KR20220068512A - Manufacturing method of roter with forged slot - Google Patents

Abstract

The present invention relates to a method for manufacturing a rotor with a forged slot, comprising: a cutting step (S10) of forming a cylindrical front or rear segment (110, 120) weight by cutting a raw material made of steel with a press machine; a forging process (S20) of forming a segment forged body having a plurality of slot (111, 121) structures along the outer circumferential surface by hot-forging the segment weight; a surface treatment process (S30) of removing scale by putting the segment forged body into shot blast equipment and forming a preliminary segment body; a sizing process (S40) of putting the preliminary segment body into a press machine to adjust the size as desired and forming a finished segment body; a finishing process (S50) of removing scale by inputting the finished segment body into shot blast equipment and forming a finished front or rear segment body (110, 120); and an assembly process (S60) of assembling a permanent magnet (130) and a retainer in the slots (111, 121) provided in the finished front and rear segment (110, 120), thereby improving workability and productivity.

Description

A method of manufacturing a rotor having a forged slot

The present invention relates to a method for manufacturing a rotor having a forged slot, and more particularly, a configuration in which a slot structure for inserting a permanent magnet and a retainer is formed by conventional MCT processing when manufacturing a rotor mounted on an electric device such as a generator or an electric motor It relates to a rotor manufacturing method that improves workability and productivity by configuring it to be formed by a forging method by differentiating it from a forging method.

In general, an electric device in which an electromagnetic system such as an alternator is embedded includes a stator that is a stator, a rotor that is a rotor, and other components such as a regulator and a diode to induce voltage.

The stator induces alternating current by winding a stator coil around an iron core. The rotor, that is, the rotor, rotates at the center of the stator, and through this rotation, the magnetic flux is changed to generate the induced electromotive force of the stator.

The rotor combines the front segment and the rear segment so that the excitation coil enters the segment core with the shaft as the center, and the magnet is positioned between the segments, and the slip ring connects both ends of the excitation coil to transmit current through the brush.

When current flows through the excitation coil in the rotor, both ends of the rotor segment are magnetized to N and S poles, and when the rotor rotates, magnetic flux between the stator coil and the pole piece is generated to induce an electromotive force in the stator coil.

A schematic view of the configuration of a rotor provided in a typical electric machine with reference to known techniques, Korean Patent Registration No. 10-0385597 discloses a rotor body having a space for retaining the stator inside, and the arrangement in the inner space. The stator comprises a rotor body used in a small motor having a plurality of magnetic pole pieces each having magnetic pole portions at outer peripheral positions, and a coil for applying magnetic flux for magnetizing the magnetic pole portions to the magnetic pole pieces. do.

As another example, Korean Patent Application Laid-Open No. 10 - 2015 - 0131081 discloses a rotor core and a plurality of permanent magnets disposed on the rotor core, the rotor core has a plurality of slots, and each of the plurality of slots is a cylindrical surface of the rotor core. and a rotor disposed radially between the set of magnets and disposed about the rotor and comprising a plurality of teeth, each tooth comprising a cylindrical face of the rotor core and opposite tooth faces, the tooth faces being disposed on the cylindrical face of the rotor core. A rotor and a stator for a generator machine comprising a stator including an inner portion extending substantially parallel to the inner portion and an inclined portion disposed on the opposite side of the inner portion of the tooth surface.

A plurality of permanent magnets disposed in the rotor are, for example, as disclosed in Korean Patent Application Laid-Open No. 10-2013-0006493, in the rotor for an electric machine excited by magnetic poles of one or more built-in permanent magnets, a magnetic body and a direction of the rotor one or more embedded permanent magnets for a magnetic body defining a first magnetic pole N and a second magnetic pole S of alternating magnetic poles along A rotor segment is disposed therebetween, wherein the at least one retainer element constitutes a rotor of an electric machine having a built-in permanent magnet connecting the rotor segment to a section of a magnetic body.

Korean Patent Registration No. 10 - 0385597 (2003.08.19) Korean Patent Laid-Open Patent No. 10 - 2015 - 0131081 (2015.11.24) Korean Patent Laid-Open Patent No. 10 - 2013 - 0006493 (2013.01.16) Korean Patent Laid-Open Patent No. 10 - 2017 - 0087797 (2017.07.31)

Rotors mounted on electric devices such as generators and electric motors form an assembly structure in which an excitation coil is wound around the rotor shaft, and the segments on both sides that connect the front and rear fans surround the excitation coil. In order to arrange a plurality of permanent magnets in the rotor, a plurality of slots are formed in both segments.

In the conventional rotor manufacturing method, a process of rough forming both segments by hot or cold forging, an MCT processing process for forming a plurality of slot structures in both segments, and a retainer and a permanent magnet magnetized in a slot of one segment It includes a process of attaching together, and a series of processes of assembling the other segment to the one side segment to which the permanent magnet is attached.

Therefore, in the conventional rotor manufacturing method, it is necessary to build a system and professional manpower for the implementation of the MCT machining process, and in particular, approximately 24 slots in both segments must be formed through the machining process one by one, so the implementation process of the process is complicated And there is a problem that significantly lowers productivity and workability.

In addition, the conventional rotor manufacturing method has a disadvantage in that it is difficult to derive high dimensional accuracy due to problems such as the difficulty of the MCT processing and the long process time required, and the slot structure must be formed in the form of a groove.

In addition, in the case of forming the slot in the form of a groove having a structure in which both ends are blocked as in the prior art, the permanent magnet and retainer pre-magnetized in the assembly process are inserted by an attachment method that fits into one segment, and then the other segment is assembled. There is a problem in that workability is deteriorated.

Accordingly, the present invention was invented to solve the problems of the prior art as described above,

Manufacturing a rotor having a plurality of slots 111 and 121 in which the front segment 110 and the rear segment 120 are coupled so that the excitation coil enters the segment core part centering on the rotor shaft, and a permanent magnet 130 is inserted into each segment. In the method,

A cutting process (S10) of cutting a raw material made of steel with a press machine to form a cylindrical front or rear segment (110, 120) weight;

A forging process (S20) of hot-forging the segment weight to form a segment molded body forming a plurality of slot (111,121) structures along an outer circumferential surface;

A surface treatment process (S30) of putting the segment molded body into shot blasting to remove scale and forming a segment preliminary body;

A sizing process (S40) of putting the segment preliminary body into a press machine, adjusting it to a desired size, and forming a segment completed body;

A completion process (S50) of putting the segment completed body into shot blasting to remove scale and forming the front or rear segment (110, 120) complete body;

By including the assembly process (S60) of assembling the permanent magnet 130 and the retainer in the slots 111 and 121 provided in the front and rear segments 110 and 120 complete bodies, the purpose of improving workability and productivity is achieved. It is possible.

The present invention provides a method for manufacturing a rotor having a forged slot configured to form a slot structure for inserting a permanent magnet and a retainer by a forging method when manufacturing a rotor mounted on an electric device such as a generator or an electric motor.

Accordingly, the present invention has an advantage in that workability and productivity can be significantly improved compared to a configuration in which a plurality of slots formed in both segments are formed individually by MCT processing in a desired shape and size in a conventional method for manufacturing a rotor.

In addition, the present invention is effective in manufacturing a high-quality rotor that improves dimensional accuracy by minimizing problems such as dimensional errors or material waste that may occur in the conventional machining process.

1 is a process flow diagram of a method for manufacturing a rotor having a forged slot according to the present invention.
2 is a schematic perspective view of a front segment (b) and a rear segment (c) of a rotor manufactured by the method for manufacturing a rotor having a forged slot according to the present invention;
3 is a process diagram image of a method for manufacturing a rotor having a forged slot according to the present invention.
Figure 4 is a comparative example image of the assembly process (a) of the rotor manufacturing method having a forged slot according to the present invention and the assembly process (b) according to the prior art.
5 is a comparative example image of a rotor segment (a) by the method for manufacturing a rotor having a forged slot according to the present invention and a rotor segment (b) according to the prior art.

Hereinafter, the configuration and operation according to a preferred embodiment of the method for manufacturing a rotor having a forged slot of the present invention will be described in detail with reference to the accompanying drawings. In the following description, detailed descriptions of parts that can be easily implemented by those skilled in the art may be omitted. In addition, since the following description is given with reference to preferred embodiments of the present invention, the present invention is not limited by the following examples, and it is natural that various modifications may be provided without departing from the scope of the present invention. something to do.

1 is a process flow chart of a method for manufacturing a rotor having a forged slot according to the present invention, and FIG. 2 is a front segment (b) and a rear segment (c) of a rotor manufactured by the method for manufacturing a rotor having a forged slot according to the present invention. A schematic perspective view, FIG. 3 is a process schematic image of a method for manufacturing a rotor having a forged slot according to the present invention, and FIG. 4 is an assembly process (a) of a method for manufacturing a rotor having a forged slot according to the present invention and an assembly process according to the prior art A comparative example image of (b), FIG. 5 shows a comparative example image of a rotor segment (a) by the method for manufacturing a rotor having a forged slot according to the present invention and a rotor segment (b) according to the prior art.

The method of manufacturing a rotor having a forged slot to which the technology of the present invention is applied is a conventional processing method by configuring a slot structure for inserting a permanent magnet and a retainer by a forging method when manufacturing a rotor mounted on an electric device such as a generator or an electric motor It should be noted that it relates to a method of manufacturing a rotor that improves workability and productivity compared to the present invention.

For this, the rotor manufacturing method having a forged slot of the present invention combines the front segment 110 and the rear segment 120 so that the excitation coil enters the segment core part with the rotor shaft as the center, and a permanent magnet 130 in each segment. In the method for manufacturing a rotor having a plurality of slots 111 and 121 for inserting ), and the assembly process (S60), and is specifically as follows.

The cutting process (S10) is a process of cutting a raw material made of steel with a press to form a weight of the front or rear segments 110 and 120 in a cylindrical shape.

In the cutting process (S10), a raw material that is easy to derive uniform physical properties in a hot forging process (S20), which will be described later by deoxidizing in the process of making steel, such as steel, for example, killed steel is used.

In the cutting process (S10), the raw material is cut in a weight range of about 1240 to 1265 g with a 250-ton press to control so that harmful defects or burrs are not generated.

The forging process ( S20 ) is a process of hot forging the segment weight to form a segment molded body forming a plurality of slot structures 111 and 121 along an outer circumferential surface.

The forging process (S20) is a process for deriving the appearance and dimensions of the front or rear segments 110 and 120 by hot forging, and consists of a first forging process to a third forging process (S21 to S23).

The first forging process (S21) is a process of preparing a preform by heating the segment weight in a high-frequency heating furnace.

In the first forging process (S21), the segment weight formed by the cutting process (S10) is heated at a high frequency in a temperature range of about 1180 to 1280° C. for 6 to 8 seconds to form a preform in a state that can be put into a forging mold.

The secondary forging process (S22) is a process of forming a primary molded body by putting the preform into a forging mold corresponding to the shape of the front or rear segments 110 and 120 and performing hot forging.

In the secondary forging process (S22), a primary molded body is molded by a 1000-ton press using a forging mold that forms an inner mold corresponding to the outer shape of the front or rear segments 110 and 120.

The forging mold is configured to form the exterior of the front or rear segments 110 and 120 without a separate unmolded part in the primary molded body formed by the secondary forging process (S22) by reflecting all of the parts in the external appearance of the segment.

In the second forging process (S22), the front segment 110 and the rear segment 120 are formed in different forging molds, respectively, to form a slit structure at the inner end of the slot 111 formed in the front segment 110, , the inner end of the slot 121 formed in the rear segment 120 is configured to form a blocking structure.

The front segment 110 and the rear segment 120 are assembled to surround the excitation coil wound around the rotor shaft in an assembling process S60 to be described later, so that the respective slots 111 and 121 are provided in a zigzag direction.

In the second forging process (S22), a slit structure is formed at the inner end of the slot 111 in the forging die for the front segment 110, and at the inner end of the slot 121 in the forging die for the rear segment 120. By providing to form a clogging structure, the permanent magnet 130 can be assembled in a state in which both segments are assembled.

The third forging step (S23) is a process of hot forging the primary molded body, piercing the rotor shaft hole in the core, and trimming the excess attached to the outer peripheral surface to form the secondary molded body.

In the third forging process (S23), the secondary molded body is formed with a 250-ton press to remove excesses generated on the outer peripheral surface of the primary molded body in the process of the secondary forging process (S22) and form a rotor shaft hole. .

In the third forging process (S23), it is controlled so that harmful defects or burrs do not occur in the process of piercing and trimming.

The surface treatment process (S30) is a process of removing scale by injecting the segment molded body into shot blasting and forming a segment preliminary body.

In the surface treatment process (S30), the film line of the preliminary body is smoothly formed by removing various scales attached to the outside of the segment molded body that has undergone a series of forging processes (S20).

The sizing process ( S40 ) is a process of putting the segment preliminary body into a press machine, adjusting it to a desired size, and forming a segment completed body.

The sizing process (S40) is a process for deriving the appearance and dimensional accuracy of the segment preliminary body, and includes a primary sizing process (S41) and a secondary sizing process (S42).

The primary sizing process (S41) is a process of forming the primary finished body by compressing the segment preliminary body with a press machine, adjusting the thickness and height dimensions to target values, and removing the air hole.

In the primary sizing process (S41), the primary finished body is formed by compressing for several seconds with a press of 750 tons or more to remove air holes that may occur in the forging process (S20) while forming the desired thickness and core height for external dimensions. do.

The secondary sizing process (S42) is a process of forming the secondary finished body by trimming the primary finished body with a press machine and adjusting the outer diameter dimension to a target value.

In the secondary sizing process (S42), the primary finished body is compressed again for a few seconds with a 110-ton press, and the outer diameter and foot width are finally adjusted to the target values to form the secondary finished body.

The completion process (S50) is a process of removing the scale by putting the segment completion body into shot blasting, and forming the front or rear segment (110, 120) complete body.

In the completion process (S50), various scales attached to the exterior of the secondary finished body finally molded to the desired appearance and dimensions are removed, and the film line is smoothly formed to finally complete the front segment 110 and the rear segment 120. to derive

The assembling process ( S60 ) is a process of assembling the permanent magnet 130 and the retainer in the slots 111 and 121 provided in the complete body of the front and rear segments 110 and 120 .

In general, a rotor is formed by assembling parts such as a rotor shaft, a coil assembly, a front segment 110 , a rear segment 120 , a permanent magnet 130 assembly, a front fan, a rear fan, a bearing, a collar, and a slip ring.

In the assembling process (S60), after assembling the complete body of the front segment 110 and the rear segment 120 to the rotor shaft, in the opening 112 formed in the slot 111 of the front segment 110, the rear segment ( The permanent magnet 130 and the retainer are pushed toward the blockage 122 formed in the slot 121 of the 120 and configured to be assembled.

In the slots 111 and 121 of the front and rear segments 110 and 120, a slit structure is formed at the inner end of the slot 111 of the front segment 110 by each forging die in the second forging process (S22), and the rear segment (120) to form a blocking structure at the inner end of the slot (121).

In the assembling process (S60), the front segment 110 and the rear segment 120 are assembled on the rear side through the opening 112 provided on the front side among the slots 111 and 121 on both sides provided in the zigzag direction along the outer circumferential surface. It is configured to assemble by pushing the permanent magnet 130 and the retainer up to the blocking part 122 provided in the .

The difference between the method for manufacturing a rotor having a forged slot to which the technology of the present invention is applied and the prior art having the configuration as described above will be described in more detail as follows.

The method for manufacturing a rotor having a forged slot according to the present invention largely comprises a cutting step (S10) of forming a weight of the front and rear segments 110 and 120 using raw materials, and a hot forging of the weight of the segment to form a preform, a primary formed body, and a secondary The first to third forging process (S21 to S23) and a series of forging processes (S20) of forming the molded body in the order of the segment molded body surface treatment to form the preliminary body The surface treatment process (S30), the primary sizing process (S41) and the secondary sizing process (S42) of deriving dimensional accuracy from the preliminary body to form the primary finished body and the secondary finished body in the order, and the final surface treatment A completion process (S50) of forming the complete body of the front and rear segments 110 and 120 through is done

In particular, in the series of forging processes (S20) of the present invention, an additional machining process is excluded by reflecting the appearance of each part in the forging die, and the front segment 110 is provided with the opening 112 and the rear segment 120. A clogging portion 122 is formed there.

Accordingly, a smooth assembly process of the non-magnetized permanent magnet 130 and the retainer in the assembling process ( S60 ) is derived.

In contrast, in the prior art, a segment is provisionally formed through hot or cold forging using a material, and then slot machining for permanent magnet bonding is performed through a separate MCT machining process. For example, assuming that permanent magnets are arranged at approximately 24 places on both segments, the slots at 24 places must be formed through a machining process one by one.

In addition, in the prior art, because the structure of the slot is formed in the form of a groove due to the problems such as the difficulty of the MCT processing and the long process time required, the permanent magnet and retainer pre-magnetized in the final assembly process are inserted into one segment by an attachment method. After insertion, a series of steps are taken to assemble the other segment.

The method for manufacturing a rotor having a forged slot according to the present invention as described above provides a method for manufacturing a rotor having a forged slot configured to form an integral part of a slot structure for inserting a permanent magnet and a retainer by a forging method during manufacturing of the rotor.

Therefore, the present invention can significantly improve workability and productivity compared to a configuration in which a plurality of slots formed in both segments in a conventional rotor manufacturing method are individually formed by MCT processing in a desired shape and size.

In addition, the present invention has various effects such as improving dimensional accuracy and manufacturing a high-quality rotor by minimizing problems such as dimensional error or material wastage that may occur in the conventional processing process, so the industrial applicability is very high. is expected to

110: front segment
111: slot
112: opening
120: rear segment
121: slot
122: clogged part
130: permanent magnet
S10: Cutting process
S20: forging process
S21~S23: 1st to 3rd forging process
S30: surface treatment process
S40: Sizing process
S41~S42: 1st to 2nd sizing process
S50: Completion process
S60: Assembly process

Claims (5)

Manufacturing a rotor having a plurality of slots 111 and 121 in which the front segment 110 and the rear segment 120 are coupled so that the excitation coil enters the segment core part centering on the rotor shaft, and a permanent magnet 130 is inserted into each segment. In the method,
A cutting process (S10) of cutting a raw material made of steel with a press machine to form a cylindrical front or rear segment (110, 120) weight;
A forging process (S20) of hot-forging the segment weight to form a segment molded body forming a plurality of slot (111,121) structures along an outer circumferential surface;
A surface treatment process (S30) of putting the segment molded body into shot blasting to remove scale and forming a segment preliminary body;
A sizing process (S40) of putting the segment preliminary body into a press machine, adjusting it to a desired size, and forming a segment completed body;
A completion process (S50) of putting the segment completed body into shot blasting to remove scale and forming the front or rear segment (110, 120) complete body;
and an assembly step (S60) of assembling a permanent magnet (130) and a retainer in the slots (111, 121) provided in the front and rear segments (110, 120) complete body. The method of claim 1,
The forging process (S20) is,
The first forging process (S21) of preparing a preform by heating the segment weight in a high-frequency heating furnace;
A secondary forging process (S22) of putting the preform into a forging mold corresponding to the shape of the front or rear segments (110, 120) and hot forging to form a primary molded body;
A method for manufacturing a rotor having a forging slot, comprising a third forging step (S23) of hot forging the primary molded body, piercing the rotor shaft hole in the core, and trimming the excess attached to the outer peripheral surface to form the secondary molded body . 3. The method of claim 2,
In the second forging step (S22),
The front segment 110 and the rear segment 120 are formed with different forging molds, respectively, to form a slit structure at the inner end of the slot 111 formed in the front segment 110 , and the rear segment 120 is formed Rotor manufacturing method having a forged slot, characterized in that made to form a blocking structure at the inner end of the slot (121). The method of claim 1,
The sizing process (S40) is,
A primary sizing process (S41) of compressing the segment preliminary body with a press machine to adjust the thickness and height dimensions to target values, and removing air holes to form a primary finished body;
A method for manufacturing a rotor having a forged slot, characterized in that it comprises a secondary sizing step (S42) of trimming the primary finished body with a press machine and adjusting the outer diameter to a target value to form the secondary finished body. The method of claim 1,
In the assembly step (S60),
After assembling the complete body of the front segment 110 and the rear segment 120 to the rotor shaft, the slot 121 of the rear segment 120 in the opening 112 formed in the slot 111 of the front segment 110 . A method of manufacturing a rotor having a forged slot, characterized in that it is assembled by pushing the permanent magnet 130 and the retainer toward the blocking portion 122 formed in the .

Images