A process method for replacing permanent magnets of a permanent magnet motor

Abstract

The application discloses a process method for replacing permanent magnets of a permanent magnet motor, and is characterized in that, according to the replacement requirement of surface-mounted permanent magnets in the manufacturing process of the permanent magnet motor, the combination of a fixed clamp and a suction disc type electromagnet is applied to realize the quick dismounting of the permanent magnets, the fixed clamp and a pressure sensor are used to detect the assembly position and pressure receiving condition of the permanent magnets, the permanent magnets are accurately assembled in place, and the visual inspection error is avoided to cause the permanent magnets to be not assembled in place or to be over-pressured, so that the permanent magnets are cracked in different degrees, the problems of high position precision, production efficiency and operation safety requirement of the permanent magnet motor for replacing the permanent magnets are solved, and the product quality of the permanent magnet motor for replacing the permanent magnets is ensured.

Description

Technical Field

[0001] This invention relates to the field of permanent magnet motor rotor manufacturing, and in particular to a new process method for replacing permanent magnets in a permanent magnet motor. Background Technology

[0002] The permanent magnet motor rotor uses surface-mounted permanent magnets. The outer circumference of the shaft has a mounting groove structure for guiding and positioning the permanent magnets. During assembly, adhesive is used to bond and fix the permanent magnets to the shaft. Then, a non-woven tape is wound around the outer surface of the permanent magnets, and a heat-sealed protective ring is applied to secure them. Permanent magnets possess strong magnetic properties, resulting in strong attractive and repulsive forces between adjacent permanent magnets. The attraction between the permanent magnets and the shaft makes adjusting the installation position and assembly gap difficult. The gap between adjacent permanent magnets is in the range of 0.01–0.02 mm, indicating a small assembly gap. Permanent magnets are fragile; even slight collisions during assembly can cause them to break. The broken magnets adhere to the shaft and the surfaces of adjacent permanent magnets, making them extremely difficult to clean and affecting subsequent assembly quality. Breaking permanent magnets are also difficult to remove; traditional manual removal and replacement methods are extremely inefficient and fail to clean them completely. Therefore, a new process for replacing permanent magnets in permanent magnet motors based on electromagnets and pressure sensors has been invented. Summary of the Invention

[0003] The purpose of this invention is to provide a new process for replacing permanent magnets in permanent magnet motors, solving the problem of difficulty in removing and reassembling surface-mounted permanent magnets in permanent magnet motor rotors due to breakage during manufacturing, and achieving safe, fast, and accurate replacement of permanent magnets.

[0004] The technical solution steps of this invention are as follows:

[0005] 1) Position the rotor at the permanent magnet replacement station;

[0006] 2) Install an axial fixing tool and an axial tightening screw at the end of the rotor;

[0007] 3) Install radial support tools;

[0008] 4) Install the fixing fixture and alignment block on the boring bar, and tighten the fixing bolts of the fixture;

[0009] 5) Adjust the rotor position so that the rotor mounting slot is aligned with the boring bar;

[0010] 6) Install a suction cup electromagnet;

[0011] 7) Slowly move the boring bar to position the suction cup electromagnet directly above the permanent magnet to be removed;

[0012] 8) Continue pushing the suction cup electromagnet downwards along the axial direction until it contacts the permanent magnet to be removed;

[0013] 9) Turn on the power supply of the suction cup electromagnet and check the suction cup electromagnet's ability to attract permanent magnets.

[0014] 10) Slowly raise the boring bar vertically, and use the attraction force between the suction cup electromagnet and the permanent magnet to remove the permanent magnet and remove the suction cup electromagnet.

[0015] 11) Clean the rotor mounting slot. After cleaning the mounting slot, use a cleaning agent to wipe the outer surface of the rotor and the surface of the permanent magnet clean;

[0016] 12) Install a fixing clamp on the boring bar;

[0017] 13) Install a permanent magnet on the fixed fixture, place a pressure sensor between the permanent magnet and the fixed fixture, and tighten the fixture with fixing bolts;

[0018] 14) Apply adhesive to the bonding surfaces of the permanent magnet and the rotor;

[0019] 15) Move the permanent magnet slowly by moving the boring bar to a position 2mm from the bottom of the rotor mounting slot, and continue to push the permanent magnet downward along the axial direction, monitoring the pressure value of the pressure sensor, so that the permanent magnet reaches the final position;

[0020] 16) Continue pushing the permanent magnet towards the bottom of the slot until it contacts the rotor;

[0021] 17) Secure the permanent magnet using a radial support tool;

[0022] 18) Loosen the retaining clamp and slowly move the boring bar away;

[0023] 19) Tighten the permanent magnet axially with the axial clamping screw;

[0024] 20) After the permanent magnet adhesive has cured, remove the radial fixing bolts, radial support pads, radial support tools, axial tightening screws, and axial fixing tools to complete the permanent magnet assembly.

[0025] In the above-mentioned process for replacing the permanent magnet of the permanent magnet motor, in step 3, radial fixing bolts are used to assemble the permanent magnet onto the surface of the permanent magnet to temporarily support the permanent magnet, ensuring that the permanent magnet does not move radially and preventing flipping, adsorption, and collision damage when the permanent magnet is removed.

[0026] In the above-mentioned process for replacing the permanent magnet of the permanent magnet motor, in step 6, the alignment block is installed on the fixing fixture, and a suction cup electromagnet is installed on the alignment block.

[0027] In the above-mentioned process for replacing the permanent magnet of the permanent magnet motor, in step 15, when the pressure sensor shows a sudden increase in axial pressure, the movement stops, at which point the permanent magnet has reached its final axial position.

[0028] In the above-mentioned process for replacing the permanent magnet in a permanent magnet motor, in step 20, after the permanent magnet is assembled to its final position, during the curing process of the permanent magnet adhesive, a combination of fixing tools—radial fixing bolts, radial support pads, radial support tools, axial tightening screws, and axial fixing tools—is used to reliably fix the permanent magnet, ensuring reliable bonding and fixation. Compared with the prior art, the beneficial effects of this invention are:

[0029] 1. This invention is the first to realize a novel process method for replacing permanent magnets in permanent magnet motors based on electromagnets. Previously, the removal of permanent magnets using traditional manual operations or simple tooling was extremely inefficient, difficult to clean completely, and prone to damaging adjacent permanent magnets, failing to meet the requirements for removing surface-mounted permanent magnets from permanent magnet motor rotors. This invention, however, realizes a novel process method for removing permanent magnets based on a suction cup electromagnet. This method is safe, efficient, and easy to operate, solving the problem of difficult removal of surface-mounted permanent magnets from permanent magnet motor rotors due to damage during manufacturing.

[0030] 2. This invention is the first to utilize pressure sensors for assembly position and pressure detection. Previously, the axial assembly position of permanent magnets relied entirely on visual inspection, making the permanent magnets susceptible to breakage under pressure. This invention, however, achieves assembly position and pressure detection based on pressure sensors, unaffected by operator experience, thus ensuring assembly position accuracy and solving the problem of easy breakage under pressure during the reassembly of surface-mounted permanent magnets in permanent magnet motor rotors during manufacturing.

[0031] 3. This invention features quick replacement operation, high production efficiency, and the ability to overcome strong magnetic adsorption. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of removing a permanent magnet using a fixing clamp and a suction cup electromagnet.

[0033] Figure 2 This is a schematic diagram of assembling a permanent magnet using a fixing fixture and a pressure sensor.

[0034] In the diagram: 1-rotor, 2-permanent magnet, 3-radial support tool, 4-radial support pad, 5-radial fixing bolt, 6-axial fixing tool, 7-axial clamping screw, 8-fixing clamp, 9-boring rod, 10-fixing bolt, 11-aligning block, 12-suction cup electromagnet, 13-pressure sensor. Detailed Implementation

[0035] like Figure 1As shown, the permanent magnet removal method of the present invention is applied. The rotor 1 is positioned at the permanent magnet 2 removal station. An axial fixing tool 6 and an axial tightening screw 7 are installed at the end of the rotor 1. A radial support tool 3 is installed, and a radial support pad 4 is used to temporarily fix the radial support tool 3. Radial fixing bolts 5 are assembled to the surface of the permanent magnet 2. A fixing clamp 8 and a leveling block 11 are installed on the boring bar 9. The position of the rotor 1 is adjusted so that the mounting slot of the rotor 1 is aligned with the boring bar 9. A suction cup electromagnet 12 is installed on the leveling block 11. The suction cup electromagnet 12 is moved slowly by moving the boring bar 9 until it is directly above the permanent magnet 2 to be removed. The suction cup electromagnet 12 is pushed downwards axially until it contacts the permanent magnet 2 to be removed. The power supply to the suction cup electromagnet 12 is turned on, and the boring bar 9 is slowly raised vertically. Using the attraction force between the suction cup electromagnet 12 and the permanent magnet 2, the permanent magnet 2 is removed, and the suction cup electromagnet 12 is removed.

[0036] like Figure 2 As shown, the permanent magnet assembly method of the present invention is applied. A fixing clamp 8 is installed on the boring bar 9, and a permanent magnet 2 is installed on the fixing clamp 8. A pressure sensor 13 is placed between the permanent magnet 2 and the fixing clamp 8, and the fixing bolts 10 of the clamp are tightened. The permanent magnet 2 is moved slowly by moving the boring bar 9 to a position 2mm from the bottom of the rotor 1 mounting slot, and the permanent magnet 2 is pushed downwards axially. When the pressure sensor 13 shows a sudden increase in axial pressure, the movement is stopped; at this point, the permanent magnet 2 has reached its final axial position. The permanent magnet 2 is continued to be pushed towards the bottom of the slot until it contacts the rotor 1. The permanent magnet 2 is fixed using a radial support tool 3. The fixing clamp 8 is released, and the boring bar 9 is slowly removed. The axial tightening screw 7 is used to tighten the permanent magnet 2 axially.

[0037] The specific implementation process steps of this invention are as follows:

[0038] 1. Position rotor 1 at the permanent magnet 2 replacement station.

[0039] 2. Install the axial fixing tool 6 and the axial tightening screw 7 at the end of rotor 1.

[0040] 3. Install the radial support tool 3 and place it at the location of the permanent magnet 2 to be removed. Use the radial support pad 4 to temporarily fix the radial support tool 3. Assemble the radial fixing bolt 5 onto the surface of the permanent magnet 2 to temporarily support the permanent magnet 2 and prevent it from flipping over during removal.

[0041] The use of radial support tool 3, radial support pad 4 and radial fixing bolt 5 in this process can effectively prevent the permanent magnet 2 from flipping over or adsorbing with adjacent permanent magnet 2 during removal.

[0042] 4. Install the fixing clamp 8 and the alignment block 11 on the boring bar 9, and tighten the clamp with the fixing bolt 10.

[0043] 5. Adjust the position of rotor 1 so that the mounting slot of rotor 1 is aligned with boring bar 9.

[0044] The use of a fixed fixture 8 and a aligning block 11 in this implementation process can improve the alignment accuracy of the rotor 1, making the subsequent replacement of the permanent magnet 2 and assembly operations more precise.

[0045] 6. Install a suction cup electromagnet 12 on the alignment block 11.

[0046] 7. Slowly move the boring bar 9 to move the suction cup electromagnet 12 directly above the permanent magnet 2 to be removed.

[0047] 8. Continue to push the suction cup electromagnet 12 downward along the axial direction until it contacts the permanent magnet 2 to be removed.

[0048] 9. Turn on the power supply to the suction cup electromagnet 12 and check the adhesion of the suction cup electromagnet 12 to the permanent magnet 2.

[0049] 10. Slowly raise the boring bar 9 vertically, and use the attraction force between the suction cup electromagnet 12 and the permanent magnet 2 to remove the permanent magnet 2 and remove the suction cup electromagnet 12.

[0050] In this implementation process, a suction cup electromagnet 12 is used to remove the permanent magnet 2, which has the characteristics of safety, high efficiency, and simple and quick operation, and solves the problem of difficult removal of the permanent magnet 2.

[0051] 11. Clean the mounting slot of rotor 1. After cleaning the mounting slot, use a cleaning agent to wipe the outer surface of rotor 1 and the surface of permanent magnet 2 clean.

[0052] 12. Install the fixing clamp 8 on the boring bar 9.

[0053] 13. Install the permanent magnet 2 on the fixed clamp 8, place the pressure sensor 13 between the permanent magnet 2 and the fixed clamp 8, and tighten the clamp with the fixing bolt 10.

[0054] 14. Apply adhesive to the bonding surface between the permanent magnet 2 and the rotor 1.

[0055] 15. Move the permanent magnet 2 slowly by moving the boring bar 9 to a position 2mm from the bottom of the mounting slot of the rotor 1, and continue to push the permanent magnet 2 downward along the axial direction.

[0056] 16. When the pressure sensor 13 shows a sudden increase in axial pressure, stop moving. At this time, the permanent magnet 2 has reached its final axial position.

[0057] In this implementation process, pressure sensor 13 is used to detect the assembly position and pressure, which is not affected by the operator's experience, thus ensuring the accuracy of the assembly position and solving the problem that the permanent magnet 2 is easily crushed under pressure.

[0058] 17. Continue pushing the permanent magnet 2 to the bottom of the slot until it contacts the rotor 1.

[0059] 18. Use radial support tool 3 to fix permanent magnet 2.

[0060] 19. Loosen the fixing clamp 8 and slowly move the boring bar 9 away.

[0061] 20. Tighten the permanent magnet 2 axially with the axial clamping screw 7.

[0062] 21. After the adhesive of permanent magnet 2 has cured, remove the radial fixing bolt 5, radial support pad 4, radial support tool 3, axial tightening screw 7, and axial fixing tool 6 to complete the assembly of permanent magnet 2.

[0063] In this implementation process, a combination of fixing tools is used to reliably fix the permanent magnet 2 during the curing process of the adhesive, ensuring that the permanent magnet 2 is reliably bonded and fixed.

[0064] The above embodiments are merely one implementation of the permanent magnet replacement process provided by the present invention. Any other modifications to the solution provided by the present invention, including adding or reducing steps, or applying the present invention to other technical fields similar to the present invention, shall fall within the protection scope of the present invention.

Claims

1. A process for replacing the permanent magnet in a permanent magnet motor. Its features include the following steps: 1) Position the rotor (1) at the permanent magnet (2) changing station; 2) Install an axial fixing tool (6) and an axial tightening screw (7) at the end of the rotor (1); 3) Install the radial support tool (3) and place it at the position of the permanent magnet (2) to be removed. Use the radial support pad (4) to temporarily fix the radial support tool (3). Assemble the radial fixing bolt (5) to the surface of the permanent magnet (2) to temporarily support the permanent magnet (2). 4) Install the fixing clamp (8) and the alignment block (11) on the boring bar (9), and tighten the clamp with the fixing bolt (10); 5) Adjust the position of the rotor (1) so that the mounting slot of the rotor (1) is aligned with the boring bar (9); 6) Install a suction cup electromagnet (12); 7) Move the suction cup electromagnet (12) slowly using the boring bar (9) to place it directly above the permanent magnet (2) to be removed; 8) Continue to push the suction cup electromagnet (12) downward along the axial direction until it contacts the permanent magnet (2) to be removed; 9) Turn on the power supply of the suction cup electromagnet (12) and check the suction cup electromagnet (12) adsorbing the permanent magnet (2); 10) Slowly raise the boring bar (9) in the vertical direction, and use the attraction force between the suction cup electromagnet (12) and the permanent magnet (2) to remove the permanent magnet (2) and remove the suction cup electromagnet (12); 11) Clean the mounting slot of the rotor (1). After cleaning the mounting slot, use a cleaning agent to wipe the outer surface of the rotor (1) and the surface of the permanent magnet (2) clean. 12) Install the fixing clamp (8) on the boring bar (9); 13) Install a permanent magnet (2) on the fixed clamp (8), place a pressure sensor (13) between the permanent magnet (2) and the fixed clamp (8), and tighten the clamp with fixing bolts (10); 14) Apply adhesive to the bonding surface between the permanent magnet (2) and the rotor (1); 15) Move the permanent magnet (2) slowly by moving the boring bar (9) to a position 2mm from the bottom of the mounting slot of the rotor (1), and continue to push the permanent magnet (2) downward along the axial direction to the final position; 16) Continue pushing the permanent magnet (2) towards the bottom of the slot until it contacts the rotor (1); 17) Use radial support tool (3) to fix permanent magnet (2); 18) Loosen the fixing clamp (8) and slowly move the boring bar (9); 19) Tighten the axial clamping screw (7) to the permanent magnet (2) along the axial direction; 20) After the adhesive of the permanent magnet (2) has cured, remove the radial fixing bolt (5), radial support pad (4), radial support tool (3), axial tightening screw (7), and axial fixing tool (6) to complete the assembly of the permanent magnet (2).

2. The process method for replacing the permanent magnet of a permanent magnet motor according to claim 1, characterized in that: The radial fixing bolts (5) are used to assemble the permanent magnet (2) onto the surface to temporarily support the permanent magnet (2).

3. The process method for replacing the permanent magnet of a permanent magnet motor according to claim 1, characterized in that: The alignment block (11) is mounted on the fixing fixture (8), and a suction cup electromagnet (12) is mounted on the alignment block (11).

4. The process for replacing the permanent magnet in a permanent magnet motor according to claim 1, characterized in that: When the pressure sensor (13) shows a sudden increase in axial pressure, it stops moving, at which point the permanent magnet (2) has reached its final axial position.

5. The process method for replacing the permanent magnet of a permanent magnet motor according to claim 1, characterized in that: After the permanent magnet (2) is assembled to its final position, during the curing process of the adhesive on the permanent magnet (2), a combination of fixing tools consisting of radial fixing bolts (5), radial support pads (4), radial support tools (3), axial tightening screws (7), and axial fixing tools (6) is used to reliably fix the permanent magnet (2).

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