WO2024001122A1 - 一种叠压型非晶、纳米晶铁芯的制备方法 - Google Patents

一种叠压型非晶、纳米晶铁芯的制备方法 Download PDF

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WO2024001122A1
WO2024001122A1 PCT/CN2022/142392 CN2022142392W WO2024001122A1 WO 2024001122 A1 WO2024001122 A1 WO 2024001122A1 CN 2022142392 W CN2022142392 W CN 2022142392W WO 2024001122 A1 WO2024001122 A1 WO 2024001122A1
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amorphous
nanocrystalline
iron core
lamination
preparation
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PCT/CN2022/142392
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English (en)
French (fr)
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鲍绪东
霍利山
郭海
杜兴龙
马丽
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宁波中科毕普拉斯新材料科技有限公司
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Publication of WO2024001122A1 publication Critical patent/WO2024001122A1/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
    • 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
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • 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
    • 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
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/16—Mechanical energy storage, e.g. flywheels or pressurised fluids

Definitions

  • the present invention relates to the technical field of magnetic circuit components of motors, and in particular to a method for preparing a laminated amorphous and nanocrystalline iron core.
  • Motors are the most power-consuming electrical equipment in the world. Improving motor efficiency is of great significance to energy conservation and emission reduction, alleviating energy stress and environmental pollution. The improvement of motor efficiency has received great attention from countries around the world, and more and more application fields have The performance of motors has put forward higher requirements, such as aerospace, electric vehicles, robots, high-speed compressors, high-speed flywheel energy storage, turbomolecular pumps, high-speed machine tools and other application fields, which not only require motors to have high power density or high speed, but also The motor is required to have high efficiency at the same time. To achieve high power density or high speed of the motor, the frequency of the motor must be increased. However, as the frequency of the motor increases, the core loss of the motor will increase sharply, seriously affecting the efficiency of the motor.
  • Chinese patent CN105118653A "A Preparation Method of Amorphous Alloy Iron Core for Motors and Transformers" proposes that the amorphous alloy strip is first coated on both sides, Then dry the coated amorphous alloy strip, cut the amorphous alloy strip, and press it into a laminate or wind it into an iron core embryo.
  • the iron core embryo is fixed in a fixture and heated/annealed/solidified.
  • the final surface coating treatment forms the required core components.
  • this preparation process is too complex and has high requirements on the coating process.
  • the existing preparation process of amorphous nanocrystalline motor cores also adopts the preparation process of "strip pressing - heat treatment - paint dipping and curing - wire cutting".
  • This preparation method usually involves winding the strip into a magnetic ring or punching it.
  • the sheets are cut into stacks and then pressed into magnetic blocks on a fixed fixture, and then undergo a series of heat treatment, paint dipping and curing, wire cutting and other processes to finally obtain the iron core.
  • the shortcomings of this method are long processing time, high cost, and unsuitable It is suitable for batch and large-scale production applications, and the remaining materials cut during the production process cannot be recycled, resulting in serious waste of raw materials, which in turn leads to an increase in production costs.
  • the present invention aims to provide a method for preparing a laminated amorphous and nanocrystalline iron core.
  • the amorphous and nanocrystalline alloy strips are cut into several pieces according to the cross-sectional design of the core.
  • the amorphous and nanocrystalline alloy monoliths of the same shape are stacked and pressed using an automatic lamination device to obtain a laminate of amorphous and nanocrystalline laminates and a lamination jig.
  • the preparation method includes the following steps:
  • Step S1 slicing: Cut the amorphous and nanocrystalline alloy strips according to the preset cross-sectional shape and size of the finished iron core to obtain multiple cross-sections with the same shape and size as the finished iron core.
  • Step S2 lamination: stack each of the amorphous and nanocrystalline alloy monoliths on the lamination jig in sequence to form the amorphous and nanocrystalline laminate body, and then laminate the amorphous and nanocrystalline laminates.
  • the sheet body and the lamination jig are placed on the workbench in the automatic lamination device, and the amorphous and nanocrystalline lamination bodies are compacted and preliminarily shaped through the automatic lamination device to obtain The laminated assembly;
  • Step S3 heat treatment: place the laminated assembly in a heat treatment furnace for heat treatment;
  • Step S4 paint dipping treatment: place the heat-treated laminated assembly in a vacuum pressure paint dipping equipment to perform paint dipping treatment;
  • Step S5 curing and shaping: bake and solidify the laminated assembly after soaking in paint, and then disassemble the cured and shaped amorphous and nanocrystalline laminated body from the lamination jig to obtain the iron core body;
  • Step S6 surface treatment: remove the redundant insulating paint on the surface of the iron core blank, and perform surface loss reduction treatment and surface protection treatment on the iron core blank to obtain the finished iron core.
  • the base of the lamination jig is provided with at least one set of stacking positioning devices and at least one handle, and each set of the stacking positioning devices includes at least one outer positioning column and one middle positioning column.
  • each of the amorphous and nanocrystalline alloy monoliths is provided with a central hole, and the outer ring of each of the amorphous and nanocrystalline alloy monoliths is provided with at least one gap.
  • step S2 The notches of each amorphous and nanocrystalline alloy single piece are respectively inserted into the outer positioning posts, and the center holes of each amorphous and nanocrystalline alloy single piece are inserted into the middle positioning posts respectively. pillars to form the amorphous and nanocrystalline laminates.
  • the lamination device includes a workbench, a lamination jig, a pressing mechanism and a screwing mechanism.
  • the lamination jig is placed on the workbench, and a pressing mechanism is installed above the lamination jig.
  • a screwing mechanism is set up directly above the pressing mechanism, then in step S2, a pressing block and a pressing nut are inserted into the middle positioning column in sequence, and then the pressing mechanism is controlled to squeeze
  • the pressing block is compacted, and the screwing mechanism is controlled to tighten the compression nut for preliminary shaping processing to obtain the laminated assembly.
  • the step S5 includes:
  • Step S51 Bake the laminated assembly after the paint dipping process at a temperature of 130°C-200°C and keep it warm for 1-8 hours;
  • Step S52 Cool the baked laminated assembly to normal temperature, and then disassemble the laminated assembly to obtain the iron core blank.
  • the amorphous and nanocrystalline alloy strip is cut by at least one of punch cutting, die cutting, electric discharge cutting, plasma cutting, laser cutting and water jet cutting. .
  • the heat treatment temperature is 250°C-580°C
  • the holding time is 1-5 hours
  • the temperature of the laminated body is cooled to below 200°C with the furnace body, and then cooled to Normal temperature.
  • the lamination jig is made of one of stainless steel, tool steel, titanium alloy, and ceramics.
  • step S6 the surface loss reduction treatment of the iron core body is performed by soaking in a weak acid solution; the surface protection treatment of the iron core body is uniformly coated with self-drying insulating paint. deal with.
  • the preparation method of the present invention can use batch cutting methods such as punching and die cutting to cut strips, which greatly improves production efficiency.
  • the entire process does not require wire cutting processes, and the cut waste strips can also be remelted. Utilization can significantly reduce production costs and make the production of amorphous and nanocrystalline iron cores more environmentally friendly and energy-saving;
  • the preparation method of the present invention uses a compression mechanism and a screwing mechanism to compress and fix the laminated body, with accurate positioning, high automatic lamination production efficiency, standardization of production process parameters, and conducive to mass production.
  • Figure 1 is a flow chart of the steps of the method in a preferred embodiment of the present invention.
  • Figure 2 is a schematic structural diagram of a lamination fixture in a preferred embodiment of the present invention.
  • Figure 3 is a schematic structural diagram of an automatic lamination device in a preferred embodiment of the present invention.
  • Figure 4 is a specific flow chart of step S5 in a preferred embodiment of the present invention.
  • Figure 5 is a graph showing core loss curves of amorphous and nanocrystalline iron cores in Example 1, Example 2, Comparative Example 1 and Comparative Example 2 in the preferred embodiment of the present invention.
  • a method for preparing a nanocrystalline alloy stator core for a motor is provided.
  • the cross-section design is cut into several amorphous and nanocrystalline alloy monoliths with the same shape, and an automatic lamination device is used to stack and press the cut amorphous and nanocrystalline alloy monoliths to obtain amorphous and nanocrystalline laminates and laminates.
  • the laminated assembly of the laminate jig is then subjected to heat treatment, paint dipping and curing treatment, and the cured amorphous and nanocrystalline laminated body is disassembled from the lamination jig to obtain the iron core blank body, and perform surface treatment on the iron core blank to obtain the finished iron core.
  • the preparation method includes the following steps:
  • Step S1 slicing: Cut the amorphous and nanocrystalline alloy strips according to the preset cross-sectional shape and size of the finished iron core to obtain multiple amorphous strips with the same shape and size as the cross-section of the finished iron core. , nanocrystalline alloy single piece;
  • Step S2 lamination: stack each amorphous and nanocrystalline alloy single piece on the lamination jig in sequence to form an amorphous and nanocrystalline laminate body, and then place the amorphous and nanocrystalline laminate body and the lamination jig. Go to the workbench in the automatic lamination device, and use the automatic lamination device to compact and preliminarily shape the amorphous and nanocrystalline laminated bodies to obtain a laminated assembly;
  • Step S3 heat treatment: place the laminated assembly in a heat treatment furnace for heat treatment;
  • Step S4 paint dipping treatment: place the heat-treated laminated assembly in a vacuum pressure paint dipping equipment for paint dipping treatment;
  • Step S5 curing and shaping: bake and solidify the laminated assembly after being dipped in paint, and then disassemble the cured and shaped amorphous and nanocrystalline laminated bodies from the lamination jig to obtain an iron core body;
  • Step S6 surface treatment: remove the redundant insulating paint on the surface of the iron core body, and perform surface loss reduction treatment and surface protection treatment on the iron core body to obtain the finished iron core.
  • interlayer bonding was used to fix amorphous or nanocrystalline alloy sheets.
  • this method has problems of weak bonding and interlayer cracking
  • an automatic laminating device was used to The amorphous and nanocrystalline laminated bodies are fixed between layers to ensure the mechanical stability of the core and avoid core damage caused by interlayer cracking caused by weak bonding and uneven stress.
  • amorphous and nanocrystalline alloy sheets of the same shape can be obtained with only one cutting, and the entire preparation process of the iron core only requires one heat treatment, which greatly shortens the time of the preparation process.
  • the amorphous and nanocrystalline iron core prepared at the same time has excellent magnetic properties and mechanical properties.
  • the preparation method is suitable for preparing both an amorphous iron core and a nanocrystalline iron core.
  • an amorphous iron core only the amorphous alloy strip needs to be processed. Multiple amorphous alloy monoliths of the same shape are obtained by cutting, and then the amorphous iron core can be prepared through the subsequent steps of this preparation method.
  • a nanocrystalline iron core only the nanocrystalline alloy strip needs to be prepared. A plurality of nanocrystalline alloy monoliths of the same shape are obtained by cutting, and then a nanocrystalline iron core can be prepared through subsequent steps of the preparation method.
  • the temperature of the heat treatment needs to be adjusted.
  • the base 2 of the lamination fixture 1 is provided with at least one set of stacking positioning devices and at least one handle 3, and each set of stacking positioning devices includes at least one The outer positioning post 4 and the central positioning post 5.
  • each amorphous or nanocrystalline alloy single piece is provided with a central hole 6, and each amorphous or nanocrystalline alloy single piece is provided with a notch 7 on the outer ring. Then in step S2 , insert the notch 7 of each amorphous and nanocrystalline alloy piece into the outer positioning post 4 respectively, and penetrate the center hole 6 of each amorphous and nanocrystalline alloy piece into the middle positioning post 5 respectively to form an amorphous, nanocrystalline alloy piece.
  • the cross-section of the outer positioning post 4 is wedge-shaped, and the apex of the wedge faces the outer positioning post 4.
  • the outer positioning post 4 is engraved with dimensions to facilitate the operator to measure and calculate the amorphous and nanocrystalline laminates. 8 height.
  • the cross section of the notch 7 on the amorphous or nanocrystalline alloy single piece is adapted to the cross section size of the outer positioning post 4 .
  • the amorphous and nanocrystalline laminate body 8 is composed of several layers of amorphous and nanocrystalline alloy sheets stacked on the lamination jig 1, and each amorphous or nanocrystalline alloy sheet has a gap 7.
  • the notch 7 is fully engaged with one side of the outer positioning post 4, and the pressure block 12 is also provided with the same notch 7.
  • the amorphous and nanocrystalline alloy monolithic Arranged in an orderly manner the amorphous and nanocrystalline alloy single pieces are pressure-impregnated by the pressing block 12 and tightened and fixed by the automatic lamination device to obtain a laminated assembly.
  • the core loss of the nanocrystalline iron core prepared by this preparation method is only 2.52W/kg, which is much lower than the nanocrystalline iron core prepared by the traditional method. core loss.
  • the lamination device includes a workbench 9, a lamination jig 1, a pressing mechanism 10, and a screwing mechanism 11.
  • the lamination jig 1 is placed on the workbench 9
  • a pressing mechanism 10 is set up above the lamination jig 1
  • a screwing mechanism 11 is set up directly above the pressing mechanism 10 (other devices and connection methods are not shown in the figure), then in step S2, a pressing mechanism 11 is set up directly above the pressing mechanism 10.
  • the block 12 and a compression nut 13 are inserted into the middle positioning column 5 in sequence, and then the compression mechanism 10 is controlled to squeeze the compression block 12 for compaction processing, and the screwing mechanism 11 is controlled to tighten the compression nut 13 for preliminary shaping processing. , to obtain the laminated assembly.
  • step S5 includes:
  • Step S51 Bake the impregnated laminated assembly at a temperature of 130°C-200°C and keep it warm for 1-8 hours;
  • step S52 the baked laminated assembly is cooled to normal temperature, and then the laminated assembly is disassembled to obtain an iron core body.
  • step S1 the method of cutting the amorphous or nanocrystalline alloy strip is punching cutting, die cutting, electric spark cutting, plasma cutting, laser cutting and water jet cutting. At least one.
  • the cutting method is not limited in this embodiment. It only needs to be punched cutting, die cutting, electric spark cutting, plasma cutting, laser cutting and water cutting. At least one of the knife cutting methods can be used to cut the amorphous or nanocrystalline alloy strip.
  • the heat treatment temperature is 250°C-580°C
  • the heat preservation time is 1-5 hours
  • the temperature of the laminated body is cooled to below 200°C along with the furnace body. Then cool to room temperature.
  • the heat treatment process is generally divided into heating, insulation and cooling.
  • the laminated assembly is heated to 250°C-580°C in the heating stage, and the heated laminated assembly is treated in the insulation stage. Insulate for 1-5 hours.
  • the laminated assembly after the insulation is dropped to below 200°C with the furnace body, and then cooled to normal temperature.
  • the material of the lamination fixture 1 is one of stainless steel, tool steel, titanium alloy, and ceramics.
  • the material of the lamination jig 1 is not limited, and stainless steel, tool steel, titanium alloy, or ceramics can be used.
  • stainless steel is used as the manufacturing material of the lamination jig 1 in this embodiment.
  • step S6 the surface loss reduction treatment of the iron core body is performed by immersing it in a weakly acidic solution.
  • step S6 the surface protection treatment of the core body is uniformly coated with self-drying insulating paint.
  • Step S1 slicing: According to the shape of the finished circular iron core, use punching and cutting to transversely cut the iron-based nanocrystalline soft magnetic alloy strip to obtain multiple circular nanocrystalline alloy single pieces with a size of 50*40mm;
  • Step S2 lamination: Stack the nanocrystal alloy monoliths on the lamination jig 1 in sequence to obtain a nanocrystal laminated body, press the pressing block 12 on the upper surface of the nanocrystal laminated body, and then use an automatic laminating device
  • the nanocrystal laminated body is compacted and preliminarily shaped to obtain a laminated assembly. Specifically, the height of the obtained nanocrystal laminated body is 20mm;
  • Step S3 heat treatment: Under vacuum conditions and when the heat treatment temperature is above 550°C, heat treat the laminated assembly after compaction and preliminary shaping, and keep it warm for 2 hours. The temperature of the nanocrystal laminated body cools down with the furnace body. to below 200°C and then cooled to normal temperature;
  • Step S4 paint dipping treatment: place the heat-treated laminated assembly in a vacuum pressure paint dipping equipment for paint dipping treatment;
  • Step S5 curing and shaping: bake and solidify the laminated assembly after being dipped in paint, and then disassemble the nanocrystal laminated body to obtain an iron core body with a size of 50*40*20mm;
  • Step S6 surface treatment: remove the redundant insulating paint on the surface of the iron core body, and perform surface loss reduction treatment and surface protection treatment on the iron core body to obtain the finished iron core.
  • the AC and DC superimposed soft magnetic testing device MATS-2010SA was used to test the prepared nanocrystalline iron core with the stacked and fixed method. It was found that the core loss of the nanocrystalline iron core with the stacked and fixed method was when the frequency was 1kHz and the magnetic flux density was 1.0T. Only 2.52W/kg.
  • Example 2 the same soft magnetic alloy strip as in Example 1 was used, and Fe-Si-B-Nb-Cu iron-based nanocrystalline soft magnetic alloy strip with an average strip thickness of 20 ⁇ 2 ⁇ m was used.
  • the specific steps as follows:
  • Step S1 strip pressing and forming: wind the iron-based nanocrystalline soft magnetic alloy strip into a magnetic ring with a size of 65*55*63mm or cut it into a square sheet with a size of 60*60mm.
  • the material is placed on a steel plate with a fixing device, and then another steel plate is pressed on the magnetic ring or sheet, and the upper and lower steel plates are fixed with screws, so that the magnetic ring or sheet is pressed into a 20mm high magnetic block;
  • Step S2 heat treatment: The magnet block obtained in step S1 is placed in a vacuum heat treatment furnace for heat treatment at 550°C and kept for 2 hours. After the temperature of the magnet block cools down to 200°C with the furnace body, it is then cooled to normal temperature;
  • Step S3 paint dipping and curing: Dip the magnet block obtained in step S2 into paint, and then cure it at 150°C, keep it for 2 hours and then air-cool to room temperature;
  • Step S4 wire cutting: The magnet block cured in step S3 is wire-cut according to the structure and size of the finished iron core to obtain a finished iron core with a size of 50*40*20mm.
  • the AC and DC superimposed soft magnetic testing device MATS-2010SA was used to test the prepared iron core and found that the average core loss of the nanocrystalline iron core was only 4.48W/kg when the frequency was 1kHz and the magnetic flux density was 1.0T.
  • a different amorphous alloy strip is selected from that in Embodiment 1.
  • Fe-Si-B iron-based amorphous soft magnetic alloy strip with an average strip thickness of 20 ⁇ 2 ⁇ m is used.
  • the heat treatment temperature is 390°C.
  • the preparation method is the same as that of Example 1, and the size of the iron core prepared is the same as that of Example 1.
  • the loss test results of the iron core prepared by this method are shown in Table 1.
  • Example 2 the same amorphous alloy strip as in Example 2 was used. Fe-Si-B iron-based amorphous soft magnetic alloy strip with an average strip thickness of 20 ⁇ 2 ⁇ m was used.
  • the other preparation methods were the same as those in Comparative Example 1. The preparation method is the same, and the dimensions of the finished iron core are the same as those in Example 2.
  • the loss test results of the iron core prepared by this method are shown in Table 1.
  • the core loss of the nanocrystalline iron core prepared in Example 1 is only 2.52W/kg, and the amorphous iron core prepared in Example 2
  • the core loss is 4.832W/kg, while the core loss of the nanocrystalline core prepared in Comparative Example 1 is 4.48W/kg, and the core loss of the amorphous iron core prepared in Comparative Example 2 is 6.99W. /kg. It can be seen that under the same test environment, the core loss of the nanocrystalline iron core prepared by the method of the present invention for the same soft magnetic alloy strip is lower than the core loss of the nanocrystalline iron core prepared by the traditional method.
  • the amorphous iron core made by the traditional method When the magnetic flux density Bm remains unchanged and the frequency f is gradually increased, it can be found that the amorphous iron core made by the traditional method, the amorphous iron core made by the preparation method of the present invention, and the nanocrystalline magnetic core made by the traditional method can be found.
  • the difference in core loss between the amorphous iron core and the nanocrystalline iron core prepared by the preparation method of the present invention is getting larger and larger.
  • the amorphous iron core and nanocrystalline iron core prepared by the preparation method of the present invention still have lower core loss and far superior performance. Much higher than iron cores prepared by other methods.
  • the amorphous and nanocrystalline iron cores prepared by the method of the present invention have excellent soft magnetic properties, and their core loss is lower than that of the amorphous and nanocrystalline iron cores prepared by the traditional method.
  • the core loss is low, so it shows that the amorphous and nanocrystalline iron core obtained by using amorphous and nanocrystalline alloy strips and the preparation method of the present invention has excellent high magnetic permeability and low core loss, and through Figure 5
  • the core loss curve shows that under the premise that the magnetic flux density remains unchanged, as the frequency in the test environment increases, the reduction effect of the core loss of the amorphous and nanocrystalline iron cores prepared by the preparation method of the present invention becomes more obvious.

Abstract

本发明提供一种叠压型非晶、纳米晶铁芯的制备方法，将非晶、纳米晶合金带材按照铁芯的横截面设计切割成若干具有相同形状的非晶、纳米晶合金单片，并利用自动叠压装置将切割好的非晶、纳米晶合金单片堆叠压制得到非晶、纳米晶叠片体和叠片治具组合的叠压组合体，随后对叠压组合体进行热处理、浸漆和固化处理，从叠片治具上拆解下固化定型后的非晶、纳米晶叠片体得到铁芯坯体，并对铁芯坯体进行表面处理得到铁芯成品。有益效果本发明中的制备方法为叠压固定法，所制备得到的非晶、纳米晶铁芯相比于常规方法制备得到的非晶、纳米晶铁芯具有更低铁芯损耗的软磁特性，适合高效批量生产，制备工艺流程短且可对废带材进行重熔利用，有效降低生产成本。

Description

一种叠压型非晶、纳米晶铁芯的制备方法 技术领域
本发明涉及电机的磁路零部件技术领域，尤其涉及一种叠压型非晶、纳米晶铁芯的制备方法。
背景技术
电机是世界上耗电量最高的电气设备，提高电机效率对节能减排、缓解能源紧张和环境污染均具有重大意义，电机效率的提高受到世界各国的高度重视，越来越多的应用领域对电机的性能提出了更高的要求，例如航空航天、电动汽车、机器人、高速压缩机、高速飞轮储能、涡轮分子泵、高速机床等应用领域，不仅要求电机具有高功率密度或者高转速，还要求电机同时具有高效率，要实现电机的高功率密度或者高转速必须提高电机的频率，然而随着电机频率的提高电机的铁芯损耗将会急剧增加，严重影响电机的效率。
传统的电机铁芯多采用硅钢铁芯，但硅钢的铁芯损耗高且铁芯发热严重，随着高速高频电机的广泛应用，传统硅钢铁芯已经逐渐不能满足高速高频电机的使用要求。需要一种新的材料来替代硅钢材料制备铁芯，非晶纳米晶合金作为一种新型材料，与传统的硅钢材料相比，具有高磁导率、低损耗的优势，且已经在高速高频电机上展现出很好的应用优势和前景，如中国专利CN105118653A《一种电机、变压器用非晶合金铁芯的制备方法》提出方法是：先对非晶合金带材进行双 面涂层处理，然后烘干经涂层处理的非晶合金带材、切割非晶合金带材，并压制成层叠体或卷绕成铁芯胚、将铁芯胚固定在夹具中并进行加热/退火/固化，最后表面涂层处理形成所需铁芯部件。但是本制备工艺太过于复杂，且对涂覆工艺要求高。此外，现有的制备非晶纳米晶电机铁芯也采用“带材压制成型-热处理-浸漆固化-线切割”的制备工艺，这种制备方法通常是将带材卷绕成磁环或者冲裁成片材堆叠然后在固定夹具上压制成磁块，然后进行一系列的热处理、浸漆固化、线切割等工艺最终获得铁芯，但是该方法不足之处在于加工时间长、成本高，不适于批量化、规模化生产应用，而且在生产过程中切割的余料产生无法回收利用，使得原材料浪费严重，进而导致生产成本增加。
发明内容
针对现有技术中存在的问题，本发明旨在提供一种叠压型非晶、纳米晶铁芯的制备方法，将非晶、纳米晶合金带材按照铁芯的横截面设计切割成若干具有相同形状的非晶、纳米晶合金单片，并利用一自动叠压装置将切割好的非晶、纳米晶合金单片堆叠压制得到非晶、纳米晶叠片体和叠片治具组合的叠压组合体，随后对所述叠压组合体进行热处理、浸漆和固化处理，从所述叠片治具上拆解下固化定型后的所述非晶、纳米晶叠片体得到铁芯坯体，并对所述铁芯坯体进行表面处理得到铁芯成品。
优选的，所述制备方法包括以下步骤:
步骤S1，切片：根据预先设定的所述铁芯成品的横截面形状和 尺寸对非晶、纳米晶合金带材进行切割，以得到多个与所述铁芯成品的横截面具有相同形状和尺寸的所述非晶、纳米晶合金单片；
步骤S2，叠压：将各所述非晶、纳米晶合金单片依次堆叠至所述叠片治具上形成所述非晶、纳米晶叠片体，随后将所述非晶、纳米晶叠片体和所述叠片治具放置到所述自动叠压装置内的工作台上，通过所述自动叠压装置将所述非晶、纳米晶叠片体进行压实和初步定型处理，得到所述叠压组合体；
步骤S3，热处理：将所述叠压组合体放置于热处理炉中进行热处理；
步骤S4，浸漆处理：将热处理后的所述叠压组合体放置于真空压力浸漆设备中，进行浸漆处理；
步骤S5，固化定型：将浸漆后的叠压组合体进行烘烤固化，随后从所述叠片治具上拆解下固化定型的所述非晶、纳米晶叠片体，得到所述铁芯坯体；
步骤S6，表面处理：去掉所述铁芯坯体表面的冗余绝缘漆，并对所述铁芯坯体进行表面降损处理和表面保护处理，得到所述铁芯成品。
优选的，所述叠片治具的底座上设有至少一组叠压定位装置和至少一提手，每组所述叠压定位装置包括至少一外定位柱和一中定位柱。
优选的，各所述非晶、纳米晶合金单片上分别开设有一中心孔，各所述非晶、纳米晶合金单片的外环上分别开设有至少一缺口，则所 述步骤S2中，将各所述非晶、纳米晶合金单片的所述缺口分别卡入所述外定位柱，并将各所述非晶、纳米晶合金单片的所述中心孔分别穿入所述中定位柱，以形成所述非晶、纳米晶叠片体。
优选的，所述叠压装置包括工作台、叠片治具、压紧机构和旋拧机构，所述叠片治具置于工作台上，所述叠片治具的上方架设有一压紧机构，所述压紧机构的正上方架设有一旋拧机构，则所述步骤S2中，将一压块和一压紧螺帽依次穿入所述中定位柱，随后控制所述压紧机构挤压所述压块进行压实处理，并控制所述旋拧机构旋紧所述压紧螺帽进行初步定型处理，以得到所述叠压组合体。
优选的，所述步骤S5包括：
步骤S51，在130℃-200℃温度下对浸漆处理后的所述叠压组合体进行烘烤，并保温1-8小时；
步骤S52，将烘烤处理后的所述叠压组合体冷却至常温，随后拆解所述叠压组合体得到所述铁芯坯体。
优选的，所述步骤S1中，对所述非晶、纳米晶合金带材进行切割的方式为冲片切割、模切、电火花切割、等离子切割、激光切割和水刀切割中的至少一种。
优选的，所述步骤S3中，热处理温度为250℃-580℃，保温时间为1-5小时，且在保温结束后所述叠片体的温度随炉体降温至200℃以下，然后冷至常温。
优选的，所述叠片治具的材料为不锈钢、工具钢、钛合金、陶瓷中的一种。
优选的，所述步骤S6中，对所述铁芯坯体进行表面降损处理的方式为弱酸性溶液浸泡；对所述铁芯坯体进行表面保护处理的方式为均匀涂覆自干绝缘漆处理。
上述技术方案具有如下优点或有益效果：
1)本发明中的制备方法可采用冲片、模切等批量化切割方式对带材进行切割，大大提高生产效率，整个过程无需线切割工艺，且切割掉的废带材还可以进行重熔利用，大幅降低生产成本，使非晶、纳米晶铁芯的生产更加环保节能；
2)本发明中的制备方法采用压紧机构和旋拧机构对叠片体进行压紧和固定，定位精准、自动叠压生产效率高，实现生产工艺参数的标准化，有利于批量化生产。
附图说明
图1为本发明的较佳的实施例中，本方法的步骤流程图；
图2为本发明的较佳的实施例中，叠片治具的结构示意图；
图3为本发明的较佳的实施例中，自动叠压装置的结构示意图；
图4为本发明的较佳的实施例中，步骤S5的具体流程图；
图5为本发明的较佳的实施例中，实施例一、实施例二、对比例一和对比例二中非晶、纳米晶铁芯的铁芯损耗曲线图。
附图说明：1、叠片治具；2、底座；3、提手；4、外定位柱；5、中定位柱；6、中心孔；7、缺口；8、非晶、纳米晶叠片体；9、工作台；10、压紧机构；11、旋拧机构；12、压块；13、压紧螺帽。
具体实施方式
下面结合附图和具体实施例对本发明进行详细说明。本发明并不限定于该实施方式，只要符合本发明的主旨，则其他实施方式也可以属于本发明的范畴。
本发明的较佳的实施例中，基于现有技术中存在的上述问题，现提供一种电机用纳米晶合金定子铁芯的制备方法，将非晶、纳米晶合金带材按照铁芯的横截面设计切割成若干具有相同形状的非晶、纳米晶合金单片，并利用一自动叠压装置将切割好的非晶、纳米晶合金单片堆叠压制得到非晶、纳米晶叠片体和叠片治具组合的叠压组合体，随后对叠压组合体进行热处理、浸漆和固化处理，从叠片治具上拆解下固化定型后的非晶、纳米晶叠片体得到铁芯坯体，并对铁芯坯体进行表面处理得到铁芯成品。
本发明的较佳的实施例中，如图1所示，制备方法包括以下步骤:
步骤S1，切片：根据预先设定的铁芯成品的横截面形状和尺寸对非晶、纳米晶合金带材进行切割，以得到多个与铁芯成品的横截面具有相同形状和尺寸的非晶、纳米晶合金单片；
步骤S2，叠压：将各非晶、纳米晶合金单片依次堆叠至叠片治具上形成非晶、纳米晶叠片体，随后将非晶、纳米晶叠片体和叠片治具放置到自动叠压装置内的工作台上，通过自动叠压装置将非晶、纳米晶叠片体进行压实和初步定型处理，得到叠压组合体；
步骤S3，热处理：将叠压组合体放置于热处理炉中进行热处理；
步骤S4，浸漆处理：将热处理后的叠压组合体放置于真空压力 浸漆设备中，进行浸漆处理；
步骤S5，固化定型：将浸漆后的叠压组合体进行烘烤固化，随后从叠片治具上拆解下固化定型的非晶、纳米晶叠片体，得到铁芯坯体；
步骤S6，表面处理：去掉铁芯坯体表面的冗余绝缘漆，并对铁芯坯体进行表面降损处理和表面保护处理，得到铁芯成品。
具体地，本实施例中，以往固定非晶、纳米晶合金单片均采用层间粘接的方法，考虑到该方法存在粘接不牢固、层间开裂的问题，因此采用自动叠压装置对非晶、纳米晶叠片体进行层间固定，使铁芯的机械稳定性得到了保证，避免了因粘接不牢固、因受力不均匀而造成的层间开裂导致铁芯损坏的问题。
具体地，本实施例中，仅需一次切割就可得到多个相同形状的非晶、纳米晶合金单片，并且铁芯的整个制备过程只需要进行一次热处理，大大缩短了制备流程的时间，同时制备得到的非晶、纳米晶铁芯的磁性能和机械性能均十分优异。
具体地，本实施例中，本制备方法既适用于制备得到非晶铁芯，也适用于制备得到纳米晶铁芯，当需要制备得到非晶铁芯时，只需对非晶合金带材进行切割得到多个相同形状的非晶合金单片，随后通过本制备方法的后续步骤即可制备得到非晶铁芯，而当需要制备得到纳米晶铁芯时，只需对纳米晶合金带材进行切割得到多个相同形状的纳米晶合金单片，随后通过本制备方法的后续步骤即可制备得到纳米晶铁芯。
优选的，通过本制备方法分别制备非晶铁芯和纳米晶铁芯时需要对热处理的温度进行调整。
本发明的较佳的实施例中，如图2所示，叠片治具1的底座2上设有至少一组叠压定位装置和至少一提手3，每组叠压定位装置包括至少一外定位柱4和一中定位柱5。
本发明的较佳的实施例中，各非晶、纳米晶合金单片上分别开设有一中心孔6，各非晶、纳米晶合金单片的外环上分别开设有一缺口7，则步骤S2中，将各非晶、纳米晶合金单片的缺口7分别卡入外定位柱4，并将各非晶、纳米晶合金单片的中心孔6分别穿入中定位柱5，以形成非晶、纳米晶叠片体8。
具体地，本实施例中，外定位柱4的横截面为楔形，楔形的顶点朝向外定位柱4，外定位柱4上刻有尺寸，以方便操作人员测量计算非晶、纳米晶叠片体8的高度。
优选的，非晶、纳米晶合金单片上的缺口7的横截面与外定位柱4的横截面大小适配。
优选的，非晶、纳米晶叠片体8由若干层非晶、纳米晶合金单片在叠片治具1上堆叠而成，每个非晶、纳米晶合金单片上均有一缺口7，缺口7与外定位柱4的一侧卡接完全，压块12上亦设有相同的缺口7，通过缺口7、外定位柱4、中定位柱5三者使得非晶、纳米晶合金单片有序排列，由压块12压浸非晶、纳米晶合金单片并由自动叠压装置拧紧固定获得叠压组合体。
优选的，当磁通密度为1.0T、频率为1000Hz时，通过本制备方 法制备得到的纳米晶铁芯的铁芯损耗仅为2.52W/kg，大大低于传统法制备得到的纳米晶铁芯的铁芯损耗。
本发明的较佳的实施例中，如图3所示，叠压装置包括工作台9、叠片治具1、压紧机构10、旋拧机构11，叠片治具1置于工作台9上，叠片治具1的上方架设有一压紧机构10，压紧机构10的正上方架设有一旋拧机构11(其余装置及连接方式未在图中显示)，则步骤S2中，将一压块12和一压紧螺帽13依次穿入中定位柱5，随后控制压紧机构10挤压压块12进行压实处理，并控制旋拧机构11旋紧压紧螺帽13进行初步定型处理，以得到叠压组合体。
本发明的较佳的实施例中，如图4所示，步骤S5包括：
步骤S51，在130℃-200℃温度下对浸漆处理后的叠压组合体进行烘烤，并保温1-8小时；
步骤S52，将烘烤处理后的叠压组合体冷却至常温，随后拆解叠压组合体得到铁芯坯体。
本发明的较佳的实施例中，步骤S1中，对非晶、纳米晶合金带材进行切割的方式为冲片切割、模切、电火花切割、等离子切割、激光切割和水刀切割中的至少一种。
具体地，本实施例中，考虑到常用的切割方式具有很多种，因此本实施例中并不限定切割方式，只需通过冲片切割、模切、电火花切割、等离子切割、激光切割和水刀切割中的至少一种对非晶、纳米晶合金带材进行切割即可。
本发明的较佳的实施例中，步骤S3中，热处理温度为 250℃-580℃，保温时间为1-5小时，且在保温结束后叠片体的温度随炉体降温至200℃以下，然后冷至常温。
具体地，本实施例中，热处理的流程一般分为加热、保温和冷却，本制备方法在加热阶段将叠压组合体加热至250℃-580℃，在保温阶段对加热后的叠压组合体保温1-5小时，在冷却阶段将保温结束后的叠压组合体随炉体下降至200℃以下，然后冷至常温。
本发明的较佳的实施例中，叠片治具1的材料为不锈钢、工具钢、钛合金、陶瓷中的一种。
具体地，本实施例中，并不限定叠片治具1的制作材料，使用不锈钢或工具钢或钛合金或陶瓷均可。
优选的，本实施例中使用不锈钢作为叠片治具1的制作材料。
本发明的较佳的实施例中，步骤S6中，对铁芯坯体进行表面降损处理的方式为弱酸性溶液浸泡。
本发明的较佳的实施例中，步骤S6中，对铁芯坯体进行表面保护处理的方式为均匀涂覆自干绝缘漆处理。
实施例一：
本实施例中，选用带材平均厚度为20±2μm的Fe-Si-B-Nb-Cu铁基纳米晶软磁合金带材，为了测试性能方便，本实施例和对比例全部制备成圆环形的铁芯，具体步骤如下：
步骤S1，切片：根据圆环形铁芯成品的形状，采用冲片切割的方式横向切割铁基纳米晶软磁合金带材得到多个尺寸为50*40mm的圆环形纳米晶合金单片；
步骤S2，叠压：将纳米晶合金单片依次堆叠至叠片治具1上获得纳米晶叠片体，将压块12压置于纳米晶叠片体的上表面，然后利用自动叠压装置对纳米晶叠片体进行压实和初步定型处理得到叠压组合体。具体的，获得的纳米晶叠片体的高度为20mm；
步骤S3，热处理：在抽真空条件下且热处理温度为550℃以上时对压实和初步定型处理后的叠压组合体进行热处理，并保温2小时，纳米晶叠片体的温度随炉体降温至200℃以下后冷至常温；
步骤S4，浸漆处理：将热处理后的叠压组合体放置于真空压力浸漆设备中，进行浸漆处理；
步骤S5，固化定型：将浸漆后的叠压组合体进行烘烤固化，随后拆解下纳米晶叠片体得到尺寸为50*40*20mm的铁芯坯体；
步骤S6，表面处理：去掉铁芯坯体表面的冗余绝缘漆，并对铁芯坯体进行表面降损处理和表面保护处理得到铁芯成品。
利用交直流叠加软磁测试装置MATS-2010SA对制备得到的叠压固定法纳米晶铁芯进行测试发现在频率为1kHz、磁通密度为1.0T时叠压固定法纳米晶铁芯的铁芯损耗仅为2.52W/kg。
对比例一：
本对比例中，选用与实施例一中相同的软磁合金带材，选用带材平均厚度为20±2μm的Fe-Si-B-Nb-Cu铁基纳米晶软磁合金带材，具体步骤如下：
步骤S1，带材压制成型：将铁基纳米晶软磁合金带材卷绕成尺寸为65*55*63mm的磁环或裁切成尺寸为60*60mm的方形片材，将 磁环或片材置入一带有固定装置的钢板上，然后将另一钢板压在磁环或片材上，并用螺钉固定上下钢板，使磁环或片材压制成20mm高的磁块；
步骤S2，热处理：步骤S1获得的磁块置于真空热处理炉中进行550℃的热处理并保温2小时，待磁块的温度随炉体降温至200℃以后冷至常温；
步骤S3，浸漆固化：将步骤S2中得到的磁块进行浸漆处理，随后于150℃下进行固化处理，保温2小时后风冷至常温；
步骤S4，线切割：将步骤S3中固化后的磁块按照铁芯成品的结构和尺寸进行线切割得到尺寸为50*40*20mm铁芯成品。
利用交直流叠加软磁测试装置MATS-2010SA对制备得到的铁芯进行测试发现在频率为1kHz、磁通密度为1.0T时纳米晶铁芯的铁芯损耗均值仅为4.48W/kg。
实施例二：
本实施例中，选用与实施例一不同的非晶合金带材，选用带材平均厚度为20±2μm的Fe-Si-B铁基非晶软磁合金带材，热处理温度为390℃，其余制备方法与实施例一的制备方法相同，制得的铁芯尺寸与实施例一相同，该方法制备的铁芯得损耗测试结果如表1所示。
对比例二：
本对比例中，选用与实施例二相同的非晶合金带材，选用带材平均厚度为20±2μm的Fe-Si-B铁基非晶软磁合金带材，其余制备方法与对比例一的制备方法相同，制得的铁芯成品尺寸与实施例二相同， 该方法制备的铁芯的损耗测试结果如表1所示。
表1实施例一、实施例二及对比例一和对比例二制备的铁芯在不同频率f及磁通密度Bm下的铁芯损耗
Figure PCTCN2022142392-appb-000001
在频率f为1kHz，磁通密度Bm为1T的测试环境下，实施例一中制得的纳米晶铁芯的铁芯损耗仅在2.52W/kg，实施例二中制得的非晶铁芯的铁芯损耗为4.832W/kg，而对比例一中制得的纳米晶铁芯的铁芯损耗为4.48W/kg，对比例二中制得的非晶铁芯的铁芯损耗为6.99W/kg。可知在相同测试环境下，同一软磁合金带材通过本发明方法制备得到的纳米晶铁芯的铁芯损耗比通过传统方法制备得到的纳米晶铁芯的铁芯损耗低。
在磁通密度Bm不变的情况下，逐渐升高频率f，可以发现传统 方法制得的非晶铁芯和本发明制备方法制得的非晶铁芯、传统方法制得的纳米晶磁芯和本发明制备方法制得的纳米晶铁芯之间铁芯损耗的差值越来越大，但是本发明制备方法非晶铁芯、纳米晶铁芯仍具有较低的铁芯损耗，性能远远高于其他方法制备得到的铁芯。
综上，由表1可知，采用本发明方法制备得到的非晶、纳米晶铁芯具有优异的软磁性能，其铁芯损耗比传统方法制备得到的非晶铁芯、纳米晶铁芯的铁芯损耗低，因此说明采用非晶、纳米晶合金带材和本发明的制备方法得到的非晶、纳米晶铁芯具备优异的高磁导率和低的铁芯损耗，且通过图5中的铁芯损耗曲线图可以发现在磁通密度不变的前提下，随着测试环境中频率的增加，本发明制备方法制得的非晶、纳米晶铁芯的铁芯损耗的减少效果越明显。
以上所述仅为本发明较佳的实施例，并非因此限制本发明的实施方式及保护范围，对于本领域技术人员而言，应当能够意识到凡运用本说明书及图示内容所作出的等同替换和显而易见的变化所得到的方案，均应当包含在本发明的保护范围内。

Claims (10)

  1. 一种叠压型非晶、纳米晶铁芯的制备方法，其特征在于，将非晶、纳米晶合金带材按照铁芯的横截面设计切割成若干具有相同形状的非晶、纳米晶合金单片，并利用一自动叠压装置将切割好的非晶、纳米晶合金单片堆叠压制得到非晶、纳米晶叠片体和叠片治具组合的叠压组合体，随后对所述叠压组合体进行热处理、浸漆和固化处理，从所述叠片治具上拆解下固化定型后的所述非晶、纳米晶叠片体得到铁芯坯体，并对所述铁芯坯体进行表面处理得到铁芯成品。
  2. 根据权利要求1所述的制备方法，其特征在于，所述制备方法包括以下步骤:
    步骤S1，切片：根据预先设定的所述铁芯成品的横截面形状和尺寸对非晶、纳米晶合金带材进行切割，以得到多个与所述铁芯成品的横截面具有相同形状和尺寸的所述非晶、纳米晶合金单片；
    步骤S2，叠压：将各所述非晶、纳米晶合金单片依次堆叠至所述叠片治具上形成所述非晶、纳米晶叠片体，随后将所述非晶、纳米晶叠片体和所述叠片治具放置到所述自动叠压装置内的工作台上，通过所述自动叠压装置将所述非晶、纳米晶叠片体进行压实和初步定型处理，得到所述叠压组合体；
    步骤S3，热处理：将所述叠压组合体放置于热处理炉中进行热处理；
    步骤S4，浸漆处理：将热处理后的所述叠压组合体放置于真空压力浸漆设备中，进行浸漆处理；
    步骤S5，固化定型：将浸漆后的叠压组合体进行烘烤固化，随 后从所述叠片治具上拆解下固化定型的所述非晶、纳米晶叠片体，得到所述铁芯坯体；
    步骤S6，表面处理：去掉所述铁芯坯体表面的冗余绝缘漆，并对所述铁芯坯体进行表面降损处理和表面保护处理，得到所述铁芯成品。
  3. 根据权利要求2所述的制备方法，其特征在于，所述叠片治具的底座上设有至少一组叠压定位装置和至少一提手，每组所述叠压定位装置包括至少一外定位柱和一中定位柱。
  4. 根据权利要求2所述的制备方法，其特征在于，各所述非晶、纳米晶合金单片上分别开设有一中心孔，各所述非晶、纳米晶合金单片的外环上分别开设有至少一缺口，则所述步骤S2中，将各所述非晶、纳米晶合金单片的所述缺口分别卡入所述外定位柱，并将各所述非晶、纳米晶合金单片的所述中心孔分别穿入所述中定位柱，以形成所述非晶、纳米晶叠片体。
  5. 根据权利要求1所述的制备方法，其特征在于，所述叠压装置包括工作台、叠片治具、压紧机构和旋拧机构，所述叠片治具置于工作台上，所述叠片治具的上方架设有一压紧机构，所述压紧机构的正上方架设有一旋拧机构，则所述步骤S2中，将一压块和一压紧螺帽依次穿入所述中定位柱，随后控制所述压紧机构挤压所述压块进行压实处理，并控制所述旋拧机构旋紧所述压紧螺帽进行初步定型处理，以得到所述叠压组合体。
  6. 根据权利要求2所述的制备方法，其特征在于，所述步骤S5 包括：
    步骤S51，在130℃-200℃温度下对浸漆处理后的所述叠压组合体进行烘烤，并保温1-8小时；
    步骤S52，将烘烤处理后的所述叠压组合体冷却至常温，随后拆解所述叠压组合体得到所述铁芯坯体。
  7. 根据权利要求2所述的制备方法，其特征在于，所述步骤S1中，对所述非晶、纳米晶合金带材进行切割的方式为冲片切割、模切、电火花切割、等离子切割、激光切割和水刀切割中的至少一种。
  8. 根据权利要求2所述的制备方法，其特征在于，所述步骤S3中，热处理温度为250℃-580℃，保温时间为1-5小时，且在保温结束后所述叠片体的温度随炉体降温至200℃以下，然后冷至常温。
  9. 根据权利要求1所述的制备方法，其特征在于，所述叠片治具的材料为不锈钢、工具钢、钛合金、陶瓷中的一种。
  10. 根据权利要求2所述的制备方法，其特征在于，所述步骤S6中，对所述铁芯坯体进行表面降损处理的方式为弱酸性溶液浸泡；对所述铁芯坯体进行表面保护处理的方式为均匀涂覆自干绝缘漆处理。
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