WO2024045322A1

WO2024045322A1 - Manufacturing method for magnetic element

Info

Publication number: WO2024045322A1
Application number: PCT/CN2022/129451
Authority: WO
Inventors: 王一奇; 何俊明; 胡佳俊; 严露露
Original assignee: 浙江盘毂动力科技有限公司
Priority date: 2022-09-02
Filing date: 2022-11-03
Publication date: 2024-03-07
Also published as: CN115346791A

Abstract

Provided in the present invention is a manufacturing method for a magnetic element. The manufacturing method comprises the following steps: S1, manufacturing an integral magnetic element of a required shape; and S2, sequentially cutting two sides of the integral magnetic element to obtain a segmented type magnetic element, wherein before cutting of each side of the integral magnetic element, the other side of the integral magnetic element is integral. The integral magnetic element is prevented from falling apart; and a subsequent magnetic segment splicing process is omitted, thus improving the forming efficiency of segmented type magnetic elements, ensuring consistency of products and facilitating automated production.

Description

A method of manufacturing magnetic components

Technical field

The present invention relates to the technical field of magnetic components, and in particular to a manufacturing method of magnetic components.

Background technique

Electromagnetic devices are used to generate electromagnetism to achieve corresponding work, and are divided into motors and electromagnets. An electric motor, for example, consists of a rotating part called the rotor, and a stationary part called the stator, which combine to produce torque. Generally speaking, the stator of the motor includes a stator core and windings that receive current and are used for operation. The rotor is equipped with a plurality of magnets. The stator and the rotor interact to cause the rotor to rotate relative to the stator.

When magnetic components such as magnets move in a non-uniform magnetic field or are in a magnetic field that changes with time, the current induced in the magnetic components causes energy loss, which is called eddy current loss. The eddy current loss will cause the magnetic components to heat up, thereby affecting the operating performance of the motor. .

The most common way to reduce eddy current losses is to segment, and then stack multiple segmented magnetic segments (such as silicon steel sheets) to form a magnetic component. In this process, multiple magnetic segments obtained by cutting need to be spliced in a preset order, and adhesive is added between two adjacent magnetic segments one by one to form a magnetic element. Not only is the manufacturing process cumbersome, time-consuming and labor-intensive, but also Manufacturing costs increase significantly. In addition, after the existing magnetic segments are cut, the cutting surface needs to be polished, and then a binder is added between the polished cutting surfaces of the two magnetic segments to achieve the bonding of the two magnetic segments. Therefore, when the magnetic segments are formed A lot of waste is produced during the process, making the material utilization rate low.

Contents of the invention

The purpose of the present invention is to overcome the above-mentioned shortcomings of the prior art and provide a manufacturing method for magnetic components that effectively improves the manufacturing and molding efficiency. The object of the present invention can be achieved through the following technical solutions:

A method for manufacturing magnetic components, including the following steps:

S1. Make the overall magnetic component of the required shape;

S2. Cut both sides of the integral magnetic element sequentially to produce segmented magnetic elements, and before cutting each side of the integral magnetic element, the other side of the integral magnetic element is integrated.

As a preferred embodiment, step S2 includes:

Glue is injected into the gap formed by cutting on one side of the integral magnetic element, so that the glue injection gap is integrated on one side of the integral magnetic element.

As a preferred embodiment, step S2 includes:

S21. Cut a margin on one side of the integral magnetic component, and inject glue into the first gap formed by the cutting;

S22. Cut the other side of the integral magnetic element to form a second gap that intersects with the first gap, and inject glue into the second gap.

As a preferred embodiment, in step S21, a plurality of first slits are simultaneously cut on one side of the integral magnetic element, and the plurality of first slits are along the radial direction of the integral magnetic element. arranged at intervals; further, in step S22, a plurality of second slits are simultaneously cut and formed on the other side of the integral magnetic element, and the second slits correspond to the first slits one by one.

As a preferred embodiment, the first gap and the second gap are respectively provided on both sides of the integral magnetic element 200 in the axial direction or the circumferential direction.

As a preferred embodiment, before each glue injection, the method further includes:

The surface of the cut integral magnetic element is cleaned.

As a preferred embodiment, the first gap and the second gap are located on the same straight line;

Alternatively, the first slit and the second slit are arranged at an angle;

Alternatively, the second slit includes a straight edge and a hypotenuse, the straight edge is parallel to the first slit, and the hypotenuse is obliquely connected between the straight edge and the first slit.

As a preferred embodiment, the width of the first slit and the second slit ranges from 0.05 to 0.2 mm.

As a preferred embodiment, the overall magnetic element has a sector-shaped, rectangular or trapezoidal shape.

As a preferred embodiment, the integral magnetic element is made of permanent magnet material.

Compared with the existing technology, this technical solution has the following advantages:

First, before cutting each side of the integral magnetic element, ensure that the other side of the integral magnetic element is integrated to prevent the integral magnetic element from falling apart and facilitate the cutting of the gap on the other side of the integral magnetic element. Formed, segmented magnetic components can be produced directly. Compared with traditional manufacturing methods, the subsequent splicing process of each magnetic segment is omitted, thereby improving the molding efficiency of the segmented magnetic components.

Second, glue injection is used to ensure that the other side of the integral magnetic element is integrated, while ensuring the insulation between the magnetic segments formed by cutting, and at the same time ensuring the overall strength of the segmented magnetic element.

Third, the grinding process is omitted, which not only improves the molding efficiency, but also avoids the problem of low material utilization caused by grinding.

Fourth, it can also ensure product consistency and is conducive to automated production.

The present invention will be further described below in conjunction with the accompanying drawings and examples.

Description of drawings

Figure 1 is a schematic diagram of one side of the integral magnetic component of the present invention after being cut;

Figure 2 is a schematic structural diagram of the first embodiment of the segmented magnetic element according to the present invention;

Figure 3 is a schematic structural diagram of a second embodiment of the segmented magnetic element according to the present invention;

Figure 4 is a schematic structural diagram of the third embodiment of the segmented magnetic element according to the present invention.

In the picture: 100a integral magnetic component, 100b segmented magnetic component, 110 magnetic segment, 1000 gap, 1001 first gap, 1002 second gap, 10021 straight edge, 10022 hypotenuse.

Detailed ways

The following description is provided to disclose the invention to enable those skilled in the art to practice the invention. The preferred embodiments in the following description are only examples, and other obvious modifications may occur to those skilled in the art. The basic principles of the invention defined in the following description may be applied to other embodiments, variations, improvements, equivalents and other technical solutions without departing from the spirit and scope of the invention.

As shown in Figures 1 and 2, the manufacturing method of the magnetic component includes the following steps:

S1. Make the integral magnetic component 100a of the required shape;

S2. Cut on both sides of the integral magnetic element 100a in turn to produce a segmented magnetic element 100b. Before cutting each side of the integral magnetic element 100a, the other side of the integral magnetic element 100a is integrated. of.

By cutting on both sides of the integral magnetic element 100a to form gaps 1000 that run through the integral magnetic element 100a, the integral magnetic element 100a is segmented to form several radially arranged slits along the radial direction of the integral magnetic element 100a. Magnetic segments 110, thereby producing the segmented magnetic element 100b. It can be seen that the gap 1000 that runs through the integral magnetic element 100a is formed by two cuts. Before cutting each side of the integral magnetic element 100a, ensure that the other side of the integral magnetic element 100a is integrated to avoid the The whole magnetic element 100a falls apart, and the cutting and formation of the gap on the other side of the whole magnetic element 100a is facilitated, and the segmented magnetic element 100b can be directly manufactured. Compared with the traditional manufacturing method, the subsequent splicing of the magnetic segments 110 is omitted. The process improves the molding efficiency of the segmented magnetic component 100b, while ensuring the consistency of the product, which is conducive to automated production.

In the step S1, the shape of the integral magnetic element 100a determines the shape of the segmented magnetic element 100b. The overall magnetic element 100a may be in a regular or irregular shape, and the regular shape includes the cross-sectional shape of the overall magnetic element 100a being sector-shaped, rectangular, trapezoidal, etc. When the cross-sectional shape of the integral magnetic element 100a is sector-shaped, and the axial dimension (thickness) of the integral magnetic element 100a is small, the manufactured segmented magnetic element 100b can be applied to the stator of an axial magnetic field motor. Iron core etc.

The integral magnetic element 100a can be made of permanent magnet materials with a certain conductivity and can be made by powder metallurgy. The permanent magnet materials include but are not limited to neodymium iron boron, alnico, samarium cobalt, etc.

In the step S2, cuts are made on both sides of the integral magnetic element 100a to form gaps 1000 that block the transmission path of the eddy current, so as to reduce the eddy current loss, effectively avoid the temperature rise caused by the eddy current loss, and thereby prevent the magnetic The demagnetization phenomenon of segment 110 occurs and affects the service life. Referring to Figure 1 and Figure 2, the step S2 includes:

S21. Cut a margin on one side of the integral magnetic component 100a, and inject glue into the first gap 1001 formed by the cutting;

S22. Cut the other side of the integral magnetic element 100a to form a second gap 1002 that intersects the first gap 1001, and inject glue into the second gap 1002.

The first gap 1001 and the second gap 1002 intersect and communicate to form a gap 1000 that separates the integral magnetic element 100a. It can be seen that the gap 1000 is formed by secondary cutting. In the step S21, the right side of the integral magnetic element 100a is cut to form the first gap 1001. At this time, a margin is reserved from the first gap 1001 to the left side of the integral magnetic element 100a. That is, the left side of the integral magnetic element 100a is integrated, that is, when cutting the first slit 1001, the integral magnetic element 100a will not be segmented. And in the step S21, glue is injected into the first gap 1001 so that the right side of the cut integral magnetic element 100a is integrated, so that the integral magnetic element 100a can be processed in the step S22. Cutting is performed on the left side of the magnetic element 100a without causing segmentation of the integral magnetic element 100a, thereby eliminating the subsequent splicing process.

In addition, after the integral magnetic element 100a is cut to form the first slit 1001 and the second slit 1002, glue is injected into the first slit 1001 and the second slit 1002 at the same time, which is the same as the traditional manufacturing method. Generally speaking, omitting the grinding process not only improves the molding efficiency, but also avoids the problem of low material utilization caused by grinding. To further explain, in the traditional manufacturing method, in order to achieve the bonding effect between the magnetic segments 110, the cutting surface needs to be polished. In this application, when each side of the integral magnetic element 100a is cut, the other side of the integral magnetic element 100a is integrated to prevent the inability to bond.

The width of the first gap 1001 and the second gap 1002 ranges from 0.05 to 0.2 mm. The width refers to the width of the first gap 1001 and the second gap 1002 on the integral magnetic element 100a. Regarding the radial dimension, it should be noted that the width dimensions of the first slit 1001 and the second slit 1002 may be the same or different.

The glue may be an insulating adhesive glue to ensure insulation between the magnetic segments 110 and reliable bonding, and to ensure the overall strength of the segmented magnetic component 100b.

As shown in Figure 2, the first gap 1001 and the second gap 1002 are located on both sides of the circumferential direction of the integral magnetic element 100a. Of course, the first gap 1001 and the second gap 1002 are located on the integral magnetic element 100a. The axial sides of the magnetic element 100a can be designed according to actual needs.

Before the glue injection, the method further includes: surface cleaning of the cut integral magnetic element 100a, including using cleaning media or blowing air to remove cutting impurities on the surface of the integral magnetic element 100a. It is worth noting that when using cleaning media (especially liquid), you need to dry the surface before injecting glue into the gap.

For example, in step S21, when the first gap 1001 is cut and formed, the surface of the integral magnetic element 100a can be cleaned with a cleaning liquid to wash away the cutting impurities on the surface of the integral magnetic element 100a, ready for drying. After drying, glue is injected into the first gap 1001.

Similarly, in step S22, after the second gap 1002 is cut and formed, the surface of the integral magnetic element 100a can be cleaned with a cleaning liquid to wash away the cutting impurities on the surface of the integral magnetic element 100a for later use. After drying, glue is injected into the second gap 1002.

Since the first gap 1001 and the second gap 1002 are connected, the glue in the first gap 1001 and the second gap 1002 form one body to block the two adjacent magnetic segments 110. The segmented magnetic element 100b is then obtained.

The shape of the gap 1000 can be various, and three embodiments are introduced below:

In one embodiment, the first gap 1001 and the second gap 1002 are located on the same straight line, so that the gap 1000 is formed in a straight line, see FIG. 2 .

In another embodiment, the first slit 1001 and the second slit 1002 are arranged at an angle to form the slit 1000 having a shape as shown in FIG. 3 . The angle between the first gap 1001 and the second gap 1002 is between 120° and 180°.

In another embodiment, the second gap 1002 includes a straight edge 10021 and a hypotenuse 10022. The straight edge 10021 is parallel to the first gap 1001, and the hypotenuse 10022 is obliquely connected to the first gap 1002. between the straight edge 10021 and the first gap 1001 to form the gap 1000 with a shape as shown in FIG. 4 . The length of the straight side 10021 is close to the length of the first gap 1001, while the length of the hypotenuse 10022 is shorter and only serves the purpose of connecting the straight side 10021 and the first gap 1001.

As shown in Figures 2 to 4, the segmented magnetic element 100b includes a plurality of magnetic segments 110, and the plurality of magnetic segments 110 are arranged along the radial direction of the segmented magnetic element 100b, and adjacent Adhesive glue is provided between the two magnetic segments 110, and the adhesive glue is formed by drying glue injected with glue. When the segmented magnetic element 100b has a fan-shaped outer shape, the width of each magnetic segment 110 gradually decreases from top to bottom in the radial direction, refer to Figure 2, and the radial upper side of the segmented magnetic element 100b is The radial lower side of the segmented magnetic element 100b is a concave surface. And the shape of the magnetic segment 110 along both sides of the radial direction of the integral magnetic element 100a is determined by the gap 1000. For example, when the gap 1000 is a straight line, the shape of the magnetic segment 110 along the radial direction of the integral magnetic element 100a The radial sides are straight lines.

The sequential cutting on both sides of the integral magnetic element 100a means that one can first cut once on one side of the integral magnetic element 100a and then cut once on the other side of the integral magnetic element 100a to form A first gap 1001 and a second gap 1002 intersect. Of course, it is also possible to cut and form several first slits 1001 on one side of the integral magnetic element 100a, and then cut and form several second slits 1002 on the other side of the integral magnetic element 100a, and the The first gap 1001 and the second gap 1002 correspond to each other and intersect.

Specifically, the right side of the integral magnetic element 100a is cut once to form the first gap 1001 and glue is injected, and then one side is cut on the left side of the integral magnetic element 100a to form the second gap 1002 And inject glue, and cycle like this to form several first gaps 1001 and several second gaps 1002 on the integral magnetic element 100a, and the first gaps 1001 and the second gaps 1002 are the same. One corresponds and intersects.

Alternatively, in step S2, multiple first slits 1001 may be simultaneously cut and formed on the right side of the integral magnetic element 100a, and the plurality of first slits 1001 may be formed along the radial direction of the integral magnetic element 100a. Arrange them at intervals, and then inject glue into each first gap 1001 at the same time. Then, a plurality of second slits 1002 are simultaneously cut and formed on the right side of the integral magnetic element 100a. The plurality of second slits 1002 are arranged at intervals along the radial direction of the integral magnetic element 100a, and the integral magnetic The first slit 1001 and the second slit 1002 on both sides of the component 100a correspond one to one, and the corresponding first slit 1001 and the second slit 1002 intersect, which can effectively improve the molding efficiency. After step S2, the method further includes the following steps:

S3. Clean the residual glue on the surface of the segmented magnetic component 100b to ensure the consistency of the product size and avoid the installation restrictions caused by the residual glue.

Since the subsequent splicing process is omitted in this application, and the gap 1000 is formed by secondary cutting, a clamp can be used to fix the integral magnetic element 100a. For example, the clamp is fixed at the position where the integral magnetic element 100a is removed from cutting, and then The left and right sides of the integral magnetic element 100a are cut to form a gap 1000 that runs through the integral magnetic element 100a, and glue is injected into the gap 1000 formed by each cutting, and the above steps can be performed automatically, thereby realizing automated production.

In summary, before cutting each side of the integral magnetic element 100a, ensure that the other side of the integral magnetic element 100a is integrated to prevent the integral magnetic element 100a from falling apart and facilitate the overall magnetic element 100a. The gap on the other side is cut and formed, and the segmented magnetic element 100b can be directly manufactured. Compared with the traditional manufacturing method, the subsequent splicing process of the magnetic segments 110 is omitted, and the molding of the segmented magnetic element 100b is improved. efficiency. Glue injection is used to ensure that the other side of the integral magnetic element 100a is integrated, while ensuring the insulation between the magnetic segments 110 formed by cutting, and at the same time ensuring the overall strength of the segmented magnetic element 100b. The grinding process is also omitted, which not only improves the molding efficiency, but also avoids the problem of low material utilization caused by grinding. At the same time, it can ensure product consistency and is conducive to automated production.

The above-described embodiments are only used to illustrate the technical ideas and characteristics of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. The present invention cannot be limited only by this embodiment. The patent scope means that all equivalent changes or modifications made in accordance with the spirit disclosed in the present invention still fall within the patent scope of the present invention.

Claims

A manufacturing method of magnetic components, characterized by including the following steps:

S1. Make the integral magnetic component (100a) of the required shape;

S2. Cut on both sides of the integral magnetic element (100a) in sequence to produce a segmented magnetic element (100b), and before cutting on each side of the integral magnetic element (100a), the integral magnetic element (100a) The other side is integrated.
The manufacturing method of magnetic components according to claim 1, wherein step S2 includes:

Glue is injected into the gap (1000) formed by cutting on one side of the integral magnetic element (100a), so that the glue injection gap (1000) is integrated on one side of the integral magnetic element (100a).
The manufacturing method of magnetic components according to claim 1, wherein step S2 includes:

S21. Cut a margin on one side of the integral magnetic component (100a), and inject glue into the first gap (1001) formed by the cutting;

S22. Cut the other side of the integral magnetic element (100a) to form a second gap (1002) that intersects the first gap (1001), and inject the second gap (1002) into the second gap (1002). glue.
The manufacturing method of a magnetic element according to claim 3, characterized in that in the step S21, a plurality of the first slits (1001) are simultaneously cut and formed on one side of the entire magnetic element (100a), The plurality of first slits (1001) are arranged at intervals along the radial direction of the integral magnetic element (100a); and then in step S22, cutting is performed on the other side of the integral magnetic element (100a) at the same time. There are a plurality of second slits (1002), and the second slits (1002) and the first slits (1001) correspond one to one.
The manufacturing method of a magnetic element according to claim 3, characterized in that the first gap (1001) and the second gap (1002) are respectively provided in the axial direction or circumferential direction of the integral magnetic element (200). both sides.
The manufacturing method of magnetic components according to claim 1, characterized in that, before each injection of glue, the method further includes:

Surface cleaning is performed on the cut integral magnetic element (100a).
The manufacturing method of magnetic components according to claim 3, characterized in that the first gap (1001) and the second gap (1002) are located on the same straight line;

Alternatively, the first gap (1001) and the second gap (1002) are arranged at an angle;

Alternatively, the second gap (1002) includes a straight edge (10021) and a hypotenuse (10022). The straight edge (10021) is parallel to the first gap (1001), and the hypotenuse (10022) ) is connected obliquely between the straight edge (10021) and the first gap (1001).
The method of manufacturing a magnetic element according to claim 3, wherein the width of the first gap (1001) and the second gap (1002) ranges from 0.05 to 0.2 mm.
The method of manufacturing a magnetic element according to claim 1, wherein the overall magnetic element (100a) has an outer shape of a sector, a rectangle or a trapezoid.
The method of manufacturing a magnetic element according to claim 1, wherein the integral magnetic element (100a) is made of permanent magnet material.