A method for processing a motor rotor for a flywheel energy storage

Abstract

The application provides a motor rotor processing method for flywheel energy storage, and steps are as follows: a compensation cylinder and a split expansion sleeve are obtained respectively; the split expansion sleeve is sleeved on a mandrel, the compensation cylinder is sleeved outside the split expansion sleeve, and a compression assembly is sleeved on both ends of the mandrel, so that the compensation cylinder and the process expansion sleeve are limited between the compression assemblies on both ends of the mandrel; a tightening nut is used to push the compression assemblies on both ends to compress the expansion sleeve, and then the compensation cylinder is supported by the expansion sleeve; a magnetic steel positioning framework with a specific size is processed on the compensation cylinder; the magnetic steel is assembled on the positioning framework; a composite flywheel body meeting index requirements is wound on the magnetic steel; and the expansion sleeve, the mandrel, the compression assembly and the tightening nut are removed, so that a required motor rotor assembly is obtained. The application ensures accurate positioning of the magnetic steel in the circumferential and axial directions, reduces structural deformation in the whole processing, and ensures reliable demolding of the composite wheel body after winding.

Description

Technical Field

[0001] This application relates to the field of motor rotor processing technology, and more specifically, to a method for processing motor rotors for flywheel energy storage. Background Technology

[0002] Flywheel energy storage is a mechanical energy storage technology. The flywheel itself is the core component of the flywheel energy storage system. Its function is to increase the rotor's limiting angular velocity, reduce the rotor's weight, and maximize the energy storage capacity of the flywheel energy storage system.

[0003] To achieve a lightweight design, two types of motor rotor assemblies need to be designed with a common rotor structure. However, due to the large number of magnet blocks, if they cannot be accurately positioned during assembly, it will not only increase the difficulty of magnet assembly, but also cause unevenness on the magnet surface, affecting the winding quality of the subsequent composite flywheel body. Summary of the Invention

[0004] In view of the above problems, this application provides a method for machining a motor rotor for flywheel energy storage, which involves machining an annular frame on the surface of a compensating cylinder to ensure accurate positioning of the magnets in the circumferential and axial directions.

[0005] To achieve the above objectives, the embodiments of this application provide the following technical solutions:

[0006] A method for machining a motor rotor for flywheel energy storage, comprising the following steps:

[0007] Obtain the compensation cylinder and the separate expansion sleeve respectively;

[0008] The split expansion sleeve is fitted onto the mandrel, and the compensation cylinder is fitted onto the outside of the split expansion sleeve. Clamping components are fitted onto both ends of the mandrel so that the compensation cylinder and the expansion sleeve are limited between the clamping components at both ends of the mandrel.

[0009] Tighten the nuts to push the clamping components at both ends to press the expansion sleeve against the expansion sleeve, thereby supporting the compensation cylinder through the expansion sleeve;

[0010] A magnetic steel positioning frame of a specific size is machined on the compensation cylinder;

[0011] Magnets are mounted on the positioning frame;

[0012] A composite material flywheel body meeting the specified requirements is wound onto a magnet;

[0013] Remove the expansion sleeve, spindle, clamping assembly, and tighten the nut to obtain the required motor rotor assembly.

[0014] The method for machining a motor rotor for flywheel energy storage in this application adopts a scheme of machining an annular skeleton on the surface of the compensating cylinder to ensure accurate positioning of the magnets in the circumferential and axial directions. Addressing the technical challenges of thin-walled long aluminum components being prone to deformation and the compensating cylinder assembly being prone to deformation due to preload when winding the composite material wheel body, the method in this application is based on a mandrel support and separate demolding process, which reduces structural deformation during the entire machining process and ensures reliable demolding of the composite material wheel body after winding.

[0015] As an improvement to the shape of the expansion sleeve end face in the above steps of this application, the inner side of the upper and lower end faces of the split expansion sleeve is formed into an expansion sleeve conical surface. In this improvement, by setting the inner side of the end face as a conical surface, it is beneficial for the clamping assembly to slowly and evenly apply force to the expansion sleeve along the conical surface, which is beneficial for evenly tightening the expansion sleeve, and thus beneficial for using the clamping assembly to evenly and stably support the compensation cylinder.

[0016] As an improvement to the clamping assembly in the above steps of this application, the clamping assembly includes: a clamping member having a top-pressing surface and a clamping surface; the top-pressing surface includes a conical surface and a flat surface, the conical surface being able to mate with the expansion sleeve conical surface formed by the end faces of the two ends of the expansion sleeve near the inner side; the flat surface being able to mate with the bottom surface of the compensation cylinder and the expansion sleeve; the clamping surface is the outer top surface of the clamping member, which is able to mate with the bottom surface of the tightening nut. In this improvement, the conical surface being able to mate with the expansion sleeve conical surface formed by the end faces of the two ends of the expansion sleeve near the inner side allows the clamping member to smoothly press the expansion sleeve against it, thereby stably supporting the compensation cylinder through the expansion sleeve; the flat surface being able to mate with the bottom surface of the compensation cylinder and the expansion sleeve allows the clamping member to limit the end faces of the compensation cylinder and the expansion sleeve. The clamping surface is the outer top surface of the clamping member, which allows the tightening nut to tighten the clamping assembly, ultimately clamping the compensation cylinder and the expansion sleeve.

[0017] As one embodiment of the steps described above in this application, the diameter of the cylindrical cavity formed by the inner side of the split expansion sleeve is larger than the diameter of the mandrel cylinder. This design ensures that the expansion sleeve is outside the mandrel, and under the pressure of the clamping assembly, the increased diameter of the cylindrical cavity formed by the inner side of the expansion sleeve supports the compensation cylinder.

[0018] As an improvement to the above steps in this application, the clamping assembly further includes: limiting members located on the upper and lower surfaces of the compensation cylinder, respectively, and on the outside of the expansion sleeve. This design allows for individual limiting of the compensation cylinder.

[0019] As an improvement to the connection method between the limiting member and the compensation cylinder in the above steps of this application, the limiting member and the compensation cylinder are connected by an insertion fit.

[0020] As a further improvement to the connection method between the limiting member and the compensation cylinder in the above steps of this application, the side of the limiting member that contacts the compensation cylinder is provided with a protrusion or groove, and the top surface of the compensation cylinder is provided with a groove or protrusion that corresponds to the position of the protrusion or groove.

[0021] Furthermore, the radius of the limiting component is set such that the flywheel body can be limited within the limiting component.

[0022] This application also provides a lightweight motor rotor assembly, obtained by the above-described processing method, comprising a CPA rotor, a high-speed drive motor rotor, and a compensating cylinder, wherein the CPA rotor and the high-speed drive motor rotor share the compensating cylinder.

[0023] The beneficial effects of this application are as follows:

[0024] To achieve a lightweight design, this application discloses a lightweight motor rotor assembly, including a CPA rotor, a high-speed drive motor rotor, and a compensating cylinder, wherein the CPA rotor and the high-speed drive motor rotor share the compensating cylinder. To ensure the manufacturability and structural rigidity of the motor assembly rotor, the two types of motor assemblies adopt a common rotor structure: that is, an integrated compensating cylinder structure is used as the support structure for the magnets of the two types of motor rotors, and the magnets of the high-speed motor are also attached to the compensating cylinder. This facilitates structural processing and improves the structural strength of the rotor assembly.

[0025] This application proposes a method for machining a motor rotor for flywheel energy storage, which involves machining an annular frame on the surface of the compensating cylinder to ensure accurate positioning of the magnets in the circumferential and axial directions. Addressing the technical challenge of easily deformable thin-walled, long-dimensional aluminum components, and the tendency for the compensating cylinder assembly to deform due to preload during the winding of the composite material wheel, this application employs a process scheme based on mandrel support and separate demolding to reduce structural deformation throughout the machining process and ensure reliable demolding of the composite material wheel after winding.

[0026] In addition to the technical problems solved by this application, the technical features constituting the technical solutions, and the advantages brought about by the technical features of these technical solutions as described above, other technical problems that this application can solve, other technical features contained in the technical solutions, and the advantages brought about by these technical features will be further explained in detail with reference to the accompanying drawings. Attached Figure Description

[0027] Figure 1 A schematic diagram of the lightweight design of the motor rotor assembly in this application;

[0028] Figure 2 A schematic diagram of the method in this application;

[0029] Figure 3 A schematic diagram of the method in step ⑤ in the embodiments of this application;

[0030] Figure 4 An exploded view of the method in step ⑤ in the embodiments of this application;

[0031] In the picture,

[0032] 1. Compensating sleeve; 2. Expansion sleeve; 21. Expansion sleeve conical surface; 3. Mandrel; 4. Clamping assembly; 41. Clamping component; 411. Conical surface; 412. Flat surface; 413. Clamping surface; 42. Limiting component; 5. Tightening nut; 6. Magnet; 11. Frame; 7. Flywheel body; 8. Motor rotor assembly; 9. Fixing component. Detailed Implementation

[0033] The following will be combined with the appendix Figures 1-4 The embodiments of the technical solution of this application are described in detail below. The following embodiments are only used to illustrate the technical solution of this application more clearly, and are therefore only examples and should not be used to limit the scope of protection of this application.

[0034] To achieve a lightweight design, as shown in Figure 1, this application discloses a lightweight motor rotor assembly, including a CPA rotor, a high-speed drive motor rotor, and a compensating cylinder, wherein the CPA rotor and the high-speed drive motor rotor share the compensating cylinder 1. Figure 1 The lightweight motor rotor assembly of this application adopts a common rotor structure, and the magnets all adopt a Helbeck array structure, where BB is the CPA rotor cross-section and AA is the high-speed drive motor rotor cross-section. From Figure 1 As can be seen, the compensated pulse motor has a large structural size (rotor outer diameter of 200mm, length exceeding 250mm, and numerous magnet blocks (120 blocks). To achieve CPA discharge performance, the CPA compensation cylinder is designed to be 5mm thick, while the inner wall thickness of the magnets in the high-speed drive motor is designed to be 1.5mm. To ensure CPA electrical performance and to guarantee the machinability and structural rigidity of the motor assembly rotor, both types of motor assemblies adopt a common rotor structure: that is, an integrated compensation cylinder 1 structure is used as the support structure for the rotor magnets 6 of both types of motors. The magnets 6 of the high-speed motor are also attached to the compensation cylinder 1. This facilitates structural machining and improves the structural strength of the rotor assembly.

[0035] Because there are many magnet blocks, if they cannot be accurately positioned during the assembly process, it will not only increase the difficulty of assembling the magnets, but also cause unevenness on the surface of the magnets, affecting the winding quality of the subsequent composite flywheel body.

[0036] To address this technical problem, embodiments of this application also propose a scheme of machining an annular frame 11 on the surface of the compensation cylinder 1 to ensure accurate positioning of the magnet in the circumferential and axial directions.

[0037] Specific processing methods such as Figures 2-4 A method for machining a motor rotor for flywheel energy storage, comprising:

[0038] The compensation cylinder 1 and the split expansion sleeve 2 are obtained respectively. Figure 2① in the middle;

[0039] The split expansion sleeve 2 is fitted onto the mandrel 3, and the compensating cylinder 1 is fitted onto the outside of the split expansion sleeve 2. Clamping components 4 are fitted onto both ends of the mandrel, so that the compensating cylinder 1 and the expansion sleeve 2 are limited between the clamping components 4 at both ends of the mandrel. Figure 2 ② in the middle;

[0040] Tightening the nut 5 pushes the clamping components 4 at both ends to press the expansion sleeve 2 against it, thereby supporting the compensation cylinder 1 through the expansion sleeve 2. Figure 2 ② in the middle;

[0041] A positioning frame 11 of magnet 6 of a specific size is machined on the compensation cylinder 1, namely Figure 2 ③ in the middle;

[0042] Magnets 6 are assembled on the positioning frame 11, that is... Figure 2 ④ in the middle;

[0043] A composite material flywheel body 7 meeting the specified requirements is wound around magnet 6, i.e. Figure 2 ⑤ in the middle;

[0044] Remove the expansion sleeve 2, spindle 3, clamping assembly 4, and tighten the nut 5 to obtain the required motor rotor assembly 8. Optionally, after removing the expansion sleeve 2, spindle 3, clamping assembly 4, and tightening the nut 5, a fixing piece 9 can be placed at the positions used to clamp the compensation cylinder 1 on both sides.

[0045] In this embodiment, the compensating cylinder 1 and the expansion sleeve 2 are prepared in advance, and the compensating cylinder 1 is made of aluminum. The compensating cylinder is used to form the skeleton of the positioning magnet 6. The expansion sleeve is used to support the compensating cylinder 1, which facilitates operations such as machining the positioning skeleton 11 of the magnet 6, assembling the magnet 6, and winding the flywheel body 7 on the expansion sleeve.

[0046] The mandrel 3 can be a rod-shaped body with threads at both ends. Specifically, the mandrel 3 may include a support portion 31 for supporting the expansion sleeve 2, a movable portion 32 for connecting the clamping assembly 4, and a threaded portion 33 for connecting the tightening nut 5. The mandrel 3 is the support and positioning structure of the motor rotor processing method for flywheel energy storage in this embodiment. The split expansion sleeve 2 is sleeved on the mandrel 3, and the compensation cylinder 1 is sleeved on the outside of the split expansion sleeve 2. The clamping assembly 4 is sleeved at both ends of the mandrel, so that the compensation cylinder 1 and the expansion sleeve 2 are limited between the clamping assemblies 4 at both ends of the mandrel.

[0047] The split expansion sleeve 2 can be selected as a cylindrical expansion sleeve 2 formed by three expansion sleeves 2, or a cylindrical expansion sleeve 2 formed by two split expansion sleeves 2, or a cylindrical expansion sleeve 2 formed by four split expansion sleeves 2, preferably two split expansion sleeves 2. The diameter of the cylindrical cavity formed by the inner side of the split expansion sleeve 2 is larger than the diameter of the cylinder of the mandrel 3. In this embodiment, the purpose of setting the expansion sleeve 2 as a split expansion sleeve 2 is to enable the various components of the split expansion sleeve 2 to expand outward from the center of the mandrel 3 under the action of the tightening nut 5 pushing the clamping components 4 at both ends, and finally to support the compensation cylinder 1 by the expansion sleeve 2. After the compensation cylinder 1, expansion sleeve 2, mandrel 3, and clamping components 4 are assembled and the nut 5 is tightened, the tightening nut 5 is respectively connected to the threads at both ends of the mandrel 3. The tightening nut 5 is used to push the clamping components 4 at both ends to tighten the expansion sleeve 5, and thus the expansion sleeve 5 supports the compensation cylinder 1. This process further strengthens the connection between the mandrel 3, the compensating cylinder 1, and the expansion sleeve 2, and ensures the stable positioning of the compensating cylinder 1, which guarantees that the aluminum structure will not deform during the machining of the magnet frame on the compensating cylinder 1.

[0048] After ensuring the stable positioning of the compensating cylinder 1, a positioning frame 11 of specific dimensions for the magnet 6 can be machined on the compensating cylinder 1. The positioning frame is used to fix the magnet, and then the magnet 6 is assembled on the positioning frame 11. The magnet is the core component of the motor rotor, used to generate a magnetic field. After winding the composite material flywheel body 7 that meets the specifications on the magnet 6, the expansion sleeve 2, mandrel 3, clamping assembly 4, and tightening nut 5 are removed to obtain the required motor rotor assembly 8. The use of composite material technology gives the flywheel body higher strength and lighter weight, meeting the requirements of lightweight design.

[0049] The above-described embodiments of this application describe a method for machining a motor rotor for flywheel energy storage. A ring-shaped frame is machined on the surface of the compensation cylinder to ensure accurate positioning of the magnets in the circumferential and axial directions. This addresses the technical challenges of thin-walled, long-dimensional aluminum components being prone to deformation, and the compensation cylinder assembly being easily deformed due to pre-tightening force when winding the composite material wheel body. The above-described process scheme based on mandrel support and separate demolding reduces structural deformation during the entire machining process and ensures reliable demolding of the composite material wheel body after winding.

[0050] Based on the above embodiments, in one embodiment of this application, the inner side of the upper and lower end faces of the split expansion sleeve 2 forms an expansion sleeve cone surface 21.

[0051] In this embodiment, because the radius of the conical surface gradually decreases from the ground to the apex, the force applied by the clamping assembly on the conical surface changes slowly and uniformly. Since the conical inclined surface better disperses pressure, it reduces impact and vibration during the clamping process, improves clamping stability, and the inclined surface design makes it easier to adjust the clamping surface when subjected to vertical pressure. This helps ensure accurate alignment of the clamping assembly with the top surface of the expansion sleeve 2 and facilitates adjustment of the clamping force.

[0052] Based on the above embodiments, in one embodiment of this application, the clamping assembly 4 includes: a clamping member 41, which has a top clamping surface and a clamping surface 413; the top clamping surface includes a conical surface 411 and a flat surface 412, the conical surface 411 can cooperate with the expansion sleeve conical surface 21 formed by the end faces of the two ends near the inner side of the expansion sleeve; the flat surface 412 can cooperate with the bottom surface of the compensation cylinder 1 and the expansion sleeve 2; the clamping surface 413 is the outer top surface of the clamping member 41, which can cooperate with the bottom surface of the tightening nut 5.

[0053] In this embodiment, the conical surface 411 can cooperate with the conical surface 21 of the expansion sleeve formed by the end faces of the two ends near the inner side of the expansion sleeve. By cooperating with the conical surface of the clamping component 4 and the conical surface 21 of the expansion sleeve, it is more conducive to the slow adjustment of the clamping force, and it can also increase the contact surface of the applied force, improve the stability of the clamping process, and facilitate the use of the tightening nut 5 to push the clamping component 4 at both ends to tighten the expansion sleeve 5. During the process of the expansion sleeve 5 supporting the compensation cylinder 1, the stability of the compensation cylinder fixation and the positioning accuracy are improved.

[0054] However, in the above implementation, generally, when the lengths of the compensating cylinder 1 and the expansion sleeve 2 are the same, or when the length of the compensating cylinder 1 is greater than the length of the expansion sleeve 2, the clamping assembly 4 can simultaneously limit the movement of the compensating cylinder 1 and the expansion sleeve 2. But when the length of the compensating cylinder 1 is less than the length of the expansion sleeve 2, it cannot be guaranteed that the clamping assembly 4 will effectively limit the movement of the compensating cylinder 1. To solve this problem, based on the above embodiments, as follows... Figure 4 In one embodiment of this application, the clamping assembly 4 further includes a limiting member 42 located on the upper and lower surfaces of the compensation cylinder 1 and on the outside of the expansion sleeve 2.

[0055] Furthermore, the limiting member 42 is inserted into the compensating cylinder 1. In an optional embodiment, the side of the limiting member that contacts the compensating cylinder is provided with a protrusion or groove, and the top surface of the compensating cylinder is provided with a groove or protrusion that corresponds to the position of the protrusion or groove.

[0056] Based on the above embodiments, in order to limit the flywheel body during the processing, the radius of the limiting member is set such that the flywheel body can be limited within the limiting member.

[0057] Furthermore, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0058] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "set," "equipped with," "connected," and "installed" 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 direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application according to the specific circumstances.

[0059] 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 them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for machining a motor rotor for flywheel energy storage, characterized in that, include: The compensation cylinder (1) and the split expansion sleeve (2) are obtained respectively. The split expansion sleeve (2) is fitted onto the mandrel (3), and the compensation cylinder (1) is fitted onto the outside of the split expansion sleeve (2). The clamping components (4) are fitted onto both ends of the mandrel, so that the compensation cylinder (1) and the expansion sleeve (2) are limited between the clamping components (4) at both ends of the mandrel. Using the tightening nut (5), push the clamping components (4) at both ends to press against the expansion sleeve (2), thereby supporting the compensation cylinder (1) through the expansion sleeve (2); A positioning frame (11) of magnet (6) of a specific size is machined on the compensation cylinder (1). Magnets (6) are assembled on the positioning frame (11). A composite material flywheel body (7) that meets the index requirements is wound on the magnet (6); Remove the expansion sleeve (2), spindle (3), clamping assembly (4), and tighten the nut (5) to obtain the required motor rotor assembly (8).

2. The processing method as described in claim 1, characterized in that, The upper and lower end faces of the split expansion sleeve (2) near the inner side form the expansion sleeve cone surface (21).

3. The processing method as described in claim 2, characterized in that, The clamping assembly (4) includes: a clamping member (41), which has a pressing surface and a clamping surface (413). The tightening surface includes a conical surface (411) and a flat surface (412). The conical surface (411) can be matched with the conical surface (21) of the expansion sleeve formed by the end faces of the two ends near the inner side of the expansion sleeve; the flat surface (412) can be matched with the bottom surface of the compensating cylinder (1) and the expansion sleeve (2). The clamping surface (413) is the outer top surface of the clamping part (41), which can be matched with the bottom surface of the tightening nut (5).

4. The processing method as described in claim 1, characterized in that, The diameter of the cylindrical cavity formed by the inner side of the split expansion sleeve (2) is greater than the diameter of the cylinder of the mandrel (3).

5. The processing method as described in claim 1, characterized in that, The clamping assembly (4) further includes a limiting member (42) located on the top and bottom surfaces of the compensation cylinder (1) and on the outside of the expansion sleeve (2).

6. The processing method as described in claim 5, characterized in that, The limiting member (42) and the compensation cylinder (1) are inserted into each other.

7. The processing method as described in claim 6, characterized in that, The limiting member (42) has a protrusion or groove on the side that contacts the compensation cylinder (1), and the top surface of the compensation cylinder (1) has a groove or protrusion that corresponds to the position of the protrusion or groove.

8. The processing method as described in claim 5, characterized in that, The radius of the limiting component is set such that the flywheel body can be limited within the limiting component (42).

9. A lightweight motor rotor assembly, characterized in that, The material is obtained by any of the processing methods described in claims 1 to 8, including a CPA rotor, a high-speed drive motor rotor, and a compensating cylinder (1), wherein the CPA rotor and the high-speed drive motor rotor share the compensating cylinder (1).

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