A manufacturing device and method for a rotor core of an embedded segmented skew pole permanent magnet motor

Abstract

This invention discloses a manufacturing apparatus for an embedded segmented skew-pole rotor core, comprising a base (1), a lower pressure plate (2) mounted on the base (1), a boss (20) integrally provided in the middle of the lower pressure plate (2), the inner cavity of the boss (20) being coaxially connected with the central hole of the base (1); a ring of top-lifting screws (16) uniformly installed on the lower pressure plate (2) around the outer periphery of the boss (20); a pad (3) is supported on all the top-lifting screws (16), and a pressure plate adapter groove (21) is provided in the center of the pad (3) for a rotor pressure plate (103) to pass through; the apparatus also includes a leveling template (4), a lamination pressure plate (5), a magnet assembly fixture (6), and an upper pressure plate (7). This invention is reasonably designed and has good practical application value.

Description

Technical Field

[0001] This invention belongs to the field of permanent magnet synchronous traction motor technology, and relates to the assembly of embedded segmented skewed pole permanent magnet motor rotors. Specifically, it is a special manufacturing device and method for simultaneously performing segmented skewed pole permanent magnet motor rotor core stacking, embedded magnet assembly, and rotor potting. Background Technology

[0002] Permanent magnet synchronous traction motors (PMSMs) have advantages such as simple structure, small size, light weight, and high energy efficiency, and are widely used in various fields. However, due to the cogging effect and the influence of non-sinusoidal magnetic fields, PMSMs generally have large tooth harmonics, cogging torque, and torque pulsation, which affect motor performance and generate significant vibration and noise. Therefore, this research explores the use of stator skewed slots or rotor skewed pole structures to eliminate tooth harmonics, cogging torque, and torque pulsation.

[0003] Currently, the permanent magnet synchronous motors developed by the applicant typically employ a stator skewed slot structure, while the rotor skewed pole structure is being used for the first time. For example... Figure 2 As shown, the segmented skew-pole rotor of this motor has its lamination keyways and magnet slots offset by an angle θ. During lamination stacking, the laminations are positioned by a key on the shaft and the keyways. Each pole achieves segmented skew-pole core stacking by forward and reverse lamination. The magnets have an embedded structure, requiring them to be built into the magnet slots of each pole core. After assembly, the magnets need to be sealed and fixed with sealant. Because the rotor has a skew-pole structure, the magnet slots of each core segment interfere with each other, making it impossible to assemble and seal the magnets as with a straight-slot rotor after the entire core is stacked.

[0004] The existing technical solution involves manufacturing the rotor by splitting it into several rotor core units along the axial direction. The rotor laminations adopt a snap-fit ​​structure. Each rotor core unit is first stacked into a rotor unit by the snap-fit ​​points on the laminations. Magnets are then installed in the magnet slots of each rotor core unit and sealed with sealant. Finally, all rotor core units are assembled on the shaft by forward and reverse assembly and heat fitting, thus completing the assembly of the segmented skew-pole embedded permanent magnet rotor. The existing technical solutions have the following drawbacks: First, the rotor laminations with snap-fit ​​structures have long mold manufacturing cycles and high costs, requiring significant effort and expense in prototype testing. Furthermore, they are more difficult to manufacture and have a higher scrap rate compared to laminations with ordinary structures. Second, each core unit requires a dedicated stacking fixture for stacking, making the manufacturing process cumbersome. Third, after the magnets of each core unit are assembled, when assembling them with the shaft, the lamination shaft hole and the outer diameter of the shaft are generally interference-fitted. Since the core unit is a single unit with assembled magnets, it cannot be directly pressed into the shaft using cold pressing. A hot-fitting method is required for assembly. After high-temperature heating, the magnets experience a certain degree of irreversible magnetic flux loss, and the sealant melts and leaks, affecting product performance. Summary of the Invention

[0005] The purpose of this invention is to design a dedicated assembly device for segmented skewed pole embedded permanent magnet rotors, which can quickly complete the four processes of segmented skewed pole rotor lamination, core stacking, magnet assembly, and magnet glue filling in an integrated manner, thereby shortening the operation time and improving the operation efficiency.

[0006] This invention is achieved using the following technical solution:

[0007] A manufacturing apparatus for an embedded segmented skewed pole rotor core includes a base, on which a lower pressure plate is mounted. A boss is integrally provided in the middle of the lower pressure plate, and the inner cavity of the boss is coaxially connected with the central hole of the base. A ring of top-lifting screws is uniformly installed on the lower pressure plate around the outer periphery of the boss. A pad is supported on all the top-lifting screws, and a pressure plate adapter groove is provided in the center of the pad for the rotor pressure plate on one side to pass through.

[0008] It also includes a leveling template, a stacking plate, a magnet assembly fixture, and an upper pressure plate. The leveling template is mounted on top of a pad during use. After the leveling template is secured to the boss of the lower pressure plate with fastening screws, the pad fits seamlessly with the leveling template under the support of the lifting screw below it. The stacking plate is mounted on top of the pad during use and applies downward pressure. The magnet assembly fixture is mounted on top of the pad during use and applies downward pressure. The upper pressure plate is mounted on top of the pad during use and applies downward pressure.

[0009] During assembly, a core key is mounted on the rotating shaft, and the rotor pressure plate on one side is fitted to the bottom shoulder of the rotating shaft through a heat fitting. After the bottom of the rotating shaft is inserted into the inner cavity hole of the boss on the lower pressure plate, its upper shoulder is supported and placed in the stepped groove of the boss.

[0010] A further preferred embodiment uses a hydraulic cylinder to provide pressure, with the following specific structure:

[0011] A ring of hydraulic cylinders is evenly installed around the outer perimeter of the lower pressure plate on the outer side of the boss. The pad plate has slots for placing the hydraulic cylinders. The stacked pressure plate has pull rod through holes I corresponding to the positions of the hydraulic cylinders. A pull rod passes through each pull rod through hole I, and the lower end of the pull rod connects to the corresponding hydraulic cylinder. A pressure sleeve is fitted onto the upper part of the pull rod, and a lock nut is screwed in. Similarly, the magnet assembly fixture has pull rod through holes III corresponding to the positions of the hydraulic cylinders. A pull rod passes through each pull rod through hole III, and the lower end of the pull rod connects to the corresponding hydraulic cylinder. A pressure sleeve is fitted onto the upper part of the pull rod, and a lock nut is screwed in. The upper pressure plate has pull rod through holes IV corresponding to the positions of the hydraulic cylinders. A pull rod passes through each pull rod through hole IV, and the lower end of the pull rod connects to the corresponding hydraulic cylinder. A lock nut is screwed into the upper end of the pull rod.

[0012] A further preferred embodiment uses a hydraulic press to provide the pressure, with the following specific structure:

[0013] The stacked plate has evenly spaced pull rod through holes I, and the pad has evenly spaced pull rod through holes II. Pull rods are inserted into the corresponding pull rod through holes I and II. The lower end of the pull rod is fixedly connected to the lower platen, and a pressure sleeve is fitted onto the upper part of the pull rod before a locking nut is screwed in. The base is located on the lower worktable of the hydraulic press. A pressure cylinder is placed on the stacked platen, and the upper worktable of the hydraulic press applies downward pressure to the stacked platen through the pressure cylinder before tightening the locking nut. Similarly, the magnet assembly fixture has evenly spaced pull rod through holes III, and the pad has evenly spaced pull rod through holes II. Pull rods are inserted into the corresponding pull rod through holes III and II. The lower end of the pull rod is fixedly connected to the lower platen, and a pressure sleeve is fitted onto the upper part of the pull rod before a locking nut is screwed in. The base is located on the lower worktable of the hydraulic press, and a pressure cylinder is placed on the magnet assembly fixture. The upper worktable of the hydraulic press applies downward pressure to the magnet assembly fixture through the pressure cylinder before tightening the locking nut.

[0014] The upper pressure plate has evenly spaced pull rod through holes IV, and the pad plate has evenly spaced pull rod through holes II. Pull rods are inserted into the corresponding pull rod through holes IV and II. The lower ends of the pull rods are fixedly connected to the lower pressure plate. The lower surface of the upper pressure plate has a stepped groove for placing the other rotor pressure plate. After the other rotor pressure plate is assembled on the upper part of the rotating shaft, a round nut is screwed into it through the central hole of the stepped groove. The base is located on the lower worktable of the hydraulic press. A tightening nut fixture and a pressure cylinder are placed sequentially on the upper pressure plate. After the upper worktable of the hydraulic press applies downward pressure to the upper pressure plate through the pressure cylinder, the round nut is tightened by the tightening nut fixture.

[0015] The key technical points of this invention are: simultaneous manufacturing of rotor stacking and magnet assembly with glue, stacking of skewed rotor cores with non-clamping structure laminations, vertical magnet assembly, pressure-holding magnet glue injection, determination of axial process pressure, integrated skewed rotor mechanism, skewed rotor core manufacturing, hydraulic cylinder type rotor core pressure holding mechanism, hydraulic press type rotor core pressure holding mechanism, and magnet glue injection anti-leakage mechanism.

[0016] (1) Simultaneous manufacturing of rotor stacking and magnet assembly and potting: After the three-step process of stacking, magnet assembly and magnet potting is completed for each pole core unit, the next pole core unit is manufactured. In this scheme, after the stacking of each pole core unit is completed, the magnet assembly and magnet potting are carried out simultaneously under the pressure of the core unit. The pressure of the core unit is stable before and after the magnet assembly and potting, and there is no relative displacement in the axial and circumferential directions of the core unit, which can ensure that the magnet is intact and undamaged.

[0017] (2) Stacking of skew pole rotor core with laminations without snap-fit ​​points: The core unit stacking adopts a method of stacking laminations directly on the shaft at room temperature with the help of a pneumatic stacker. The bottom is used to make the pad plate close to the core. Finally, the core teeth are pre-pressed and pressurized multiple times by the hydraulic cylinder. This ensures that the core teeth are not deformed and the core is dense. At the same time, it avoids the situation that the core and magnet need to be heated due to interference fit during the later assembly of each core unit, which would cause magnetic flux loss of the magnet and melting and loss of sealant.

[0018] (3) Vertical magnet assembly: The magnet is assembled vertically, and a magnet tensioning fixture is used at the top to tighten the bottom of the magnet from the glue-filling grooves on both sides. This prevents the magnet from being quickly sucked into the iron core during assembly and causing damage, ensuring that the magnet is assembled smoothly, slowly and completely.

[0019] (4) Pressure-holding magnet potting: In order to meet the requirement of core stacking coefficient ≥ 0.97, when potting the magnet, use a four-cylinder hydraulic cylinder (or hydraulic press) in conjunction with the magnet assembly fixture to tighten the core. Select the same pressure parameters as when stacking the plates. Potting the magnet is carried out under pressure-holding condition to ensure that the sealant does not leak out while ensuring the core stacking coefficient.

[0020] (5) Determination of axial process pressure: Under the premise of the core stacking coefficient requirement, the friction caused by the interference fit when the rotor laminations of each pole are directly assembled with the shaft, the influence of burrs between each rotor lamination, the influence of core pressure and depressurization on magnets and sealant, and the influence of the manufacturing of the next pole of the core unit on the pressure of the previous pole core unit are considered. The core pre-pressure, magnet assembly pressure, and magnet glue filling pressure are determined to ensure that the three pressures are consistent. Finally, a hydraulic cylinder with appropriate pressure is selected.

[0021] (6) Integrated manufacturing of skewed-pole rotor: The multiple tooling for the four processes of rotor lamination, core pressing, magnet assembly, and magnet potting are integrated into one unit, realizing the simultaneous manufacturing of skewed-pole rotor lamination, pressing, magnet assembly, and potting. This facilitates operation, simplifies the manufacturing process, and improves manufacturing quality. The base and lower pressure plate are connected by bolts, which provide support and fixation for the device. The tie rod holes of the lamination pressure plate and magnet assembly tooling are waist-shaped arc holes, ensuring that the tie rods can pass smoothly when the rotor laminations are stacked in both directions. The lifting screw is connected to the lower pressure plate. By adjusting the lifting screw, the pad is brought into contact with the leveling template, ensuring that the pad is fully in contact with the rotor laminations during the lamination process and preventing the sealant from leaking from the bottom of the core during magnet potting. The pressing device uses a four-cylinder hydraulic cylinder (or hydraulic press), which, together with the top nut, pressure pad, lamination pressure plate, or magnet assembly tooling, achieves uniformity and consistency in lamination pressing.

[0022] (7) Rotor core skew pole manufacturing: including lamination pressure plate and magnet assembly fixture. When manufacturing the first pole core unit, the lamination pressure plate (face up) is used in conjunction with the pneumatic stacker to stack the rotor laminations (face up) into the shaft in small quantities and multiple times. After the core is pressurized by the core pressurization and pressure holding mechanism, the magnet assembly fixture (face up) is used to hold the core pressure for magnet assembly and magnet potting. When manufacturing the second pole core unit, the rotor laminations, lamination pressure plate and magnet assembly fixture are placed with the reverse side up, and the manufacturing steps of the first pole core unit are repeated to achieve rotor core skew pole.

[0023] (8) Hydraulic cylinder type rotor core pressurization and pressure holding mechanism: The core pressurization mechanism is supported and fixed by the base and the lower pressure plate. When the core laminations are pressurized, the lamination pressure plate is used, along with the top locking nut, the pressure pad, and the one-way four-vertical hydraulic cylinder, to ensure the maximum contact area with the rotor laminations while achieving uniformity and consistency of lamination pressurization. When assembling and potting the magnets, the lamination pressure plate is replaced with the magnet assembly tooling, along with the top locking nut, the pressure pad, and the one-way four-vertical hydraulic cylinder, to complete the magnet assembly and potting under pressure holding condition, so that the core pressure remains unchanged before and after magnet assembly and before and after potting, minimizing the risk of magnet damage and sealant leakage and cracking.

[0024] (9) Hydraulic press type rotor core pressurization and pressure holding mechanism: The pressure device is changed from oil cylinder to hydraulic press. The usage method, function and effect are the same as the hydraulic cylinder type rotor core pressurization and pressure holding mechanism.

[0025] (10) Magnet glue injection anti-leakage mechanism: The magnet glue injection anti-leakage mechanism is supported and fixed by the base and the lower pressure plate. The leveling template, one side rotor pressure plate and the lower pressure plate are fastened with screws. The pad is gently lifted by the lifting screw. After it fits the leveling template without gap, the positioning nut on the lifting screw is tightened. Finally, the leveling template is removed to ensure that the pad and the rotor lamination are completely fitted to prevent the sealant from leaking from the bottom of the iron core.

[0026] A method for manufacturing an embedded segmented skew-pole rotor core based on the above device includes a core stacking scheme, a magnet assembly scheme, and a magnet potting scheme. (1) Core stacking scheme: The laminations are directly stacked into the rotor shaft using a pneumatic stacker. After each pole lamination is stacked, a four-cylinder hydraulic cylinder (or hydraulic press) is used in conjunction with the lamination pressing plate and pressure pads of different lengths to uniformly pre-press and press each pole core unit, reducing rotor lamination burrs and ensuring the core unit stacking coefficient. (2) Magnet assembly scheme: The magnet assembly adopts a vertical assembly method. After each section of iron length is inspected and qualified, the lamination pressing plate is replaced with a special magnet assembly tool. The hydraulic cylinder (or hydraulic press) is used to axially press and maintain pressure on the core unit. The magnet assembly tool is made of stainless steel and is used in conjunction with the magnet tensioning tool to ensure that the magnet can be smoothly and slowly installed into the core magnet slot, avoiding squeezing and collision that could cause magnet damage. (3) Magnet potting scheme: Before the core laminations are stacked, a tooling pad is installed at the bottom. Before potting, the baffle is pressed against the bottom rotor lamination with a lifting screw. The upper and lower end faces of the core unit are in a pressure-holding state at the same time. At this time, the magnet potting is carried out to ensure that there is no leakage of sealant. After the sealant solidifies, each pole rotor lamination and magnet can be connected into a dense whole to achieve the requirement of stacking coefficient ≥0.97.

[0027] The manufacturing method specifically includes the following steps:

[0028] 1) Assemble and connect the base, lower pressure plate, and top screw together using bolts.

[0029] 2) Assemble the iron core key onto the rotating shaft, then heat one side of the rotor pressure plate and assemble it onto the bottom shoulder of the rotating shaft, and vertically place it into the boss of the lower pressure plate.

[0030] 3) Adjust the rotating shaft in the circumferential direction so that the ventilation hole of one side rotor pressure plate is aligned with the screw hole on the end face of the lower pressure plate. Place the leveling template and use fastening screws to fasten the leveling template, one side rotor pressure plate and the lower pressure plate to the boss.

[0031] 4) After lifting the jacking screw to ensure that the pad and the leveling template are in close contact without gaps, tighten the positioning nut on the jacking screw, and finally remove the leveling template.

[0032] 5) Place 10-15 rotor laminations along the shaft with the front side of the laminations facing up, and use a pneumatic stacker to press the rotor laminations into the shaft.

[0033] 6) Continue stacking laminations to the specified height for the first pole, place the lamination pressure plate with the front side facing up, and install the pressure pad on the pull rod. After tightening the lock nut, start the oil cylinder (or oil press) to pre-press and apply pressure F. Measure the core length under pressure holding conditions.

[0034] 7) Based on the measurement results, adjust the core length (to ensure that the magnet does not bear the downward pressure applied by the next pole core after assembly, the core length must be greater than the magnet height), replace the lamination pressure plate with the magnet assembly fixture, with the front of the magnet assembly fixture facing up, and install the pressure pad on the pull rod, and tighten the lock nut; ① (representing the hydraulic cylinder type, the same below) start the hydraulic cylinder to apply pressure F and maintain the pressure. Under the pressure-maintaining state, use the magnet tensioning fixture to install the magnet into the core magnet slot; or, ② (representing the hydraulic press type, the same below) place the pressure cylinder on the magnet assembly fixture, start the hydraulic press to pre-press and apply pressure F, under the pressure-maintaining state, use a torque wrench to tighten the lock nut and then release the pressure, converting the applied pressure into the pull rod tightening torque, remove the pressure cylinder, and under the pressure-maintaining state, use the magnet tensioning fixture to install the magnet into the core magnet slot.

[0035] 8) Under pressure, after all magnets are assembled, pour the prepared sealant into the grooves on both sides of the magnets. After filling with sealant, let it stand until the sealant cures; ① Depressurize the hydraulic cylinder and remove the locking nut, pressure pad, and magnet assembly fixture; or ② Replace the pressure cylinder, start the hydraulic press to pressurize, remove the locking nut and pressure pad under pressure, then depressurize the hydraulic press, and finally remove the magnet assembly fixture; The first pole rotor core unit assembly is complete.

[0036] 9) When assembling the second pole core unit, place the rotor laminations, lamination plates, and magnet assembly fixtures with the reverse side facing up, and then perform steps 5) to 8) to achieve rotor skew poles.

[0037] 10) For subsequent core unit assembly, repeat steps 5) to 8) or step 9) according to the skew pole requirements until the entire core unit is manufactured.

[0038] 11) After placing the other rotor pressure plate on the top of the core, fit the rotating shaft and screw in the round nut. Place the upper pressure plate on the other rotor pressure plate (the other rotor pressure plate is located in the stepped groove of the upper pressure plate, and the round nut is exposed in the central hole of the stepped groove); ① Tighten the locking nut on the pre-tightening rod, start the hydraulic cylinder to apply pressure F, and use the tightening nut fixture to tighten the round nut in the pressure holding state; or, ② First place the tightening nut fixture on the upper pressure plate, then place the pressure cylinder, start the hydraulic press to apply pressure F, and use the tightening nut fixture to tighten the round nut in the pressure holding state (at this time, there is a window on the pressure cylinder for rotating the tightening nut fixture).

[0039] 12) Depressurize the hydraulic cylinder or hydraulic press, and remove the nuts and all tooling. Finally, tighten the permanent magnet baffles at both ends of the rotor to the rotor pressure plates on both sides, and the skewed pole rotor manufacturing is complete.

[0040] The assembly device and method described in this invention can meet the requirements for assembling and manufacturing skewed rotor cores, and have the following advantages:

[0041] 1. This manufacturing method can realize the manufacturing of skewed pole iron cores of rotor laminations without snap-fit ​​points, and solves the problem that magnets cannot be assembled and glued due to the obstruction of magnet slots when the skewed pole iron core cannot be manufactured into individual rotor units.

[0042] 2. This manufacturing device significantly reduces the operational difficulty of stacking, magnet assembly, and magnet potting, eliminates the need to change tooling for each step of rotor core manufacturing, and realizes simultaneous manufacturing of skewed rotor stacking, magnet assembly, and potting, thereby improving motor quality.

[0043] 3. This manufacturing device can be applied to rotor stacking, magnet assembly, and glue filling of motors with different core lengths and different numbers of skew poles in this series of motors, realizing multiple uses of one device and saving the production cycle and manufacturing cost of special tooling.

[0044] This invention is reasonably designed and has great practical application value. Attached Figure Description

[0045] Figure 1 This diagram illustrates the structure of a segmented skew-pole embedded permanent magnet rotor.

[0046] Figure 2 This is a schematic diagram of the cross-sectional profile of the magnet slot of a segmented skew-pole embedded permanent magnet rotor.

[0047] Figure 3 This is a flowchart illustrating the manufacturing process of a segmented, skew-pole embedded permanent magnet rotor.

[0048] Figure 4a A schematic diagram showing the manufacturing process of the first section of the core of an embedded segmented skew-pole permanent magnet rotor (hydraulic cylinder type).

[0049] Figure 4b express Figure 4a This diagram illustrates the completed manufacturing process of an embedded segmented skew-pole permanent magnet rotor (hydraulic cylinder type).

[0050] Figure 5a A schematic diagram showing the manufacturing process of the first section of the core of an embedded segmented skew-pole permanent magnet rotor (hydraulic press type).

[0051] Figure 5b This diagram illustrates the completed manufacturing process of an embedded segmented skew-pole permanent magnet rotor (hydraulic press type).

[0052] Figure 6 A schematic diagram of a skewed rotor lamination.

[0053] Figure 7a This diagram illustrates a structure applicable to hydraulic cylinder type pads.

[0054] Figure 7b This is a schematic diagram of a pad structure suitable for hydraulic presses.

[0055] Figure 8This is a schematic diagram of a stacked pressure plate.

[0056] Figure 9 This is a schematic diagram of the assembly fixture for magnets.

[0057] Figure 10a This diagram shows the assembly of the leveling pad (magnetic glue-filling and leak-proof mechanism).

[0058] Figure 10b This diagram shows the completed assembly of the leveling pad (magnetic glue-filling and leak-proof mechanism).

[0059] Figure 11a This diagram illustrates the hydraulic cylinder assembly of the laminated platen (used for manufacturing skewed poles of the rotor core).

[0060] Figure 11b This diagram illustrates the pressure-holding state after the hydraulic cylinder assembly of the laminated platen (used for manufacturing the skew poles of the rotor core) is completed.

[0061] Figure 12a This diagram illustrates the hydraulic cylinder assembly of a magnet assembly fixture (used for manufacturing skew poles of rotor core).

[0062] Figure 12b This diagram illustrates the pressure-holding state after the completion of the hydraulic cylinder assembly of the magnet assembly fixture (used for manufacturing the skew poles of the rotor core).

[0063] Figure 13a This diagram illustrates the hydraulic press assembly of the laminated platen (used for manufacturing skewed poles of the rotor core).

[0064] Figure 13b This diagram illustrates the pressure holding state after the lamination pressure plate (used for manufacturing rotor core skew poles) has been assembled using a hydraulic press.

[0065] Figure 14a This diagram illustrates a hydraulic press assembly tooling system for magnet assembly (used in the manufacture of rotor core skew poles).

[0066] Figure 14b This diagram illustrates the pressure holding state after the completion of the hydraulic press assembly of the magnet assembly fixture (used for manufacturing the skew poles of the rotor core).

[0067] In the diagram: 1-Base, 2-Lower pressure plate, 3-Padded plate, 4-Leveling template, 5-Layered pressure plate, 6-Magnet assembly fixture, 7-Upper pressure plate, 8-Tie rod, 9-Pressure sleeve, 10-Hydraulic cylinder, 11-Locking nut, 12-Upper worktable of hydraulic press, 13-Lower worktable of hydraulic press, 14-Pressure cylinder, 15-Tightening nut fixture, 16-Elevating screw, 17-Positioning nut, 18-Fasting screw, 19 - Pull rod through hole I, 20- convex seat, 21- pressure plate adapter groove, 22- slot, 23- pull rod through hole II, 24- pull rod through hole III; 100- segmented (pole) core unit, 101- rotating shaft, 102- core key, 103- one side rotor pressure plate, 104- shaft shoulder, 105- rotor lamination, 106- the other side rotor pressure plate, 107- round nut, 108- magnet, A- magnet groove cross-section. Among them, pull rod through hole I and pull rod through hole III are both oblong arc holes. Detailed Implementation

[0068] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0069] The permanent magnet synchronous motor rotor to be assembled and manufactured in this embodiment of the invention is as follows: Figure 1 As shown, multiple segmented iron cores are assembled on the rotating shaft 101. Each segment (pole) iron core includes several rotor laminations and magnets. Each segment (pole) iron core is formed by stacking rotor laminations with a thickness of 0.3mm. The rotor laminations are made of cold-rolled non-oriented silicon steel sheets.

[0070] This invention relates to a segmented, skew-pole embedded permanent magnet motor rotor assembly device, employing both hydraulic cylinder and hydraulic press structures, which are interchangeable. The device is simple to manufacture, constructed entirely of high-strength stainless steel, and is easy to operate. It integrates four processes: rotor lamination, core pressurization, magnet assembly, and magnet encapsulation, ensuring the rotor meets a lamination factor ≥0.97, and that the sealant is successfully injected and cured without leakage.

[0071] The segmented skewed pole embedded permanent magnet motor rotor assembly and manufacturing method described in this invention can achieve integrated operation of four processes: lamination, pressing, assembly, and glue filling of the segmented skewed pole rotor core, without using a snap-fit ​​structure for the rotor laminations and without subjecting the magnets to high-temperature heating. This shortens the operation time and improves the operation efficiency.

[0072] Example 1

[0073] A manufacturing apparatus (cylinder type) for an embedded segmented skewed pole rotor core, such as... Figure 4aAs shown, the system includes a base 1, on which a lower pressure plate 2 is mounted by screws. A boss 20 is integrally formed in the center of the lower pressure plate 2, and the inner cavity of the boss 20 is coaxially connected to the central hole of the base 1. A rotor pressure plate 103 on one side is thermally fitted onto the bottom shoulder 104 of the rotating shaft 101. After the rotating shaft 101 is vertical, its bottom is inserted into the inner cavity of the boss 20, and its upper shoulder 104 is supported by the stepped groove of the boss 20. The lower end of the rotating shaft 101 is inserted into the center of the base 1. Four lifting screws 16 (located on the same circumference) are evenly installed on the lower pressure plate 2 around the outer periphery of the boss 20; all lifting screws 16 are supported by a pad 3.

[0074] like Figure 7a As shown, the center of the pad 3 is provided with a pressure plate adapter groove 21 for the rotor pressure plate 103 on one side to pass through; the pad 3 is provided with a slot 22 for placing the oil cylinder 20 (the four slots are evenly distributed at 90 degrees).

[0075] It also includes leveling template 4 and stacking plate 5 (such as...) Figure 8 As shown), magnet assembly fixture 6 (as shown) Figure 9 (as shown) and the upper pressure plate 7.

[0076] Magnetic glue-filling and leak-proof glue mechanism, such as Figure 10a , 10b As shown, the lifting screw 16, pad 3, leveling template 4, and fastening screws 18 constitute the magnet sealing glue leak-proof mechanism. Supported and fixed by the base 1 and lower pressure plate 2, the leveling template 4 is lowered along the rotating shaft 101 and assembled above the pad 3. Four fastening screws 18 are inserted into the inner ring of the leveling template 4, passing through the ventilation holes of one side rotor pressure plate and screwed into the threaded holes on the boss 20, thus fastening one side rotor pressure plate 103 to the boss 20 of the lower pressure plate 2. The pad 3 is gently lifted by the lifting screw 16, and after the pad 3 and leveling template 4 are in close contact without gap, the positioning nut 17 on the lifting screw 16 below is tightened. Finally, the leveling template 4 is removed to ensure that the pad 3 is completely in contact with the subsequently assembled rotor laminations, thereby preventing the magnet sealant from leaking from the bottom of the iron core.

[0077] Rotor core skew pole manufacturing (pressure holding) mechanism, such as Figure 11a , 11b and Figure 12a , Figure 12b As shown, the lamination plate 5 and the magnet assembly fixture 6 are necessary components for manufacturing the rotor core skew poles. When manufacturing the first pole core unit, the lamination plate 5 (face up, as shown) is used. Figure 8 (As shown) In conjunction with the pneumatic stacker, the rotor laminations 105 (face up, as shown) are placed... Figure 6 (As shown) The plates are stacked into the rotating shaft 101 in small quantities and multiple times, and pressure is applied by the iron core pressure holding mechanism; the stacking pressure plate 5 is replaced with the magnet assembly fixture 6 (face up, as shown). Figure 9As shown), the core is pressurized and held again by the core pressurization and holding mechanism. Under the core pressure holding state, the magnets are assembled and glued. When manufacturing the second pole core unit, the rotor lamination 105, lamination plate 5, and magnet assembly fixture 6 are placed with their reverse sides facing up. The manufacturing steps of the first pole core unit are repeated to achieve the magnetic pole deflection of the rotor core.

[0078] like Figure 11a , 11b As shown, the hydraulic cylinder 10, pull rod 8, stacked plate 5, pressure sleeve 9, and locking nut 11 constitute a hydraulic cylinder-type iron core pressure-pressurizing and pressure-maintaining mechanism. The stacked plate 5 is mounted above the pad 3 during use, and downward pressure is applied to the stacked plate 5. This pressure is provided by a hydraulic cylinder, which is a one-way four-vertical type. Four hydraulic cylinders 10 (located on the same circumference) are evenly installed on the lower pressure plate 2 around the outer periphery of the boss 20. The upper part of each hydraulic cylinder 10 is fitted into the slot 22 of the pad 3. Four pull rod through holes I19 (elliptical holes) are provided on the stacked plate 5 corresponding to the positions of the hydraulic cylinders. A pull rod 8 passes through each pull rod through hole I19, and the lower end of the pull rod 8 is connected to the corresponding hydraulic cylinder 10. After the pressure sleeve 9 is fitted onto the upper part of the pull rod 8, the locking nut 11 is screwed in. Supported and fixed by base 1 and lower pressure plate 2, when the core laminations are pressurized, lamination pressure plate 5 is placed on the upper part of rotor lamination 105, and pressure pad 9 is placed in tie rod 8. Locking nut 11 is tightened, and one-way four-vertical cylinder 10 is started to complete the pressurization, ensuring the maximum contact area with rotor lamination 105 while achieving uniformity and consistency of lamination pressurization.

[0079] Figure 12a , Figure 12b As shown, the hydraulic cylinder 10, pull rod 8, magnet assembly fixture 6, pressure pad 9, and locking nut 11 constitute a hydraulic cylinder-type iron core pressure-pressurizing and pressure-holding mechanism. During use, the magnet assembly fixture 6 is mounted above the pad 3, and downward pressure is applied to it, also provided by the hydraulic cylinder. The magnet assembly fixture 6 has pull rod through holes III 24 corresponding to the hydraulic cylinder positions. A pull rod 8 passes through each pull rod through hole III 24, and the lower end of the pull rod 8 is connected to the corresponding hydraulic cylinder 10. The upper part of the pull rod 8 is fitted with a pressure sleeve 9, and then the locking nut 11 is screwed in. Before magnet assembly, the stacked pressure plate 5 is replaced with the magnet assembly fixture 6, and the hydraulic cylinder 10 pressure operation is repeated. Magnet assembly and magnet glue injection are completed under pressure-holding conditions. After the sealant cures, the hydraulic cylinder 10 is depressurized, and the locking nut 11, pressure pad 9, and magnet assembly fixture 6 are removed. This pressure-pressurizing and pressure-holding mechanism can ensure that the core pressure remains constant before and after magnet assembly and sealant application, minimizing the risk of magnet damage and sealant leakage and cracking.

[0080] After the multi-pole core unit is fabricated, it is finally assembled using the upper pressure plate 7. For example... Figure 4bAs shown, the upper pressure plate 7 is assembled above the pad 3 during use, and downward pressure is applied to the upper pressure plate 7. A pull rod through hole IV is provided on the upper pressure plate 7 corresponding to the position of the hydraulic cylinder. A pull rod 8 passes through each pull rod through hole IV, and the lower end of the pull rod 8 is connected to the corresponding hydraulic cylinder 10. The upper end of the pull rod 8 is screwed into a locking nut 11. The lower surface of the upper pressure plate 7 has a stepped groove for placing the other rotor pressure plate 106. After the other rotor pressure plate 106 is assembled on the upper part of the rotating shaft 101, a round nut 107 is screwed into it through the central hole of the stepped groove. The hydraulic cylinder 10 pressurization operation is repeated. Under pressure holding conditions, the round nut 107 is tightened by the tightening nut fixture 15.

[0081] Using the aforementioned manufacturing apparatus, a specific manufacturing method for an embedded segmented skew-pole rotor core is described, as follows: Figure 3 As shown, the assembly process involves directly stacking laminations on the rotating shaft. Each core unit is stacked, pressurized, and then its length is checked. After passing the checks, magnets are assembled and sealed with sealant under pressure. The next (pole) core unit is then manufactured after the sealant has cured, until the entire core is complete. This process includes the following steps:

[0082] 1) Assemble and connect the base 1, the lower pressure plate 2, and the top screw 16 together with bolts.

[0083] 2) Assemble the core key 102 onto the rotating shaft 101, and then assemble one side rotor pressure plate 103 onto the shaft shoulder 104 of the rotating shaft 101 by heat fitting, and then vertically place it into the boss 20 of the lower pressure plate 2.

[0084] 3) Adjust the rotating shaft 101 in the circumferential direction so that the ventilation hole of the rotor pressure plate 103 on one side is aligned with the screw hole on the end face of the boss 20 of the lower pressure plate 2. Place the leveling template 4 and use the fastening screws 18 to fasten the leveling template 4, the rotor pressure plate 103 on one side and the boss 20 of the lower pressure plate 2.

[0085] 4) Use an adjustable wrench to gently lift the jacking screw 16, ensuring that the pad 3 and the leveling template 4 fit together without gaps. Then tighten the positioning nut 17 on the jacking screw 16 and finally remove the leveling template 4.

[0086] 5) Place rotor laminations 105 along the shaft 101, placing a small number of rotor laminations 105 with the front side facing up each time, and use the pneumatic stacker multiple times to press the rotor laminations 105 into the shaft 101.

[0087] 6) Continue stacking the laminations to the specified height of the first pole, place the lamination pressure plate 5 (face up), and install the pressure pad 9 on the pull rod 8. After tightening the locking nut 11, start the oil cylinder 10 to pre-pressurize and apply pressure F. Under pressure holding conditions, use a digital caliper to measure the core length at the L position marked in Figure 4a. This L area avoids the influence of the strong magnet generated by the magnet on the accuracy of the electronic equipment, which can ensure the accurate measurement of the core length.

[0088] 7) Based on the measurement results, adjust the core length (to ensure that the magnet does not bear the downward pressure applied by the next pole core after the magnet is assembled, the core length must be greater than the magnet height), replace the lamination pressure plate 5 with the magnet assembly fixture 6, with the front of the magnet assembly fixture 6 facing up, and install the pressure pad 9 on the pull rod 8. After tightening the locking nut 11, start the oil cylinder 10 to apply pressure F and maintain the pressure. Under the pressure-maintaining state, use the magnet tensioning fixture to slowly and smoothly install the magnet into the core magnet slot.

[0089] 8) Under pressure, after all magnets are assembled, pour the prepared sealant into the grooves on both sides of magnet 108. After filling with sealant, let it stand until the sealant cures. Then, release the pressure from cylinder 10 and remove locking nut 11, pressure pad 9, and magnet assembly fixture 6. The first pole rotor unit assembly is complete.

[0090] 9) When assembling the second pole core unit, place the rotor lamination 105, lamination plate 5, and magnet assembly fixture 6 with the reverse side facing up, and then perform steps 5) to 8) to achieve rotor skew poles.

[0091] 10) For subsequent core unit assembly, repeat steps 5) to 8) or step 9) according to the skew pole requirements until the entire core unit is manufactured.

[0092] Note: When preparing rotor core units with different poles, select pressure pads of different lengths.

[0093] 11) For example Figure 4b As shown, after placing the other side rotor pressure plate 106 on the top of the core, the round nut 107 is fitted into the rotating shaft 101. The upper pressure plate 7 is placed on the other side rotor pressure plate, the locking nut 11 on the pre-tightening rod is tightened, the oil cylinder 10 is started to apply pressure F, and the round nut 107 is tightened using the tightening nut fixture 15 under the pressure holding state.

[0094] 12) Depressurize cylinder 10, remove nuts and all tooling. Finally, tighten the permanent magnet baffles at both ends of the rotor to the rotor pressure plates on both sides, and the skewed pole rotor manufacturing is complete.

[0095] Example 2

[0096] A manufacturing apparatus (hydraulic press type) for an embedded segmented skewed pole rotor core, such as... Figure 5aAs shown, the system includes a base 1, on which a lower pressure plate 2 is mounted by screws. A boss 20 is integrally formed in the center of the lower pressure plate 2, and the inner cavity of the boss 20 is coaxially connected to the central hole of the base 1. A rotor pressure plate 103 on one side is fitted to the bottom shoulder 104 of the rotating shaft 101 via a heat-shrink fitting. After the rotating shaft 101 is vertical, its bottom is inserted into the inner cavity of the boss 20, and its upper shoulder 104 is supported by the stepped groove of the boss 20. The lower end of the rotating shaft 101 is inserted into the center of the base 1. Four lifting screws 16 (located on the same circumference) are evenly installed on the lower pressure plate 2 around the outer periphery of the boss 20; all lifting screws 16 are supported by a pad 3.

[0097] like Figure 7b As shown, the center of the pad 3 has a pressure plate adapter groove 21 for the rotor pressure plate 103 on one side to pass through; the pad 3 has four through holes II 23 for the tie rod 8 to pass through (distributed at 90 degrees).

[0098] It also includes leveling template 4 and stacking plate 5 (such as...) Figure 8 As shown), magnet assembly fixture 6 (as shown) Figure 9 (as shown) and the upper pressure plate 7.

[0099] The magnetic glue-filling and leak-proof mechanism is similar to... Figure 10a , 10b As shown (only the pad structure is different, using as follows) Figure 7b The following components constitute the magnet sealing glue anti-leakage mechanism: pad 1), lifting screw 16, pad 3, leveling template 4, and fastening screws 18. Supported and fixed by base 1 and lower pressure plate 2, the leveling template 4 is lowered along the rotating shaft 101 and assembled above the pad 3. Four fastening screws 18 are inserted into the inner ring of the leveling template 4, passing through the ventilation holes of one side rotor pressure plate and screwed into the threaded holes of the boss 20, thus fastening one side rotor pressure plate 103 to the boss 20 of the lower pressure plate 2. The pad 3 is gently lifted by the lifting screw 16, and after the pad 3 and leveling template 4 are in close contact without gap, the positioning nut 17 on the lifting screw 16 below is tightened. Finally, the leveling template 4 is removed to ensure that the pad 3 is completely in contact with the subsequently assembled rotor laminations, thereby preventing the magnet sealant from leaking from the bottom of the iron core.

[0100] Rotor core skew pole manufacturing (pressure holding) mechanism, such as Figure 13a , 13b and Figure 14a , Figure 14b As shown, the lamination plate 5 and the magnet assembly fixture 6 are necessary components for manufacturing the rotor core skew poles. When manufacturing the first pole core unit, the lamination plate 5 (face up, as shown) is used. Figure 8 (As shown) In conjunction with the pneumatic stacker, the rotor laminations 105 (face up, as shown) are placed... Figure 6(As shown) The plates are stacked into the rotating shaft 101 in small quantities and multiple times, and pressure is applied by the iron core pressure holding mechanism; the stacking pressure plate 5 is replaced with the magnet assembly fixture 6 (face up, as shown). Figure 9 As shown), the core is pressurized and held again by the core pressurization and holding mechanism. Under the core pressure holding state, the magnets are assembled and glued. When manufacturing the second pole core unit, the rotor lamination 105, lamination plate 5, and magnet assembly fixture 6 are placed with their reverse sides facing up. The manufacturing steps of the first pole core unit are repeated to achieve the magnetic pole deflection of the rotor core.

[0101] like Figure 13a , 13b As shown, the tie rod 8, the stacked pressure plate 5, the pressure sleeve 9, the locking nut 11, and the pressure cylinder 14 constitute a hydraulic press-type iron core pressure-pressuring and pressure-maintaining mechanism. During use, the stacked pressure plate 5 is assembled above the pad 3, and downward pressure is applied to the stacked pressure plate 5, provided by a hydraulic press. Tie rod through holes I 19 are evenly distributed on the stacked pressure plate 5, and tie rod through holes II 23 are evenly distributed on the pad 3. Tie rods 8 are inserted into the corresponding tie rod through holes I 19 and II 23. The lower end of the tie rod 8 is fixedly connected to the lower pressure plate 2, and the upper part of the tie rod 8 is fitted with the pressure sleeve 9 and then screwed into the locking nut 11. Figure 5a As shown, the base 1 is located on the lower worktable 13 of the hydraulic press, and the pressure cylinder 14 is placed on the lamination plate 5. The upper worktable 12 of the hydraulic press applies downward pressure to the lamination plate 5 through the pressure cylinder 14, and then the locking nut 11 is tightened. With the base 1 and the lower pressure plate 2 for support and fixation, when the core laminations are pressurized, the lamination plate 5 and the pressure cylinder 14 are placed on the upper part of the rotor laminations 105, and the hydraulic press is started to complete the pressurization. This ensures the maximum contact area with the rotor laminations 108 while achieving uniformity and consistency in the lamination pressurization.

[0102] Figure 14a , Figure 14b As shown, the pull rod 8, magnet assembly fixture 6, pressure pad 9, locking nut 11, and pressure cylinder 14 constitute a hydraulic press-type iron core pressure-pressurizing and pressure-maintaining mechanism. During use, the magnet assembly fixture 6 is mounted above the pad 3, and downward pressure is applied to it, also provided by a hydraulic press. The magnet assembly fixture 6 has evenly spaced pull rod through holes III 24, and the pad 3 has evenly spaced pull rod through holes II 23. Pull rods 8 are inserted into the corresponding pull rod through holes III 24 and II 23. The lower end of the pull rod 8 is fixedly connected to the lower pressure plate 2, and the upper part of the pull rod 8 is fitted with the pressure sleeve 9 and then screwed into the locking nut 11. Figure 5aAs shown, base 1 is located on the lower worktable 13 of the hydraulic press. A pressure cylinder 14 is placed on the magnet assembly fixture 6. The upper worktable 12 of the hydraulic press applies downward pressure to the magnet assembly fixture 6 through the pressure cylinder 14, and then tightens the locking nut 11. Before magnet assembly, the stacked pressure plate 5 is replaced with the magnet assembly fixture 6. A pressure pad 9 is placed in the pull rod 8. The hydraulic press is started to apply pressure and maintain pressure. Under pressure maintenance, a torque wrench is used to tighten the locking nut 11, and then the hydraulic press is depressurized, converting the applied pressure into a pull rod tightening torque. The pressure cylinder 14 is removed, and the magnet assembly and magnet encapsulation are completed under the tightened pull rod condition. After the sealant has cured, the pressure cylinder 14 is placed back in the hydraulic press, and the hydraulic press is started to apply pressure. Under pressure maintenance, the locking nut 11 and pressure pad 9 are removed, then the hydraulic press is depressurized, and finally the magnet assembly fixture 6 is removed. This pressure-pressurizing and pressure-holding mechanism can ensure that the core pressure remains constant before and after magnet assembly and sealant application, minimizing the risk of magnet damage and sealant leakage and cracking.

[0103] After the multi-pole core unit is fabricated, it is finally assembled using the upper pressure plate 7. For example... Figure 5b As shown, the upper pressure plate 7 is assembled above the pad 3 during use, and downward pressure is applied to the upper pressure plate 7, which is also provided by a hydraulic press. The upper pressure plate 7 has evenly spaced pull rod through holes IV, and the pad 3 has evenly spaced pull rod through holes II 23. Pull rods 8 are inserted into the corresponding pull rod through holes IV and II 23. The lower end of the pull rod 8 is fixedly connected to the lower pressure plate 2 (at this time, the upper end of the pull rod 8 does not need to be tightened with the locking nut 11, and the pressure is provided by the hydraulic press). The base 1 is located on the lower worktable 13 of the hydraulic press, and the upper worktable 12 of the hydraulic press applies downward pressure to the upper pressure plate 7 through the pressure cylinder 14. The lower surface of the upper pressure plate 7 is provided with a stepped groove for placing the other rotor pressure plate 106. After the other rotor pressure plate 106 is assembled on the upper part of the rotating shaft 101, the round nut 107 is screwed into it through the central hole of the stepped groove. First, the tightening nut fixture 15 is placed on the upper pressure plate 7, and then the pressure cylinder 14 is placed (the tightening nut fixture is located inside the pressure cylinder, and the tightening nut fixture is rotated through the window opened on the pressure cylinder). The hydraulic press is started to pressurize and maintain pressure. Under the pressure-maintaining state, the round nut 107 is tightened by the tightening nut fixture 15.

[0104] Using the aforementioned manufacturing apparatus, a specific manufacturing method for an embedded segmented skew-pole rotor core is described, as follows: Figure 3 As shown, the assembly process involves directly stacking laminations on the rotating shaft. Each core unit is stacked, pressurized, and then its length is checked. If it passes the test, the magnets are assembled and sealed with sealant under pressure. After the sealant cures, the next core unit is manufactured, and this process continues until the entire core is complete. The process includes the following steps:

[0105] 1) Assemble and connect the base 1, the lower pressure plate 2, and the top screw 16 together with bolts.

[0106] 2) Assemble the core key 102 onto the rotating shaft 101, and then assemble one side rotor pressure plate 103 onto the shaft shoulder 104 of the rotating shaft 101 by heat fitting, and then vertically place it into the boss 20 of the lower pressure plate 2.

[0107] 3) Adjust the rotating shaft 101 in the circumferential direction so that the ventilation hole of the rotor pressure plate 103 on one side is aligned with the screw hole on the end face of the boss 20 of the lower pressure plate 2. Place the leveling template 4 and use the fastening screws 18 to fasten the leveling template 4, the rotor pressure plate 103 on one side and the boss 20 of the lower pressure plate 2.

[0108] 4) After lifting the jacking screw 16, ensure that the pad 3 and the leveling template 4 are in close contact without gaps, tighten the positioning nut 17 on the jacking screw 16, and finally remove the leveling template 4.

[0109] 5) Place the rotor lamination 105 along the shaft 101 with the front side of the rotor lamination 105 facing up, and use a pneumatic press to press the rotor lamination 105 into the shaft 101.

[0110] 6) Continue stacking the laminations to the specified height of the first pole, place the lamination pressure plate 5 with the front side facing up, and install the pressure pad 9 on the pull rod 8. After tightening the locking nut 11, place the pressure cylinder 14 on the lamination pressure plate 5, start the hydraulic press to pre-press and apply pressure F, and measure the core length under pressure holding conditions.

[0111] 7) Based on the measurement results, adjust the core length (to ensure that the magnet does not bear the downward pressure applied by the next pole core after assembly, the core length must be greater than the magnet height), replace the lamination pressure plate 5 with the magnet assembly fixture 6, with the front of the magnet assembly fixture 6 facing upwards, and install the pressure pad 9 on the pull rod 8. After tightening the locking nut 11, place the pressure cylinder 14 on the magnet assembly fixture 6, start the hydraulic press for pre-pressurization and pressure F, and use a torque wrench to tighten the locking nut 11 under pressure holding conditions, then release the pressure to convert the pressure into the pull rod tightening torque. Remove the pressure cylinder 14, and use the magnet tensioning fixture under pressure holding conditions to slowly and smoothly install the magnet into the core magnet slot.

[0112] 8) Under pressure, after all magnets are assembled, pour the prepared sealant into the grooves on both sides of magnet 108. After filling with sealant, let it stand until the sealant cures. Then, put the pressure cylinder 14 back in, start the hydraulic press to pressurize, remove the locking nut 11 and pressure pad 9 under pressure, then release the pressure from the hydraulic press, and finally remove the magnet assembly fixture 6; the first pole rotor core unit assembly is complete.

[0113] 9) When assembling the second pole core unit, place the rotor lamination 105, lamination plate 5, and magnet assembly fixture 6 with the reverse side facing up, and then perform steps 5) to 8) to achieve rotor skew poles.

[0114] 10) For subsequent core unit assembly, repeat steps 5) to 8) or step 9) according to the skew pole requirements until the entire rotor core is manufactured.

[0115] Note: When preparing rotor core units with different poles, select pressure pads and pressure cylinders of different lengths.

[0116] 11) After placing the rotor pressure plate 106 on the top of the core, fit the round nut 107 into the rotating shaft 101. Place the tightening nut fixture 15 and the pressure cylinder 14 on the upper pressure plate 7 in sequence. Start the hydraulic press to apply pressure F. Under pressure holding conditions, use the tightening nut fixture 15 to tighten the round nut 107.

[0117] 12) Depressurize the hydraulic press and remove all tooling; tighten the permanent magnet baffles at both ends of the rotor with the rotor pressure plates on both sides, and the skewed pole rotor is manufactured.

[0118] The segmented skewed pole embedded permanent magnet rotor assembly described in this invention is one of the key processes in the manufacturing of high-speed permanent magnet synchronous traction motors. Applied to the production and manufacturing of this type of motor, the segmented skewed pole embedded permanent magnet motor rotor assembly manufacturing device and method can realize and quickly complete the four processes of rotor core lamination, pressurization, magnet assembly, and magnet glue potting in an integrated manner, thereby improving work efficiency, reducing costs and manufacturing cycle, and improving motor quality and performance.

[0119] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the embodiments of the present invention have been described in detail, those skilled in the art should understand that modifications or equivalent substitutions to the technical solutions of the present invention do not depart from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of protection of the claims of the present invention.

Claims

1. A manufacturing apparatus for an embedded segmented skewed pole rotor core, comprising a base (1), characterized in that: A lower pressure plate (2) is installed on the base (1). A boss (20) is integrally provided in the middle of the lower pressure plate (2). The inner cavity of the boss (20) is coaxially connected with the central hole of the base (1). A ring of top-lifting screws (16) is evenly installed on the lower pressure plate (2) around the outer periphery of the boss (20). A pad (3) is supported on all the top-lifting screws (16). A pressure plate adapter groove (21) for the rotor pressure plate (103) on one side to pass through is opened in the center of the pad (3). It also includes a leveling template (4), a stacking plate (5), a magnet assembly fixture (6), and an upper plate (7); When in use, the leveling template (4) is mounted on top of the pad (3). After the leveling template (4) is fastened to the convex seat (20) of the lower pressure plate (2) by fastening screws (18), the pad (3) fits against the leveling template (4) without gap under the support of the lifting screw (16) below it. The stacked pressure plate (5) is assembled above the pad plate (3) during use, and downward pressure is applied to the stacked pressure plate (5); The magnet assembly fixture (6) is assembled above the pad (3) during use, and downward pressure is applied to the magnet assembly fixture (6); The upper pressure plate (7) is assembled above the pad (3) during use, and downward pressure is applied to the upper pressure plate (7); The rotor pressure plate (103) on one side is thermally fitted to the shoulder (104) at the bottom of the rotating shaft (100). After the bottom of the rotating shaft (101) is inserted into the inner cavity of the boss (20), its upper shoulder (104) is supported and placed in the stepped groove of the boss (20). The pressure is provided by a hydraulic cylinder; a ring of hydraulic cylinders (10) is evenly installed on the lower pressure plate (2) around the outer periphery of the boss (20), and a slot (22) for placing the hydraulic cylinders (10) is provided on the pad plate (3); The stacked pressure plate (5) has a pull rod through hole I (19) corresponding to the position of the oil cylinder. A pull rod (8) passes through each pull rod through hole I (19). The lower end of the pull rod (8) is connected to the corresponding oil cylinder (10). A pressure sleeve (9) is fitted on the upper part of the pull rod (8) and then a lock nut (11) is screwed in. Similarly, the magnet assembly fixture (6) has a pull rod through hole III (24) corresponding to the position of the oil cylinder. A pull rod (8) passes through each pull rod through hole III (24). The lower end of the pull rod (8) is connected to the corresponding oil cylinder (10). A pressure sleeve (9) is fitted on the upper part of the pull rod (8) and then a lock nut (11) is screwed in. Alternatively, pressure can be provided using a hydraulic press; The stacked platen (5) is evenly provided with pull rod through holes I (19), and the pad plate (3) is evenly provided with pull rod through holes II (23). Pull rods (8) are inserted into the corresponding pull rod through holes I (19) and pull rod through holes II (23). The lower end of the pull rod (8) is fixedly connected to the lower platen (2). After the upper part of the pull rod (8) is fitted with a pressure sleeve (9), a locking nut (11) is screwed in. The base (1) is located on the lower worktable (13) of the hydraulic press. A pressure cylinder (14) is placed on the stacked platen (5). The upper worktable (12) of the hydraulic press applies downward pressure to the stacked platen (5) through the pressure cylinder (14) and then tightens the locking nut (11). Similarly, the magnet assembly fixture (6) is provided with pull rod through holes III (24) evenly, and the pad plate (3) is provided with pull rod through holes II (23) evenly. Pull rods (8) are inserted into the corresponding pull rod through holes III (24) and pull rod through holes II (23). The lower end of the pull rod (8) is fixedly connected to the lower pressure plate (2). After the upper part of the pull rod (8) is fitted with a pressure sleeve (9), a locking nut (11) is screwed in. The base (1) is located on the lower worktable (13) of the hydraulic press. A pressure cylinder (14) is placed on the magnet assembly fixture (6). The upper worktable (12) of the hydraulic press applies downward pressure to the magnet assembly fixture (6) through the pressure cylinder (14) and then tightens the locking nut (11).

2. The manufacturing apparatus for an embedded segmented skewed pole rotor core according to claim 1, characterized in that: The lower surface of the upper pressure plate (7) is provided with a stepped groove for placing the other side rotor pressure plate (106). After the other side rotor pressure plate (106) is assembled on the upper part of the rotating shaft (101), a round nut (107) is screwed into it through the central hole of the stepped groove. The round nut (107) is tightened by the tightening nut tool (15).

3. The manufacturing apparatus for an embedded segmented skewed pole rotor core according to claim 1, characterized in that: Four hydraulic cylinders (10) are evenly installed on the lower pressure plate (2) around the outer periphery of the boss (20). The hydraulic cylinders are one-way four-vertical type hydraulic cylinders.

4. A method for manufacturing an embedded segmented skewed pole rotor core, characterized in that: Includes the following steps: 1) Assemble and connect the base (1), the lower pressure plate (2), and the lifting screw (16) together with bolts; 2) Assemble the core key (102) onto the rotating shaft (101), and then fit the rotor pressure plate (103) on one side onto the bottom shoulder (104) of the rotating shaft (101) through a heat fitting, and then vertically place it into the boss (20) of the lower pressure plate (2); 3) Adjust the rotating shaft (101) in the circumferential direction so that the ventilation hole of the rotor pressure plate (103) on one side is aligned with the screw hole on the end face of the boss (20) of the lower pressure plate (2). Place the leveling template (4) and use the fastening screws (18) to fasten the leveling template (4), the rotor pressure plate (103) on one side and the boss (20) of the lower pressure plate (2); 4) After lifting the jacking screw (16), ensure that the pad (3) and the leveling template (4) fit together without gap, tighten the positioning nut (17) on the jacking screw (16), and finally remove the leveling template (4). 5) Place the rotor laminations (105) along the shaft (101) with the front of the rotor laminations (105) facing up, and use a pneumatic press to press the rotor laminations (105) into the shaft (101); 6) Continue stacking the laminations to the specified height of the first pole, place the lamination pressure plate (5) with the front side facing up, and put the pressure pad (9) on the pull rod (8). After tightening the locking nut (11), start the oil cylinder (10) to pre-press and apply pressure F. Measure the core length under the pressure holding state. 7) Based on the measurement results, adjust the core length. The core length is greater than the magnet height. Replace the stacked plate (5) with the magnet assembly fixture (6). The magnet assembly fixture (6) is facing up. Put the pressure pad (9) on the pull rod (8). After tightening the locking nut (11), start the oil cylinder (10) to apply pressure F and maintain the pressure. Under the pressure-maintaining state, use the magnet tensioning fixture to put the magnet into the core magnet slot. 8) Under pressure, after all magnets are assembled, pour the prepared sealant into the grooves on both sides of the magnet (108), let it stand until the sealant is cured, release the pressure of the oil cylinder (10), and remove the locking nut (11), pressure pad (9), and magnet assembly fixture (6); the first pole rotor unit is assembled. 9) When assembling the second pole core unit, place the rotor laminations (105), lamination plate (5), and magnet assembly fixture (6) with the reverse side facing up, and perform steps 5) to 8) for the rest to achieve rotor skew poles; 10) For subsequent core unit assembly, repeat steps 5) to 8) or step 9) according to the skew pole requirements until the entire core unit is manufactured. 11) After placing the rotor pressure plate (106) on the top of the core, put the round nut (107) into the shaft (101), start the oil cylinder (10) to apply pressure F, and use the tightening nut fixture (15) to tighten the round nut (107) under the pressure holding state. 12) Depressurize the oil cylinder (10), remove the nuts and all tooling, and tighten the rotor permanent magnet baffles at both ends and the rotor pressure plates on both sides. The skew pole rotor is now manufactured.

5. A method for manufacturing an embedded segmented skewed-pole rotor core according to claim 4, characterized in that: The pressure provided by the hydraulic cylinder is replaced by that provided by the hydraulic press.

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