WO2020077556A1 - 一种线性涡流制动装置用制动磁极结构及其制造工艺 - Google Patents

一种线性涡流制动装置用制动磁极结构及其制造工艺 Download PDF

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WO2020077556A1
WO2020077556A1 PCT/CN2018/110614 CN2018110614W WO2020077556A1 WO 2020077556 A1 WO2020077556 A1 WO 2020077556A1 CN 2018110614 W CN2018110614 W CN 2018110614W WO 2020077556 A1 WO2020077556 A1 WO 2020077556A1
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Prior art keywords
magnetic pole
coil
pole structure
iron core
structure according
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PCT/CN2018/110614
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English (en)
French (fr)
Inventor
刘京
张东升
刘寅虎
牛瑞
朱新宇
曹云丽
余毅权
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南京中车浦镇海泰制动设备有限公司
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Priority claimed from CN201811201318.0A external-priority patent/CN109256931A/zh
Priority claimed from CN201811201380.XA external-priority patent/CN109256917A/zh
Application filed by 南京中车浦镇海泰制动设备有限公司 filed Critical 南京中车浦镇海泰制动设备有限公司
Publication of WO2020077556A1 publication Critical patent/WO2020077556A1/zh

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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
    • H02K3/00—Details of windings
    • H02K3/02—Windings characterised by the conductor material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K49/00—Dynamo-electric clutches; Dynamo-electric brakes
    • H02K49/02—Dynamo-electric clutches; Dynamo-electric brakes of the asynchronous induction type
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K49/00—Dynamo-electric clutches; Dynamo-electric brakes
    • H02K49/02—Dynamo-electric clutches; Dynamo-electric brakes of the asynchronous induction type
    • H02K49/04—Dynamo-electric clutches; Dynamo-electric brakes of the asynchronous induction type of the eddy-current hysteresis type

Definitions

  • the invention belongs to the technical field of rail vehicle braking systems, and in particular relates to a brake magnetic pole suitable for a magnetic levitation train and a manufacturing process thereof.
  • linear eddy current braking technology is to use the magnetic field generated by the energized braking pole to generate eddy current on the side guide rail under high-speed conditions.
  • the magnetic field generated by the eddy current interacts with the original magnetic field to attract, thus generating a braking force.
  • the braking force is finally transmitted to the bogie of the vehicle through the brake pole core, yoke, and tie rod assembly, thereby achieving braking.
  • the maximum speed of Shanghai magnetic levitation train is 500km / h
  • the magnetic pole used in the linear eddy current brake device used on the train the rated magnetomotive force of a single magnetic pole is 20.4KA. Due to the severe restrictions on space and weight, the magnetomotive force required to be generated is relatively large.
  • the use of aluminum film winding coil technology has the problems of difficulty in manufacturing, high cost, difficulty in winding process and welding process.
  • the maximum running speed of the new-generation magnetic levitation train is 600km / h. According to the deceleration requirements, it is calculated that the magnetic momentum needed to be provided by the brake pole is as high as 21.7kA. If the brake pole current is increased forcibly, the coil may be burned, resulting in brake failure and serious consequences. In the case that the structure, size, weight and other requirements of the entire product have not been relaxed, it is extremely challenging for the design of the brake magnetic pole.
  • the technical problem to be solved by the present invention is to overcome the above-mentioned shortcomings of the prior art and provide a brake magnetic pole structure for a linear eddy current brake device and a manufacturing process thereof.
  • the magnetic pole structure provided by the present invention includes:
  • Iron core used to conduct magnetic circuit and transfer braking force
  • Insulation layer set on the periphery of the iron core, used to isolate the coil and the iron core;
  • the coil is wound on the periphery of the insulating layer by enameled wire, which is used to generate magnetomotive force after being energized;
  • the support layer is provided on the periphery of the coil to improve the packaging strength
  • Fixed cable ties spaced along the periphery of the iron core, are used to tighten the coil and fix the fixed coil and the support layer (2) together;
  • the encapsulation layer wrapped around the magnetic pole structure, is used to close the coil and fasten it outside the iron core.
  • the invention is mainly composed of epoxy resin encapsulation layer, glass fiber net, insulating tape, heat shrinkable cable tie, iron core, coil assembly and terminal post.
  • the iron core is low carbon steel with good magnetic permeability, good magnetic permeability and high strength. It mainly has the function of conducting the magnetic circuit and transmitting the braking force;
  • the insulating tape mainly plays the role of electrical isolation and mechanical isolation between the iron core and the enameled wire;
  • coil The component is the excitation part, which generates a strong magnetic momentum after being energized;
  • the terminal is an electrical interface that introduces external energy into the coil component;
  • the heat shrinkable cable tie heat shrinks the coil and the support layer (glass fiber mesh) to ensure that The frameless coil will not be loose; the addition of the support layer (glass fiber mesh) can further strengthen the mechanical strength of the encapsulation layer;
  • the epoxy resin encapsulation layer is an insulating adhesive layer, which on the one hand increases the mechanical strength in the encapsulation area, on the other hand Insul
  • the magnetic pole structure of the present invention further has a terminal, the terminal and the cable end of the coil are electrically connected by a crimping terminal, and the encapsulation layer fixes the terminal to one side of the coil.
  • the present invention has designed a wire outlet structure form, which avoids the above problems, and uses crimping terminals that are easy to weld with copper and have good electrical conductivity to be crimped on the enameled wire after the paint is stripped, so that the wire and the crimping terminal are rigidly combined , And then solder the crimping terminal to the terminal, this way to ensure the integrity of the circuit, due to the good solderability between the crimping terminal (using copper material, such as H59, H62, etc.) and copper, the final welding machinery The strength is very reliable.
  • the cable end of the coil is stripped of paint and crimped with a crimping terminal, and the crimping terminal is welded to the terminal post, and the cable end of the coil is wrapped with an insulating sleeve near the crimping terminal.
  • the insulation sleeve is made of heat-shrinkable tube to prevent the extra leakage cable from contacting the outside world, which can provide double-layer electrical and mechanical protection.
  • the above magnetic pole structure is particularly suitable for the linear eddy current braking device of the magnetic suspension train.
  • the rated power of the magnetic pole can reach 3.2KW, the magnetomotive potential energy can reach 21.7kA, the heat resistance temperature is not less than F grade (155 ° C), the IP grade meets IP67, and the insulation withstand voltage meets AC2.4kV (1kHz) lasts for 1min, and the weight is not more than 24kg. It can meet the requirements of brake poles for the new generation of magnetic levitation trains.
  • the manufacturing process of the magnetic pole structure provided by the present invention includes the following steps:
  • Step 1 Arrange fixed cable ties at intervals around the core;
  • Step 2 The outer periphery of the iron core is bound with an insulating layer, and the fixing cable tie is fixed on the outer surface of the iron core;
  • Step 3 Wind the coil around the insulation layer
  • Step 4 Set a support layer around the coil, and tighten and fix the cable tie to fasten the support layer and the coil together;
  • Step 5 Place a binding post on one side of the coil, crimp the cable end of the coil and crimp the crimping terminal, and then solder the crimping terminal to the terminal;
  • Step 6 Put the magnetic pole structure into the encapsulation mold for vacuum encapsulation and curing, to complete the encapsulation of the magnetic pole structure.
  • Winding the winding with aluminum enameled wire eliminating the need for independent control of the insulating film and the absence of folding after the aluminum film and the insulating film are wrapped, greatly reducing the cost and the difficulty of the winding process;
  • the magnetic pole structure prepared by the process of the invention can reach the rated power of 3.2kw, the magnetodynamic potential energy can reach 21.7kA, the heat resistance temperature is not less than F grade (155 °C), and the IP grade meets IP67, insulation withstand voltage meets AC2.4kV (1kHz) for 1min strength, weight is not more than 24kg. It can meet the requirements of brake poles for the new generation of magnetic levitation trains.
  • FIG. 1 is a plan view of the brake magnetic pole.
  • Fig. 2 is a cross-sectional view taken along line A-A of Fig. 1.
  • Fig. 3 is a schematic diagram of the outlet method of the brake magnetic pole.
  • Fig. 4 is a partially enlarged view of the cross section of the brake magnetic pole.
  • Fig. 5 is a schematic diagram of fixing the heat shrinkable cable tie on the iron core.
  • Figure 6 is a schematic diagram of vacuum glue filling.
  • the magnetic pole structure of this embodiment is a braking magnetic pole structure suitable for a linear eddy current braking device of a magnetic suspension train.
  • the dimensions of the magnetic pole structure are: length 382.5 mm, width 167 mm, and height 51 mm.
  • the brake magnetic pole mainly includes an iron core 5, an insulating tape 3, a coil 6, a heat shrinkable cable tie 4, a glass fiber mesh 2, an epoxy resin encapsulation layer 1, and a binding post 7.
  • the iron core 5 is made of low carbon steel with good magnetic permeability and high strength, which is used to conduct the magnetic circuit and transmit the braking force.
  • the chamfer of the iron core 5 should not be less than 28mm, which can prevent the enameled wire from protruding at the junction of the chamfer and the straight edge.
  • the upper and lower sides of the outer periphery of the iron core 5 are provided with a circle of concave steps C, and the coil cable is wound around the periphery of the area between the two steps.
  • the size of the concave step is about 2 mm wide and 4 mm high.
  • the step reserves a certain space. After the epoxy resin is cured in the space, the axial displacement of the coil assembly is hindered to a certain extent.
  • the insulating tape 3 is provided on the periphery of the iron core 5 (the area between the two steps) to isolate the coil 4 and the iron core 5.
  • the insulating tape uses glass fiber tape.
  • the coil 6 is wound on the periphery of the insulating tape 3 by using aluminum enameled wire, which is used to generate magnetomotive force after being energized.
  • the insulating tape 3 is made of glass fiber.
  • the glass fiber mesh 2 is arranged on the periphery of the coil to improve the encapsulation strength.
  • the support layer adopts a high-strength mesh structure, so that the encapsulant can penetrate, and the coil 6 and the glass fiber mesh 2 are combined more tightly and firmly.
  • the glass fiber mesh 2 is used.
  • other mesh-like structural materials with higher strength, such as carbon fiber mesh can also be used.
  • the heat shrinkable cable tie 4 is arranged along the periphery of the iron core 5 to fix the coil 6 and fix the coil 6 and the support layer 2 together.
  • the insulating tape 3 is used to fix the heat-shrink ties 4 to the periphery of the iron core 5 at intervals, and then the coil 6 is wound. This facilitates the fixing of the heat shrinkable bandage 4 and the winding of the coil 6.
  • Comprehensive consideration of size restrictions, strength, etc. requires that the thickness of the heat shrinkable cable tie is not less than 0.3mm.
  • the epoxy resin encapsulation layer 1 is wrapped outside the magnetic pole structure and used to close the coil 6 and fasten it outside the iron core.
  • the minimum thickness of the epoxy resin layer should not be less than 1 mm.
  • the terminal 7, the terminal 7 and the cable end of the coil 6 are electrically connected by a crimping terminal 8, and the epoxy resin encapsulation layer 1 fixes the terminal 7 to the side of the coil 6.
  • the crimp terminal 8 is made of copper.
  • the cable end of the coil 6 is stripped of paint and crimped with the crimping terminal 8, and the crimping terminal 8 is welded and fixed to the terminal 7 (B is the welding place in the figure), and the cable end of the coil 6 A heat shrinkable sleeve 9 is wrapped near the crimping terminal 8.
  • Step 1 Heat shrink bands 4 are arranged at intervals around the core 5, specifically, as shown in FIG. 5, the heat shrink band 4 is fixed to the corresponding position on the iron core with glue to ensure that the heat shrink band 4 is wound around the enameled wire No displacement occurs during the process;
  • Step 2 the outer periphery of the iron core 5 is taped with insulating tape 3, and the heat shrinkable cable tie 4 is fixed on the outer surface of the iron core 5;
  • Step 3 Wind the coil 6 around the insulating tape 3;
  • Step 4 A support layer 2 is provided on the periphery of the coil 6, and the heat shrinkable cable tie 4 is tightened to fasten the glass fiber mesh 2 and the coil 6 together;
  • Step 5 Place the terminal 7 on one side of the coil 6, and remove the paint from the coil 6 by crimping with the crimping terminal 8.
  • the cable end of the coil 6 is wrapped with an insulating sleeve near the crimping terminal 8 9 (In this example, the insulating sleeve 9 is a heat shrinkable tube), and then the crimping terminal 8 and the terminal 7 are welded and fixed;
  • Step 6 the magnetic pole structure is put into the glue pouring mold 11, the glue pouring mold is put into the vacuum box 13 to perform vacuum glue pouring, and the glue injection port 12 is located at the bottom of the glue pouring mold 11.
  • the product is encapsulated with epoxy resin glue, so that the coil 6 and the terminal 7 are fixed, and the mechanical strength in the encapsulation area is increased, which plays the role of insulation and moisture resistance.
  • After filling place the filling mold in the thermostat to cure, and cure in stages according to the curing requirements of epoxy resin adhesive: 6h, 80 °C -2h, 90 °C -2h, 100 °C -8h, 130 °C, curing is completed After cooling, demold.
  • the present invention may have other embodiments. All technical solutions formed by equivalent replacement or equivalent transformation fall within the scope of protection required by the present invention.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)

Abstract

本发明涉及一种线性涡流制动装置用制动磁极结构,包括：铁芯，用于导通磁路和传递制动力；绝缘层，设置于铁芯外围，用于隔绝线圈和铁芯；线圈，采用漆包线绕设于绝缘层外围，通电后用于产生磁动势；支撑层，设置于线圈外围，用于提高封装强度；固定扎带，沿铁芯外围间隔的设置，用于将线圈和支撑层固定在一起；封装层，包裹于磁极结构外，用于对线圈进行封闭并将其紧固于铁芯外。本发明制动磁极额定功率约为3.2kW(单个磁极)，磁动势最大为21.7kA，耐热温度不小于F级，IP等级满足IP67要求，绝缘耐压满足AC2.4kV1000HZ要求，重量不大于24kg。可以满足新一代磁悬浮列车用对制动磁极的要求。

Description

[根据细则26改正31.10.2018]　一种线性涡流制动装置用制动磁极结构及其制造工艺 技术领域
本发明属于轨道车辆制动系统技术领域，具体涉及一种适用于磁悬浮列车的制动磁极，以及其制造工艺。
背景技术
现有磁悬浮列车多采用线性涡流制动装置进行紧急制动。线性涡流制动技术是利用高速条件下，制动磁极通电产生的磁场在侧面导轨产生涡流，根据麦克斯韦定律以及楞次定律，涡流产生的磁场与原磁场相互作用吸引，从而产生了制动力，该制动力通过制动磁极铁芯、磁轭、拉杆组件最终传递到车辆转向架上，从而实现制动。
上海磁悬浮列车最高时速为500km/h,车上使用的线性涡流制动装置用磁极，单个磁极的额定磁动势20.4KA。由于空间和重量等限制比较苛刻，需要产生的磁动势比较大，目前采用铝膜缠绕线圈技术存在制造难度大、造价高、缠绕工艺以及焊接工艺难度大等问题。
新一代磁悬浮列车的最高运行时速为600km/h，根据减速要求，推算出制动磁极需要提供的磁动势高达21.7kA。如果强行加大制动磁极电流，可能会烧坏线圈，造成制动失效，后果严重。在整个产品的结构和尺寸、重量等要求并未有所放松的情况下，对制动磁极的设计来说，极具挑战。
发明内容
本发明所要解决的技术问题是，克服现有技术的上述缺点，提供一种线性涡流制动装置用制动磁极结构及其制造工艺。
为了解决以上技术问题，本发明提供的磁极结构,包括：
铁芯，用于导通磁路和传递制动力；
绝缘层，设置于铁芯外围，用于隔绝线圈和铁芯；
线圈，采用漆包线绕设于绝缘层外围，通电后用于产生磁动势；
支撑层，设置于线圈外围，用于提高封装强度；
固定扎带，沿铁芯外围间隔的设置，用于扎紧线圈，以及将固定线圈和支撑层(2)固定在一起；
封装层，包裹于磁极结构外，用于对线圈进行封闭并将其紧固于铁芯外。
本发明主要由环氧树脂封装层、玻纤网、绝缘胶带、热缩扎带、铁芯、线圈组件以及接线柱组成。铁芯为导磁性较好的低碳钢，导磁性好而且强度高，主要有导通磁路以及传递制动力作用；绝缘胶带主要起到了铁芯与漆包线之间的电气隔离和机械隔离；线圈组件为励磁部分，主要通电后产生强大的磁动势；接线柱是电气接口，将外界能量引入线圈组件；热缩扎带将线圈与支撑层(玻纤网)进行热缩紧固，保证了无骨架线圈不会松散；支撑层(玻纤网)的加入可以进一步加强封装层的机械强度；环氧树脂封装层是绝缘胶层，一方面增加封装区域内的机械强度，另一方面起到了绝缘和防潮作用。
进一步的，本发明磁极结构，还具有接线柱,所述接线柱与线圈的线缆端部之间通过压接端子电连接，封装层将接线柱固定于与线圈的一侧。
由于现有磁极结构采用的是铝漆包线，接线柱是黄铜，两者的互焊性比较差，严重影响了生产的进度和产品本身的焊接强度。本发明设计了一种出线结构形式，较好地避免了上面的问题，在脱漆后的漆包线上使用与铜易焊接而且导电性良好的压接端子压接，使导线和压接端子硬性结合，然后将压接端子与接线柱进行焊接，该方式即保证了电路的完整性，由于压接端子(采用铜材质，例如H59，H62等)与铜之间良好的焊接性，最终焊接的机械强度十分牢靠。
更进一步的，所述线圈的线缆端部脱漆与压接端子压接，压接端子与接线 柱焊接固定，所述线圈的线缆端部靠近压接端子处包裹有绝缘套管。
绝缘套管选用热缩管，防止多余外漏的线缆与外界接触，可以起到电气和机械双层保护。
上述磁极结构，特别适合应用于磁悬浮列车的线性涡流制动装置。
本发明在不改变原有磁极产品尺寸的情况下，磁极额定功率可达到3.2KW，磁动势能达到21.7kA，耐热温度不小于F级(155℃)，IP等级满足IP67，绝缘耐压满足AC2.4kV(1kHz)持续1min强度，重量不大于24kg。可以满足新一代磁悬浮列车用对制动磁极的要求。
此外，本发明提供的磁极结构的制造工艺，包括以下步骤：
步骤1、铁芯外围间隔地布置固定扎带；
步骤2，铁芯外围绑上绝缘层，将固定扎带固定在铁芯外表面；
步骤3、在绝缘层外绕制绕线圈；
步骤4、线圈的外围设置支撑层，并收紧固定扎带，将支撑层和线圈紧固在一起；
步骤5、线圈的一侧放置接线柱，并将线圈的线缆端部脱漆后与压接端子压接，然后压接端子与接线柱焊接固定；
步骤6、将磁极结构放入灌胶模具中进行真空灌胶，并进行固化，完成磁极结构的封装。
本发明具有以下优点：
1、用铝制漆包线进行绕制绕组，省去了对绝缘薄膜的独立控制要求以及不存在铝膜和绝缘膜换行后折叠情况，大大降低了成本和绕制工艺难度；
2、线圈缠绕好后，用热缩扎带进行热缩紧固，保证了无骨架线圈不会松散。
3、在漆包线上压接与铜易焊金属材料(例如铜)，然后将其直接和接线柱 焊接起来，该优化方法使焊接处由4处减少为2处，且增加焊接强度和可靠性；
4、利用环氧树脂真空封装，大大减少了产品中空气气隙含量，增加最终产品的导热性能和绝缘性能。
本发明工艺制备的磁极结构，在不改变原有磁极产品尺寸的情况下，磁极额定功率可达到3.2KW，磁动势能达到21.7kA，耐热温度不小于F级(155℃)，IP等级满足IP67，绝缘耐压满足AC2.4kV(1kHz)持续1min强度，重量不大于24kg。可以满足新一代磁悬浮列车用对制动磁极的要求。
附图说明
图1是制动磁极的俯视图。
图2是图1的A-A剖视图。
图3是制动磁极的出线方式示意图。
图4是制动磁极横截面局部放大图。
图5是热缩扎带在铁芯上固定示意图。
图6是真空灌胶示意图。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述。
如图1至图4所示，本实施例磁极结构为适用于磁悬浮列车线性涡流制动装置的制动磁极结构，磁极结构的尺寸为：长382.5mm，宽167mm，高51mm。制动磁极主要包括有铁芯5、绝缘胶带3、线圈6、热缩扎带4、玻璃纤维网2、环氧树脂封装层1和接线柱7。
其中，铁芯5，选用导磁性好而且强度高的低碳钢，用于导通磁路和传递制动力。在满足磁通要求的情况下，铁芯5的倒角应不小于28mm，可以防止漆包线 在倒角与直边交界处凸起情况，一方面防止漆包线局部受力容易损伤，一方面防止线圈尺寸超出设计要求。铁芯5外周的上下各设置有一圈内凹的台阶C，线圈的线缆绕设于所述两个台阶之间的区域的外围。内凹台阶尺寸约为宽2mm，高4mm，该台阶预留一定的空间，在该空间内环氧树脂固化后，在一定程度上阻碍了线圈组件在轴向方面的位移。
绝缘胶带3，设置于铁芯5外围(两个台阶之间的区域)，用于隔绝线圈4和铁芯5。本实施例中绝缘胶带使用玻璃纤维胶带。
线圈6，采用铝漆包线绕设于绝缘胶带3外围，通电后用于产生磁动势。本例中，绝缘胶带3采用玻璃纤维材质的绝缘胶带。
玻璃纤维网2，设置于线圈外围，用于提高封装强度，支撑层采用强度高的网状结构，使得封装胶能够渗入，将线圈6和玻璃纤维网2结合的更紧密和稳固。本例选用玻璃纤维网2，除此之外还可以采用其他具有较高强度的网状结构材质，如碳纤维网等。
热缩扎带4，沿铁芯5外围间隔的设置，用于固定线圈6，以及将线圈6和支撑层2固定在一起。本例中，先利用绝缘胶带3将热缩扎带4间隔的固定于铁芯5外围，然后再绕线圈6。这样有利于热缩扎带4的固定和线圈6的绕制。综合考虑尺寸限制、强度等要求热缩扎带厚度不低于0.3mm。
环氧树脂封装层1，包裹于磁极结构外，用于对线圈6进行封闭并将其紧固于铁芯外,环氧树脂层最小厚度应不小于1mm。
接线柱7,接线柱7与线圈6的线缆端部之间通过压接端子8电连接，环氧树脂封装层1将接线柱7固定于与线圈6的一侧。压接端子8为铜材质。
如图3所示，线圈6的线缆端部脱漆，与压接端子8压接，压接端子8与接线柱7焊接固定(图中B为焊接处)，线圈6的线缆端部靠近压接端子8处包裹有热缩 套管9。
本实施例制动磁极的制造工艺，包括以下步骤：
步骤1、铁芯5外围间隔地布置热缩扎带4,具体的，如图5所示利用胶水将热缩扎带4固定在铁芯上的对应位置，保证热缩扎带4在漆包线缠绕过程中不发生位移；
步骤2，铁芯5外围绑上绝缘胶带3，将热缩扎带4固定在铁芯5外表面；
步骤3、在绝缘胶带3外绕制绕线圈6；
步骤4、线圈6的外围设置支撑层2，并收紧热缩扎带4，将玻璃纤维网2和线圈6紧固在一起；
步骤5、线圈6的一侧放置接线柱7，并将线圈6的线缆端部脱漆后与压接端子8压接，线圈6的线缆端部靠近压接端子8处包裹绝缘套管9(本例中，绝缘套管9为热缩管)，然后压接端子8与接线柱7焊接固定；
步骤6、如图6所示，将磁极结构放入灌胶模具11中，将灌胶模具放入真空箱13内，进行真空灌胶，注胶口12位于灌胶模具11的底部。本实施例中，利用环氧树脂胶对产品进行封装，使线圈6和接线柱7得到固定，并且增加封装区域内的机械强度，起到了绝缘和防潮的作用。灌胶完后将灌胶模具放在恒温箱内固化，按照环氧树脂胶的固化要求进行分阶段固化：6h，80℃-2h，90℃-2h，100℃-8h，130℃，固化完成后，冷却脱模。
除上述实施例外，本发明还可以有其他实施方式。凡采用等同替换或等效变换形成的技术方案，均落在本发明要求的保护范围。

Claims (20)

  1. 一种磁极结构,包括：
    铁芯(5)，用于导通磁路和传递制动力；
    绝缘层(3)，设置于铁芯(5)外围，用于隔绝线圈(4)和铁芯(5)；
    线圈(6)，采用漆包线绕设于绝缘层(3)外围，通电后用于产生磁动势；
    支撑层(2)，设置于线圈外围，用于提高封装强度；
    固定扎带(4)，沿铁芯(5)外围间隔的设置，用于扎紧线圈(6)，以及将固定线圈(6)和支撑层(2)固定在一起；
    封装层(1)，包裹于磁极结构外，用于对线圈(6)进行封闭并将其紧固于铁芯外。
  2. 根据权利要求1所述的磁极结构，其特征在于：还具有接线柱(7),所述接线柱(7)与线圈(6)的线缆端部之间通过压接端子(8)电连接，封装层(1)将接线柱(7)固定于与线圈(6)的一侧。
  3. 根据权利要求2所述的磁极结构，其特征在于：所述线圈(6)的线缆端部脱漆与压接端子(8)压接，压接端子(8)与接线柱(7)焊接固定，所述线圈(6)的线缆端部靠近压接端子(8)处包裹有绝缘套管(9)。
  4. 根据权利要求3所述的磁极结构，其特征在于：所述绝缘套管(9)为热缩管。
  5. 根据权利要求1所述的磁极结构，其特征在于：所述支撑层(2)为玻璃纤维网。
  6. 根据权利要求1所述的磁极结构，其特征在于：所述绝缘层(3)为绝缘胶带，所述固定扎带(4)为热缩扎带。
  7. 根据权利要求1所述的磁极结构，其特征在于：所述漆包线为铝制漆包线。
  8. 根据权利要求1所述的磁极结构，其特征在于：所述封装层(1)为环氧树脂封装层。
  9. 根据权利要求1所述的磁极结构，其特征在于：所述铁芯(5)外周的上下各设置有一圈内凹的台阶(C)，线圈的线缆绕设于所述两个台阶之间的区域的外围。
  10. 用于磁悬浮列车的线性涡流制动装置，其特征在于：具有权利要求1-9任一项所述的磁极结构。
  11. 一种磁极结构的制造工艺，包括以下步骤：
    步骤1、铁芯(5)外围间隔地布置固定扎带(4)；
    步骤2，铁芯(5)外围绑上绝缘层(3)，将固定扎带(4)固定在铁芯(5)外表面；
    步骤3、在绝缘层(3)外绕制绕线圈(6)；
    步骤4、线圈(6)的外围设置支撑层(2)，并收紧固定扎带(4)，将支撑层(2)和线圈(6)紧固在一起；
    步骤5、线圈(6)的一侧放置接线柱(7)，并将线圈(6)的线缆端部脱漆后与压接端子(8)压接，然后压接端子(8)与接线柱(7)焊接固定；
    步骤6、将磁极结构放入灌胶模具中进行真空灌胶，并进行固化，完成磁极结构的封装。
  12. 根据权利要求11所述磁极结构的制造工艺，其特征在于：线圈(6)的线缆端部靠近压接端子(8)处包裹绝缘套管(9)，所述压接端子(8)为铜材质。
  13. 根据权利要求12所述磁极结构的制造工艺，其特征在于：所述绝缘套管(9)为热缩管。
  14. 根据权利要求13所述磁极结构的制造工艺，其特征在于：步骤6中，利用环氧树脂胶对产品进行封装，灌胶完后将灌胶模具放在恒温箱内固化，按照环氧树脂胶的固化要求进行固化，固化完成后，冷却脱模。
  15. 根据权利要求11所述磁极结构的制造工艺，其特征在于：所述支撑层(2)为玻璃纤维网，绝缘层(3)为绝缘胶带，固定扎带(4)为热缩扎带,所述封装层(1)为环氧树脂封装层。
  16. 根据权利要求11所述磁极结构的制造工艺，其特征在于：步骤1中，利用胶水将固定扎带(4)固定在铁芯上的对应位置，保证固定扎带(4)在漆包线缠绕过程中不发生位移。
  17. 根据权利要求11所述磁极结构的制造工艺，其特征在于：所述铁芯(5)外周的上下各设置有一圈内凹的台阶(C)，线圈的线缆绕设于所述两个台阶之间的区域的外围。
  18. 根据权利要求11所述磁极结构的制造工艺，其特征在于：所述线圈的线缆为铝制漆包线。
  19. 根据权利要求11所述磁极结构的制造工艺，其特征在于：灌胶模具的注胶口位于灌胶模具的底部。
  20. 根据权利要求11所述磁极结构的制造工艺，其特征在于：所述压接端子的材质为铜。
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