CN212603228U

CN212603228U - Pressurized gel casting mold and apparatus

Info

Publication number: CN212603228U
Application number: CN202020379860.1U
Authority: CN
Inventors: 潘宏兴; 施亮; 邓云平
Original assignee: Kinavo Servo Motor (changzhou) Ltd
Current assignee: Kinavo Servo Motor (changzhou) Ltd
Priority date: 2020-03-24
Filing date: 2020-03-24
Publication date: 2021-02-26
Anticipated expiration: 2030-03-24

Abstract

The invention relates to the field of pouring devices, in particular to a pressurized gel pouring mold and equipment. The lower die assembly comprises a fixed die base, a heat insulation base plate, a fixed die heating plate and a fixed die plate, wherein the fixed die base is arranged on the bottom surface of the upper layer space; a fixed die cavity is arranged on the top surface of the fixed die plate; the upper die assembly comprises a movable die base connected with the upper die fixing plate, a heat insulation cushion block, a heating plate and a movable die plate; a movable mold cavity corresponding to the fixed mold cavity is arranged on the bottom surface of the movable mold plate; two push rods are oppositely arranged on the movable mold base on the inner side of the heat insulation cushion block of the movable mold base, penetrate through the heating plate and extend into the movable mold cavity; the invention can be produced by only manufacturing a pair of moulds for one product; the time in the mould of the epoxy pressure gel process is short, so that the batch production cost is lower than that of the traditional normal pressure pouring, and the economic benefit is high; the production efficiency of the frameless hollow direct-current brushless motor stator can be greatly improved, the labor intensity is reduced, and the product quality is greatly improved.

Description

Pressurized gel casting mold and apparatus

Technical Field

The utility model relates to a pouring device field especially relates to pressurization gel casting mold and equipment.

Background

The frameless hollow brushless direct-current motor has the characteristics of small and compact size, light weight, low inertia, high power and the like, and is widely applied to various automatic devices such as cooperative robots, unmanned planes, navigation systems and the like; compared with other types of motors, the motor has the main advantages that under the same power working condition, the motor is small in size and can be directly embedded into equipment for use only by supporting the rotor through the bearing.

The motor coil is embedded in a stator core, and the mechanical strength, heat resistance, heat conductivity, insulating strength, moisture resistance and other properties of the winding are improved by processing insulating paint through immersion and dripping. The insulating varnish has small heat conductivity coefficient, and cannot completely fill gaps between enameled wires and between the enameled wires and the iron core, especially for the coil structure with extremely high slot filling rate. This just leads to the whole heat conduction effect variation of stator, and the heat that produces when the motor operation can't in time distribute, and the motor temperature rise does not accord with relevant technical specification requirement, leads to the motor to burn out when serious. Meanwhile, the whole stator structure processed by the insulating varnish still becomes loose between enameled wires under long-term electromagnetic repeated impact, so that various performances are reduced.

In order to overcome the defects of an insulating varnish impregnation process, an epoxy resin normal-pressure pouring process for integrally encapsulating a motor coil by using epoxy resin is adopted in the motor manufacturing industry at present, and various technical properties of a stator core are improved to a certain extent. However, such processes have the following problems: 1) the labor intensity is high, the production cost is high, and the mass production is not facilitated; 2) in the traditional casting process, dozens of or hundreds of molds are needed for casting the same number of products, the mold occupation is large, and the mold utilization rate is low.

SUMMERY OF THE UTILITY MODEL

An object of the utility model is to provide a technological method, service equipment and corresponding frock mould that improve frameless cavity direct current brushless motor stator production efficiency, reduce intensity of labour and product quality by a wide margin.

The technical scheme of the utility model as follows:

the pressurized gel casting mold comprises an upper mold component and a lower mold component; the lower die assembly comprises a fixed die base arranged on the bottom surface of the upper layer space, a heat insulation base plate arranged on the fixed die base, a fixed die heating plate arranged on the heat insulation base plate and a fixed die plate arranged on the fixed die heating plate; a fixed die cavity is arranged on the top surface of the fixed die plate; the upper die assembly comprises a movable die base connected with the upper die fixing plate, a heat insulation cushion block arranged on the bottom surface of the movable die base, a heating plate arranged on the bottom surface of the heat insulation cushion block, and a movable die plate arranged on the bottom surface of the heating plate; a movable mold cavity corresponding to the fixed mold cavity is arranged on the bottom surface of the movable mold plate; two push rods are oppositely arranged on the movable mold base on the inner side of the heat insulation cushion block of the movable mold base, and penetrate through the heating plate and extend into the movable mold cavity.

And a plurality of electric heating pipes are uniformly distributed on the heating plate.

The centers of the fixed die base, the heat insulation base plate and the fixed die heating plate are provided with communicated mounting holes, and sprue bushes are mounted in the mounting holes; and a sprue channel is formed in the center of the sprue bush.

The pressurized gel casting equipment comprises a machine base, a mold locking system and an injection system, wherein the mold locking system and the injection system are respectively arranged in an upper layer space and a lower layer space of the machine base; the mold locking system comprises a mold closing assembly and an injection head driving assembly; a casting mold is arranged between the mold closing assembly and the injection head driving assembly; the injection system comprises a pressurizing assembly and a material conveying assembly.

The die assembly component comprises a die assembly driver arranged on the top surface of the frame, the telescopic end of the die assembly driver penetrates through the top surface and is inserted into the upper layer space, and the end part of the die assembly driver is connected with the movable die fixing plate.

The injection head driving assembly comprises an injection head driver arranged on the top surface of the lower layer space, and the telescopic end of the injection head driver penetrates through the top surface and extends into the middle layer space of the rack; the telescopic end is connected with an injection head fixing plate, a mounting hole is formed in the injection head fixing plate, and an injection head is mounted in the mounting hole.

The pressurizing assembly comprises a pressurizing tank arranged on the bottom surface of the lower layer space, and a material storage barrel is arranged in the pressurizing tank; the side surface of the pressurizing tank is connected with the pressure regulator through an air inlet pipe.

The material conveying assembly comprises a material conveying pipe, one end of the material conveying pipe extends into the material storage tank, and the other end of the material conveying pipe is communicated with the injection head.

And the outside of the material conveying pipe is provided with a material conveying pipe electric heater.

A pressurized gel casting process, wherein in the step 1, a mould is arranged on a special epoxy resin casting machine;

step 2, adjusting the injection time, the injection pressure and the temperature of each system on a casting machine;

step 3, starting a casting machine system to heat the mold, the heat insulation box and the material conveying pipe;

step 4, mixing and vacuumizing epoxy resin A, B component glue materials on a general vacuumizing glue mixing machine to form mixed glue materials;

step 5, injecting the mixed rubber material into a storage cylinder of a casting machine;

step 6, starting a die assembly oil cylinder of the casting machine to move the movable die upwards, and carrying out die assembly after a motor stator is placed;

step 7, starting an injection head driving oil cylinder of the casting machine to enable the injection head to ascend until the injection head is tightly contacted with a mold sprue bush;

and 8, starting an injection system of the casting machine, and driving mixed rubber in the storage barrel to enter a mold cavity of the mold along the conveying pipe, the sprue bush and the runner by compressed air of a pressure regulator.

Step 9, maintaining pressure and curing;

and step 10, starting a mold closing system of the casting machine to enable the movable mold plate to ascend, and pushing the stator which is subjected to gel out of the mold cavity by a push plate.

The utility model has the advantages that: the utility model discloses a pressurization gel technology uses the mould that has seal structure, has the heating function to carry out the casting moulding of this type of motor stator on pressurization epoxy casting machine, the utility model discloses following difference and advantage have:

1. generally, only one pair of molds is needed to manufacture one product. And the time in the mould of the epoxy pressure gel process is short, so that the batch production cost is lower than that of the traditional normal pressure pouring, and the economic benefit is high.

2. The labor intensity of workers is high, the automation degree of the epoxy pressure gel process is high, the heavy work of assembling and disassembling a mold in the traditional normal pressure pouring is omitted, and the labor intensity of the workers is greatly reduced.

3. The quality of the product needs 0.1-0.5Mpa in the whole process of injection and curing in the pressure gelation process, and the process ensures that the shrinkage generated in the curing reaction process of the epoxy resin can be compensated, so the dimensional precision and the surface quality of the stator are higher than those of normal pressure casting; and meanwhile, the distribution uniformity of the internal stress of the stator is also greatly higher than that of normal pressure pouring, so that the consistency of the mechanical and electrical properties of the stator assembly is greatly improved.

Drawings

The foregoing and other objects, features, and advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings.

Wherein: FIG. 1 is a schematic structural view of the present invention;

FIG. 2 is a schematic view of the mold structure of the present invention;

in the attached drawing, 1 is a die assembly oil cylinder, 2 is a base, 3 is a movable die fixing plate, 4 is a casting die, 5 is an injection head, 6 is a conveying pipe electric heater, 7 is a conveying pipe, 8 is a pressurizing tank, 9 is a storage barrel, 10 is an insulation box, 11 is an injection head driving oil cylinder, 21 is a movable die base, 22 is a push rod, 23 is a heat insulation cushion block, 24 is an electric heating pipe, 25 is a heating plate, 26 is a movable die plate, 27 is a stator assembly, 28 is a fixed die plate, 29 is a fixed die heating plate, 210 is a heat insulation backing plate, 211 is a fixed die base, and 212 is a sprue bush.

Detailed Description

Referring to fig. 1-2, the pressurized gel casting apparatus includes a frame 2, a mold locking system and an injection system respectively disposed in an upper space and a lower space of the frame; the mold locking system comprises a mold closing assembly and an injection head driving assembly; a casting mold is arranged between the mold closing assembly and the injection head driving assembly; the injection system comprises a pressurizing assembly and a material conveying assembly. The material is conveyed to the injection head through the material conveying system through the injection system, and the injection head is moved to a corresponding position through the injection head driving assembly so as to convey the casting material into the casting mold; because the casting mold is arranged between the mold closing assembly and the injection head driving assembly, the mold closing assembly is started to drive the upper mold to move so as to realize mold closing, and then the injection head is moved to a corresponding position through the injection head driving assembly so as to facilitate casting. The pressurized epoxy pouring equipment is mainly divided into a mold locking system and an injection system. The mold locking system mainly comprises a mold closing assembly, an injection head driving assembly and the like, and the whole mold locking system is arranged in a vertical structure. The injection system mainly comprises a pressurizing assembly and a material conveying assembly.

The die assembly component comprises a die assembly driver 1 arranged on the top surface of the frame, the telescopic end of the die assembly driver penetrates through the top surface and is inserted into the upper layer space, and the end part of the die assembly driver is connected with a movable die fixing plate 3. Because the movable mould fixed plate is connected with the driver, the die closing driver can adopt a die closing oil cylinder, and the up-and-down reciprocating motion of the telescopic end of the driver can drive the movable mould fixed plate to do up-and-down reciprocating motion, so that the movable mould base of the mould is driven to move up and down, and the stator assembly is firmly clamped when the upper mould moves to the pouring position.

The injection head driving assembly comprises an injection head driver 11 arranged on the top surface of the lower layer space, and the telescopic end of the injection head driver penetrates through the top surface and extends into the middle layer space of the rack; the telescopic end is connected with an injection head fixing plate, a mounting hole is formed in the injection head fixing plate, and an injection head 5 is mounted in the mounting hole. The fixed plate is driven to move up and down through the driver, and the injection head driver can adopt an injection head oil cylinder to indirectly drive the injection head to move up and down so as to move to the position of the injection port; wherein, the injection head fixing plates on the two sides of the injection head are provided with guide holes which are matched with guide posts arranged on the bottom surface of the middle layer space, so that the injection head fixing plates are more stable when moving.

The pressurizing assembly comprises a pressurizing tank 8 arranged on the bottom surface of the lower layer space, and a material storage barrel 9 is arranged in the pressurizing tank; the side surface of the pressurizing tank is connected with the pressure regulator through an air inlet pipe. The pressurizing tank must ensure that the injection pressure of 0.1-0.5Mpa can be kept in the whole process from injection to solidification, the pressurizing medium is clean compressed air, and the pressure is adjusted by a precision pressure regulator with the use range of 0.1-1 Mpa; the material conveying action is realized by controlling compressed air by a valve, and the valve is not in direct contact with resin, so that the cleaning problem is avoided. The outer side of the pressure tank is sleeved with an insulation box 10 for insulating the injection molding materials, the insulation box controls the working temperature of the epoxy resin through an electric heating pipe and a temperature control system, and the temperature control precision is within +/-5 ℃.

The material conveying component comprises a material conveying pipe 7, one end of the material conveying pipe extends into the material storage tank, and the other end of the material conveying pipe is communicated with the injection head. The material conveying pipe is connected with the material storage barrel and enables the material in the material storage barrel to move to the injection head along the material conveying pipe after being pressurized by the pressurization tank.

And a feed delivery pipe electric heater 6 is arranged outside the feed delivery pipe. An electric heater is arranged outside the conveying pipe to ensure the fluidity of the rubber material in the conveying process.

The casting mold 4 comprises an upper mold component and a lower mold component; the lower die assembly comprises a fixed die base 211 arranged on the bottom surface of the upper layer space, a heat insulation cushion plate 210 arranged on the fixed die base, a fixed die heating plate 29 arranged on the heat insulation cushion plate and a fixed die plate 28 arranged on the fixed die heating plate; a fixed die cavity is arranged on the top surface of the fixed die plate; the upper die assembly comprises a movable die base 21 connected with the upper die fixing plate, a heat insulation pad 23 arranged on the bottom surface of the movable die base, a heating plate 25 arranged on the bottom surface of the heat insulation pad, and a movable die plate 26 arranged on the bottom surface of the heating plate; a movable mold cavity corresponding to the fixed mold cavity is arranged on the bottom surface of the movable mold plate; two push rods 22 are oppositely arranged on the movable mold base on the inner side of the heat insulation cushion block of the movable mold base, and penetrate through the heating plate and extend into the movable mold cavity. The mold mainly comprises an upper template, a lower template, a heating system and the like. In order to prevent the resin in the die cavity from generating convection and influencing the temperature gradient of the injected resin, the die adopts a unique bottom feeding mode. When fed from the bottom, the pressure provided by the pressurized can forces the epoxy resin to rise, forcing the air out of the mold and eventually out of the mold through the vent groove and the mold parting surface. After the exhaust groove and a parting surface gap (usually 0.3mm) are filled with the epoxy resin, the epoxy resin is quickly condensed into a resin sheet under the combined action of a mold heating system and rubber material reaction heat release so as to plug the gap, so that a mold cavity is completely sealed, and at the moment, the epoxy resin is continuously supplemented under the action of pressure so as to fill the gap between coils and the volume shrinkage generated by gelling until the gel reaction is finished, so that the close combination between the coils and an iron core is ensured and no air hole is generated; with the stator assembly 27 placed between the upper and lower mold cavities.

A plurality of electric heating pipes 24 are uniformly distributed on the heating plate. The resin sheets are quickly condensed into resin sheets under the combined action of a mold heating system and rubber material reaction heat release, so that gaps are blocked, and a mold cavity is completely sealed.

The centers of the fixed die base, the heat insulation base plate and the fixed die heating plate are provided with communicated mounting holes, and sprue bushes 212 are mounted in the mounting holes; and a sprue channel is formed in the center of the sprue bush. Because the mounting hole is communicated with the fixed die cavity, the sprue bush is arranged, so that the pouring material can flow into the fixed die cavity conveniently.

The pressurized gel casting process includes the following steps: step 1, installing a mould on a special epoxy resin casting machine; step 2, adjusting the injection time, the injection pressure and the temperature of each system on a casting machine; step 3, starting a casting machine system to heat the mold, the heat insulation box and the material conveying pipe; step 4, mixing and vacuumizing epoxy resin A, B component glue materials on a general vacuumizing glue mixing machine to form mixed glue materials; step 5, injecting the mixed rubber material into a storage cylinder of a casting machine; step 6, starting a die assembly oil cylinder of the casting machine to move the movable die upwards, and carrying out die assembly after a motor stator is placed; step 7, starting an injection head driving oil cylinder of the casting machine to enable the injection head to ascend until the injection head is tightly contacted with a mold sprue bush; step 8, starting an injection system of the casting machine, and driving mixed rubber in a storage barrel to enter a mold cavity along a conveying pipe, a sprue bush and a runner by compressed air of a pressure regulator; step 9, maintaining pressure and curing; and step 10, starting a mold closing system of the casting machine to enable the movable mold plate to ascend, and pushing the stator which is subjected to gel out of the mold cavity by a push plate. Installing a mould with a heating function on a special epoxy resin casting machine; and adjusting the injection time, the injection pressure and the temperature of each system according to the technological requirements of the product. Starting a system to heat the mold, the heat insulation box and the material conveying pipe to a process specified temperature; mixing and vacuumizing epoxy resin A, B component sizing materials selected by technical drawings on a general vacuumizing glue mixer according to the proportion specified by the technical specification of manufacturers; during small-batch production, the materials can be mixed, mixed and vacuumized in a manual weighing mode; injecting the mixed and vacuumized rubber material into a material storage cylinder of a special epoxy resin casting machine; starting a die assembly oil cylinder to move a movable die upwards, and assembling the die after a motor stator is placed; starting an injection head driving oil cylinder to enable the injection head to ascend until the injection head is tightly contacted with a die sprue bush; starting an injection system, and driving epoxy resin to enter a die cavity along a conveying pipe, a sprue bush and a runner by compressed air; maintaining the pressure and curing; and starting the mold closing system to lift the movable mold plate, and pushing the stator which is subjected to gel out of the mold cavity by the push plate.

And the injection pressure in the step 8 is 0.1-0.5 Mpa.

The above is only the preferred embodiment of the present invention, not to the limitation of the present invention in any form, all the techniques of the present invention are substantially any simple modification and equivalent changes to the above embodiments, all falling within the protection scope of the present invention.

Claims

1. The pressurized gel casting mold is characterized by comprising an upper mold component and a lower mold component; the lower die assembly comprises a fixed die base arranged on the bottom surface of the upper layer space, a heat insulation base plate arranged on the fixed die base, a fixed die heating plate arranged on the heat insulation base plate and a fixed die plate arranged on the fixed die heating plate; a fixed die cavity is arranged on the top surface of the fixed die plate; the upper die assembly comprises a movable die base connected with the upper die fixing plate, a heat insulation cushion block arranged on the bottom surface of the movable die base, a heating plate arranged on the bottom surface of the heat insulation cushion block, and a movable die plate arranged on the bottom surface of the heating plate; a movable mold cavity corresponding to the fixed mold cavity is arranged on the bottom surface of the movable mold plate; two push rods are oppositely arranged on the movable mold base on the inner side of the heat insulation cushion block of the movable mold base, and penetrate through the heating plate and extend into the movable mold cavity.

2. The pressurized gel casting mold of claim 1 wherein a plurality of electrically heated tubes are uniformly distributed on said heating plate.

3. The pressurized gel casting mold according to claim 1, wherein the fixed mold base, the heat insulation cushion plate and the fixed mold heating plate are centrally provided with a communicated mounting hole, and a sprue bush is mounted in the mounting hole; and a sprue channel is formed in the center of the sprue bush.

4. A pressurized gel casting apparatus comprising the pressurized gel casting mold of any one of claims 1-3; the mould locking device also comprises a base, a mould locking system and an injection system which are respectively arranged in the upper layer space and the lower layer space of the base; the mold locking system comprises a mold closing assembly and an injection head driving assembly; the pressurized gel casting mold is arranged between the mold closing assembly and the injection head driving assembly; the injection system comprises a pressurizing assembly and a material conveying assembly.

5. The apparatus of claim 4, wherein the clamp assembly includes a clamp actuator mounted on the top surface of the frame, the clamp actuator having a telescoping end extending through the top surface and into the upper space and an end connected to the movable mold mounting plate.

6. The apparatus of claim 4, wherein the injector drive assembly comprises an injector drive disposed on the top surface of the lower space, the injector drive having a telescoping end extending through the top surface and into the middle space of the frame; the telescopic end is connected with an injection head fixing plate, a mounting hole is formed in the injection head fixing plate, and an injection head is mounted in the mounting hole.

7. The apparatus of claim 4, wherein the pressurizing assembly comprises a pressurizing tank disposed on the bottom surface of the lower space, and a storage cylinder is disposed in the pressurizing tank; the side surface of the pressurizing tank is connected with the pressure regulator through an air inlet pipe.

8. A pressurized gel casting apparatus as claimed in claim 4 wherein said delivery assembly includes a delivery tube having one end extending into the reservoir and the other end communicating with the injection head.

9. The apparatus of claim 8, wherein an electric heater is disposed outside said delivery conduit.