A marine direct-drive permanent magnet shaft generator rotor magnetic steel assembling device

Abstract

The utility model discloses a kind of marine direct-drive permanent-magnetic shaft generator rotor magnetic steel assembling devices, it is related to permanent-magnet motor manufacturing technical field, the device is mainly composed of stop backing plate, anti-overturning cover plate, positioning block, press-in plate and transmission mechanism. Anti-overturning cover plate and transmission mechanism are assembled to positioning block. The power generated by electric or pneumatic tool is pushed press-in plate and magnetic steel after transmission mechanism buffering, magnetic steel enters rotor support magnetic pole box along the magnetic steel guide rectangular channel formed by positioning block and anti-overturning cover plate, keeps the pressure of press-in plate to magnetic steel, and all magnetic steel of one magnetic pole is pressed into rotor support magnetic pole box using stop backing plate. The device uses anti-overturning cover plate and positioning block to form magnetic steel guide rectangular channel and the structure of wave spring for motor to assemble magnetic steel, improve magnetic steel protection effect. Stop backing plate is used instead of magnetic steel assembling device to press one magnetic pole all magnetic steel, and magnetic steel is assembled in the mode that magnetic steel adhesive is completely solidified, reduce tooling quantity, reduce mold cost.

Description

Technical Field

[0001] This utility model relates to the field of permanent magnet motor manufacturing technology, specifically a marine direct-drive permanent magnet shaft generator rotor magnet assembly device. Background Technology

[0002] In a ship's shafting system, the intermediate shaft is the drive shaft located between the main engine thrust shaft and the propeller shaft. A marine direct-drive permanent magnet shaft-driven generator is a type of shaft-driven generator that mounts a rotor with permanent magnets on the ship's intermediate shaft. The intermediate shaft directly drives the rotor to create a rotating magnetic field, converting the surplus power of the ship's main engine into electrical energy. Direct-drive permanent magnet shaft-driven generators are widely recognized in the shipbuilding industry due to their low manufacturing cost and high efficiency. This type of shaft-driven generator is suitable for new shipbuilding and retrofitting most older ships. Although it has only been on the market for a short time, its market prospects are broad. This type of shaft-driven generator not only responds to the national "dual-carbon" strategy but also provides an efficient energy solution for the green and low-carbon transformation of the shipbuilding industry.

[0003] The rotor of a marine direct-drive permanent magnet shaft-driven generator consists of a rotor support, magnetic poles, magnetic pole clamping plates, and external hexagonal bolts. The rotor support is welded together from the rotor support body and the magnetic pole box. The rotor support body is machined from magnetically conductive carbon steel. The magnetic pole box is a "∩"-shaped groove formed by bending stainless steel plate. For each magnetic pole, three identical internal threads are machined on the end face of the rotor support body; the central thread is used to assemble the magnetic pole clamping plate, and the two threads on either side are process threaded holes for assembling the magnets. The magnetic pole box and the rotor support body form an approximately rectangular cavity for assembling the magnets. Multiple magnets of the same polarity are coated with magnetic adhesive and inserted into the magnetic pole box from one end. After the adhesive has completely cured, they are pressed together by the magnetic pole clamping plates and external hexagonal bolts to form a single magnetic pole. Each generator rotor has 30 to 50 magnetic poles. Magnetic poles of different polarities (NS) are evenly distributed around the outer circumference of the rotor. Marine direct-drive permanent magnet shaft-driven generators typically have a power range of 0.5–5MW, offering greater power and more magnetic poles compared to ordinary land-based permanent magnet generators. While possessing broad development prospects, the assembly of rotor magnets is challenging. The humid and hot environment of a ship's cabin makes the magnets more prone to rusting. In addition to the brittle characteristics of land-based permanent magnet motor magnets, marine direct-drive permanent magnet shaft-driven generator rotor magnets are also characterized by their large size, strong magnetic force, and high requirements for coating protection. Current technologies for assembling marine direct-drive permanent magnet shaft-driven generator rotor magnets suffer from the following defects: 1. Poor magnet protection. While existing assembly technologies incorporate magnet positioning, guiding, and pushing devices, the protection of the magnets remains inadequate. Specifically, the problems are as follows: First, when the magnet approaches the end of the pole box, due to the lack of an anti-rollover device or improper design, the magnet is prone to flipping and impacting the outer arc surface of the pole box due to the repulsive force of like magnets and the attractive force of adjacent magnets. This can cause the magnet to break or its edges to fall off, resulting in damage to the magnet itself. Second, after the magnet enters the pole box, when the spacing between like magnets is compressed, the magnet is subjected to unbuffered force, making it prone to coating cracking and damage. 2. High mold costs. The magnets of the shaft-driven generator are made of strong permanent magnets. Most parts of the magnet assembly device are made of austenitic stainless steel or non-magnetic aluminum alloy, resulting in high material and manufacturing costs. Currently, the complete curing time of the magnet adhesive at room temperature in China is about 24 hours. After the last magnet of each pole is pressed into the pole box, the magnet assembly device needs to keep pressing the magnet down until the magnet adhesive is completely cured. Direct-drive shaft-driven generators are multi-pole generators. To improve efficiency, the production of shaft-driven generators requires a large number of magnet assembly devices, resulting in huge mold costs. In summary, the existing technology for assembling rotor magnets suffers from drawbacks such as poor magnet protection and high mold costs. Utility Model Content

[0004] The technical problem to be solved by this utility model is: in order to overcome the defects of poor magnet protection effect and high mold cost in the assembly process of rotor magnets in the prior art, this utility model provides a rotor magnet assembly device for marine direct-drive permanent magnet shaft generator. The magnet protection effect is improved by the rectangular guide channel composed of positioning blocks and anti-rollover cover plates and the wave spring for motor in the transmission mechanism. All magnets of one magnetic pole are pressed by the anti-reverse pressure plate and the magnet adhesive is allowed to cure, thereby reducing the number of molds and reducing mold cost, and thus completing the assembly of the rotor magnets of marine direct-drive permanent magnet shaft generator.

[0005] The technical solution adopted by this utility model to solve its technical problem is: a marine direct-drive permanent magnet shaft generator rotor magnet assembly device, including a first hexagon socket head cap screw, a second hexagon socket head cap screw, a backstop pressure plate, an anti-tipping cover plate, a third hexagon socket head cap screw, a positioning block, a pressing plate, a fourth hexagon socket head cap screw, and a transmission mechanism. The anti-tipping cover plate and the transmission mechanism are assembled to the positioning block. The power generated by the electric or pneumatic tool is buffered by the wave spring in the motor of the transmission mechanism and then pushes the pressing plate. The pressing plate pushes the magnets into the rotor support pole box along the rectangular magnet guide channel formed by the positioning block and the anti-tipping cover plate. While maintaining the pressure of the pressing plate on the magnets, the backstop pressure plate presses all the magnets of one pole into the rotor support pole box and waits for the magnet adhesive to cure. After the backstop pressure plate is assembled to the rotor support, the rotor magnet assembly device is moved to assemble the magnets of the next new pole.

[0006] The aforementioned marine direct-drive permanent magnet shaft generator rotor magnet assembly device includes an inner arc flange machined at the end of the positioning block that contacts the rotor support body. The arc surface of the flange mates with the outer cylindrical surface of the rotor support pole box end for positioning, and is mounted on the rotor support using two second hexagonal head screws. A guide groove is machined axially on the upper surface of the positioning block. The guide groove and the anti-overturning cover plate form a rectangular magnetic guide channel that connects to the magnet assembly opening on the end face of the rotor support pole box. The magnet is positioned by the guide groove of the positioning block, inserted into the positioning block, and guided into the pole box by the rectangular magnetic guide channel formed by the guide groove and the anti-overturning cover plate. The width of the guide groove of the positioning block and the length of the magnet are in sliding fit. An anti-backlash plate opening groove is machined on the outer side of the arc flange of the positioning block to reserve assembly space for pressing the anti-backlash plate onto the rotor support body.

[0007] The aforementioned marine direct-drive permanent magnet shaft-driven generator rotor magnet assembly device comprises a transmission mechanism consisting of a bearing sleeve, a shaft elastic retaining ring, a motor wave spring, a deep groove ball bearing, a bore elastic retaining ring, a positioning block connecting plate, and a lead screw. The positioning block connecting plate connects the transmission mechanism and the positioning block using two fourth-order hexagon socket head cap screws. The lead screw transmits power. The deep groove ball bearing is fixed to the lead screw by the shaft elastic retaining ring. The motor wave spring, an industry standard component, buffers the axial force between the deep groove ball bearing and the bearing sleeve. The bearing sleeve houses the deep groove ball bearing and the motor wave spring, transmits the lead screw pressure, and pushes the pressing plate to move the magnet. The bore elastic retaining ring connects the bearing sleeve, the motor wave spring, and the deep groove ball bearing into a single unit. Power generated by a general-purpose electric or pneumatic tool converts the rotation of the lead screw into the axial translation of the bearing sleeve via the transmission mechanism, and the pressing plate presses the magnet into the magnetic pole box.

[0008] The above-mentioned marine direct-drive permanent magnet shaft generator rotor magnet assembly device includes a press-in plate, which is a rectangular aluminum alloy plate. The magnet is positioned by a rectangular guide channel composed of positioning blocks and anti-rollover cover plates, and the axial force transmitted from the bearing sleeve of the transmission mechanism is transmitted to press the magnet into the magnetic pole box. The width and thickness of the press-in plate are smaller than the length and thickness of the magnet. The end of the press-in plate that contacts the magnet is machined with an anti-reverse pressure plate opening groove to reserve assembly space for the anti-reverse pressure plate to be pressed into the rotor support body.

[0009] The above-mentioned marine direct-drive permanent magnet shaft generator rotor magnet assembly device includes an anti-rollover cover plate positioned by a combination of the anti-rollover cover plate stop and the positioning block guide groove, which is installed on the positioning block by a third internal hexagonal head screw. The magnetic steel guide rectangular channel formed by the upper plane of the anti-rollover cover plate stop and the positioning block guide groove is used for guiding and positioning the magnet into the magnetic pole box. The width of the anti-rollover cover plate is generally not less than the width of one magnet, which is used to prevent the magnet from flipping onto the outer arc surface of the magnetic pole box or the rotor support body due to the magnetic field force before entering the magnetic pole box. The anti-rollover cover plate has an anti-reverse pressure plate opening groove on one side to reserve assembly space for the anti-reverse pressure plate to be pressed into the rotor support body. After the anti-rollover cover plate and the positioning block are assembled, a gap is left between the side of the anti-rollover cover plate and the outer end face of the arc flange of the positioning block to facilitate observation of whether the positioning block and the magnetic pole box are correctly positioned. The purpose of installing two anti-rollover covers and leaving a gap between the two anti-rollover covers is to increase the length of the magnetic steel guide rectangular channel and facilitate observation of the movement of the magnet in the guide groove.

[0010] The above-mentioned marine direct-drive permanent magnet shaft generator rotor magnet assembly device uses two first internal hexagonal head screws to press all the magnets of one pole into the rotor bracket pole box until the magnet adhesive is completely cured.

[0011] The beneficial effects of this utility model are as follows: This utility model uses an anti-rollover cover plate and positioning blocks to form a rectangular channel for guiding the magnet, thereby press-fitting and positioning the magnet. This prevents the magnet from rolling over and impacting the outer arc surface of the magnet pole box or the rotor support body before entering the magnet pole box. The use of a wave spring in the transmission mechanism reduces the pressure impact on the magnet, effectively eliminating the protective defects of traditional magnet assembly devices, such as body breakage, edge chipping, and coating cracking during magnet assembly. The use of a backstop pressure plate instead of the traditional magnet assembly device that presses one magnet pole while waiting for the magnet adhesive to fully cure reduces the number of molds required, effectively eliminating the high mold cost of traditional magnet assembly devices. Attached Figure Description

[0012] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0013] Figure 1 This is a front view of the rotor magnet assembly device;

[0014] Figure 2 For along Figure 1 Sectional view of line AA in the middle;

[0015] Figure 3 This is the main view of the positioning block;

[0016] Figure 4 For along Figure 3 Sectional view of the middle BB line;

[0017] Figure 5 For along Figure 3 A cross-sectional view of the CC line;

[0018] Figure 6 This is the main view of the transmission mechanism;

[0019] Figure 7 for Figure 6 Enlarged view of part I in the middle section;

[0020] Figure 8 This is a sectional view of the bearing sleeve;

[0021] Figure 9 This is the main view of the positioning block connecting plate;

[0022] Figure 10 This is a top view of the positioning block connecting plate;

[0023] Figure 11 This is the main view of the lead screw;

[0024] Figure 12 This is the main view of the press-in plate;

[0025] Figure 13 This is a top view of the press-in plate;

[0026] Figure 14 Main view of the cover plate to prevent tipping;

[0027] Figure 15 Top view of the cover plate to prevent tipping;

[0028] Figure 16 Main view of the stop-retraction pressure plate;

[0029] Figure 17 For along Figure 16 Sectional view of the DD line;

[0030] Figure 18 Top view of the rotor of a marine direct-drive permanent magnet shaft generator;

[0031] Figure 19 For along Figure 18 Sectional view of the middle EE line;

[0032] Figure 20 for Figure 19 Enlarged schematic diagram of part II;

[0033] Figure 21 Top view of the rotor support;

[0034] Figure 22 for Figure 21 Enlarged schematic diagram of part III;

[0035] Figure 23 For along Figure 21 Sectional view of the middle FF line;

[0036] Figure 24 for Figure 23 Enlarged view of part IV in the middle section;

[0037] Figure 25 This is a front view of the magnet; the arrows in the diagram indicate the direction of magnetization.

[0038] Figure 26 Top view of the magnet;

[0039] Figure 27 This is a schematic diagram showing the circumferential distribution of the magnetic poles on the rotor of a 36-pole marine direct-drive shaft-driven generator.

[0040] In the diagram: 1. First socket head cap screw, 2. Second socket head cap screw, 3. Anti-reverse pressure plate, 4. Anti-rollover cover plate, 5. Third socket head cap screw, 6. Positioning block, 7. Press-in plate, 8. Fourth socket head cap screw, 9. Transmission mechanism, 10. Bearing sleeve, 11. Shaft retaining ring, 12. Wave spring for motor, 13. Deep groove ball bearing, 14. Hole retaining ring, 15. Positioning block connecting plate, 16. Lead screw, 17. Rotor support body, 18. Magnetic pole box, 19. Magnet, 20. Magnetic pole cover plate, 21. External hex bolt. Detailed Implementation

[0041] The present invention will now be described in further detail. See below. Figures 1 to 27 A marine direct-drive permanent magnet shaft-driven generator rotor magnet assembly device comprises a first hexagon socket head cap screw 1, a second hexagon socket head cap screw 2, a backlash prevention plate 3, an anti-tipping cover 4, a third hexagon socket head cap screw 5, a positioning block 6, a pressing plate 7, a fourth hexagon socket head cap screw 8, and a transmission mechanism 9. The transmission mechanism 9 is assembled to the positioning block 6 via the fourth hexagon socket head cap screw 8. The anti-tipping cover 4 is assembled to the positioning block 6 via the third hexagon socket head cap screw 5. The second hexagon socket head cap screw 2 assembles the positioning block 6 to the rotor support body 17. The first hexagon socket head cap screw 1 assembles the backlash prevention plate 3 to the rotor support body 17, thus pressing all the magnets 19 of one magnetic pole into the magnetic pole box 18.

[0042] Positioning block 6 is the clamping body of the magnet assembly device, a fundamental component of the device. It provides positioning and guidance for the magnet 19 and the pressing plate 7, and offers assembly space for installing the anti-reverse pressure plate 3. Positioning block 6 is made of 316L stainless steel. The choice of 316L stainless steel is based on the clamping body's requirements for non-magnetic conduction and mechanical strength. Its structure is as follows... Figure 3 , Figure 4 , Figure 5 As shown. The end of the positioning block 6 that contacts the rotor support body 17 has a flange with an arc surface, and the flange has 2-φa and 2-φb through holes drilled on it. The radius Ra1 of the arc surface of the flange is the same as the radius Ra2 of the arc surface of the rotor support body 17. The spacing A1 of the 2-φa through holes is the same as the spacing A2 of the two Md threaded holes of the rotor support body 17 separated by one pole box. The radius Rb1 of the circle containing the 2-φa through holes is the same as the radius Rb2 of the circle containing the Md threaded holes of the rotor support body 17. The diameter of the 2-φa through holes is designed to allow the major diameter of the Md threaded screw to pass through, that is, to allow the major diameter of the second internal hexagon head screw 2 to pass through. The positioning block 6 uses the arc surface Ra1 and the cylindrical surface Ra2 of the rotor support body 17 as positioning mating surfaces, and the two second internal hexagon head screws 2 pass through the 2-φa holes to achieve the assembly of the positioning block 6 and the rotor support body 17.

[0043] A guide groove with a width C1 and a depth D is machined along the axial direction on the upper surface of the positioning block 6. The function of the guide groove is to realize the installation positioning and axial sliding guidance of the magnet 19 and the pressing plate 7 on the positioning block 6. The width dimension C1 of the guide groove is the same as the inner cavity dimension C2 of the magnetic pole box 18, and is 0.2 to 0.3 mm larger than the length dimension C3 of the magnet 19. The dimension E1 of the position from the bottom surface of the guide groove to the positioning arc surface Ra1 is 0 to 0.1 mm smaller than the dimension E2 of the rotor support body 17. The purpose of the dimension E1 being smaller than the dimension E2 is that when the magnet 19 enters the rotor support body 17 from the lower plane, the magnet 19 moves from the lower plane. If the dimension E1 is larger than the dimension E2, when the magnet 19 leaves the guide groove of the positioning block 6 and fully enters the rotor support body 17, the magnet 19 moves from the lower plane, and the attraction between the two will cause the magnet to impact and stick to the rotor support body 17, which may cause the magnet 19 to break or its edges to fall off. The purpose of controlling the difference between dimensions E1 and E2 to be less than 0.1mm is to ensure that magnet 19 can smoothly move from the guide groove of positioning block 6 to the magnet support plane of rotor support body 17 with the help of the chamfered edge of the lower plane of magnet 19, instead of colliding with rotor support body 17. The depth dimension D of the guide groove and the closed dimension F1 after assembly with the stop height dimension P of the anti-rollover cover plate 4 and the inner cavity dimension F2 between rotor support body 17 and magnetic pole box 18 are the same, and are 0.2 to 0.3mm larger than the thickness dimension F3 of magnet 19. That is, the guide groove of positioning block 6 and the upper plane of the stop of anti-rollover cover plate 4 form a rectangular guide channel of magnet with width C1 and height F1. The rectangular guide channel of magnet and magnet 19 form a sliding fit clearance of 0.2 to 0.3mm in both the length and thickness directions of magnet. When machining positioning block 6, the positioning accuracy of magnet 19 and rotor support magnetic pole box 18 is ensured by controlling the size and position accuracy of guide groove, positioning arc surface Ra1 and 2-φa circular hole. To facilitate the insertion of the magnet 19 into the guide groove of the positioning block 6, a 4x45° chamfer is machined on the two groove edges at the middle position of the guide groove. The chamfer starts at the side of the anti-rollover cover 4 away from the outer edge of the arc flange, and the chamfer length is approximately twice the width T of the magnet 19. The specific position and length are determined to facilitate the insertion of the magnet 19 into the guide groove. A groove with a width of H is machined on the bottom surface of the guide groove to provide space for the bearing sleeve 10 to push the pressing plate 7 to move. The groove width H is greater than the outer diameter φf of the bearing sleeve 10 but less than the guide groove width C1. The groove extends axially to the lower part of the anti-rollover cover 4. The magnet 19 and the pressing plate 7 are positioned on both sides of the guide groove, inserted into the positioning block 6, and slide along the axial direction of the guide groove.

[0044] The purpose of machining 2-φb through holes on the arc flange surface of the positioning block 6 is to reserve space for the cylindrical heads of the two first hexagon socket head cap screws 1. After the last magnet 19 of a magnetic pole is pressed into the rotor support pole box 18, the anti-reverse pressure plate 3 needs to be installed while the pressing plate 7 holds the magnet 19 under pressure. For this purpose, two first hexagon socket head cap screws 1 are used to pass through the arc flange of the positioning block 6 and connect to the two Md internal threads at a distance B2 on the rotor support body 17 to assemble the anti-reverse pressure plate 3 onto the rotor support body 17. The anti-reverse pressure plate 3 presses all the magnets 19 in a magnetic pole into the pole box 18 until the magnet adhesive is completely cured. The distance B1 between the 2-φb through holes of the positioning block 6 and the distance B2 between the two Md threaded holes of the same magnetic pole of the rotor support are the same, and the radius Rb1 of the circle containing the 2-φb through holes is equal to the radius Rb2 of the circle containing the two Md threaded holes of the rotor support. The diameter of the 2-φb through hole is based on the outer diameter of the cylindrical head of the first internal hexagonal head screw 1.

[0045] One end face of the positioning block 6 is tapped with a 2-Ma internal thread for connecting the transmission mechanism 9. The size of the 2-Ma internal thread is determined by the pressure required for pressing the magnet. The 2-Ma internal thread spacing G1 is the same as the 2-φc through-hole spacing G2 of the positioning block connecting plate 15 of the transmission mechanism 9. The transmission mechanism 9 is assembled onto the positioning block 6 using two fourth internal hexagon head screws 8.

[0046] The upper surface of the positioning block 6 is threaded with 4-Mb internal threads for installing two anti-rollover covers 4. The anti-rollover covers 4 are positioned by aligning the stop N with the guide groove width C1, and are assembled onto the positioning block 6 by two third hexagon socket head cap screws 5 screwed into Mb. The design of the 4-Mb internal thread position ensures that after the anti-rollover covers 4 are assembled, there is a 5mm gap between the outer side of the arc flange of the positioning block 6 and the side of the anti-rollover covers 4, and a 10mm gap between the two anti-rollover covers. These two gaps are reserved to facilitate observation of whether the guide groove of the positioning block 6 is correctly positioned relative to the pole box 18, and the movement of the magnet 19 within the guide groove. If the positioning block 6 and the pole box 18 are not correctly positioned, the magnet 19 may engage with or collide with the rotor support body 17 or the pole box 18 during assembly, requiring correction.

[0047] The outer side of the arc flange of the positioning block 6 is machined with a groove for the anti-reverse pressure plate with a width K1 and a depth J1. Its function is to reserve space for the anti-reverse pressure plate 3 to be assembled into the rotor support body 17. The dimensions of width K1 and depth J1 are determined by the length dimension K4 and the thickness dimension J4 of the anti-reverse pressure plate 3, respectively, so as to facilitate the insertion of the anti-reverse pressure plate 3.

[0048] The transmission mechanism 9 converts the rotational power generated by an electric or pneumatic tool into axial translational thrust, which pushes the pressing plate 7 and the magnet 19 to move. Simultaneously, the wave spring 12 in the motor of the transmission mechanism 9 provides pressure buffering for the magnet 19 as it enters the magnetic pole box 18. Its structure is as follows: Figures 6 to 11 As shown. The transmission mechanism 9 consists of a bearing sleeve 10, a shaft elastic retaining ring 11, a motor wave spring 12, a deep groove ball bearing 13, a hole elastic retaining ring 14, a positioning block connecting plate 15, and a lead screw 16. The transmission mechanism 9 converts the rotational power generated by the electric or pneumatic tool into axial translational thrust through the thread action of the lead screw 16 and the positioning block connecting plate 15, and then through the inner ring, rolling elements, and outer ring of the deep groove ball bearing 13. This thrust is then pushed by the motor wave spring 12 and the bearing sleeve 10 to push the pressing plate 7 along the guide groove of the positioning block 6, pushing the magnet 19 into the magnetic pole box 18.

[0049] The bearing sleeve 10 serves to house the deep groove ball bearing 13 and the wave spring 12 for the motor, transmitting pressure to move the magnet 19 by pushing the pressure plate 7. The bearing sleeve 10 is made of 316L stainless steel and has the following structure: Figure 8 As shown. The material was chosen based on its non-magnetic properties and mechanical strength. The inner bore dimension φe of the bearing sleeve 10 and the deep groove ball bearing 13 is determined by the outer diameter of the bearing, with a tolerance of H7. The groove dimension φd of the elastic retaining ring 14 for the mounting hole is designed according to national standards, and the groove position of the elastic retaining ring 14 is determined by the working height of the wave spring 12 for the motor and the thickness of the deep groove ball bearing 13. The bottom groove of the bearing sleeve 10 is a relief groove.

[0050] The wave spring 12 for motors is an elastic element with multiple wavy peaks and valleys on a thin circular ring, made of 65Mn material. The wave spring 12 is an industry standard part, meeting the requirements of "JB_T 7590-2005 Technical Conditions for Steel Wave Springs for Motors". This elastic element reduces the axial impact force between the deep groove ball bearing 13 and the bearing sleeve 10, thus buffering the impact of the transmission mechanism 9 on the magnet 19 and protecting the magnet 19 body and its outer coating.

[0051] The deep groove ball bearing 13 is a sealed deep groove ball bearing to improve its service life. The deep groove ball bearing 13 is installed between the bearing sleeve 10 and the lead screw 16 to ensure that the press-in plate 7 is only subjected to translational thrust and not rotational torque. This ensures that there is no relative rotational tendency between the contact surface of the press-in plate 7 and the magnet 19, protecting the external coating of the magnet 19. The deep groove ball bearing 13, the shaft retaining ring 11, and the bore retaining ring 14 are national standard parts.

[0052] The function of the positioning block connecting plate 15 is to connect the transmission mechanism 9 and the positioning block 6 and form a threaded pair with the lead screw 16, as shown in the figure. Figure 9 , Figure 10As shown. The positioning block connecting plate 15 is machined from 316L stainless steel plate. This material was chosen based on its non-magnetic properties and mechanical strength. The fourth internal hexagon socket head cap screw 8 uses a 2-φc through hole to mount the positioning block connecting plate 15 onto the positioning block 6. The diameter of the 2-φc hole matches the 2-Ma hole in the positioning block 6, and the distance G2 between the two 2-φc holes is the same as the distance G1 between the 2-Ma holes in the positioning block 6. The internal thread Mc is used to form a threaded pair with the lead screw 16, and its specifications are the same as the thread of the lead screw 16.

[0053] The function of the lead screw 16 is to transfer the torque generated by the electric or pneumatic tool through its internal thread engagement with the positioning block connecting plate 15, thereby moving the bearing sleeve 10 back and forth. Its structure is as follows: Figure 11 As shown. The lead screw 16 is machined from 45 steel after quenching and tempering. The outer diameter φg is used to assemble the deep groove ball bearing 13, and its size is determined by the inner diameter of the bearing. The outer diameter tolerance is selected as k6. The groove at the outer end of φg is used to assemble the shaft elastic retaining ring 11. The groove size and position dimensions refer to the relevant mechanical design manual. The outer diameter φh is the bearing positioning step, and its size refers to the relevant parameters in the bearing sample. The groove between φg and φh is the grinding wheel runout groove. The axial length L of the Mc thread is determined by the depth required for the pressing plate 7 to press the magnet 19 into the magnetic pole box 18. The size of Mc is determined by the maximum repulsive force between the magnets and the compressive stability of the lead screw.

[0054] The function of the press-in plate 7 is to transmit the pressure of the transmission mechanism bearing sleeve 10 to the magnet 19 and to provide assembly space for installing the anti-reverse pressure plate 3. Its structure is as follows: Figure 12 , Figure 13 As shown. The press-in plate 7 is made of 7075 aluminum alloy. This material was chosen because it is non-magnetic and reduces damage to the magnets. The length of the press-in plate 7 is generally four times the width T of the magnet, and the width of the press-in plate 7 is 1mm smaller than the length C3 of the magnet. The thickness of the press-in plate 7 is 1mm smaller than the thickness F3 of the magnet. To ensure that the press-in plate 7 can enter the magnetic pole box 18 and is easy to process, two bevels are machined on one side of the press-in plate 7, so that the press-in plate 7 can slide smoothly within the magnetic pole box 18. An anti-reverse pressure plate opening slot is machined on the end face of the press-in plate 7 to reserve space for the anti-reverse pressure plate 3 to be assembled onto the rotor support body 17. The width K2 and depth J2 of the anti-reverse pressure plate opening slot are the same as the dimensions K1 and J1 of the anti-reverse pressure plate opening slot of the positioning block 6, respectively.

[0055] The function of the anti-rollover cover 4 is to form a rectangular guide channel for the magnet with the guide groove of the positioning block 6, which provides positioning and guidance for the magnet 19 and the press-in plate, and provides assembly space for the installation of the anti-rollover pressure plate 3. Its structure is as follows: Figure 14 , Figure 15As shown. The anti-tilting cover 4 is made of 7075 aluminum alloy. The choice of aluminum alloy, besides being non-magnetic, is mainly based on its low hardness to reduce surface damage to the magnet 19. The anti-tilting cover 4 prevents the magnet 19 from flipping onto the outer arc surface of the magnet 18 or the rotor support body 17 during its entry into the magnetic pole box 18 via the guide groove of the positioning block 6, due to the influence of the surrounding magnetic field. Each magnet 19 experiences complex forces before entering the magnetic pole box 18. The rotor support body 17 around the magnetic pole box exerts an attractive force on the magnet 19 to be installed, and adjacent already installed magnets also exert an attractive force on the magnet 19 to be installed. If there are already magnets in the magnet 19 to be installed, a repulsive force will also be generated between magnets of the same polarity. The magnitude and direction of the resultant magnetic force will change as the assembly process progresses. Especially when assembling the last magnet of the last pole, the attractive forces of the opposite magnetic poles on both sides and the rotor support body on the magnet to be assembled, combined with the repulsive forces of the magnets of the same magnetic pole, will cause the magnet 19 to fail to enter the inner cavity of the pole box 18 and instead flip and collide with the outer arc surface of the pole box 18 or the rotor support body 17 if the magnet assembly device does not have a reliable magnet constraint design. Therefore, a fixed anti-flip cover 4 is designed at the end of the positioning block 6 near the pole box. The rectangular magnet guide channel formed by the upper plane of the anti-flip cover 4 and the guide groove of the positioning block 6 constrains and positions the magnet 19 as it enters the pole box 18 in the up, down, left, and right directions to solve the magnet assembly positioning problem. The rotor magnet assembly device has two anti-flip covers 4. The total length of the rectangular guide channel formed by the two anti-rollover covers 4 and the positioning block 6 is determined by the resultant force of the magnetic field on the magnet 19 to be installed. The goal is to ensure that the magnet 19, after being placed in the guide groove of the positioning block 6, can easily enter the rectangular guide channel under the anti-rollover cover 4 without flipping and colliding with the outer arc surface of the pole box 18 or the rotor support body 17. The purpose of setting two anti-rollover covers 4 is not only to increase the length of the rectangular guide channel to ensure the magnet 19 can smoothly enter, but also to facilitate observation of the movement of the magnet 19 within the guide groove of the positioning block 6 before entering the pole box 18, allowing for timely preventative measures. The width M of a single anti-rollover cover 4 is generally not less than the width T of one magnet 19. The stop N of the anti-rollover cover 4 is clearance-fitted with the guide groove C1 of the positioning block 6. The 2-φi through hole and the two transverse threaded holes in the 4-Mb section of the positioning block 6 are in an assembly relationship. When machining the positioning stop N, control the stop height P to ensure that the closed dimension F1 formed after the third internal hexagonal head screw 5 assembles the anti-rollover cover 4 onto the positioning block 6 is 0.2-0.3 mm larger than the thickness F3 of the magnet 19. A backlash plate opening groove is machined on the side of the anti-rollover cover 4 to reserve space for the backlash plate 3 to be assembled onto the rotor support body 17. The width K3 of the backlash plate opening groove of the anti-rollover cover 4 is the same as the K1 of the backlash plate opening groove of the positioning block 6. The depth J3 of the backlash plate opening groove of the anti-rollover cover 4, after being increased by 5 mm, is the same as the depth J1 of the backlash plate opening groove of the positioning block 6.

[0056] The function of the anti-reverse pressure plate 3 is to fix the last magnet 19 of a magnetic pole to the magnetic pole box 18 and wait for the magnet adhesive to fully cure. Its structure is as follows: Figure 16 , Figure 17 As shown, the anti-reverse pressure plate 3 is assembled onto the rotor support body 17 using two first hexagon socket head cap screws 1. This ensures that the anti-reverse pressure plate 3 presses all the magnets 19 of a magnetic pole into the magnetic pole box 18, allowing the magnet adhesive to fully cure. The anti-reverse pressure plate 3 is made of 316L stainless steel, chosen for its non-magnetic properties and mechanical strength. After the last magnet 19 of a magnetic pole is pressed into the magnetic pole box 18 by the pressing plate 7, before the magnet adhesive fully cures, the last magnet 19 will move outward, or even out of the magnetic pole box 18, due to the repulsive force between adjacent magnets of the same magnetic pole. This necessitates that the magnet assembly device remain pressed on the last magnet until the magnet adhesive fully cures. This results in a large demand for magnet assembly devices and high mold costs. To address the high mold costs, the anti-reverse pressure plate 3 is designed. The 2-φk through holes in the anti-reverse pressure plate 3 are used to assemble the anti-reverse pressure plate 3 onto the rotor support body 17. The hole diameter φk matches the size Md of the rotor support body 17, and the 2-φk hole spacing B3 is the same as the B2 dimension of the rotor support body 17. The dimension Q from the center line of the 2-φk hole to the edge position is determined by ensuring that the anti-reverse pressure plate 3 can be assembled onto the rotor support body 17 without interfering with the outer circle Ra2. The width dimension S is sufficient to press down on the magnet 19. The length dimension K4 of the anti-reverse pressure plate 3 is determined by the 2-φk hole spacing B3 and the cylindrical head dimension of the first internal hexagon socket head cap screw 1. The plate thickness J4 is selected to be 1.5 times the major diameter of the thread of the first internal hexagon socket head cap screw 1. To improve the pressing effect of the anti-reverse pressure plate 3, 0.2mm is removed from the flat portion in contact with the rotor support body 17 to ensure reliable pressing of the magnet 19 by the anti-reverse pressure plate 3.

[0057] The method of using this utility model is as follows:

[0058] The following example illustrates the usage of this invention using the assembly of a 36-pole marine direct-drive permanent magnet shaft-driven generator rotor magnet. The operation steps of the marine direct-drive permanent magnet shaft-driven generator rotor magnet assembly device are as follows:

[0059] The first step is to assemble the rotor magnet assembly device. The lead screw 16 is screwed into the positioning block connecting plate 15 via the Mc thread. The deep groove ball bearing 13 is heat-fitted onto the outer diameter φg of the bearing stop on the lead screw 16. After the bearing cools, it is fixed with a shaft elastic retaining ring 11. The bearing sleeve 10 is placed into the motor wave spring 12 and then fitted onto the outer diameter of the deep groove ball bearing 13. The bearing is secured with a hole elastic retaining ring 14 to complete the assembly of the transmission mechanism 9. After the transmission mechanism 9 is assembled, it is connected to the positioning block 6 via the positioning block connecting plate 15 using two fourth hexagon socket head cap screws 8. The anti-rollover cover plate 4's stop N is positioned with the guide groove C1 of the positioning block 6. The two anti-rollover cover plates 4 are assembled onto the positioning block 6 using four third hexagon socket head cap screws 5. The dimensions C1 and F1 of the magnet guide rectangular channel formed by the anti-rollover cover plate 4 and the positioning block 6 are measured, completing the assembly of the marine direct-drive permanent magnet shaft-driven generator magnet assembly device.

[0060] The second step is to assemble the rotor magnet assembly into the rotor bracket. Place the rotor bracket as follows: Figure 23 The rotor is placed vertically on the work surface. Positioned using the Ra1 arc surface of the positioning block 6 and the Ra2 arc surface of the rotor support body 17, the rotor magnet assembly device is vertically installed onto the rotor support using two second hexagon socket head cap screws 2. The positional difference between the three planes of the magnet guide rectangular channel (formed by the anti-tipping cover 4 and positioning block 6) and the magnetic pole box 18 is checked to be no more than 0.2mm. The height difference between the bottom surface of the guide groove of the positioning block 6 and the magnet support plane of the rotor support body 17 is ≤0.1mm, and the magnet support surface of the rotor support body 17 is higher than the bottom surface of the guide groove of the positioning block 6. This ensures that the magnet 19 smoothly enters the magnetic pole box 18 through the magnet guide rectangular channel of the rotor magnet assembly device. To ensure smooth production, an unmagnetized magnet is purchased as a test piece to verify the dimensions of the magnet guide rectangular channel of the rotor magnet assembly device, the dimensions of the rotor support magnetic pole box, and the correct positions of both. Pay special attention to the following two situations: 1. Whether the unmagnetized magnet will jam with the magnetic pole box 18 and the rotor support body 17 when it first enters the magnetic pole box. When assembling the magnetized magnet, any jamming under the action of magnetic force will cause damage to the surface coating or the body of the magnet; 2. Using the unmagnetized magnet to simulate the magnetized magnet, when the magnet assembly device has just fully entered the magnetic pole box 18, predict whether the magnetized magnet will suddenly be attracted to the rotor body 17 due to the position deviation between the bottom surface of the guide groove of the positioning block 6 and the magnet support surface of the rotor support body 17, resulting in impact damage to the magnet 19. After checking that there are no errors, use an electric or pneumatic tool to rotate the lead screw 16 to move the bearing sleeve 10 to the uppermost position near the positioning block connecting plate 15 as the initial position for pressing the magnet.

[0061] The third step is to assemble the lower pole cover plate 20 of the rotor support and mark the pole numbers. Use hex bolts 21 to assemble the pole cover plate 20 to the lower end face of the pole box 18 of the rotor support. To facilitate explanation of the pressing process of each pole magnet, the pole corresponding to the guide groove of the current rotor magnet assembly device is designated as pole N1. Use a marker to mark each pole box 18 sequentially along the circumference on the outer arc surface as N1, S1, N2, S2, N3, S3, ..., N18, S18. The poles are distributed circumferentially as follows... Figure 27 As shown. At this time, the two second internal hexagonal head screws 2 are respectively assembled with one Md internal thread of the S1 and S18 magnetic pole boxes of the rotor support body 17, fixing the rotor magnet assembly device at the position of pressing N1 pole magnet.

[0062] Step 4: Pressing in the N1 pole magnet box. To ensure operator safety and smooth magnet assembly, pressing in the magnet is generally done by 3-4 people working together. The specific steps are as follows: 1. Separating the magnets. Currently, the domestic supply of magnets consists of 4-5 magnets of the same polarity separated by plastic plates in strips. Before assembly, the magnets must be separated one by one using a magnet separation device. 2. Checking the magnet polarity. Check the magnet polarity to confirm that the magnet to be assembled has the same magnetism as the marking on the pole box. 3. Applying magnet adhesive. One person holds the magnet while another applies magnet adhesive to all six sides of the magnet. 4. Assembling the magnet into the rotor magnet assembly device. Hold the magnet with the arc side facing outwards, away from the central axis of the rotor support, and position it using the two sides of the guide groove of positioning block 6. Place the magnet 19 into the guide groove at the chamfered edge of the guide groove of positioning block 6. After magnet 19 enters the guide groove, press the arc surface of the magnet by hand and push magnet 19 along the two sides and bottom of the guide groove into the rectangular guide channel formed by the anti-rollover cover plate 4 and the positioning block 6. Under the action of magnetic force, after releasing the hand, the first magnet 19 will quickly move along the rectangular guide channel to the end of the magnetic pole box 18 and engage with the rotor support body 17. 5. Press the magnet into the magnetic pole box. Insert the open slot end of the press-in plate 7 downward into the guide groove of the positioning block 6, hold the press-in plate 7 and push it to the side of magnet 19. Use an electric or pneumatic tool to rotate the hexagonal head of the screw 16 to provide power. The transmission mechanism 9 presses magnet 19 into the magnetic pole box 18 through the press-in plate 7 with an axial displacement of 1 to 2 times the width T of the magnet, so as to leave space for the assembly of the next magnet. After each magnet is pressed in, reverse the electric or pneumatic tool to restore the bearing sleeve 10 to the initial position of the pressed magnet. The electric or pneumatic tool should be made of aluminum or stainless steel if possible. The operator should ensure that tools are kept away from the magnets. 6. Press in subsequent magnets of the same pole. Repeat steps 1 to 5 to press the magnets into the pole box one by one. Since magnets of the same polarity repel each other, the subsequent magnet will push the preceding magnet towards the bottom of the pole box during the pressing process. After the last magnet of this pole is pressed into the pole box, while maintaining the pressure of the pressing plate 7 on the magnet 19, with the raised surface of the anti-reverse pressure plate 3 facing the magnet 19, insert the anti-reverse pressure plate 3 into the anti-reverse pressure plate assembly slot of the anti-tipping cover plate 4, the pressing plate 7, and the positioning block 6. Then, use two first hexagon socket head cap screws 1 to assemble the anti-reverse pressure plate 3 onto the rotor support body 17, fixing all the magnets 19 of one pole in the pole box 18 and waiting for the magnet adhesive of this pole to fully cure.

[0063] Step 5: Press-fit the subsequent N-pole magnets. After securing all N1 pole magnets to the pole box with anti-reverse clamps, disassemble the rotor magnet assembly device at the N1 pole position. Using two second hexagon socket head cap screws 2 and their corresponding Md internal threads on the S1 and S2 pole boxes, move the rotor magnet assembly device to the position for assembling the N2 pole box. Repeat step 4 (press-fitting the N1 pole magnets) to complete the assembly of the N2 through N18 pole magnets sequentially.

[0064] Step 6: Press-fit the S-pole magnet. After 24 hours at room temperature, the magnet adhesive is fully cured. Once the magnets are reliably bonded, remove the retaining plates 3 at the N1 and N2 pole boxes 18. Using the corresponding Md internal threads of the N1 and N2 pole boxes 18, install the rotor magnet assembly device into the S1 pole box 18. Repeat step 4 for assembling the N1 pole box magnets, assembling the S-pole magnet 19 into the S1 pole box 18, completing the S1 pole magnet assembly. When assembling the S2 to S17 pole magnets sequentially, only remove the retaining plate 3 of the adjacent N-pole for each S-pole. This is to fully utilize the time difference in curing of the adhesive between the assembled pole magnets, compressing the magnet assembly cycle. The assembly steps for the S2 to S18 pole magnets are the same as those for the S1 pole magnet. To further improve productivity, if the mold investment cost is acceptable, two sets of rotor magnet assembly devices can be manufactured. When assembling the N pole magnets, assemble the two sets of devices in sequence as N1 to N9 and N10 to N18 respectively. Before assembling the S pole magnets after completing the N pole assembly, ensure that the adhesive on the N pole magnets to be removed from the anti-reverse pressure plate has completely cured. Then, assemble the S1 to S9 and S10 to S18 pole magnets in sequence for both sets of devices.

[0065] Step 7: Remove the S-pole anti-reverse pressure plate and assemble the magnetic pole cover plate. After the adhesive on the magnet inside the S-pole has completely cured, remove the anti-reverse pressure plate 3 at the S-pole and use hex bolts 21 to assemble the magnetic pole cover plate 20 onto the rotor support body 17. This completes the assembly of the rotor magnets for a marine direct-drive permanent magnet shaft-driven generator.

Claims

1. A marine direct-drive permanent magnet shaft generator rotor magnet assembly device, comprising a first inner hexagonal cylindrical head screw (1), a second inner hexagonal cylindrical head screw (2), a retreat-stop pressing plate (3), an anti-overturning cover plate (4), a third inner hexagonal cylindrical head screw (5), a positioning block (6), a pressing-in plate (7), a fourth inner hexagonal cylindrical head screw (8), a transmission mechanism (9), characterized in that: The positioning block (6) guide groove and the anti-rollover cover plate (4) stop plane form a rectangular channel for guiding the magnet; the end of the lead screw (16) in the transmission mechanism (9) is equipped with a deep groove ball bearing (13), a wave spring (12) for the motor and a bearing sleeve (10); the anti-reverse pressure plate (3) presses on all the magnets (19) of a magnetic pole and waits for the magnet adhesive to fully cure.

2. The direct-driven permanent-magnet shaft generator rotor magnetic steel assembling device for marine use according to claim 1, characterized in that, The positioning block (6) has a guide groove machined along the axial direction on its upper plane and an opening groove machined on the outer side of the arc flange end.

3. The direct-driven permanent-magnet shaft generator rotor magnetic steel assembling device for marine use according to claim 1, characterized in that, The anti-tumble cover (4) has an opening groove machined on its side.

4. The direct-driven permanent-magnet shaft generator rotor magnetic steel assembling device for marine use according to claim 1, characterized in that, The press-in plate (7) has an opening groove machined on one end face along its length.

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