron core supporting hydraulic cylinder provides back pressure during sheet blanking, the spreading thickness of the adhesive is ensured to meet the requirement of a finished product, and the electromagnetic performance of the iron core after forming is reliable.
Working principle: the punching and laminating integrated design is adopted by the die, the punching and laminating are simultaneously carried out, the laminating process adopts a mechanically automatic rotary laminating mechanism, the production efficiency of the iron core is improved, the manufacturing cost is saved, and when the punching sheet is formed, adhesive is sprayed on the inner wall of the central shaft hole of the rotor iron core and the surface with a groove body structure, the silicon steel sheet and the silicon steel sheet are connected by adopting the bonding mode of spraying glue, compared with the traditional welding and riveting connection mode, the efficiency of a motor finished product can be improved by connecting the motor iron core by adopting the bonding mode, the generated noise, vibration and acoustic vibration roughness is smaller, the integral bonding strength of the rotor iron core is high, the durability is better, the iron loss is reduced, the magnetic flux density is increased, the number of spraying points of the quick curing accelerator and the adhesive is changed, all the spraying points of the quick curing accelerator and all the spraying adhesive points are fully contacted and fully mixed when laminating, realizing the quick solidification of the adhesive, or can directly contact the redundant adhesive points with the iron core blanking sheet instead of combining with the quick solidification promoter, solidifying the adhesive which is not combined with the quick solidification promoter under natural conditions after blanking, laminating and discharging the stamping sheet, realizing the combination of the quick solidification and the natural solidification of the solidifying agent under room temperature, effectively increasing the solidification connection strength between the iron core sheet layers, improving the integral structural strength of the iron core, providing reliable guarantee for the motor iron core when in use, monitoring each step of the rotor iron core manufacturing by arranging a plurality of detection procedures, finding out the cause of the problem at the first time when the problem occurs, thereby effectively reducing further loss, being beneficial to the optimization work of the rotor iron core manufacturing process, promote market competition, the mass production of convenient production type enterprise carries out timely recovery with the defective product that detects simultaneously and can effectively stop the damage, avoids the defective product further to flow down, is favorable to promoting rotor core's final yield.
The foregoing has shown and described the basic principles and main features of the present invention and the advantages of the present invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, and that the above embodiments and descriptions are merely illustrative of the principles of the present invention, and various changes and modifications may be made without departing from the spirit and scope of the invention, which is defined in the appended claims. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. An integrated forming process of split rotor core is characterized in that: the method comprises the following forming steps:
s1, firstly, manufacturing a proper stamping die according to a predesigned rotor core shape, mounting the stamping die subjected to experiment qualification on a machine, preparing a silicon steel sheet blank with proper size, stamping the silicon steel sheet into a core blank through a stamping machine, adopting a blanking and laminating integrated design for the die, carrying out blanking and laminating simultaneously, adopting a mechanical automatic rotary laminating mechanism for the laminating process, conveying the silicon steel blank to the middle of a stamping die for blanking, spraying an adhesive and a bonding catalyst on the surface of the blank, enabling the adhesive to be quickly solidified through contact between the catalyst and the adhesive, forming a rotor core, stopping spraying the adhesive after the number of the rotor core reaches a preset number, and transporting the rotor core from the stamping die one by one through a transporting device;
s2, spraying adhesive on the inner wall of a central hole and the surface with a groove body structure after blanking a sheet of the rotor core, adopting a glue spraying bonding mode between the silicon steel sheet and the silicon steel sheet, arranging an accelerator spraying station outside a die, spraying a quick curing accelerator on the blank from an accelerator spraying port before the blank enters a blanking die through a transported wheel, and arranging a rotor core spraying station in the die;
s3, spraying points of the quick curing accelerator are uniformly distributed in a round shape, spraying stations of the quick curing accelerator can be arranged at any position before a rotor core adhesive spraying station, the quick curing of the adhesive can be guaranteed by reasonably selecting the spraying stations according to the design requirement of a die, the spraying stations of the adhesive in a blanking die are generally arranged at the previous station of blanking, the spraying ports adopt an integral structure with a plurality of adhesive spraying channels, and the adhesive is sprayed to all the adhesive points on a sheet under the action of applied pressure;
s4, the bonding glue spraying modes of the rotor iron core and the stator iron core can be divided into 2 modes of inner ring spraying and outer ring spraying, each adhesive spraying mode comprises a plurality of glue spraying points, the specific glue spraying point number is determined according to the groove-shaped number of the iron core, the glue spraying points are reasonably arranged, the glue spraying area on the iron core is ensured to be sufficient, meanwhile, glue overflow during lamination is avoided, 2 modes of an inner spraying ring and an outer spraying ring are arranged at a quick curing agent spraying station, each curing agent spraying mode also comprises a plurality of spraying points, the number of quick curing accelerator spraying points and the number of adhesive spraying points can be equal, the positions are in a corresponding relation, all quick curing accelerator points sprayed are in full contact and are fully mixed when all adhesive points sprayed are laminated, and quick curing of the adhesive is realized;
s5, taking the outer edge of a blanked rotor groove body as the appearance characteristic of a blanked rotor iron core sheet, blanking the rotor iron core into a guide channel through blanking the outer contour of the rotor, fixing the rotor iron core with the previously blanked rotor iron core to form an iron core finished product, forming a round hole site on a strip, taking the round hole site as a preformed hole of the blanked stator iron core sheet in the blanking process, fully mixing and solidifying a quick solidification promoter among sheets with an adhesive to realize tight combination among iron core sheets, and in the blanking process, enabling each iron core sheet in the channel to be mutually adhered more firmly through downward stamping force and upward lifting action of a supporting hydraulic cylinder at the bottom of the iron core blanking guide channel to form a semi-finished iron core strip;
s6, after the strip pressing is finished, taking the manufactured semi-finished iron core out of the equipment through a mechanical arm, vertically placing the semi-finished iron core on a conveyor belt, transferring the semi-finished rotor iron core to a dimension detection procedure through the conveyor belt, measuring the height diameter and the inner diameter of a shaft hole of the rotor iron core through an infrared laser detector, uploading monitoring data to a main control chip for data comparison, transferring the rotor iron core to an industrial detection camera for image comparison detection after the detection data are qualified, monitoring whether the semi-finished iron core has a shape defect through an image comparison technology, and if the dimension detection and the shape detection are all passed, continuing to work through the conveyor belt, and transferring the rotor iron core to a next rotor shaft entering procedure;
s7, when the semi-finished rotor core is conveyed to the front of the rotor shaft inserting machine through the conveying belt, the rotor core can be clamped through the mechanical arm, the rotor core is vertically placed below the shaft inserting opening, the rotor rotating shaft can be inserted into the shaft hole in the middle of the rotor core through the rotor shaft inserting machine, after the rotor shaft inserting machine finishes the shaft inserting of the rotor core, the mechanical arm transfers the rotor core to the rotating shaft positioning machine, the iron core is placed on the positioning table through the mechanical arm, then the hydraulic rods on the upper portion and the lower portion of the iron core are synchronously started, the rotating shaft is positioned through centering clamping, after the rotating shaft positioning is finished, the fixing rings are sleeved on two sides of the rotating shaft through the small mechanical arm, quick adhesive is smeared on one side close to the fixing rings, then the fixing rings are pressurized through the pressurizing sleeves on two sides, after the quick adhesive is solidified, the complete fixation of the iron core and the rotating shaft can be completed through the fixing rings, and after the rotor shaft inserting is completed, the rotor core is conveyed to a manual detection and packaging process through the mechanical arm and the conveying belt.
2. The split rotor core integrated molding process according to claim 1, wherein: the quick curing accelerator and the glue spraying mechanism in the step S3 have the functions of timely glue delivery, accurate glue quantity, adjustable glue quantity and glue delivery speed and capability of completing glue delivery, and in addition, the manufacturing economy, manufacturability and other factors should be considered.
3. The split rotor core integrated molding process according to claim 1, wherein: and if the rotor core does not pass through the detection procedure in the step S6, the rotor core is taken down by the mechanical arm and placed into the feed box, the recovery detection is waited for manually, the maintenance is carried out after the detection can be carried out, the step S6 is carried out again, and if the detection does not have the maintenance condition, the rotor core is split and recovered.
4. The split rotor core integrated molding process according to claim 1, wherein: in the step S7, after the rotor core enters the manual detection and packaging process, a worker performs random sampling detection (10 are randomly extracted from every 100 cores for detection) on each batch of cores, packages and stores the batch of rotor cores after detection and no defective products, and performs all detection on the batch of cores if defective products (less than 2) occur in sampling detection; if more defective products (more than or equal to 3) are detected, all the rotor cores in the batch and the front and back three batches are detected.
5. The split rotor core integrated molding process according to claim 1, wherein: in the step S2, the glue spraying position of the accelerator spraying station is positioned below the blank, so that the male die does not need to be unset, when the blank reaches the adhesive spraying station, the adhesive spraying opening sprays adhesive at the specific position of the blanking sheet, and the quick curing accelerator is sprayed on the blank to obtain the effect of quick curing the adhesive structure by utilizing the catalysis effect of the quick curing accelerator on the adhesive, so that the finished product efficiency of the iron core is improved.
6. The split rotor core integrated molding process according to claim 1, wherein: in the step S5, since the thickness of the iron core is increased when each piece of blanking sheet is blanked, in order to enable the strip to be smoothly conveyed to the next station in the blanking process, the back pressure exists on the supporting hydraulic cylinder, and when each piece of blanking sheet is blanked, each time one piece of blanking sheet is added, the hydraulic cylinder correspondingly descends by the distance of the thickness of one piece of iron core, so that the pressing force of bonding each time is unchanged.
7. The split rotor core integrated molding process according to claim 1, wherein: in the step S4, the glue spraying amount of each adhesive spraying station needs to be determined by the size of the blanking sheet, and in order to obtain the iron core structure with reliable adhesion, the diameter of the glue drop is generally smaller than 1 mm, and the inner spraying and outer spraying modes are selected.
8. The split rotor core integrated molding process according to claim 1, wherein: in the step S5, after the silicon steel sheets are discharged, when the stacked materials are waiting to be pressed, the height of the to-be-pressed strip materials is detected through an infrared laser detector, if the height is too high, the silicon steel sheets with the corresponding number are taken down, if the height is too low, the silicon steel sheets with the corresponding number are added, after the height reaches the standard, the weight of the silicon steel sheet strip materials is measured through a weight measuring instrument, whether the weight of the silicon steel sheet strip materials reaches the specified weight is detected, if the weight reaches the specified weight, the pressing is continued, and if the weight does not reach or exceed the specified weight, the laser marking is carried out on the strip materials after the pressing.
9. The split rotor core integrated molding process as claimed in claim 8, wherein: after the laser marked rotor core enters the step S7, the marked rotor core can be identified through an industrial detection camera in the detection process, and is taken down through a mechanical arm and put into a recovery box to wait for recovery.
10. The split rotor core integrated molding process according to claim 1, wherein: in the step S2, the thickness of the adhesive layer between the silicon steel sheets is not more than 0.003mm.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202310381365.2A CN116404827A (en) | 2023-04-11 | 2023-04-11 | Integrated forming process of split rotor core |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116780839A (en) * | 2023-08-22 | 2023-09-19 | 苏州范斯特机械科技有限公司 | Lamination method and production equipment of adhesive type iron core and adhesive type laminated iron core |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116780839A (en) * | 2023-08-22 | 2023-09-19 | 苏州范斯特机械科技有限公司 | Lamination method and production equipment of adhesive type iron core and adhesive type laminated iron core |
| CN116780839B (en) * | 2023-08-22 | 2023-11-03 | 苏州范斯特机械科技有限公司 | Lamination method and production equipment of adhesive type iron core and adhesive type laminated iron core |
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