A centrifugally cast motor rotor with an exhaust structure and a preparation method thereof

Abstract

The present invention belongs to the field of motor rotor manufacturing, and particularly relates to a centrifugal casting motor rotor with an exhaust structure and a preparation method thereof, which includes an upper aluminum end ring, a rotor core, and a lower aluminum end ring arranged successively from top to bottom. The rotor core is provided with casting aluminum grooves, and aluminum bars formed by casting are arranged in the casting aluminum grooves. An exhaust channel is arranged on the rotor core. One end of the exhaust channel is connected to the lower aluminum end ring, and the other end is communicated with the shaft hole of the rotor core. The present invention can solve problems such as air holes, thin bars, fine lines, and split bars generated during the solidification process of aluminum liquid due to small exhaust volume.

Description

Technical Field

[0001] The present invention belongs to the field of motor rotor manufacturing, and particularly relates to a centrifugal casting motor rotor with an exhaust structure and a preparation method thereof. Background Art

[0002] The production process flow of a fixed-frequency rotor includes:

[0003] 1. The rotor punching sheet is punched by a high-speed punch press, and the rotor core is made by using an automatic overlapping process.

[0004] 2. The centrifugal casting process is used, and the aluminum liquid is cast in the casting groove and the aluminum end ring by using centrifugal force. The centrifugal casting process is to heat the rotor core and pour the aluminum liquid into the casting mold under the condition of high-speed rotation to complete the casting.

[0005] 3. After casting is completed, demolding is carried out, and the sizes of the upper and lower aluminum end rings are ensured by the tooling mold.

[0006] The traditional rotor core has no exhaust holes and exhaust grooves. During the centrifugal casting process, the aluminum liquid is poured into the casting groove, compressing the air in the groove, but there is no space for the gas to be discharged as soon as possible. During the solidification process of the aluminum liquid, problems such as air holes, thin strips, fine lines, and split strips will occur. And the density of aluminum decreases, seriously affecting the performance of the motor. Summary of the Invention

[0007] In order to make up for the deficiencies of the prior art, the present invention provides a technical solution for a centrifugal casting motor rotor with an exhaust structure and a preparation method thereof.

[0008] A centrifugal casting motor rotor with an exhaust structure provided by the present invention includes an upper aluminum end ring, a rotor core, and a lower aluminum end ring which are arranged in sequence from top to bottom. The rotor core has a casting groove, and an aluminum strip formed by casting is arranged in the casting groove. An exhaust passage is arranged on the rotor core. One end of the exhaust passage is connected to the lower aluminum end ring, and the other end is communicated with the shaft hole of the rotor core.

[0009] Further, the exhaust passage includes a communicated exhaust hole and an exhaust groove. The lower end of the exhaust hole is connected to the lower aluminum end ring, and the exhaust groove is communicated with the shaft hole of the rotor core.

[0010] Further, the rotor core includes a plurality of rotor sheets stacked in sequence from bottom to top. Among them, the plurality of rotor sheets are divided into a first rotor sheet group, a second rotor sheet group, and a third rotor sheet group from top to bottom. The exhaust groove is arranged on the second rotor sheet group, and the exhaust hole is arranged on the third rotor sheet group.

[0011] Further, the second rotor sheet group includes one second rotor sheet, and the exhaust groove is arranged on this second rotor sheet.

[0012] Further, a number of exhaust grooves are distributed around the second rotor sheet.

[0013] Further, the third rotor sheet group includes a plurality of third rotor sheets, through holes are provided on each third rotor sheet, the through hole positions on different third rotor sheets correspond to and communicate with each other to form exhaust holes, and the through hole positions on the third rotor sheets also correspond to the exhaust groove positions in the second rotor sheet group.

[0014] Further, a number of through holes are distributed around the third rotor sheet.

[0015] The present invention also provides a preparation method for a centrifugally cast motor rotor, including:

[0016] S100: Manufacture a rotor core and process an exhaust passage on the rotor core;

[0017] S200: Place the rotor core into a mold and perform a centrifugal casting process to cast aluminum bars, an upper aluminum end ring and a lower aluminum end ring. During the centrifugal casting process, the aluminum liquid is poured into the aluminum casting groove of the rotor core, so that the air in the aluminum casting groove is squeezed into the part of the mold cavity corresponding to the lower aluminum end ring, and is discharged from the shaft hole of the rotor core through the exhaust passage of the rotor core;

[0018] S300: Demold after casting is completed to obtain a motor rotor.

[0019] Further, the operation of S100 includes: respectively manufacturing the first rotor sheet group, the second rotor sheet group and the third rotor sheet group. When manufacturing the second rotor sheet group, process exhaust grooves on the second rotor sheet; when manufacturing the third rotor sheet group, process through holes on the third rotor sheet.

[0020] Further, in S200, before pouring the aluminum liquid, first install a plug at the upper end of the shaft hole of the rotor core to block the shaft hole.

[0021] Compared with the prior art, the present invention adds a structure of an exhaust passage on the rotor core. During the preparation process of the present invention, when the aluminum liquid enters the aluminum casting groove, the gas can be discharged from the lower exhaust passage along the way, ensuring the quality of the aluminum casting. And because the present invention uses centrifugal force to cast the rotor, under the action of centrifugal force, the aluminum liquid will not be thrown out from the exhaust passage, and the gas can be discharged smoothly. In this way, problems such as pores, thin bars, fine lines, and cracked bars generated due to small exhaust volume during the solidification process of the aluminum liquid are solved. At the same time, the density of aluminum is also increased, thereby improving the performance of the motor. The test comparison test results show that the motor efficiency can be improved by about 0.5%. Description of the Drawings

[0022] Figure 1 It is a schematic structural diagram of Embodiment 1;

[0023] Figure 2Schematic diagram of the first rotor sheet in Embodiment 1;

[0024] Figure 3 Schematic diagram of the second rotor sheet in Embodiment 1;

[0025] Figure 4 Schematic diagram of the third rotor sheet in Embodiment 1;

[0026] Figure 5 Flow chart of Embodiment 2. Detailed implementation manners

[0027] In the description of the present invention, it should be understood that the orientation or positional relationships indicated by the terms "one end", "the other end", "outer side", "upper", "inner side", "horizontal", "coaxial", "central", "end portion", "length", "outer end", etc. are based on the orientation or positional relationships shown in the drawings. These are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present invention.

[0028] The present invention will be further described below with reference to the drawings.

[0029] Embodiment 1

[0030] Please refer to Figures 1-4 , a centrifugal casting motor rotor with an exhaust structure, which includes an upper aluminum end ring 1, a rotor core 2, and a lower aluminum end ring 3 arranged in sequence from top to bottom. The rotor core 2 has a cast aluminum groove 200, and a cast aluminum bar 4 is arranged in the cast aluminum groove 200. An exhaust channel is arranged on the rotor core 2. One end of the exhaust channel is connected to the lower aluminum end ring 3, and the other end is communicated with the shaft hole 201 of the rotor core 2.

[0031] Continue to refer to Figure 1 , the exhaust channel includes a communicated exhaust hole 202 and an exhaust groove 203. The exhaust hole 202 is arranged vertically, the exhaust groove 203 is arranged horizontally. The lower end of the exhaust hole 202 is connected to the lower aluminum end ring 3, and the exhaust groove 203 is communicated with the shaft hole 201 of the rotor core 2.

[0032] Continue to refer to Figure 1 , the rotor core 2 includes a plurality of rotor sheets arranged in sequence from bottom to top and fixedly connected by an automatic stacking and buckling process. Among them, these rotor sheets are divided into a first rotor sheet group, a second rotor sheet group, and a third rotor sheet group from top to bottom. The exhaust groove 203 is arranged on the second rotor sheet group, and the exhaust hole 202 is arranged on the third rotor sheet group.

[0033] Among them, the first rotor sheet group includes a plurality of first rotor sheets 2a. The first rotor sheets 2a are ordinary rotor sheets, and the structure is as Figure 2As shown, a number of casting grooves 200 are distributed around its edge.

[0034] Among them, the second rotor sheet group only includes one second rotor sheet 2b, and the structure of the second rotor sheet 2b is as Figure 3 shown. The exhaust groove 203 is arranged on this second rotor sheet 2b. Specifically, there are a number of exhaust grooves 203, which are distributed around the second rotor sheet 2b. A number of casting grooves 200 are also distributed around the edge of the second rotor sheet 2b. The distance between the exhaust groove 203 and the center of the second rotor sheet 2b is less than the distance between the casting groove 200 and the center of the second rotor sheet 2b.

[0035] Among them, the third rotor sheet group includes multiple third rotor sheets 2c, and the structure of the third rotor sheet 2c is as Figure 4 shown. A number of through holes 204 are distributed around each third rotor sheet 2c. The positions of the through holes 204 on different third rotor sheets 2c correspond and communicate to form an exhaust hole 202. Moreover, the positions of the through holes 204 on the third rotor sheet 2c also correspond to the positions of the outer ends of the exhaust grooves 203 in the second rotor sheet group. Specifically, a number of casting grooves 200 are also distributed around the edge of the third rotor sheet 2c. The distance between the through hole 204 and the center of the third rotor sheet 2c is less than the distance between the casting groove 200 and the center of the third rotor sheet 2c.

[0036] The positions of the casting grooves 200 of the above three rotor sheets correspond, and communicate to form a cast aluminum groove 205.

[0037] It should be noted that the second rotor sheet group can also adopt multiple second rotor sheets 2b, and the third rotor sheet assembly can also adopt a single third rotor sheet 2c.

[0038] Embodiment 2

[0039] Please refer to Figure 5 , a preparation method of a centrifugal casting motor rotor, including:

[0040] S100 Manufacture the rotor core 2, and process an exhaust passage on the rotor core 2;

[0041] S200 Place the rotor core 2 into the mold, and perform the centrifugal casting process. Specifically, the rotor core 2 is heated and the aluminum liquid is poured into the mold under the condition of high-speed rotation. The centrifugal force is used to make the aluminum liquid cast into the aluminum bar 4, the upper aluminum end ring 1 and the lower aluminum end ring 3, and the casting is completed. During the centrifugal casting process, the aluminum liquid is poured into the cast aluminum groove 200 of the rotor core 2, so that the air in the cast aluminum groove 200 is squeezed into the part of the mold cavity corresponding to the lower aluminum end ring 3, and is discharged from the shaft hole 201 of the rotor core 2 through the exhaust passage of the rotor core 2;

[0042] S300 After the casting is completed, demold to obtain the motor rotor. The sizes of the upper aluminum end ring 1 and the lower aluminum end ring 3 are guaranteed by the mold.

[0043] Furthermore, the operation of S100 includes: punching out the first rotor plate group, the second rotor plate group and the third rotor plate group respectively by a high-speed punching machine, and using an automatic overlapping process to make them into a rotor core 2, and when making the second rotor plate group, processing an exhaust groove on the second rotor plate 2b; when making the third rotor plate group, processing a through hole 204 on the third rotor plate 2c.

[0044] Furthermore, in the above S200 , before casting the aluminum liquid, a plug 5 is first installed at the upper end of the shaft hole 201 of the rotor core 2 to block the shaft hole 201 .

[0045] It can be understood that the present embodiment adds the structure of the exhaust channel to the rotor core 2. During the preparation process, when the aluminum liquid enters the aluminum casting tank 200, the gas can be discharged from the exhaust channel below, ensuring the quality of the cast aluminum. Because the present invention uses centrifugal force to cast the rotor, under the action of centrifugal force, the aluminum liquid will not be thrown out from the exhaust channel, and the gas can be discharged smoothly. This solves the problems of pores, thin strips, fine lines, cracks, etc. caused by small exhaust volume during the solidification of aluminum liquid. At the same time, the density of aluminum is also increased, thereby improving the performance of the motor. The experimental comparison test results show that the motor efficiency can be increased by about 0.5%.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A centrifugally cast motor rotor with an exhaust structure, comprising an upper aluminum end ring (1), a rotor core (2), and a lower aluminum end ring (3) arranged in sequence from top to bottom. The rotor core (2) has casting aluminum grooves (205), and casting aluminum bars (4) formed by casting are arranged in the casting aluminum grooves (205). It is characterized in that, An exhaust passage is provided on the rotor core (2), one end of the exhaust passage is connected to the lower aluminum end ring (3), and the other end is communicated with the shaft hole (201) of the rotor core (2); The exhaust passage includes a communicated exhaust hole (202) and an exhaust groove (203), the lower end of the exhaust hole (202) is connected to the lower aluminum end ring (3), and the exhaust groove (203) is communicated with the shaft hole (201) of the rotor core (2); The rotor core (2) includes a plurality of rotor sheets stacked in sequence from bottom to top. Among them, the plurality of rotor sheets are divided into a first rotor sheet group, a second rotor sheet group, and a third rotor sheet group from top to bottom. The exhaust groove (203) is provided on the second rotor sheet group, and the exhaust hole (202) is provided on the third rotor sheet group; The second rotor sheet group includes one or more second rotor sheets (2b), and the exhaust groove (203) is provided on the second rotor sheet (2b); The third rotor sheet group includes one or more third rotor sheets (2c), and through holes (204) are provided on each of the third rotor sheets (2c).

2. The centrifugally cast motor rotor with an exhaust structure according to claim 1, characterized in that, A plurality of exhaust grooves (203) are circumferentially arranged on the second rotor sheet (2b).

3. The centrifugally cast motor rotor with an exhaust structure according to claim 1, characterized in that, The third rotor sheet group includes a plurality of third rotor sheets (2c), through holes (204) are provided on each of the third rotor sheets (2c), the positions of the through holes (204) on different third rotor sheets (2c) correspond to each other and are communicated to form an exhaust hole (202), and the positions of the through holes (204) on the third rotor sheets (2c) also correspond to the positions of the exhaust grooves (203) in the second rotor sheet group.

4. The centrifugally cast motor rotor with an exhaust structure according to claim 3, characterized in that, A plurality of through holes (204) are circumferentially arranged on the third rotor sheet (2c).

5. A method for preparing a centrifugally cast motor rotor as described in any one of claims 1-4, characterized in that, Including: S100 fabricate the rotor core (2) and machine an exhaust passage on the rotor core (2); S200 place the rotor core (2) into a mold and perform a centrifugal casting process to cast aluminum bars (4), an upper aluminum end ring (1), and a lower aluminum end ring (3). During the centrifugal casting process, molten aluminum is poured into the casting aluminum groove (200) of the rotor core (2), so that the air in the casting aluminum groove (200) is squeezed into the part of the mold cavity corresponding to the lower aluminum end ring (3), and is discharged from the shaft hole (201) of the rotor core (2) through the exhaust passage of the rotor core (2); S300 demold after casting to obtain a motor rotor.

6. The preparation method of a centrifugally cast motor rotor according to claim 5, characterized in that, The operation of S100 includes: fabricating the first rotor sheet group, the second rotor sheet group, and the third rotor sheet group respectively. When fabricating the second rotor sheet group, machine an exhaust groove on the second rotor sheet (2b); when fabricating the third rotor sheet group, machine a through hole (204) on the third rotor sheet (2c).

7. A method for preparing a centrifugally cast motor rotor according to claim 5, characterized in that, In S200, before pouring molten aluminum, first install a plug (5) at the upper end of the shaft hole (201) of the rotor core (2) to block the shaft hole (201).

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