A production process for an integrated carbon fiber shell assembly

Abstract

The present invention discloses a production process for an integrated carbon fiber shell assembly. The technical solution includes the following steps: S1. Shaft sleeve and rear end cover molding: The carbon fiber shaft sleeve and rear end cover are molded using a compression molding method. During production, prepreg is laid layer by layer and placed on a press for heating and pressurization curing. After curing, a three-coordinate CNC center processes the shaft sleeve and rear end cover to their dimensions. S2. Coolant return pipe molding: The coolant return pipe is made of austenitic stainless steel 1Cr18Ni9Ti, and the connecting pipe is welded to form an integrated structure. S3. Casing molding: The casing body is a carbon fiber shell, integrally molded with a metal stator. The casing body is molded using a vacuum bagging method, and embedded parts are molded using high-temperature carbon fiber fabric prepreg. This process is simple and easy to implement, and the products produced are of high quality and long life.

Description

Technical Field

[0001] The present invention relates to the field of generator production, and in particular to a production process for an integrated carbon fiber shell assembly. Background Art

[0002] The composite generator casing primarily consists of the housing, rear end cover, and bushing. The housing encloses the motor stator and houses nine coolant return lines to effectively transfer heat from the stator. Mounting lugs securely connect the housing to other components. The rear end cover is connected to the housing at its perimeter and to the shaft seat at its center to ensure overall coaxiality. The bushing sits between the shaft and rotor, driving the rotor through the shaft sleeve.

[0003] In the current production process, most components are made of metal, which is heavy and difficult to process during production and manufacturing, and needs to be improved. Summary of the Invention

[0004] In view of the problems mentioned in the background technology, the purpose of the present invention is to provide a production process for an integrated carbon fiber shell assembly to solve the problems mentioned in the background technology.

[0005] The above technical objectives of the present invention are achieved through the following technical solutions:

[0006] A production process for an integrated carbon fiber shell assembly comprises the following steps:

[0007] S1. Shaft sleeve and rear end cover molding: The carbon fiber shaft sleeve and rear end cover are molded by molding. During production, the prepreg is laid layer by layer and placed on a press for heating and pressurizing to cure. After curing, the shaft sleeve and rear end cover are processed into place according to the size by the three-coordinate CNC center.

[0008] S2. Coolant return pipe molding: The coolant return pipe is made of austenitic stainless steel 1Cr18Ni9Ti, and the connecting pipe is welded into an integrated structure:

[0009] S3. Casing molding: The main body of the casing is a carbon fiber shell, which is integrally molded with the metal stator. The main body of the casing is molded by vacuum bag pressing. The embedded parts are molded with high-temperature carbon fiber fabric prepreg. The shape is processed after molding. The embedded parts are placed on the mold demoulding ring, and then the stator is placed on the embedded part one. The coolant return pipe is installed one by one close to the stator according to the process requirements. The embedded part two is placed on the top of the stator and positioned through the center connecting hole and the connecting hole on the top of the mold. Finally, the high-temperature carbon fiber fabric prepreg is laid layer by layer on the outer surface of the embedded parts and the stator to achieve the overall coverage of the coolant return pipe and the stator. After laying 5 to 6 layers, the bubbles wrapped in the laying process are fully removed by vacuuming at room temperature. After all the layers are laid, the mold with the blank is placed in an oven for vacuuming and heating for curing.

[0010] S4. Assembly: Assemble the qualified casing, bushing and rear end cover into an assembly.

[0011] Preferably, the main body processing process of the housing specifically includes the following sub-steps: blank production, demoulding, machining, grinding and repairing, drilling, and installation of metal parts.

[0012] Preferably, the blank making sub-step, demoulding sub-step, and punching sub-step are all subjected to quality inspection.

[0013] Preferably, after the S3 housing is formed, the outer surface of the housing is polished and repaired, the top of the housing is machined to ensure flatness, and the connection interfaces on the housing are punched using tooling.

[0014] Preferably, after the S3 housing is formed, a bushing made of stainless steel 1Cr18Ni9Ti is installed at the connection position of the housing interface by gluing and screwing.

[0015] Preferably, after the S1 shaft sleeve and the rear end cover are formed, a bushing made of stainless steel 1Cr18Ni9Ti is installed at the interface position of the rear end cover by gluing and screwing.

[0016] In summary, the present invention mainly has the following beneficial effects:

[0017] The production process of the integrated carbon fiber shell assembly is simple and reasonable, and the integrated carbon fiber shell assembly produced has good comprehensive mechanical properties and service life; the carbon fiber shaft sleeve and carbon fiber rear end cover are formed by the molding method, and the prepreg is laid layer by layer and placed on a press for heating and pressurizing for curing during production. After curing, the three-coordinate CNC center processes them into place according to the size of the shaft sleeve and rear end cover, which can ensure the stability and accuracy of the molding; by making the main body of the casing a carbon fiber shell, the weight can be reduced, and by adopting the vacuum bag compression molding method, the advantages of fast molding and high efficiency can be achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is the casing structure diagram;

[0019] Figure 2 This is the rear end cover structure diagram;

[0020] Figure 3 This is the shaft sleeve structure diagram;

[0021] Figure 4 Schematic diagram of the casing mold;

[0022] Figure 5 It is a schematic diagram of a single coolant return pipe;

[0023] Figure 6 This is a schematic diagram of embedded parts;

[0024] Figure 7 This is a schematic diagram of embedded part 2;

[0025] Figure 8 The effect diagram of the stator after installation;

[0026] Figure 9 It is the embedded diagram of the casing interface;

[0027] Figure 10 Pre-buried diagram for the rear end cover interface;

[0028] Figure 11 Create a process flow chart for the enclosure. DETAILED DESCRIPTION

[0029] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0030] refer to Figures 1 to 11 , a one-piece carbon fiber shell assembly production process, comprising the following steps:

[0031] S1. Shaft sleeve and rear end cover molding: The carbon fiber shaft sleeve and rear end cover are molded by molding. During production, the prepreg is laid layer by layer and placed on a press for heating and pressurizing to cure. After curing, the shaft sleeve and rear end cover are processed into place according to the size by the three-coordinate CNC center.

[0032] S2. Coolant return pipe molding: The coolant return pipe is made of austenitic stainless steel 1Cr18Ni9Ti, and the connecting pipe is welded into an integrated structure:

[0033] S3. Casing molding: The main body of the casing is a carbon fiber shell, which is integrally molded with the metal stator. The main body of the casing is molded by vacuum bag pressing. The embedded parts are molded with high-temperature carbon fiber fabric prepreg. The shape is processed after molding. The embedded parts are placed on the mold demoulding ring, and then the stator is placed on the embedded part one. The coolant return pipe is installed one by one close to the stator according to the process requirements. The embedded part two is placed on the top of the stator and positioned through the center connecting hole and the connecting hole on the top of the mold. Finally, the high-temperature carbon fiber fabric prepreg is laid layer by layer on the outer surface of the embedded parts and the stator to achieve the overall coverage of the coolant return pipe and the stator. After laying 5 to 6 layers, the bubbles wrapped in the laying process are fully removed by vacuuming at room temperature. After all the layers are laid, the mold with the blank is placed in an oven for vacuuming and heating for curing.

[0034] S4. Assembly: Assemble the qualified casing, bushing and rear end cover into an assembly.

[0035] The main body processing process of the housing specifically includes the following sub-steps: blank production, demoulding, machining, grinding and repairing, drilling, and installation of metal parts.

[0036] Among them, the blank making sub-step, demoulding sub-step, and punching sub-step are all subject to quality inspection.

[0037] Among them, after the S3 casing is formed, the outer surface of the casing is polished and repaired, the top of the casing is machined to ensure flatness, and the connection interface on the casing is punched using tooling.

[0038] After the S3 casing is formed, a bushing made of stainless steel 1Cr18Ni9Ti is installed at the connection position of the casing interface by gluing and screwing.

[0039] Among them, after the S1 shaft sleeve and the rear end cover are formed, the rear end cover interface is installed with a bushing made of stainless steel 1Cr18Ni9Ti by gluing and screwing.

[0040] Among them, the production process steps of this integrated carbon fiber shell assembly are simple and reasonable, and the integrated carbon fiber shell assembly produced has good comprehensive mechanical properties and lifespan; the carbon fiber sleeve and carbon fiber rear end cover are formed by the molding method, and the prepreg is laid layer by layer and placed on a press for heating and pressurizing curing during production. After curing, the three-coordinate CNC center processes them into place according to the size of the sleeve and rear end cover, which can ensure the stability and accuracy of the molding; by making the main body of the casing a carbon fiber shell, the weight can be reduced, and by adopting the vacuum bag compression molding method, the advantages of fast molding and high efficiency can be achieved.

[0041] The production of composite material parts, including the housing, rear end cover and shaft sleeve. Parts matching is shown in Table 1, and the housing structure is shown in Figure 1 , rear end cover structure see Figure 2 , the shaft sleeve structure is optimized to the existing structure. Figure 3 .

[0042] Table 1 Parts and components list

[0043] Serial number Product Name quantity Remark 1 chassis 1 Carbon fiber shell, integrated with metal stator 2 rear end cover 1 carbon fiber 3 Bushing 1 carbon fiber

[0044] The function of the casing is to wrap the motor stator as a whole. There are 9 sets of coolant return pipes in the casing.

[0045] The heat of the stator is effectively transferred out through the heat dissipation channel, and the casing and other structures are reliably connected through the hanging ears.

[0046] The rear end cover is connected to the casing around the periphery and the center is connected to the shaft seat to ensure the overall coaxiality. The shaft sleeve is located between the shaft and the rotor, and the shaft drives the rotor to rotate at high speed through the shaft sleeve.

[0047] The main interfaces in the technical indicators are shown in Table 2.

[0048] Table 2 Main interfaces

[0049]

[0050] Key Metrics:

[0051] a) The long-term operating temperature of the casing is 120°C, and the short-term operating temperature (no more than 10 minutes) is 180°C.

[0052] b) The coolant return pipeline inside the casing is well sealed as a whole and reliably connected to the shell.

[0053] c) Long-term operating temperature of rear end cover and sleeve: 60℃~80℃.

[0054] d) The total mass of the housing (excluding the stator), rear end cover and sleeve shall not exceed 11 kg (tentative).

[0055] Material selection plan:

[0056] Different materials are selected according to the operating temperature requirements of each component. The selected materials are shown in Table 3.

[0057] The main performances are shown in Table 4.

[0058] Table 3 Selected materials

[0059] Serial number Material name Material grade Remark 1 High temperature carbon fiber fabric prepreg W-3052 2 Medium temperature carbon fiber fabric prepreg WP-3011 3 Medium temperature unidirectional carbon fiber prepreg USN15000 4 film J-168

[0060] Table 4 Mechanical properties of high temperature carbon fiber fabric prepreg

[0061] Performance Project average value Tensile strength MPa 0° / 90° 770 / 521 Tensile modulus GPa 0° / 90° 62.8 / 61.5 Compression strength MPa 0° / 90° 418 / 428 Compression modulus GPa 0° / 90° 57 / 59.2 Bending strength MPa 0° 749 Flexural modulus GPa 0° 54.9 Short beam shear strength MPa 54.4 In-plane shear strength MPa 82.7 In-plane shear modulus GPa 2.71

[0062] Table 5 Mechanical properties of medium temperature carbon fiber fabric prepreg

[0063] Performance Project average value Tensile strength MPa 0° / 90° 871 / 651 Tensile modulus GPa 0° / 90° 64.2 / 60.2 Compression strength MPa 0° / 90° 433 / 380 Bending strength MPa 0° 854.1 Flexural modulus GPa 0° 50.9 Longitudinal and transverse shear strength MPa 121.9 Longitudinal and transverse shear modulus GPa 8.05

[0064] Table 6 Mechanical properties of medium temperature unidirectional carbon fiber prepreg

[0065] Performance Project average value Tensile strength MPa 0° / 90° 2265.8 / 32.5 Tensile modulus GPa 0° / 90° 129.1 / 8.3 Compression strength MPa 0° / 90° 535.4 / 98.3 Bending strength MPa 0° 1261.2 Flexural modulus GPa 0° 99.8 Longitudinal and transverse shear strength MPa 94.9 Longitudinal and transverse shear modulus GPa 7.1

[0066] In the process plan:

[0067] Mould solution: The casing is to be formed using a metal male mould. The mould is designed with a demoulding ring and a stator expansion restriction structure in the direction of the lamination. The mould structure is shown in Figure 4 .

[0068] Coolant return pipe solution: The coolant return pipe is made of austenitic stainless steel 1Cr18Ni9Ti, and the connecting pipes are welded into an integrated structure to ensure good structural sealing. Figure 5 .

[0069] Main process methods:

[0070] Main process of the casing: The casing body is to be formed by vacuum bag pressing. The main equipment of vacuum bag pressing is oven, forming mold and vacuum system. In order to achieve accurate placement of the stator, the embedded part 1 and embedded part 2 are formed first. Figure 6 As shown, embedded parts Figure 7 As shown, the embedded parts are made of high temperature carbon fiber fabric prepreg and processed after molding. Place the embedded part 1 on the mold release ring, and then place the stator on the embedded part 1. Figure 8 As shown. Install the coolant return pipes one by one close to the stator according to the process requirements, place the embedded part 2 on the top of the stator, and achieve reliable positioning through the center connection hole and the connection hole on the top of the mold. Finally, lay the high-temperature carbon fiber fabric prepreg layer by layer on the embedded part and the outer surface of the stator to achieve the overall coverage of the coolant return pipe and the stator. After laying 5 to 6 layers, use room temperature vacuuming to fully remove the bubbles wrapped in the laying process. After all the layers are laid, put the mold with the blank into the oven for vacuuming and heating to solidify. The equipment required for this process is simple, the density between the layers of the parts is good, and the cost is relatively low. After the casing is formed, the outer surface of the casing is polished and repaired, and the top of the casing is machined to ensure flatness. Use tooling to punch holes for the connection interface on the casing. The casing interface is used to install a stainless steel 1Cr18Ni9Ti bushing by gluing and screwing. There are 3 types of bushing specifications, and the interface size is shown in Figure 9 .

[0071] The main process of the rear end cover: The rear end cover is to be formed by compression molding, and the main equipment for compression molding is a press. The prepreg is laid layer by layer and placed on the press to heat and pressurize for curing. After curing, the three-coordinate CNC center performs net processing according to the rear end cover dimensions. The rear end cover interface is installed with a stainless steel 1Cr18Ni9Ti bushing by gluing and screwing. There are two bushing specifications in total. The interface type is shown in Figure 10

[0072] Main process methods of sleeves:

[0073] The shaft sleeve is to be formed by compression molding. The prepreg is laid layer by layer and placed on a press for heating and pressurizing for curing. After curing, it is processed into place according to the size of the shaft sleeve by a three-coordinate CNC center.

[0074] Process flow:

[0075] The production process of the casing is more complicated than the other two parts. The process flow is explained by taking the casing as an example. The casing production includes process preparation, blank production, demoulding, machining, grinding and repairing, drilling, installation of metal parts and other production links. The process flow is shown in Figure 11 .

[0076] quality:

[0077] The casing, rear end cover and bushing were modeled to estimate the mass of each component, as shown in Table 7.

[0078] Table 7 Detailed list of component quality

[0079]

[0080] The stator mass is calculated to be approximately 1.2 kg through modeling, with a total mass of 9.9 kg, meeting the design requirements. The integrated carbon fiber shell assembly solution was discussed from the perspectives of material selection, key process methods, and technical specifications. The process methods for fabricating the carbon fiber shell assembly were also explained, and the process flow was clarified. The solution was demonstrated to be feasible and meet the technical requirements for the integrated carbon fiber shell assembly.

[0081] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A production process for an integrated carbon fiber shell assembly, characterized by: The following steps are involved: S1. Shaft sleeve and rear end cover molding: The carbon fiber shaft sleeve and rear end cover are molded by molding. During production, the prepreg is laid layer by layer and placed on a press for heating and pressurizing to cure. After curing, the shaft sleeve and rear end cover are processed into place according to the size by the three-coordinate CNC center. S2. Coolant return pipe molding: The coolant return pipe is made of austenitic stainless steel 1Cr18Ni9Ti, and the connecting pipe is welded into an integrated structure: S3. Casing molding: The main body of the casing is a carbon fiber shell, which is integrally molded with the metal stator. The main body of the casing is molded by vacuum bag pressing. The embedded parts are molded by high-temperature carbon fiber fabric prepreg. The shape is processed after molding. The embedded parts are placed on the mold demoulding ring, and then the stator is placed on the embedded part one. The coolant return pipe is installed one by one close to the stator according to the process requirements. The embedded part two is placed on the top of the stator and positioned through the center connecting hole and the connecting hole on the top of the mold. Finally, the high-temperature carbon fiber fabric prepreg is laid layer by layer on the embedded parts and the outer surface of the stator to achieve the overall coating of the coolant return pipe and the stator. After laying 5 to 6 layers, the bubbles wrapped in the laying process are fully removed by vacuuming at room temperature. After all the layers are laid, the mold strip blank is placed in an oven for vacuuming and heating for curing; S4. Assembly: Assemble the qualified casing, bushing and rear end cover into an assembly.

2. The process for producing an integrated carbon fiber shell assembly according to claim 1, characterized in that: The main body processing process of the housing specifically includes the following sub-steps: blank production, demoulding, machining, grinding and repairing, drilling, and installation of metal parts.

3. The process for producing an integrated carbon fiber shell assembly according to claim 2, characterized in that: The blank making sub-step, demoulding sub-step and punching sub-step are all subjected to quality inspection.

4. The process for producing an integrated carbon fiber shell assembly according to claim 1, characterized in that: After the S3 housing is formed, the outer surface of the housing is polished and repaired, the top of the housing is machined to ensure flatness, and the connection interfaces on the housing are punched using tooling.

5. The process for producing an integrated carbon fiber shell assembly according to claim 1, characterized in that: After the S3 casing is formed, a bushing made of stainless steel 1Cr18Ni9Ti is installed at the connection position of the casing interface by gluing and screwing.

6. The process for producing an integrated carbon fiber shell assembly according to claim 1, characterized in that: After the S1 shaft sleeve and the rear end cover are formed, a bushing made of stainless steel 1Cr18Ni9Ti is installed at the interface position of the rear end cover by gluing and screwing.

Images