A method for manufacturing a motor shaft and a motor shaft assembly manufactured using the method

Abstract

The present invention relates to the technical field of motor shafts, and in particular to a method for manufacturing a motor shaft and a motor shaft assembly manufactured by the method; the present invention first performs a performance simulation test on a designed motor shaft model through CAE series software, then analyzes the results of the simulation test, and then optimizes the motor shaft model according to the analysis results, and then imports the optimized motor shaft model data into a 3D metal printer, and prints the motor shaft through 3D printing technology, and then grinds and polishes, scans and performs non-destructive flaw detection on the printed motor shaft in turn, and finally performs a load test on the motor shaft and performs experimental tests on various performances of the motor shaft; the present invention can effectively solve the problems of poor finished product quality yield and poor production capacity in the prior art.

Description

Technical Field

[0001] The present invention relates to the technical field of motor shafts, and in particular to a method for manufacturing a motor shaft and a motor shaft assembly manufactured using the method. Background Art

[0002] At present, the motor shaft is generally made by processing round steel blanks. In the existing motor shaft processing process, a round steel blank cutting device is required to cut the round steel into corresponding lengths, and then the round steel is ribbed and polished.

[0003] A cutting device for producing motor shafts is disclosed in the patent document with application number: CN201921470991.4, including a bottom plate, a workbench, a cutting assembly, and a protective assembly. The workbench is in the shape of a rectangular table and is arranged parallel to the top of the bottom plate through a support column fixed to the bottom plate. The top surface of the workbench begins to have a groove along its length direction, and the bottom surface of the groove begins to have a material trough for placing the motor shaft along its length direction. A through hole is longitudinally penetrated on one side of the workbench. The cutting assembly includes a pushing mechanism and a cutting mechanism. The pushing mechanism contains a baffle plate slidingly arranged in the material trough, and the baffle plate is used to push the end of the motor shaft in the material trough to the through hole. The cutting mechanism includes a collecting box, a vertical plate, a second motor, and a cutting saw. The collecting box is horizontally arranged above the bottom plate and below the through hole. A driving member for driving the collecting box to rise and fall is arranged on the bottom plate. The utility model has a simple structure, is convenient for cutting and using round steel blanks for processing motor shafts, has a protective function, and is highly safe.

[0004] However, it still has the following shortcomings in practical application:

[0005] First, the quality yield of the finished product is not good, because the production of the motor shaft needs to be divided into several processes and requires more manual intervention, which makes the produced motor shaft have a larger tolerance.

[0006] Second, the production capacity is poor because it cannot produce motor shafts with complex structures, especially hollow motor shafts or motor shafts with internal structures. Summary of the invention

[0007] The purpose of the present invention is to solve the shortcomings of the prior art and the problems raised in the above background technology.

[0008] In order to achieve the above object, the present invention adopts the following technical solution: a method for manufacturing a motor shaft, comprising the following steps:

[0009] Step 1, use industrial design software to perform three-dimensional modeling on the pre-designed motor shaft to obtain a three-dimensional model;

[0010] Step 2, import the data of the 3D model into the CAE series software and use the CAE series software to perform work simulation, so as to simulate and test various performances of the motor shaft;

[0011] Step 3, if all performance indicators in the simulation test meet the standards, proceed to the following Step 4; if any performance indicator in the simulation test does not meet the standards, return to the above Step 1 and optimize the structure and material selection of the three-dimensional model;

[0012] Step 4, import the data of the 3D model into the 3D metal printer, and print the motor shaft through the 3D metal printer;

[0013] Step 5, grind and polish the motor shaft;

[0014] Step 6, perform a three-dimensional scan on the shape of the motor shaft to verify whether its shape meets the design requirements;

[0015] Step 7, perform non-destructive testing on the motor shaft to check whether its internal structure meets the design requirements;

[0016] Step 8, install the motor shaft onto the motor and conduct a test run with load, so as to experimentally test various performances of the motor shaft.

[0017] Furthermore, in the Step 1, before three-dimensional modeling of the motor shaft is performed, the product requirements should be analyzed and the parameter index framework of the motor shaft should be determined;

[0018] In the Step 3, the parameter index framework cannot be exceeded when optimizing the structure and material selection of the model.

[0019] Furthermore, in Step 4, the specific steps of the 3D metal printer when printing the motor shaft are as follows:

[0020] ①. Spread the metal powder evenly into a thin layer;

[0021] ② Metal powder is sintered on the surface to be printed by high-power laser;

[0022] ③. Repeat the above steps ① and ② in sequence to print the metal shaft.

[0023] Furthermore, the size of the metal powder is between 0.1 nm and 1000 μm, the thickness of the metal powder is between 0.1 nm and 2 mm, and the metal powder is any one of carbon steel and alloy steel;

[0024] The 3D metal printer is also equipped with an electromagnet, an ultrasonic vibrator and a semiconductor refrigeration plate;

[0025] The electromagnet is used to generate a magnetic field in a vertical direction, so as to suppress the dust of the metal powder when the powder spreading mechanism spreads the metal powder on the workbench;

[0026] The ultrasonic vibrator is used to flatten, compact and evenly vibrate the metal powder on the workbench;

[0027] The semiconductor refrigeration plate is arranged inside the workbench, so that the cold energy on the cold end of the semiconductor refrigeration plate can cool down the metal powder and the printed motor shaft through heat conduction, thereby indirectly achieving rapid cooling of the sintered part.

[0028] Furthermore, the working space inside the 3D metal printer is in a vacuum state or is filled with an inert gas;

[0029] After the powder spreading mechanism has finished spreading the material, the electromagnet will generate an alternating magnetic field in the vertical direction, thereby demagnetizing the metal powder and the motor shaft of the printing;

[0030] After the 3D metal printer finishes printing the motor shaft, the electromagnet and the semiconductor refrigeration plate are turned off, the ultrasonic vibrator is started, and at the same time, the recovery mechanism is started to recover the metal powder on the workbench.

[0031] Furthermore, the metal powder collected by the recycling component is sequentially subjected to the following steps:

[0032] Ⅰ. Screening: screening out metal powders that do not meet the standards;

[0033] II. Mixing: mixing the unqualified metal powder with bentonite in a weight ratio of 1:40-60;

[0034] III, deposition, adding alkaline solution into the mixed solution and taking out the reactants;

[0035] IV, calcination, placing the reactants in a vacuum furnace and calcining them into blocks at 1000-1200 degrees Celsius;

[0036] V, reduction and purification, reducing the calcined metal blocks;

[0037] VI, Powdering, converting metal blocks into metal powder.

[0038] Furthermore, in the Step 5, the motor shaft is polished by any one of mechanical polishing, chemical polishing, electrolytic polishing, ultrasonic polishing, fluid polishing or magnetic abrasive polishing, or a combination of the above different polishing methods;

[0039] In the Step 6, the motor shaft is scanned by laser to construct its appearance features, so as to determine whether its appearance dimensions meet the design requirements;

[0040] In Step 7, the motor shaft is scanned by CT to detect whether there are any hidden damages inside the motor shaft and whether the internal structure of the motor shaft meets the design requirements.

[0041] Furthermore, in the Step 8, if all performance indicators of the motor shaft in the experimental test meet the standards, the motor shaft is put into actual production; if any performance indicator of the motor shaft in the experimental test does not meet the standards,

[0042] Then return to the above Step 1 and repeat Step 2, Step 3, Step 4, Step 5, Step 6, Step 7 and Step 8 in sequence.

[0043] A motor shaft assembly comprises a motor shaft and a support member arranged inside the motor shaft. The motor shaft is coaxially provided with a cavity cooperating therewith along its axial direction. The shaft body of the motor shaft is divided into a rib section, a rotor core mounting section, a shaft oil seal section and a load section from one end to the other.

[0044] Furthermore, a support member is provided in the cavity, the support member is radially arranged along the radial direction of the motor shaft, the support member body is loose and porous, and the support member and the motor shaft are integrally formed.

[0045] Compared with the prior art, the advantages and positive effects of the present invention are:

[0046] The present invention firstly performs a performance simulation test on a designed motor shaft model through CAE series software, then analyzes the results of the simulation test, and then optimizes the motor shaft model according to the analysis results, and then imports the optimized motor shaft model data into a 3D metal printer, and prints the motor shaft through 3D printing technology, and then sequentially grinds and polishes, scans and performs non-destructive flaw detection on the printed motor shaft, and finally performs a load test on the motor shaft and performs experimental tests on various performances of the motor shaft.

[0047] Among them, the 3D metal printer can realize the integrated molding of motor shafts with complex structures, reducing the difficulty of production; at the same time, the 3D metal printer itself has extremely high precision, combined with subsequent grinding and polishing, scanning, non-destructive testing and load operation measurement, the final motor shaft produced has extremely high product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 This is a direct view of the motor shaft under the first viewing angle of the present invention;

[0049] Figure 2It is an intuitive diagram of the motor shaft after being partially cut away and separated from the support member at a second viewing angle of the present invention;

[0050] Figure 3 This is a schematic diagram of the internal structure of the 3D metal printer in the present invention;

[0051] The numbers in the figure represent: 1-motor shaft; 2-electromagnet; 3-ultrasonic vibrator; 4-semiconductor refrigeration plate; 5-powder spreading mechanism; 6-workbench; 7-support; 8-cavity; 9-ribbed section; 10-rotor core installation section; 11-shaft oil seal section; 12-load section. DETAILED DESCRIPTION

[0052] In order to more clearly understand the above-mentioned purpose, features and advantages of the present invention, the present invention is further described below in conjunction with the accompanying drawings and embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0053] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways than those described herein. Therefore, the present invention is not limited to the specific embodiments of the following disclosure.

[0054] A motor shaft assembly of this embodiment, referring to Figure 1-3 The motor shaft assembly includes a motor shaft 1 and a support member 7 disposed inside the motor shaft 1. The motor shaft 1 is coaxially provided with a cavity 8 cooperating therewith along its axial direction. The shaft body of the motor shaft 1 is divided into a rib section 9, a rotor core installation section 10, a shaft oil seal section 11 and a load section 12 from one end to the other. In addition, a support member 7 is further provided in the cavity 8. The support member 7 is radially shaped along the radial direction of the motor shaft 1. The support member 7 body is loose and porous. The support member 7 and the motor shaft 1 are integrally formed.

[0055] The reasons why the motor shaft 1 is designed to be hollow in the present invention are as follows:

[0056] First, from the perspective of force, the thicker the motor shaft 1 is and the closer it is to the outer surface, the smaller the shear stress under the action of torque, which is inversely proportional to the cube of the diameter (this is without considering the influence of stress concentration).

[0057] Secondly, the output spline of the general motor shaft 1 is a stress concentration location with a small diameter and a back-cut groove, and the hollow part is generally located in the middle of the motor shaft 1, which is basically not subject to stress. From the perspective of strength, there is a need to reduce the weight in the middle and make it hollow without affecting the strength.

[0058] In addition, in terms of the motor's speed changing ability, that is, the moment of inertia, the lighter the rotating parts, the better. In general, the torsional stiffness and bending stiffness of the motor shaft 1 have little effect on electromagnetic and critical speed, so the hollow motor shaft 1 can also maximize the speed changing ability without affecting other performance.

[0059] It is worth noting that the support member 7 is integrally formed in the cavity 8 in order to further enhance the torsional rigidity and bending rigidity of the motor shaft 1 itself.

[0060] A method for manufacturing a motor shaft comprises the following steps:

[0061] Step 1, use industrial design software to perform three-dimensional modeling on the pre-designed motor shaft 1 to obtain a three-dimensional model (Note: before performing three-dimensional modeling on the motor shaft 1, the product requirements should be analyzed and the parameter indicator framework of the motor shaft 1 should be determined).

[0062] Step 2, import the data of the three-dimensional model into the CAE series software and use the CAE series software to perform work simulation, so as to simulate and test various performances of the motor shaft 1.

[0063] Step 3, if all performance indicators in the simulation test meet the standards, proceed to the following Step 4. If any performance indicators in the simulation test do not meet the standards, return to the above Step 1 and optimize the structure and material selection of the 3D model (Note: when optimizing the structure and material selection of the model, the parameter indicator framework cannot be exceeded).

[0064] Step 4, import the data of the three-dimensional model into the 3D metal printer, and print the motor shaft 1 through the 3D metal printer.

[0065] Worth noting:

[0066] In Step 4, the specific steps of the 3D metal printer when printing the motor shaft 1 are as follows:

[0067] ①, evenly spread the metal powder into a thin layer. In this process, the ultrasonic vibrator 3 is used to emit ultrasonic waves to quickly vibrate and compact the metal powder, which will also help the metal powder to deposit quickly. At the same time, in this process, the excess metal powder needs to be recovered.

[0068] ② The metal powder on the surface to be printed is sintered by high-power laser. In this process, only the oriented metal powder will be sintered; at the same time, the sintered part will be cooled down quickly under the action of the cooling component.

[0069] ③. Repeat the above steps ① and ② in sequence to print the metal shaft.

[0070] Step 5, grind and polish the motor shaft 1.

[0071] It is worth noting that the motor shaft 1 is polished by any one of mechanical polishing, chemical polishing, electrolytic polishing, ultrasonic polishing, fluid polishing or magnetic abrasive polishing, or a combination of the above different polishing methods.

[0072] Step 6, perform a three-dimensional scan on the shape of the motor shaft 1 to verify whether its shape meets the design requirements.

[0073] It is worth noting that: the motor shaft 1 adopts laser scanning to construct its appearance characteristics, so as to determine whether its appearance dimensions meet the design requirements.

[0074] Step 7, perform non-destructive testing on the motor shaft 1 to check whether its interior is hidden and whether the internal structure meets the design requirements.

[0075] It is worth noting that: the motor shaft 1 uses CT scanning to detect whether there is any hidden damage inside the motor shaft 1 and whether the internal structure of the motor shaft 1 meets the design requirements.

[0076] Step 8, install the motor shaft 1 onto the motor and conduct a test run with load, so as to experimentally test various performances of the motor shaft 1.

[0077] It is worth noting that: if all performance indicators of the motor shaft 1 meet the standards in the experimental test, the motor shaft 1 will be put into actual production. If any performance indicator of the motor shaft 1 does not meet the standards in the experimental test, return to the above Step 1 and repeat Step 2, Step 3, Step 4, Step 5, Step 6, Step 7 and Step 8 in sequence.

[0078] ❶ It is worth noting that in the above Step 1 to Step 8, the size of the metal powder is between 0.1nm and 1000μm, the thickness of the metal powder is between 0.1nm and 2mm, and the metal powder is any one of carbon steel or alloy steel.

[0079] ❷It is worth noting that the 3D metal printer is also equipped with an electromagnet 2, an ultrasonic vibrator 3 and a semiconductor refrigeration plate 4.

[0080] The function of the electromagnet 2 is to provide a unidirectional uniform magnetic field perpendicular to the surface of the workbench 6, so that the metal powder in a floating state will be quickly deposited on the surface of the workbench 6 under the gravitational force of the magnetic field. And when the powder spreading mechanism 5 completes the spreading, the electromagnet 2 will generate an alternating magnetic field in the vertical direction, thereby demagnetizing the metal powder and the printed motor shaft 1.

[0081] The ultrasonic vibrator 3 assists the powder spreading mechanism 5 (the powder spreading mechanism 5 is provided by the 3D metal printer itself and is prior art and need not be elaborated on) to evenly distribute the metal powder on the surface of the workbench 6 .

[0082] The semiconductor refrigeration plate 4 is arranged inside the workbench 6, so that the cold energy on the cold end of the semiconductor refrigeration plate 4 can cool down the metal powder and the printed motor shaft 1 through heat conduction, thereby indirectly achieving rapid cooling of the sintered part.

[0083] In summary, the functions of the electromagnet 2, the ultrasonic vibrator 3 and the semiconductor refrigeration plate 4 are not only to improve the quality of the 3D metal printer printing motor shaft 1, but also to improve the speed of the 3D metal printer printing motor shaft 1; thereby reducing the production cost of the 3D metal printer printing motor shaft 1.

[0084] ❸It is worth noting that:

[0085] The working space inside the 3D metal printer is in a vacuum state or filled with inert gas, which can prevent the laser sintered part from being oxidized.

[0086] After the 3D metal printer prints the motor shaft 1, the electromagnet 2 and the semiconductor refrigeration plate 4 are turned off, the ultrasonic vibrator 3 is started, and the recovery mechanism is started to recover the metal powder on the workbench 6 at the same time, in order to prevent the metal powder from adhering to the workbench 6 and not being effectively recovered.

[0087] ❹It is worth noting that:

[0088] The metal powder collected by the recycling component is subjected to the following steps:

[0089] Ⅰ. Screening: Screen out metal powders that do not meet the requirements.

[0090] Ⅱ. Mixing: Mix the unqualified metal powder with bentonite at a weight ratio of 1:40~60. The physical adsorption and chemical stability of bentonite itself will not cause flammability and explosion when mixed with metal powder, and the operation process is extremely safe.

[0091] III. Deposition: Add alkaline solution to the mixed solution and take out the reactants. In this process, the chemical principle of acid-base neutralization is used to destroy the original chemical structure of the metal or alloy, making the originally unstable chemical bonds stable.

[0092] IV. Calcination: The reactants are placed in a vacuum furnace and calcined into blocks at 1000-1200 degrees Celsius. In this process, the active metal powder is completely inert by high-temperature drying and crystallization, and no longer has an adverse effect on people's lives.

[0093] V. Reduction purification: reducing the calcined metal blocks.

[0094] VI, Powdering, remaking the metal block into metal powder and use it for the next 3D metal printing.

[0095] The above description is only a preferred embodiment of the present invention and does not limit the present invention in other forms. Any technician familiar with the profession may use the technical content disclosed above to change or modify it into an equivalent embodiment with equivalent changes and apply it to other fields. However, any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still falls within the protection scope of the technical solution of the present invention.

Claims

1. A method for manufacturing a motor shaft, characterized in that: A support member (7) is arranged inside the motor shaft (1); the motor shaft (1) is provided with a cavity (8) coaxially along its axial direction to cooperate with the support member; the shaft body of the motor shaft (1) is divided into a rib section (9), a rotor core installation section (10), a shaft oil seal section (11) and a load section (12) in sequence from one end to the other end; A support member (7) is provided in the cavity (8); the support member (7) is radially arranged along the radial direction of the motor shaft (1); the support member (7) has a loose and porous body; and the support member (7) and the motor shaft (1) are integrally formed. The following steps are involved: Step 1, using industrial design software to perform three-dimensional modeling on the pre-designed motor shaft (1), thereby obtaining a three-dimensional model; Step 2, importing the data of the three-dimensional model into CAE series software and performing work simulation through the CAE series software, thereby performing simulation tests on various performances of the motor shaft (1); Step 3: If all performance indicators in the simulation test meet the standards, proceed to Step 4 below; if any performance indicator in the simulation test does not meet the standards, return to Step 1 above and optimize the structure and material selection of the three-dimensional model; Step 4, importing the data of the three-dimensional model into the 3D metal printer, and printing the motor shaft (1) using the 3D metal printer; Step 5, grinding and polishing the motor shaft (1); Step 6, performing a three-dimensional scan on the shape of the motor shaft (1) to verify whether its shape meets the design requirements; Step 7, perform nondestructive testing on the motor shaft (1) to check whether there are any hidden flaws inside and whether the internal structure meets the design requirements; Step 8, installing the motor shaft (1) onto the motor and performing a load test run, thereby experimentally testing various performances of the motor shaft (1); In Step 4, the specific steps of the 3D metal printer when printing the motor shaft (1) are as follows: ①. Spread the metal powder evenly into a thin layer; ② Metal powder is sintered on the surface to be printed by high-power laser; ③. Repeat the above steps ① and ② in sequence to print the metal shaft; The size of the metal powder is between 0.1 nm and 1000 μm, the thickness of the metal powder is between 0.1 nm and 2 mm, and the metal powder is any one of carbon steel and alloy steel; The 3D metal printer is further provided with an electromagnet (2), an ultrasonic vibrator (3) and a semiconductor refrigeration plate (4); The electromagnet (2) is used to generate a unidirectional magnetic field in a vertical direction, thereby suppressing dusting of the metal powder when the powder spreading mechanism (5) spreads the metal powder on the workbench (6); The ultrasonic vibrator (3) is used to flatten, compact and evenly vibrate the metal powder on the workbench (6); The semiconductor refrigeration plate (4) is arranged inside the workbench (6), so that the cold energy on the cold end of the semiconductor refrigeration plate (4) cools down the metal powder and the printed motor shaft (1) by heat conduction, thereby indirectly achieving rapid cooling of the sintered part; The working space inside the 3D metal printer is in a vacuum state or is filled with an inert gas; After the powder spreading mechanism (5) has completed spreading the material, the electromagnet (2) will generate an alternating magnetic field in the vertical direction, thereby demagnetizing the metal powder and the printed motor shaft (1); After the 3D metal printer has finished printing the motor shaft (1), the electromagnet (2) and the semiconductor refrigeration plate (4) are turned off, the ultrasonic vibrator (3) is started, and at the same time, the recovery mechanism is started to recover the metal powder on the workbench (6); The metal powder collected by the recycling component is subjected to the following steps: Ⅰ. Screening: screening out metal powders that do not meet the standards; II. Mixing: mixing the unqualified metal powder with bentonite in a weight ratio of 1:40-60; III, deposition, adding alkaline solution into the mixed solution and taking out the reactants; IV, calcination, placing the reactants in a vacuum furnace and calcining them into blocks at 1000-1200 degrees Celsius; V, reduction and purification, reducing the calcined metal blocks; VI, Powdering, converting metal blocks into metal powder.

2. The method for manufacturing a motor shaft according to claim 1, characterized in that: In the Step 1, before three-dimensional modeling of the motor shaft (1) is performed, product requirements should be analyzed and a parameter index framework of the motor shaft (1) should be determined; In the Step 3, the parameter index framework cannot be exceeded when optimizing the structure and material selection of the model.

3. The method for manufacturing a motor shaft according to claim 1, characterized in that: In the Step 5, the motor shaft (1) is polished by any one of mechanical polishing, chemical polishing, electrolytic polishing, ultrasonic polishing, fluid polishing or magnetic abrasive polishing, or a combination of the above different polishing methods; In Step 6, the motor shaft (1) is constructed with laser scanning to obtain its external features. So as to judge whether its external dimensions meet the design requirements; In Step 7, the motor shaft (1) is scanned by CT to detect whether there are any hidden damages inside the motor shaft (1) and whether the internal structure of the motor shaft (1) meets the design requirements.

4. The method for manufacturing a motor shaft according to claim 1, characterized in that: In the Step 8, if all performance indicators of the motor shaft (1) meet the standards in the experimental test, the motor shaft (1) is put into actual production; if any performance indicator of the motor shaft (1) does not meet the standards in the experimental test, Then return to the above Step 1 and repeat Step 2, Step 3, Step 4, Step 5, Step 6, Step 7 and Step 8 in sequence.

Images