A manufacturing process for a long stator of a maglev traction linear motor

Abstract

The application discloses a manufacturing process for a long stator of a maglev traction linear motor, and belongs to the field of stator processing. The long stator of the maglev traction linear motor is made of self-adhesive coating electrical steel, which replaces the traditional mechanical fixing mode. After the initial lamination is completed, the long stator can be sent into a constant-temperature box for heating and solidification, so that the adhesive coating of the lamination is glued, and the long stator core forms an integral whole. The manufacturing process for the long stator of the maglev traction linear motor does not change the electromagnetic scheme and structure of the long stator linear synchronous motor. By optimizing the modular structure of the long stator and the process design method, the long stator structure design and process design flow are simplified, the production qualification rate and efficiency of the long stator module are improved, the environmental adaptability of the long stator module is improved, the convenience of large-batch automatic production is realized, and the production cost is reduced.

Description

Technical Field

[0001] This invention belongs to the field of stator processing, specifically relating to a manufacturing process for a long stator of a magnetic levitation traction linear motor. Background Technology

[0002] Maglev trains are train systems that employ a contactless electromagnetic levitation, guidance, and drive system. They rely on electromagnetic attraction or repulsion to levitate and guide the train, achieving zero mechanical contact between the train and the ground track, and utilize the driving force of a linear motor to propel the train. The long stator structure, as the most crucial component of the linear motor, directly affects the overall performance of the linear motor.

[0003] The overall manufacturing process of long stators mainly includes lamination, stacking, epoxy casting, and curing. In the existing long stator production process, especially during the stacking process, most iron cores are fastened using welding, bolting, riveting, or self-locking. However, this method introduces several problems: First, localized short circuits can occur at the welded or riveted joints, disrupting the original magnetic field lines and leading to magnetic degradation. Furthermore, the burning of the coating during welding generates harmful gases, polluting the environment and endangering operator health. Second, although the iron core becomes a single unit, it is only partially secured, making it prone to noise during magnetization and resonance. Finally, regardless of whether it's welding, bolting, self-locking, or riveting, the fixing method only provides point fixation of the chip, resulting in insufficient connection strength, which is insufficient for applications requiring high fastening strength. Summary of the Invention

[0004] In response to one or more of the above-mentioned defects or improvement needs of the existing technology, the present invention provides a manufacturing process for a long stator of a magnetic levitation traction linear motor. This process simplifies the design of the long stator production process, improves the qualification rate and efficiency of long stator module production, and enhances the environmental adaptability of the long stator module, thereby achieving the convenience of mass automated production and reducing production costs.

[0005] To achieve the above objectives, the present invention provides a manufacturing process for a long stator of a magnetic levitation traction linear motor, comprising the following steps:

[0006] S100: Pre-treat the electrical steel and apply a self-adhesive coating to each piece of electrical steel;

[0007] S200: Place multiple processed electrical steels into a stacking mold for stacking operation;

[0008] S300: After the iron core is stacked, it is placed in a constant temperature box for heating and curing, so that the adhesive coating on the surface of the electrical steel is glued together, and the long stator iron core is formed into a whole.

[0009] S400: Assemble the dovetail key onto the formed iron core, and then perform vacuum potting.

[0010] S500: Completes the machining operation of the stator core.

[0011] As a further improvement of the present invention, in step S200, after placing multiple electrical steels into the stacking mold, the electrical steels are pre-tightened by clamping bolts.

[0012] As a further improvement of the present invention, in step S400, the surface of the dovetail key needs to be subjected to cathodic electrophoresis treatment before it is installed on the iron core.

[0013] As a further improvement of the present invention, in step S400, when vacuum potting is performed on the assembled iron core, multiple air holes are formed on the surface of the potting mold to remove air holes generated in the product after potting.

[0014] As a further improvement of the present invention, step S200 specifically includes the following steps:

[0015] Place sufficient electrical steel into the stacking mold;

[0016] The overall height of the electrical steel is measured using measuring tools; if the height meets the requirements, proceed to the next step; otherwise, continue placing the electrical steel.

[0017] Screw the stacked bolts into the stacked bolt holes and tighten the electrical steel from both sides.

[0018] As a further improvement of the present invention, the thickness of the self-adhesive coating layer is 0.5 to 1 μm.

[0019] As a further improvement of the present invention, in step S100, the pretreatment operation of the electrical steel includes the appearance inspection, shearing, fine blanking and deburring of the electrical steel.

[0020] Based on this, the present invention also provides a stacking mold for a long stator of a magnetic levitation traction linear motor, which includes a base plate and two vertical end plates and two transverse end plates disposed on the top of the base plate;

[0021] The two vertical end plates and the two horizontal end plates enclose a receiving space on the base for accommodating electrical steel; and

[0022] A toothed pressure plate is also provided on the vertical end plate, the shape of which matches the shape of the electrical steel, and is used to limit the electrical steel placed into the accommodating space.

[0023] As a further improvement of the present invention, at least one support bar is provided in the accommodating space, and it is parallel to the vertical end plate.

[0024] As a further improvement of the present invention, a plurality of pre-tightening bolt holes are also formed on the toothed pressure plate; and

[0025] Multiple stacked bolts are threaded onto the vertical end plate.

[0026] The aforementioned improved technical features can be combined with each other as long as they do not conflict with each other.

[0027] Overall, compared with the prior art, the technical solutions conceived in this invention have the following advantages:

[0028] (1) The manufacturing process of the long stator of the magnetic levitation traction linear motor of the present invention uses self-adhesive coated electrical steel instead of the traditional mechanical fixing method. After the initial stacking is completed, it can be sent into a constant temperature box for heating and curing to ensure that the adhesive coating of the bonding lamination is glued and the long stator core is formed as a whole. The stacking pre-tightening method of stacking bolts can use ordinary stacking molds instead of self-adhesive silicon steel sheet stacking molds, simplifying the process and making it easy to achieve large-scale mass production.

[0029] (2) The manufacturing process of the long stator of the magnetic levitation traction linear motor of the present invention can effectively realize mold design, long stator structure design and process flow, as well as ensure the dimensional tolerance of the long stator core and improve the yield; at the same time, it reduces the cost of raw materials and facilitates mass automated production, thereby achieving simple process and low cost.

[0030] (3) The manufacturing process of the long stator of the magnetic levitation traction linear motor of the present invention, without changing the electromagnetic scheme and structure of the long stator linear synchronous motor, proposes a stacking mold by optimizing the modular structure and process design method of the long stator, thereby simplifying the structural design and process design process of the long stator, improving the production qualification rate and efficiency of the long stator module, improving the environmental adaptability of the long stator module, thereby realizing the convenience of mass automated production and reducing production costs. Attached Figure Description

[0031] Figure 1 This is an overall flowchart of the manufacturing process for the long stator of the magnetic levitation traction linear motor in this embodiment of the invention;

[0032] Figure 2 This is a schematic diagram of the overall structure of the stacking mold used in the manufacturing process of the long stator of the magnetic levitation traction linear motor in an embodiment of the present invention; Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0034] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0035] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0036] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0037] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0038] Example:

[0039] Please see Figure 1 and Figure 2 The manufacturing process for the long stator of a magnetic levitation traction linear motor in a preferred embodiment of the present invention includes the following steps:

[0040] S100: Pre-treat the electrical steel and apply a self-adhesive coating to each piece of electrical steel.

[0041] Specifically, the pretreatment of electrical steel laminations includes four stages: visual inspection, shearing, fine blanking, and deburring. The quality of the blanking directly affects the quality of the core laminations, so the burr height must be strictly controlled. Therefore, it is preferable that the burr height of the blanking laminations does not exceed 0.05mm.

[0042] More preferably, the thickness of the self-adhesive coating is greater than that of the conventional coating, which directly affects its stacking factor. The thickness of the self-adhesive film is preferably 0.5 to 1 μm.

[0043] It is understandable that most traditional iron cores are fastened using welding, bolts, riveting, or self-locking. However, when non-oriented electrical steel sheets are laminated and then fastened into an iron core using welding or other methods, the following problems are likely to occur: First, local short circuits may occur at the weld or riveting points, causing the original magnetic field lines to become disordered and leading to deterioration of the magnetism. Second, although the iron core becomes a whole, it is only partially fastened, which can easily generate noise during magnetization resonance. Third, regardless of whether it is welding, bolting, self-locking, or riveting, the fixing method is only a local point fixation of the chip, with low connection strength, making it difficult to meet the requirements of high fastening strength in applications.

[0044] Therefore, this application uses a self-adhesive coating to connect multiple electrical steels, resulting in better fastening after assembly, less susceptibility to bleed images, and high connection stability.

[0045] Furthermore, the specific components and preparation process of the self-adhesive coating are conventional technologies in the field (such as Chinese patent, patent number: 200510029249.6; patent name: high temperature resistant water-based self-adhesive coating; this component coating is only one of many embodiments, and its specific components are not specifically limited here, as long as they can meet the above requirements), and will not be described in detail here.

[0046] S200: The processed electrical steel is placed into a stacking mold for stacking.

[0047] Based on this, the present invention also provides a stacking mold for stacking linear motor stators. It mainly includes a base plate and two vertical end plates and two horizontal end plates disposed on the top of the base plate. The two vertical end plates and two horizontal end plates are respectively arranged parallel to each other on the outer periphery of the top of the base plate, thus enclosing a receiving space for placing electrical steel. At least one support bar parallel to the horizontal end plates is provided within the receiving space; a toothed pressure plate is also provided on the top of the vertical end plates to match the shape of the electrical steel and limit its movement. Simultaneously, multiple pre-tightening bolt holes are formed on the toothed pressure plate, and multiple stacking bolts are threadedly connected to the side of the vertical end plate away from the center of the base plate.

[0048] It is worth noting that since the precision of the mold itself directly affects the precision of the stator after stacking, the mold needs to be calibrated and positioned before use. During calibration, the base plate of the stacking mold is used as the bottom surface. The base plate is precision ground using a grinding machine, typically achieving a precision of 0.02mm or even higher. This ensures the flatness of the tooth grooves, tooth surfaces, and the back of the iron core, as well as the flatness of the stacked laminations, thereby ensuring that the insulation of the embedded wires in the tooth grooves is not damaged and that the dimensional tolerances of the shape are met. The four sides of the support strip are precision ground using a grinding machine, typically achieving a precision of 0.02mm. This mainly ensures the consistency of the slots and rigidity support of the electrical steel in the long stator, facilitating further stacking work. Then, vertical end plates on both sides are placed to prevent tooth pressure plates. Figure 2 As shown in the image.

[0049] In practical use, each long stator electrical steel piece is placed along one side of the transverse end plate and simultaneously embedded in the support strip of the iron core stacking mold to ensure that each long stator electrical steel piece is placed consistently and that the stacked pieces are flat. Then, once the designed number of long stator electrical steel pieces has been placed, the stacking bolts on both sides of the vertical end plate are assembled into the stacking bolt holes. When screwing in the stacking bolts on both sides, a special stacking pre-tightening wrench is used for pre-tightening, and the stacking bolts on both sides are pre-tightened alternately.

[0050] Furthermore, in actual use, when the preload of the stacking bolts reaches the design value, the stacking thickness of the long stator module is measured using a measuring tool. When the measured value is greater than the allowable width tolerance of the long stator as a whole, the stacking bolts are loosened, and the number of laminations is added again until the stacking thickness design requirements are met.

[0051] Finally, end reinforcing ribs are installed on the bolts of the toothed pressure plates on both sides, and reverse nuts are used for pre-tightening to achieve the purpose of stacking the long stator modules.

[0052] In addition, after the long stator core is stacked and released, some ends are reinforced by electric welding. After the stacking is completed, dovetail keys are installed, and the long stator core is stacked under normal pressure.

[0053] Furthermore, in maglev trains, dovetail keys are commonly used to fix the long stator to functional components using bolts. Since the track requires a strictly controlled gap of 10mm between the long stator and the train, high requirements are placed on the dimensions and mechanical properties of the dovetail keys. In addition, to ensure the long-term reliable operation of the maglev train line, the dovetail keys are exposed to the atmospheric environment, so their surfaces require cathodic electrophoresis treatment.

[0054] Therefore, before assembling the dovetail key onto the electrical steel surface, the surface of the dovetail key needs to be subjected to cathodic surge treatment. More specifically, the basic performance data is as follows: the specific parameters for the surge treatment operation are as follows: "Lead-free cathodic electrophoretic paint: black; electrophoretic paint thickness: 30~60um".

[0055] S300: After the iron core is stacked, it is placed in a constant temperature chamber for heating and curing.

[0056] Specifically, the preferred temperature of the constant temperature chamber is 180℃. This allows the adhesive coating on the surface of the electrical steel to bond together, forming the long stator core as a single unit.

[0057] S400: Vacuum encapsulation of the formed iron core.

[0058] More specifically, the potting process includes two parts: epoxy formulation and pouring process.

[0059] To further improve the quality of long stators, they must possess excellent durability and be resistant to environmental conditions such as atmospheric corrosion and radiation. Their coefficient of thermal expansion must be approximately the same as that of electrical steel. This prevents deformation or epoxy layer peeling, allowing the long stator to be used in the atmospheric environment for extended periods.

[0060] Because long stator products have very strict requirements for dimensional accuracy, the overall height dimension error must be controlled within 0.2mm, the flatness must be within 0.1mm, the draft angle must be within 5%, and epoxy resin is pressure-cast in a vacuum environment.

[0061] Furthermore, to address the issue of air pockets on the surface of the poured product, an air reservoir is formed on the surface of the potting mold, thereby eliminating air pockets on the product surface and achieving the desired effect.

[0062] Casting System: An epoxy casting system was designed, which is mainly divided into two parts: epoxy casting and vacuum system, as shown in the figure below.

[0063] S500: Completes the machining operation of the stator core.

[0064] It should be noted that the parameters of the tooth pressure plate are matched with the parameters of the iron core tooth groove, and its mounting hole is the preload hole for the stacking preload bolt. The tooth pressure plate is inclined inward, and its inclination angle is preferably 3 to 5°. The tooth pressure plates on both sides of the stator iron core are inclined towards the center of the stacking to enhance the stacking effect and ensure the stacking preload force.

[0065] (1) The manufacturing process of the long stator of the magnetic levitation traction linear motor of the present invention uses self-adhesive coated electrical steel instead of the traditional mechanical fixing method. After the initial stacking is completed, it can be sent into a constant temperature box for heating and curing to ensure that the adhesive coating of the bonding lamination is glued and the long stator core is formed as a whole. The stacking pre-tightening method of stacking bolts can use ordinary stacking molds instead of self-adhesive silicon steel sheet stacking molds, simplifying the process and making it easy to achieve large-scale mass production.

[0066] (2) The manufacturing process of the long stator of the magnetic levitation traction linear motor of the present invention can effectively realize mold design, long stator structure design and process flow, as well as ensure the dimensional tolerance of the long stator core and improve the yield; at the same time, it reduces the cost of raw materials and facilitates mass automated production, thereby achieving simple process and low cost.

[0067] (3) The manufacturing process of the long stator of the magnetic levitation traction linear motor of the present invention, without changing the electromagnetic scheme and structure of the long stator linear synchronous motor, proposes a stacking mold by optimizing the modular structure and process design method of the long stator, thereby simplifying the structural design and process design process of the long stator, improving the production qualification rate and efficiency of the long stator module, improving the environmental adaptability of the long stator module, thereby realizing the convenience of mass automated production and reducing production costs.

[0068] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A manufacturing process for a long stator of a magnetic levitation traction linear motor, characterized in that, It includes the following steps: S100: Pre-treat the electrical steel and apply a self-adhesive coating to each electrical steel, the thickness of which is 0.5~1µm; S200: Place multiple processed electrical steels into a stacking mold for stacking operation; Specifically, the following steps are included: Place sufficient electrical steel into the stacking mold; The overall height of the electrical steel is measured using measuring tools; if the height meets the requirements, proceed to the next step; otherwise, continue placing the electrical steel. Screw the stacked bolts into the stacked bolt holes and tighten the electrical steel from both sides; The stacking mold includes a base plate and two vertical end plates and two horizontal end plates set on the top of the base plate. The two vertical end plates and two horizontal end plates are respectively set parallel to each other on the outer periphery of the top of the base plate, thus enclosing and forming an accommodating space. A toothed pressure plate is also set on the top of the vertical end plate to match the shape of the electrical steel. The toothed pressure plate is inclined inward at an angle of 3~5°. At least one support bar is also set in the accommodating space, and it is parallel to the vertical end plate. Each long stator electrical steel is placed along one side of the horizontal end plate and embedded in the support bar of the iron core stacking mold. Multiple pre-tightening bolt holes are formed on the toothed pressure plate. Multiple stacking bolts are also threaded on the side of the vertical end plate away from the center of the base plate. When the stacking bolts on both sides are screwed in, a special stacking pre-tightening wrench is used for pre-tightening and stacking, and the stacking bolts on both sides are pre-tightened alternately. S300: After the iron core is stacked, it is placed in a constant temperature box for heating and curing, so that the adhesive coating on the surface of the electrical steel is glued together, and the long stator iron core is formed into a whole. S400: Assemble the dovetail key onto the formed iron core, and then perform vacuum potting. In step S400, when vacuum potting is performed on the assembled iron core, multiple pores are formed on the surface of the potting mold to remove pores generated in the potted product. S500: Completes the machining operation of the stator core.

2. The manufacturing process for the long stator of a magnetic levitation traction linear motor according to claim 1, characterized in that, In step S200, after placing multiple electrical steels into the stacking mold, the electrical steels are pre-tightened by clamping bolts.

3. The manufacturing process for the long stator of a magnetic levitation traction linear motor according to claim 1 or 2, characterized in that, In step S400, the surface of the dovetail key needs to be subjected to cathodic electrophoresis before it is installed onto the iron core.

4. The manufacturing process for the long stator of a magnetic levitation traction linear motor according to claim 1, characterized in that, In step S100, the pretreatment operation of the electrical steel includes visual inspection, shearing, fine blanking, and deburring of the electrical steel.

5. A stacking mold for a long stator of a magnetic levitation traction linear motor, based on the manufacturing process for a long stator of a magnetic levitation traction linear motor as described in any one of claims 1-4, characterized in that... It includes a base plate and two vertical end plates and two horizontal end plates set on the top of the base plate; The two vertical end plates and the two transverse end plates enclose a receiving space on the base plate to receive electrical steel; and A toothed pressure plate is also provided on the vertical end plate, the shape of which matches the shape of the electrical steel, and is used to limit the electrical steel placed into the accommodating space.

6. The stacking mold for the long stator of a magnetic levitation traction linear motor according to claim 5, characterized in that, Multiple pre-tightening bolt holes are also formed on the toothed pressure plate; and Multiple stacked bolts are threaded onto the vertical end plate.

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