Production process of amorphous alloy stator

Abstract

This invention relates to a manufacturing process for amorphous alloy stators in the field of motor stator manufacturing. The process includes the following steps: first, partial bonding; second, stamping laminations; third, stacking and fixing; fourth, heat treatment; fifth, impregnation and curing; and sixth, wire cutting. Under the bonding effect in the bonding area, the non-bonded areas can also be precisely positioned, ensuring accurate positioning of the non-bonded areas of adjacent amorphous alloy strips. The two stamping processes ensure the accuracy and stability of the stamped laminations, improving product yield. Furthermore, the continuous unwinding and feeding, along with continuous stamping, ensures high efficiency. Wire cutting after impregnation and curing further enhances the precision control of the amorphous alloy stator. Since the interior of the annular core has already been removed by a single stamping die, the wire cutting process and time are significantly reduced, further improving production efficiency.

Description

Technical Field

[0001] This invention relates to the field of motor stator manufacturing processes, specifically to the manufacturing processes of amorphous alloy stators. Background Technology

[0002] The stator core is a critical component of an electric motor, and its performance directly affects the motor's efficiency and overall performance. Commonly used stator cores include silicon steel sheet stator cores, neodymium iron boron magnet stator cores, and amorphous alloy stator cores. These are typically made of stacked metal sheets and feature uniformly distributed slots for housing the stator windings. Among these, amorphous alloy stator cores, with their low loss, high stability, and good heat resistance, are suitable for high-precision applications.

[0003] The manufacturing process of amorphous alloy stator cores involves several key steps, each requiring specific equipment and precise control of relevant parameters to ensure stator quality and performance. Existing manufacturing processes for amorphous alloy stator cores mainly include the following steps:

[0004] The first step is cutting. According to the size requirements of the stator core, the amorphous alloy strip is cut into amorphous alloy sheets of appropriate shape and size.

[0005] The second step is stamping, which uses a mold to stamp the amorphous alloy sheet into a slotted structure for the stator core.

[0006] The third step is stacking, where the stamped amorphous alloy sheets are stacked together in a certain order and direction to form the overall structure of the stator core.

[0007] The fourth step is welding and fixing. The stacked stator core is welded and fixed to ensure the stability and reliability of the structure.

[0008] The fifth step is insulation coating and curing. The welded and fixed stator core is placed into the impregnation equipment, and after impregnation, it is placed into the curing equipment for heating and curing.

[0009] The aforementioned manufacturing process for amorphous alloy stator cores has the following drawbacks: In the steps of cutting amorphous alloy strips and stamping, existing technologies typically employ two methods. One method involves directly cutting a single strip and then stamping it, resulting in a shape that matches the cross-sectional shape of the stator. The advantage of this method is that the cutting and stamping of the single strip requires less sophisticated molds, leading to relatively lower costs and higher cutting and stamping precision. However, its disadvantages are also significant: it requires separate cutting into suitable shapes and sizes each time, followed by a single stamping process, resulting in low production efficiency. Another method involves simultaneously stamping multiple strips. Before stamping, these strips need to be bonded together, specifically using adhesive to bond adjacent strips together. After bonding, the strips are cut into suitable shapes and sizes before stamping. This method significantly improves production efficiency, but its disadvantages include extremely high requirements for the molds used in simultaneously stamping multiple strips. The molds are prone to damage during the stamping process, and the precision of multi-layer stamping is difficult to control, making it hard to guarantee the dimensional accuracy and structural consistency of each stamped piece. Furthermore, adhesive bonding leaves glue residue between adjacent stamped pieces, which is not heat-resistant and affects subsequent heat treatment processes, thus impacting the product performance and structural stability of the stator core. Additionally, current production processes only control overall precision through stamping; the welding and insulation coating processes after stamping will affect the overall precision of the stator core. Summary of the Invention

[0010] The purpose of this invention is to address the above-mentioned shortcomings and provide a manufacturing process for amorphous alloy stators, which can improve the production efficiency of amorphous alloy stators, as well as enhance the performance and structural stability of the products. This solves the technical problems of low production efficiency and difficulty in controlling product performance in the prior art.

[0011] The objective of this invention is achieved through the following means:

[0012] The manufacturing process for amorphous alloy stators includes the following steps:

[0013] The first step is partial bonding. The rolled amorphous alloy strip is divided into bonding area and non-bonding area. The non-bonding area has the same cross-sectional shape as the preset molecule. All areas of the rolled amorphous alloy strip except the non-bonding area belong to the bonding area. A bonding station for amorphous alloy strip and a bonding mechanism located at the bonding station are set up. Two or more rolls of amorphous alloy strip are unwound separately. The amorphous alloy strips are continuously unwound and neatly stacked together before entering the bonding station. The bonding mechanism is used to bond the bonding areas of two adjacent neatly stacked amorphous alloy strips into one piece.

[0014] The second step is stamping the sheet. The next station after the bonding station is the stamping station. The stamping station is equipped with a stamping mechanism, which includes a primary stamping die and a secondary stamping die. The amorphous alloy strip that has been bonded together is sequentially fed into the primary stamping die and the secondary stamping die. The primary stamping die is used to punch an inner ring with an inner diameter that matches the cross-sectional shape of the preset numeral. The secondary stamping die is used to punch an outer ring with an outer diameter that matches the cross-sectional shape of the preset numeral, so that the non-bonding area is stamped into a ring-shaped sheet that is detached from the bonding area by the secondary stamping die.

[0015] The third step is stacking and fixing. The stamped annular laminations are stacked together in a certain order and direction using a stator stacking machine, and the stacked annular laminations are fixed together to ensure that there are no gaps between adjacent annular laminations, thereby forming an annular iron core. This ensures that the stacked annular iron core has sufficient structural strength and electrical performance.

[0016] The fourth step is heat treatment, in which the stacked annular iron core is placed in a heating device for heat treatment.

[0017] The fifth step is varnish impregnation and curing. The heat-treated annular iron core is placed into the varnish impregnation equipment, which has a precise temperature control system and varnish circulation system. The annular iron core is immersed in the insulating varnish of the varnish impregnation equipment to ensure that the varnish can be evenly adhered to the surface and interior of the annular iron core. After varnish impregnation, the annular iron core is placed in the curing equipment for heating and curing. During the curing process, the solvent in the varnish will evaporate, and the varnish film will gradually solidify and adhere to the surface of the annular iron core, forming a strong insulating layer.

[0018] Step 6: Wire cutting. Fix the cured annular iron core onto the fixture on the workbench. Set the wire cutting machine according to the preset cross-sectional shape of the stator, start the wire cutting machine, and begin the cutting process. Cut along the programmed path on the annular iron core to form slots for embedding the stator windings. After the wire cutting is completed, the overall structure of the amorphous alloy stator is formed.

[0019] Furthermore, in the first step, the bonding mechanism employs a sequential coating and pressing process. The coating process applies adhesive to the bonding area using a coating machine. After coating, the pressing process joins two adjacent, neatly stacked amorphous alloy strips together, bonding their bonding areas together with the adhesive. Both the coating and pressing processes can be continuously performed in an assembly line, thereby improving overall production efficiency. Specifically, a roller coater can be used to evenly apply the adhesive to the bonding area. The roller coater head can be designed with textured surfaces corresponding to the bonding area. The coating of the bonding area is completed as the roller coater head rolls. This coating method is a common technique used with roller coaters. Besides roller coaters, other coating methods can also be used, such as spray coating or adhesive coating. The pressing process can use pressing rollers to press the coated bonding area. During the continuous roll feeding process, after the coating is completed, pressing continues. Because the bonding area is coated with adhesive, the bonding areas of two adjacent neatly stacked amorphous alloy strips are bonded together under the pressing action of the pressing rollers. Under the bonding action of the bonding area, the non-bonded areas can also be accurately positioned.

[0020] Furthermore, in the first step, the bonding mechanism employs spot welding, using spot welding equipment to weld and fix the bonding areas of two adjacent, neatly stacked amorphous alloy strips. Specifically, welding assembly line processes and welding robot assembly lines can be used. These processes are widely used in large-scale production, meeting the demands of high-volume, high-efficiency production, thereby improving production efficiency and quality. Assembly lines have a high degree of automation, significantly improving production efficiency. In addition, the welding robot production line system intelligently identifies the workpieces, and the control system schedules the welding robots at each station, automatically adjusting welding parameters according to the workpiece specifications to achieve intelligent welding. This process has a very high degree of automation, enabling automatic workpiece conveying and batch welding with stable welding quality. Moreover, welding robot assembly lines can reduce the labor intensity of workers and help improve product efficiency.

[0021] Furthermore, in the second step, a stamping die simultaneously cuts several toothed holes corresponding to the slot positions. Cutting these toothed holes not only assists in the clamping of stacked pieces and allows for precise positioning of the annular stamping pieces, but also reduces the number of wire cutting steps and time, further improving production efficiency, as the toothed holes correspond to the slot positions.

[0022] Furthermore, in the fourth step, the heat treatment process requires the use of atmosphere control equipment to provide an inert gas environment. Heating is carried out under the protection of inert gas to prevent oxidation of the annular iron core during the heating process. The heat treatment time is 2.5-3.5 hours, and the heat treatment control temperature is 400-450 degrees Celsius.

[0023] Furthermore, in the fifth step, before impregnation and curing, the annular iron core needs to be blown with air to leave gaps between adjacent annular stampings, so that the paint can enter the annular stampings to form a paint film.

[0024] Furthermore, in the fifth step, the immersion process is divided into immersion under normal pressure and immersion under vacuum. The immersion process is completed in the following steps: first, immersion under normal pressure for 20-40 minutes, then immersion under vacuum for 50-70 minutes, then immersion under normal pressure for 20-40 minutes, and finally immersion under vacuum for 20-40 minutes.

[0025] The beneficial effects of this invention are as follows:

[0026] 1) The production process adopts a continuous unwinding method, setting up bonding areas and non-bonding areas. The bonding areas of two adjacent neatly stacked amorphous alloy strips are bonded together. Under the bonding effect of the bonding area, the non-bonding area can also be accurately positioned, which can ensure the accurate positioning of the non-bonding area of ​​two adjacent amorphous alloy strips. The production process can allocate the number of amorphous alloy strips stacked according to the stamping capacity of the stamping mechanism. The non-bonding area is consistent with the cross-sectional shape of the preset numerator. Then, the non-bonding area is stamped into a ring-shaped stamp that is separated from the bonding area through two consecutive punching processes. Since the bonding area is bonded together, the accuracy and stability of the stamped stamp can be ensured in the two punching processes, thereby improving the product yield. Moreover, the continuous unwinding and feeding and continuous stamping work efficiency of the whole process are high. Separating two dies and stamping twice can reduce the overall cost and accuracy requirements of the stamping die. Stamping into a ring-shaped stamp twice makes it easier to stack and fix it later.

[0027] 2) By separating the bonding and non-bonding areas, the punching accuracy is ensured while preventing foreign matter such as glue from remaining between adjacent annular laminations. This allows for heat treatment of the annular core, improving the performance and structural stability of the amorphous alloy stator. After the varnish is impregnated and cured, wire cutting is performed. The accuracy of the amorphous alloy stator can be further precisely controlled through wire cutting. Since the interior of the annular core has already been punched out in one stamping die, some wire cutting processes and time can be significantly reduced, thereby further improving production efficiency. Attached Figure Description

[0028] Figure 1 A front view of the annular lamination after the completion of the second step in the manufacturing process of the amorphous alloy stator;

[0029] Figure 2 A three-dimensional structural diagram of the annular lamination after the completion of the second step in the manufacturing process of the amorphous alloy stator.

[0030] Figure 3 A front view of an annular lamination with toothed slots after the completion of the second step in the manufacturing process of the amorphous alloy stator.

[0031] Figure 4 A three-dimensional structural diagram of an annular lamination with toothed slots after the completion of the second step in the manufacturing process of the amorphous alloy stator.

[0032] Figure 5 A front view of the amorphous alloy stator after the sixth step of the manufacturing process for the amorphous alloy stator is completed;

[0033] Figure 6 This is a three-dimensional structural diagram of the amorphous alloy stator after the sixth step of the manufacturing process for the amorphous alloy stator.

[0034] In the figure, 1-ring lamination, 2-inner ring, 3-outer ring, 4-toothed hole, 5-slot, 6-amorphous alloy stator. Detailed Implementation

[0035] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0036] In this embodiment, refer to Figures 1-6 The specific manufacturing process of the amorphous alloy stator includes the following steps: First, partial bonding; second, stamping and lamination; third, stacking and fixing; fourth, heat treatment; fifth, impregnation and curing; and sixth, wire cutting. Each step is described in detail below:

[0037] The first step is partial bonding. The rolled amorphous alloy strip is divided into bonding areas and non-bonding areas. The non-bonding areas have the same cross-sectional shape as the preset mold. All areas of the rolled amorphous alloy strip except for the non-bonding areas belong to the bonding areas. A bonding station for the amorphous alloy strip and a bonding mechanism located at the bonding station are set up. Two or more rolls of amorphous alloy strip are unwound separately. The specific method can be selected according to the cutting capacity of the mold. For example, if three rolls of amorphous alloy strip are selected to be fed at the same time, the three rolls of amorphous alloy strip are unwound by independent automatic unwinding mechanisms. The three rolls of amorphous alloy strip are continuously unwound and neatly stacked together before entering the bonding station. The bonding mechanism is used to bond the bonding areas of two adjacent neatly stacked amorphous alloy strips into one. In this embodiment, the bonded amorphous alloy strip contains a three-layer structure.

[0038] The bonding mechanism in this embodiment employs a sequential coating and pressing process. The coating process applies coating to the bonding area on opposite sides of three rolls of amorphous alloy strip. Unwinding and coating continue continuously, with adhesive applied to the bonding area by a coating machine. Specifically, a roller coater can be used. The roller coater head evenly applies the adhesive to the bonding area. The roller coater head can be designed with textured surfaces corresponding to the bonding area. The coating of the bonding area is completed as the roller coater head rolls. This coating method is a common technique used in roller coaters, and area-by-area coating is also an advantage of roller coaters. This is a conventional technique in the coating field, and the detailed coating process will not be described in detail here.

[0039] After coating, three neatly stacked amorphous alloy strips are pressed together using a pressing process. The bonding areas of the three neatly stacked amorphous alloy strips are bonded together with adhesive. The pressing process can use a pressing roller to press the coated bonding areas. During continuous roll feeding, pressing continues immediately after coating is completed. Because the bonding areas are coated with adhesive, the bonding areas of the three neatly stacked amorphous alloy strips are bonded together under the pressing action of the pressing roller. Under the bonding action of the bonding areas, the non-bonded areas can also be accurately positioned, which is convenient for precise punching in the next process. Both the coating process and the pressing process can be carried out continuously in an assembly line, thereby improving the overall production efficiency.

[0040] The second step is stamping. The next station after the bonding station is the stamping station, which is equipped with a stamping mechanism. The stamping mechanism includes a primary stamping die and a secondary stamping die, with the secondary stamping die located one station below the primary stamping die. The amorphous alloy strip, after being bonded together, is sequentially fed into the primary stamping die and the secondary stamping die, as follows: Figure 1 and Figure 2 As shown, a primary stamping die is used to punch an inner ring 2 with an inner diameter matching the cross-sectional shape of the pre-set piece, and a secondary stamping die is used to punch an outer ring 3 with an outer diameter matching the cross-sectional shape of the pre-set piece. This allows the non-fitting area to be punched into a ring-shaped piece 1 detached from the fitting area by the secondary stamping die. Separating the two dies for sequential punching ensures the accuracy and stability of the stamped piece, improving product yield. It also reduces the overall cost and accuracy requirements of the stamping die, and avoids die damage. Furthermore, to facilitate stacking for the next process and to remove excess waste, such as… Figure 3 and Figure 4 As shown, a single stamping die can simultaneously punch several toothed holes 4 corresponding to the positions of slots 5. The method for punching the toothed holes 4 is similar to... Figure 1 and Figure 2The option of not punching the toothed slot 4 can be chosen by simply adding a die-cutting blade corresponding to the toothed slot 4 to the secondary stamping die. Punching the toothed slot 4 can not only be used to assist in the clamping of stacked pieces and to accurately position the annular stamping piece 1, but also ensures that the toothed slot 4 corresponds to the slot 5. This will not affect the accuracy and can reduce the wire cutting process and time, thereby further improving production efficiency.

[0041] The third step is to stack and fix the ring-shaped laminations 1. The stamped ring laminations 1 are stacked together in a certain order and direction using a stator stacking machine. The stacked ring laminations 1 are then fixed together. The stacking pressure and stacking order must be controlled to ensure that the adjacent ring laminations 1 are tightly packed without gaps, thereby forming a ring-shaped iron core. This ensures that the stacked ring-shaped iron core has sufficient structural strength and electrical performance.

[0042] The fourth step is heat treatment. The stacked annular iron core is placed in a heating device for heat treatment. The heat treatment process requires the use of an atmosphere control device to provide an inert gas environment. Heating is carried out under the protection of an inert gas to prevent oxidation of the annular iron core during heating. The heat treatment time is 3 hours, and the heat treatment temperature is controlled at 450 degrees Celsius.

[0043] The fifth step is impregnation and curing. The heat-treated annular iron core is placed into the impregnation equipment. Before impregnation and curing, the annular iron core needs to be blown with air to leave gaps between adjacent annular laminations, which facilitates the entry of paint into the annular laminations to form a paint film. Before impregnation and curing, the annular iron core needs to be cleaned and dried to remove oil, impurities, and moisture from its surface.

[0044] The impregnation equipment features a precise temperature control system and a paint circulation system. The annular iron core is immersed in the insulating paint, ensuring that the paint adheres evenly to the surface and interior of the core. After impregnation, the core is placed in a curing device for heating and curing, typically a curing oven. The curing temperature and time are set to ensure a strong and reliable insulation layer. During curing, the solvent in the paint evaporates, and the paint film gradually hardens and adheres to the surface of the core, forming a robust insulating layer.

[0045] The impregnation process in this embodiment is divided into impregnation under normal pressure and impregnation under vacuum. The impregnation process is completed according to the following steps: first, impregnation under normal pressure for 30 minutes, then impregnation under vacuum for 60 minutes, followed by impregnation under normal pressure for 30 minutes, and finally impregnation under vacuum for 30 minutes. By controlling the air pressure during the impregnation process, the impregnation coating can adhere more fully, ensuring that air bubbles in the coating are fully expelled, so that the coating can adhere more evenly to the surface and interior of the annular iron core.

[0046] Step 6: Wire EDM. Fix the cured annular core onto the fixture on the worktable. Set the wire EDM machine according to the preset stator cross-sectional shape, start the machine, and begin the cutting process. Cut along the programmed path on the annular core to create slots 5 for embedding the stator windings. Figure 5 and Figure 6 As shown, the amorphous alloy stator 6 is formed after wire cutting. Wire cutting technology is mainly used for precise cutting and shaping of the amorphous alloy stator 6 to meet the specific requirements of motor design. Wire cutting technology can precisely control the cutting path and depth to ensure that the shape and size of the amorphous alloy stator 6 meet the design requirements. By programming and controlling the movement trajectory of the cutting machine, efficient and precise cutting of stator cores with complex shapes and structures can be achieved. Since the interior of the annular core has been removed by a single stamping die, some wire cutting processes and time can be greatly reduced, thereby further improving production efficiency.

[0047] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the inventive concept, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. A manufacturing process for an amorphous alloy stator, characterized in that... The production process includes the following steps: The first step is partial bonding. The rolled amorphous alloy strip is divided into bonding area and non-bonding area. The non-bonding area has the same cross-sectional shape as the preset molecule. All areas of the rolled amorphous alloy strip except the non-bonding area belong to the bonding area. A bonding station for amorphous alloy strip and a bonding mechanism located at the bonding station are set up. Two or more rolls of amorphous alloy strip are unwound separately. The amorphous alloy strips are continuously unwound and neatly stacked together before entering the bonding station. The bonding mechanism is used to bond the bonding areas of two adjacent neatly stacked amorphous alloy strips into one piece. The second step is stamping the sheet. The next station after the bonding station is the stamping station. The stamping station is equipped with a stamping mechanism, which includes a primary stamping die and a secondary stamping die. The amorphous alloy strip that has been bonded together is sequentially fed into the primary stamping die and the secondary stamping die. The primary stamping die is used to punch an inner ring with an inner diameter that matches the cross-sectional shape of the preset numeral. The secondary stamping die is used to punch an outer ring with an outer diameter that matches the cross-sectional shape of the preset numeral, so that the non-bonding area is stamped into a ring-shaped sheet that is detached from the bonding area by the secondary stamping die. The third step is stacking and fixing. The stamped annular laminations are stacked together in a certain order and direction using a stator stacking machine, and the stacked annular laminations are fixed together to ensure that there are no gaps between adjacent annular laminations, thereby forming an annular iron core. This ensures that the stacked annular iron core has sufficient structural strength and electrical performance. The fourth step is heat treatment, in which the stacked annular iron core is placed in a heating device for heat treatment. The fifth step is varnish impregnation and curing. The heat-treated annular iron core is placed into the varnish impregnation equipment, which has a precise temperature control system and varnish circulation system. The annular iron core is immersed in the insulating varnish of the varnish impregnation equipment to ensure that the varnish can be evenly adhered to the surface and interior of the annular iron core. After varnish impregnation, the annular iron core is placed in the curing equipment for heating and curing. During the curing process, the solvent in the varnish will evaporate, and the varnish film will gradually solidify and adhere to the surface of the annular iron core, forming a strong insulating layer. Step 6: Wire cutting. Fix the cured annular iron core onto the fixture on the workbench. Set the wire cutting machine according to the preset cross-sectional shape of the stator, start the wire cutting machine, and begin the cutting process. Cut along the programmed path on the annular iron core to form slots for embedding the stator windings. After the wire cutting is completed, the overall structure of the amorphous alloy stator is formed.

2. The manufacturing process of the amorphous alloy stator according to claim 1, characterized in that: In the first step, the bonding mechanism employs a coating process and a pressing process in sequence. The coating process is used to coat the bonding area with adhesive. After coating, the two adjacent neatly stacked amorphous alloy strips are pressed together by the pressing process, so that the bonding areas of the two adjacent neatly stacked amorphous alloy strips are bonded together with adhesive.

3. The manufacturing process of the amorphous alloy stator according to claim 1, characterized in that: In the first step, the bonding mechanism is welded using a spot welding process. The bonding areas of two adjacent neatly stacked amorphous alloy strips are welded and fixed using spot welding equipment.

4. The manufacturing process of the amorphous alloy stator according to any one of claims 1-3, characterized in that: In the second step, a stamping die simultaneously punches several toothed holes corresponding to the slot positions.

5. The manufacturing process of the amorphous alloy stator according to any one of claims 1-3, characterized in that: In the fourth step, the heat treatment process requires the use of atmosphere control equipment to provide an inert gas environment. Heating is carried out under the protection of inert gas to prevent oxidation of the annular iron core during the heating process. The heat treatment time is 2.5-3.5 hours, and the heat treatment control temperature is 400-450 degrees Celsius.

6. The manufacturing process of the amorphous alloy stator according to any one of claims 1-3, characterized in that: In the fifth step, before the impregnation and curing, the annular iron core needs to be blown with air to leave gaps between adjacent annular stampings, so that the paint can enter the annular stampings to form a paint film.

7. The manufacturing process of the amorphous alloy stator according to any one of claims 1-3, characterized in that: In the fifth step, the immersion process is divided into immersion under normal pressure and immersion under vacuum. The immersion process is completed in the following steps: first, immersion under normal pressure for 20-40 minutes, then immersion under vacuum for 50-70 minutes, then immersion under normal pressure for 20-40 minutes, and finally immersion under vacuum for 20-40 minutes.

Images