A manufacturing process for a claw pole with a milled magnetic steel limit groove for a hybrid excitation generator and a claw pole and tooling

Abstract

The present invention relates to the field of claw pole manufacturing technology, and in particular, the present invention provides a manufacturing process for claw poles with milled magnetic steel limit grooves for parts used in hybrid excitation generators, as well as claw poles and tooling. The claw pole combination is placed on the same tooling and is milled using a forming cutter. The groove area where the claw pole combination matching takes effect is synchronously formed by the cutting edges on both sides of the tool. Since the claw pole itself is a rigid forging, the overall effect of the magnetic steel limit groove formed by milling in this way is: the front and rear claw poles are complementary, and the influence of the cutting factor on the groove size tends to zero. The size of the claw pole combination milling only needs to consider the assembly clearance. The hybrid excitation generator rotor assembled with the claw pole combination has a smaller clearance between the magnetic steel and the non-fitting side of the magnetic steel limit groove, an improved magnetic locking performance, and an improved overall performance.

Description

Technical Field

[0001] The invention relates to the technical field of claw pole manufacturing, in particular to a manufacturing process for a claw pole of a part milling magnetic steel limiting groove for a hybrid excitation generator, and a claw pole and a tooling. Background Art

[0002] As people's requirements for the comfort of cars are getting higher and higher, the power requirements for generators are also getting higher and higher. At the same time, people are paying more and more attention to the fuel consumption requirements of cars, so automobile OEMs are becoming more and more demanding on the weight of each component. Based on the requirements of high power and lightweight generators, many generator factories are currently beginning to study hybrid excitation generators. The difference between hybrid excitation generators and ordinary generators is that magnetic steel is embedded between the front and rear claw poles of the generator rotor, which greatly increases the magnetic conductivity of the claw poles, thereby greatly increasing the output power and efficiency of the generator.

[0003] The existing hybrid excitation generator rotor is uniformly inlaid with magnets between the claw pole combination. The magnets are inlaid in the magnet limit grooves of the front and rear claw poles, and the outer side of the magnet is tightly attached to one side of the magnet limit groove of the claw pole combination. The two limit sides need to consider the inherent gap of the assembly and the deterioration of the cutter process of the magnet limit groove formation, and the magnetic flux reaction gap of the non-fitting surface of the magnet is large.

[0004] The existing milling process of magnetic steel limit slot claw pole uses single claw processing, which results in poor tool working conditions. During the cutting process, the T-shaped blade is only subjected to force on one side, resulting in large machining vibration, high tool bar strength requirements, severe tool wear, and high tool cost.

[0005] The existing milling process for the magnetic steel limit groove claw pole uses a single-claw processing method for the groove shape, which has low production efficiency.

[0006] The existing milling process of magnetic steel limit slot claw poles requires three-coordinate detection of the slot size to ensure process quality, and the detection waiting time is long. Summary of the invention

[0007] The technical problem to be solved by the present invention is that the claw pole pairs of hybrid excitation generators used for rotor assembly are affected by the reserved machining variation gap and the inherent assembly gap, which reduces the output power and efficiency of the generator; at the same time, the existing claw pole manufacturing process has low efficiency in milling magnetic steel slots and serious tool loss, etc., which need to be further improved and optimized. The present invention provides a claw pole manufacturing process for milling magnetic steel limit grooves as a part for hybrid excitation generators, as well as claw poles and tooling, which effectively solve the above problems.

[0008] The technical solution adopted by the present invention to solve its technical problem is:

[0009] A claw pole manufacturing process for a hybrid excitation generator comprises the following steps:

[0010] (1) manufacturing two paired claw pole blanks for subsequent rotor assembly, namely a first claw pole blank and a second claw pole blank;

[0011] (2) placing the first claw pole blank and the second claw pole blank on the same tool at the same time for local milling processing to obtain a first claw pole and a second claw pole;

[0012] (3) The first claw pole and the second claw pole are used together and assembled to the rotor of the hybrid excitation generator.

[0013] Furthermore, in the step (1), the additional matching milling positioning shapes of the first claw pole blank and the second claw pole blank are located on the fan fitting surface of the claw pole, and are added in a manner that has little impact on the dynamic balance of the single claw pole, and are respectively added as the first claw pole with positioning and the second claw pole with positioning. The additional positioning shaping process uses the center hole of the claw pole and the end face of the yoke for positioning, and uses the two side surfaces of the claw shape (or the two sides of the claw width) for limiting processing to ensure that when the magnetic steel limiting groove is milled in the subsequent process, the claw pole combination can simulate the spatial relationship during the assembly of the hybrid excitation rotor and be positioned on the milling slot tooling.

[0014] Furthermore, the specific milling steps of step (2) are as follows:

[0015] ① The first pole with positioning claw is inserted into the shaft through the clearance between the center hole of the first pole with positioning claw and the center axis of the tooling, and the semi-cylindrical pin of the tooling base limits the rotation direction, and the first pole with positioning claw is placed;

[0016] ② The second belt positioning claw pole middle hole and the tooling center axis clearance fit into the shaft, the claw tips face each other, and after the yoke surfaces are fitted, a limiting pressure plate is added to fine-tune the rotation angle of the second belt positioning claw pole until the convex bulge of the limiting pressure plate matches the positioning shape of the second belt positioning claw pole;

[0017] ③ Install the gasket, tighten the screws of the suspension rod, and mill the magnetic steel limit grooves on both sides of the claw to obtain the claw pole combination.

[0018] ④ Use a special inspection fixture to perform groove-type dimension inspection on the claw pole assembly online.

[0019] Furthermore, in the step (3), the tooling is designed with limiting process shapes on the base fitting surface and the end of the central axis, a limiting pin hole shape is added to the base fitting surface, a limiting plane is milled on the end of the central axis, and limiting accessories are used to match the base limiting process shape to facilitate the claw pole combination to reproduce the spatial position relationship during assembly.

[0020] The present invention provides a first claw pole with positioning, which comprises a first claw pole body and a semicircular through groove positioning shape arranged on the first claw pole body.

[0021] The present invention provides a second claw pole with positioning, which comprises a second claw pole body and a circular countersunk positioning shape arranged on the second claw pole body.

[0022] The present invention provides a tooling, which uses a cylindrical pin body and a limiting pressure plate for cooperation. During press-fitting, a clearance fit is formed in a partial area between the first claw pole with positioning, the second claw pole with positioning, the limiting accessory and the tooling base, thereby reproducing the spatial position of the claw pole combination during rotor assembly.

[0023] The beneficial effects of the present invention are:

[0024] (1) The present invention provides a manufacturing process for claw poles with milled magnetic steel limit grooves as parts for hybrid excitation generators, as well as claw poles and tooling. The claw pole combination is placed on the same tooling and milled using a forming cutter. The groove area where the claw pole combination matching takes effect is formed synchronously by the cutting edges on both sides of the tool. Because the claw pole itself is a rigid forging, the overall effect of the magnetic steel limit groove formed by milling in this way is: the front and rear claw poles are complementary, the influence of the cutting factor on the groove size tends to zero, and the size of the claw pole combination milling only needs to consider the assembly clearance. The hybrid excitation generator rotor assembled with this claw pole combination has a smaller gap between the magnetic steel and the non-fitting side of the magnetic steel limit groove, which improves the magnetic locking performance and the overall performance.

[0025] (2) When the claw pole combination is used to mill magnetic steel slots, the tool is subjected to approximately equal cutting stress on both sides during most of the stroke, and the direction of the resistance force is opposite to the direction of tool movement. The tool working condition is good, the tool vibration is small, the required tool bar strength is reduced, the tool life is increased, and the overall tool cost is reduced.

[0026] (3) Although the number of press-fitting steps increases when milling magnetic steel slots, the claw pole combination's feature of processing two products at the same time increases the overall efficiency, thereby improving equipment utilization.

[0027] (4) After the claw pole combination is milled, a special through-type inspection fixture can be used to verify online whether it meets the customer's requirements for assembly into a hybrid excitation motor rotor. Its special forming method can ensure that the shape of the processed magnetic steel limit groove meets the magnetic steel groove depth requirements of the drawing while ensuring the tool wear size, while 100% eliminating assembly interference. The groove size detection is convenient and the production waiting time is short. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0029] Figure 1 This is a diagram of the first claw pole positioning structure of the present invention.

[0030] Figure 2 This is a diagram of the second claw pole positioning structure of the present invention.

[0031] Figure 3 It is the special tooling structure diagram of the present invention.

[0032] In the figure: A. Semi-circular through groove positioning shape, B. Circular countersunk hole positioning shape, 1. Cylindrical pin body, 2. Limiting pressure plate. DETAILED DESCRIPTION

[0033] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, which only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0034] like Figure 1-3 As shown, a claw pole manufacturing process for a hybrid excitation generator includes the following steps:

[0035] (1) manufacturing two paired claw pole blanks for subsequent rotor assembly, namely a first claw pole blank and a second claw pole blank;

[0036] (2) placing the first claw pole blank and the second claw pole blank on the same tool at the same time for local milling processing to obtain the first claw pole and the second claw pole;

[0037] (3) The first claw pole and the second claw pole are used together and assembled to the rotor of the hybrid excitation generator.

[0038] In a preferred specific embodiment, in step (1), the additional matching milling positioning shapes of the first claw pole blank and the second claw pole blank are located on the fan fitting surface of the claw pole, and are added in a manner that has little impact on the dynamic balance of the single claw pole, and are added as the first claw pole with positioning and the second claw pole with positioning, respectively. The additional positioning shaping process uses the center hole of the claw pole and the end face of the yoke for positioning, and uses the two side surfaces of the claw shape (or both sides of the claw width) for limiting processing to ensure that when the magnetic steel limiting groove is milled in the subsequent process, the claw pole combination can simulate the spatial relationship during the assembly of the hybrid excitation rotor and be positioned on the milling slot tooling.

[0039] Furthermore, the specific milling steps of step (2) are as follows:

[0040] ① The first pole with positioning claw is inserted into the shaft with clearance between the center hole of the first pole with positioning claw and the center axis of the tooling. The semi-cylindrical pin of the tooling base limits the rotation direction and places the first pole with positioning claw;

[0041] ② The second belt positioning claw pole hole and the tooling center axis clearance fit into the shaft, the claw tips face each other, and after the yoke surface is fitted, a limiting pressure plate is added to fine-tune the rotation angle of the second belt positioning claw pole until the convex bulge of the limiting pressure plate matches the positioning shape of the second belt positioning claw pole;

[0042] ③ Install the gasket, tighten the screws of the suspension rod, and mill the magnetic steel limit grooves on both sides of the claw to obtain the claw pole combination.

[0043] ④ Use a special inspection fixture to perform groove-type dimension inspection on the claw pole assembly online.

[0044] In another preferred specific embodiment, in step (3), the tooling is designed with limiting process shapes on the base fitting surface and the middle axis end, a limiting pin hole shape is added to the base fitting surface, a limiting plane is milled on the middle axis end, and limiting accessories are used to match the base limiting process shape to facilitate the claw pole combination to reproduce the spatial position relationship during assembly.

[0045] like Figure 1-2 As shown, the present invention provides a first claw pole with positioning, which includes a first claw pole body and a semi-circular through groove positioning shape provided on the first claw pole body.

[0046] The present invention provides a second claw pole with positioning, which comprises a second claw pole body and a circular countersunk positioning shape arranged on the second claw pole body.

[0047] like Figure 3 As shown, the tooling uses a cylindrical pin body and a limiting pressure plate for cooperation. During press-fitting, a clearance fit is formed in some areas between the first positioning claw pole and the second positioning claw pole and the limiting accessory and the tooling base, thereby reproducing the spatial position of the claw pole combination during rotor assembly.

[0048] Based on the above ideal embodiments of the present invention, the relevant staff can make various changes and modifications without departing from the technical concept of the present invention through the above description. The technical scope of the present invention is not limited to the contents of the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A claw pole manufacturing process for a hybrid excitation generator, characterized in that: The steps include: (1) manufacturing two paired claw pole blanks for subsequent rotor assembly, namely a first claw pole blank and a second claw pole blank; (2) placing the first claw pole blank and the second claw pole blank on the same tool at the same time for local milling processing to obtain a first claw pole and a second claw pole; (3) The first claw pole and the second claw pole are used together and assembled to the rotor of the hybrid excitation generator. In the step (1), the additional matching milling positioning shapes of the first claw pole blank and the second claw pole blank are located on the fan fitting surface of the claw pole, and are added in a way that the single claw pole has little impact on the dynamic balance, and are added as the first claw pole with positioning and the second claw pole with positioning, respectively. The additional positioning shaping process is positioned with the center hole of the claw pole and the end face of the yoke, and the two side faces of the claw shape or the two sides of the claw width are used for limiting processing to ensure that when the magnetic steel limiting groove is milled in the subsequent process, the claw pole combination can simulate the spatial relationship during the assembly of the hybrid excitation rotor and be positioned on the milling slot tooling. The specific milling steps of step (2) are as follows: ① The first pole with positioning claw is inserted into the shaft through the clearance between the center hole of the first pole with positioning claw and the center axis of the tooling, and the semi-cylindrical pin of the tooling base limits the rotation direction, and the first pole with positioning claw is placed; ② The second belt positioning claw pole middle hole and the tooling center axis clearance fit into the shaft, the claw tips face each other, and after the yoke surfaces are fitted, a limiting pressure plate is added to fine-tune the rotation angle of the second belt positioning claw pole until the convex bulge of the limiting pressure plate matches the positioning shape of the second belt positioning claw pole; ③ Install the gasket, tighten the screws of the suspension rod, and mill the magnetic steel limit grooves on both sides of the claw to obtain the claw pole combination. ④ Use a special inspection fixture to perform groove-type dimension inspection on the claw pole assembly online.

2. A claw pole manufacturing process for a hybrid excitation generator as claimed in claim 1, characterized in that: In the step (3), the tooling designs limiting process shapes on the base fitting surface and the middle shaft end, adds limiting pin hole shapes on the base fitting surface, mills the limiting plane on the middle shaft end, uses limiting accessories, and matches the base limiting process shape to facilitate the claw pole combination to reproduce the spatial position relationship during assembly.

3. A first claw pole with positioning manufactured by the claw pole manufacturing process for a hybrid excitation generator according to claim 2, characterized in that: The first claw pole with positioning comprises a first claw pole body and a semicircular through groove positioning shape arranged on the first claw pole body.

4. A second claw pole with positioning manufactured by the claw pole manufacturing process for a hybrid excitation generator according to claim 2, characterized in that: The second claw pole with positioning includes a second claw pole body and a circular countersunk positioning shape arranged on the second claw pole body.

5. A tooling for manufacturing a claw pole for a hybrid excitation generator according to claim 2, characterized in that: The tooling uses a cylindrical pin body and a limiting pressure plate for cooperation. During press-fitting, a clearance fit is formed in some areas between the first claw pole with positioning, the second claw pole with positioning, the limiting accessories and the tooling base, thereby reproducing the spatial position of the claw pole combination during rotor assembly.

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