A method for preparing a magnetic gear modulation ring

Abstract

The present application relates to the technical field of magnetic gears and composite motors, and provides a method for preparing a magnetic gear modulation ring, the method comprising: preparing a soft magnetic column based on a soft magnetic alloy strip; wherein the soft magnetic column has a concave surface and a preset redundancy; installing a carbon fiber column on the concave surface, grinding off the preset redundancy, and completing the preparation of the magnetic gear modulation ring; the present application can simultaneously achieve the load-bearing structure strength and inter-pole insulation of the modulation ring, and achieve the final precision molding of the ultra-thin modulation ring.

Description

Technical Field

[0001] The present application relates to the technical field of magnetic gears and composite motors, and in particular to a method for preparing a magnetic gear modulation ring. Background Art

[0002] Modulated magnetic gears are a new type of gear technology that can achieve torque density comparable to that of mechanical gears while avoiding the inherent defects of mechanical gears, especially vibration, noise, fatigue and overload caused by tooth contact.

[0003] The modulated magnetic gear consists of three parts: an inner ring and an outer ring composed of permanent magnets, and a modulating ring composed of alternating soft magnets and insulating materials. The three rings do not touch each other, leaving a millimeter or sub-millimeter gap, and the magnetic field strength reaches more than 1.0T.

[0004] During operation, the modulation ring is subjected to high tangential stress along the circumference and certain radial alternating stress. In order to achieve high specific torque density, the modulation ring cannot be too thick, so it must have a high-strength load-bearing structure and the function of suppressing magnetic field-induced eddy currents.

[0005] High-strength structures can be made of high-strength alloy materials or polymer composite materials. In order to prevent induced eddy currents, resin-based carbon fiber composite materials are generally used. The resin also has insulating properties and forms an alternating structure with the soft magnetic alloy material on the axial cylindrical surface, which modulates the magnetic field of the inner and outer rings, realizes the coupling of the internal and external magnetic fields, and converts the magnetic force into torque. Eddy current losses are bound to occur inside the soft magnetic material, so a multi-sheet axial stacking method is adopted, and the layers are separated by insulating glue, so that the eddy current is localized in the cross section of a single-layer sheet, which greatly reduces the overall eddy current effect.

[0006] The modulation ring is generally made up of dozens of insulating columns and hundreds of soft magnetic laminations. It requires a certain degree of coaxiality and roundness, and the laminations often fall off and deform as a whole. Therefore, its integrated manufacturing process is very difficult. In order to realize the operation of magnetic gears, incomplete methods are often used, such as using steel and titanium alloys to make modulation rings by integral machining, which sacrifices insulation and cannot suppress eddy currents; or thickening the insulating columns and laminations to improve strength, which leads to partial shielding of the magnetic field, and increases weight and volume. Therefore, most of the magnetic gears currently cannot simultaneously achieve the functions of high strength and inter-pole insulation to reduce eddy currents, resulting in the inability to further improve their specific torque density and it is difficult to increase their efficiency to more than 95%.

[0007] Therefore, one of the most important technologies in the preparation process of the new magnetic gear is to achieve the final precision molding of the ultra-thin modulation ring. Summary of the invention

[0008] In order to solve the above technical problems, the present application proposes a method for preparing a magnetic gear modulation ring, the method comprising:

[0009] A soft magnetic column is prepared based on a soft magnetic alloy strip; wherein the soft magnetic column has a concave surface and a preset redundancy;

[0010] The carbon fiber column is installed on the concave surface, and the preset redundancy is ground off to complete the preparation of the magnetic gear modulation ring.

[0011] Preferably, the method of preparing a soft magnetic column based on a soft magnetic alloy strip comprises:

[0012] The soft magnetic alloy strip is processed into a two-dimensional soft magnetic laminate with the preset redundancy; wherein the preset redundancy is used to maintain the size and strength of the circumference.

[0013] Preferably, after preparing the soft magnetic column based on the soft magnetic alloy strip, the method further comprises:

[0014] The carbon fiber column is prepared based on carbon fiber composite material; wherein the length of the carbon fiber column is greater than the length of the soft magnetic column.

[0015] Preferably, the preparation of the carbon fiber column based on the carbon fiber composite material comprises:

[0016] The carbon fiber column is prepared by compression molding or 3D printing.

[0017] Preferably, the step of installing the carbon fiber column on the concave surface, grinding off the preset redundancy, and completing the preparation of the magnetic gear modulation ring includes:

[0018] Applying adhesive on the two-dimensional soft magnetic laminate and the carbon fiber column;

[0019] Combining and positioning the two-dimensional soft magnetic laminate and the carbon fiber column in an assembly fixture to obtain a molded modulation ring;

[0020] The molded modulation ring is fixed in a preset tooling, and the preset redundancy is ground off to complete the preparation of the magnetic gear modulation ring.

[0021] Preferably, the concave surface includes an arc surface and a step surface; wherein the diameter of the arc surface is 1.2 mm.

[0022] Preferably, the magnetic gear modulation ring comprises soft magnetic columns and carbon fiber columns that are alternately assembled.

[0023] Preferably, the removing of the preset redundancy comprises:

[0024] The predetermined redundancy is ground away on an internal cylindrical grinding machine.

[0025] This application has the following technical effects:

[0026] The present application can simultaneously achieve the load-bearing structural strength and inter-electrode insulation of the modulation ring, and realize the final precision molding of the ultra-thin modulation ring. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 A schematic diagram of the structure of a magnetic gear modulation ring provided in an embodiment of the present application;

[0028] Figure 2 A schematic diagram of the structure of a two-dimensional soft magnetic laminate after processing and forming provided in an embodiment of the present application;

[0029] Among them: 1-carbon fiber column; 2-soft magnetic column. DETAILED DESCRIPTION

[0030] The preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the protection scope of the present invention.

[0031] Combined with Figure 1-2 The present application is further described in detail with specific implementation methods:

[0032] The present application provides a method for preparing a magnetic gear modulation ring, wherein the soft magnetic columns are prepared by laminating soft magnetic alloy strips, and the load-bearing insulating columns are prepared by carbon fiber composite materials, and the two are alternately assembled and arranged on a cylindrical surface to form an integral modulation ring.

[0033] In an embodiment of the present application, a method for preparing an ultra-thin high-strength modulation ring is provided, in which a two-dimensional laminate of a soft magnetic component with a certain processing allowance is integrally processed, and then three-dimensionally molded as a whole with a carbon fiber column, and then the allowance of the soft magnetic component is removed by grinding in a specific tooling to achieve the final precision molding of the ultra-thin modulation ring, thereby improving the specific torque density of the magnetic gear.

[0034] In other embodiments of the present application, a method for preparing a magnetic gear modulation ring is provided, wherein the prepared ultra-thin modulation ring comprises a soft magnetic column with soft magnetic properties and a high-strength load-bearing insulating column group, which are alternately arranged along the modulation ring column, as shown in the attached figure. Figure 1 As shown, in order to ensure that there is no radial misalignment between the two, the bonding interface between the soft magnetic column and the insulating column is an arc surface or a step surface rather than a straight surface.

[0035] Among them, the soft magnetic column is made of soft magnetic alloy strip laminations, and the load-bearing insulating column is made of resin-based carbon fiber reinforced composite material. The insulating load-bearing column (hereinafter referred to as carbon fiber column) made of carbon fiber composite material can be prepared by molding or 3D printing and other resin-based carbon fiber composite material forming methods. Its cross section should be the same as the final cross section, and the length should have a certain margin. The preparation process should maximize the strength and stiffness of the column.

[0036] The soft magnetic alloy strip is first processed into a two-dimensional laminate with a certain margin, and the margin refers to a redundant portion of 0.2 to 5 mm reserved on the outer or inner circumference of the required soft magnetic column section. Figure 2 As shown, it is used to maintain the size of the circumference and the strength of subsequent operations. After the two-dimensional soft magnetic laminate and carbon fiber column are coated with adhesive, they are assembled and positioned in the fixture as a whole. The adhesive uses different resin bases according to the use requirements and should have high strength and toughness. The two are assembled alternately on the cylindrical surface, and the soft magnetic column and the carbon fiber column are formed into an overall three-dimensional shape, and cured according to the adhesive usage method.

[0037] Furthermore, after the formed assembly is completely cured, it is taken out of the fixture and then fixed in a specific processing tool to remove the redundant parts of the soft magnetic lamination. The processing tool is used to fix the parts during the grinding process. Depending on the different redundant parts of the two-dimensional soft magnetic lamination, internal or external grinding can be used. During the processing, the equipment should be carefully adjusted to prevent local overheating or excessive feed amount from causing strong vibration and deformation, which may cause the lamination layer to detach.

[0038] The present application can effectively solve the preparation problem of the magnetic gear modulation ring, improve its reliability and processing accuracy, and ensure the high torque density characteristics of the magnetic gear.

[0039] See also Figure 1 and Figure 2 , a specific implementation method provided in other embodiments of the present application is:

[0040] In other embodiments of the present application, a method for preparing a magnetic gear modulation ring with a transmission ratio of 5 to 10 kW and a transmission ratio of 10 is provided. The modulation ring has a thickness of 2 mm and an outer diameter of 150 mm. The modulation ring is composed of a soft magnetic column 2 with soft magnetic properties and a high-strength load-bearing insulating column group, which are arranged alternately along the modulation ring column, as shown in the attached Figure 1 As shown, in order to ensure that there is no radial misalignment between the two, the bonding interface between the soft magnetic column 2 and the carbon fiber column 1 is an arc surface with a diameter of 1.2 mm.

[0041] Among them, the soft magnetic column is made of FeCo soft magnetic alloy strip lamination. FeCo soft magnetic alloy is a high-strength soft magnetic alloy with a saturation magnetic induction intensity of 2.4T, which is beneficial to increase the air gap flux density and the torque upper limit. The load-bearing insulating column is made of thermosetting epoxy resin-based carbon fiber reinforced composite material. The carbon fiber is T700 type with high specific strength. It is prepared by compression molding. Its cross-section should be the same as the final cross-section. The length is 20mm longer than the length of the soft magnetic column, which is used to connect the two end plates of the modulation ring. The FeCo soft magnetic alloy strip blank is a 0.35mm thick cold-rolled strip. It is first processed in two dimensions. The lamination includes all the soft magnetic columns in the circumference and retains a 1mm wide redundant part on the inner circle, as shown in the attached figure. Figure 2 As shown, the redundant portion is used to maintain the size of the circumference and the strength of subsequent operations.

[0042] Among them, the two-dimensional soft magnetic laminates and carbon fiber columns are coated with adhesive and then assembled and positioned in the assembly fixture. The adhesive is a two-component epoxy resin adhesive that should have high bonding strength and certain toughness and be cured at room temperature to 80°C. The two are alternately assembled and arranged on the corresponding cylindrical surface of the fixture, and cured according to the adhesive usage method to achieve overall three-dimensional molding of the soft magnetic column and the carbon fiber column. After the formed assembly is completely cured, it is taken out of the fixture and then fixed in a specific processing tooling. The redundant part of the soft magnetic laminate is ground off on an internal cylindrical grinder to obtain the attached Figure 1 The modulation ring assembly shown in the figure. High-speed, high-precision grinding machines are used for processing, small feed amounts are used during processing, and strong spray nozzles are used for coolant.

[0043] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A method for preparing a magnetic gear modulation ring, characterized in that: The method comprises: A soft magnetic column is prepared based on a soft magnetic alloy strip; wherein the soft magnetic column has a concave surface and a preset redundancy; A carbon fiber column is prepared based on a carbon fiber composite material; wherein the length of the carbon fiber column is greater than the length of the soft magnetic column; Install the carbon fiber column on the concave surface, grind off the preset redundancy, and complete the preparation of the magnetic gear modulation ring; the concave surface includes an arc surface and a step surface; the diameter of the arc surface is 1.2 mm; Wherein, the method for preparing a soft magnetic column based on a soft magnetic alloy strip comprises: Processing the soft magnetic alloy strip into a two-dimensional soft magnetic laminate having the preset redundancy; wherein the preset redundancy is used to maintain the size and strength of the circumference; Wherein, the preparation of carbon fiber column based on carbon fiber composite material comprises: The carbon fiber column is prepared by compression molding or 3D printing; The step of installing the carbon fiber column on the concave surface, grinding off the preset redundancy, and completing the preparation of the magnetic gear modulation ring includes: Applying adhesive on the two-dimensional soft magnetic laminate and the carbon fiber column; Combining and positioning the two-dimensional soft magnetic laminate and the carbon fiber column in an assembly fixture to obtain a molded modulation ring; The molded modulation ring is fixed in a preset tooling, and the preset redundancy is ground off to complete the preparation of the magnetic gear modulation ring.

2. The method according to claim 1, characterized in that The magnetic gear modulation ring comprises soft magnetic columns and carbon fiber columns which are assembled alternately.

3. The method according to claim 1, characterized in that The step of removing the preset redundancy includes: The predetermined redundancy is ground away on an internal cylindrical grinding machine.

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