Winding method of rotor fiber sheath

Abstract

The present invention provides a method for winding a rotor fiber sheath, wherein a fiber tape (20) is spirally wound around the outer periphery of an iron core (10) layer by layer, and a spiral overlapping area (D) is formed between two adjacent turns of the fiber tape (20) of each layer of the sheath. During the winding process of each layer, a fiber tape section that has been wound around the outer periphery of the iron core (10) and is no longer covered by an adjacent turn of the fiber tape (20) of the same layer forms a winding completion section (A). No resin is attached to the surface of the fiber tape (20) before winding, and during the winding process of each layer, liquid resin is uniformly applied to the surface of the winding completion section (A) of the current layer. The method for winding a rotor fiber sheath according to the present invention breaks through the limitation of the original wet winding glue supply method, so that the application of resin for each winding layer is located after the step of winding in which the fibers squeeze each other, so that the resin distribution in the overlapping area and the non-overlapping area is uniform, and the fiber sheath has a uniform thickness and a flat surface.

Description

Technical Field

[0001] The invention relates to the field of motors, and more particularly to a method for winding a rotor fiber sheath of a motor rotor. Background Art

[0002] As the motor rotor develops towards a high speed, it is necessary to improve the structural strength of the rotor so that it can maintain structural stability under high centrifugal force. One method to increase the structural strength of the rotor is to wind carbon fiber around the outer circumference of the rotor to form a carbon fiber sheath.

[0003] In the carbon fiber wet winding process, carbon fiber tapes impregnated with liquid resin are spirally wound together on the rotor surface with a certain overlap rate. The overlapping fiber tapes tend to squeeze the resin in the fiber tapes, causing the resin content (also called glue content) on various parts of the rotor surface to be uneven, and ultimately resulting in an uneven rotor surface after curing. Summary of the invention

[0004] The purpose of the present invention is to overcome or at least alleviate the deficiencies of the above-mentioned prior art and to provide a method for winding a rotor fiber sheath.

[0005] The present invention provides a method for winding a rotor fiber sheath, which is used to wind a fiber tape around the outer periphery of an iron core of a motor rotor to form a sheath, wherein:

[0006] The fiber tape is spirally wound around the outer circumference of the core layer by layer, and a spiral overlapping area is formed between two adjacent turns of the fiber tape in each layer of the sheath.

[0007] During the winding process of each layer, the fiber tape section that has been wound to a certain position on the outer periphery of the core and will no longer be covered by the fiber tape of the adjacent turns of the same layer forms a winding completion section.

[0008] The fiber tape has no resin attached to its surface before winding, but during the winding process of each layer, liquid resin is evenly applied to the surface of the winding completed section of the layer.

[0009] In at least one embodiment, the liquid resin is applied to the winding completion section by spraying or brushing.

[0010] In at least one embodiment, during the winding process of each layer, the winding speed satisfies:

[0011] When the winding of the current layer is completed, the application of resin to the winding completion section of the current layer is completed.

[0012] In at least one embodiment, during each layer winding process, the winding completed section to which the liquid resin has been applied is treated by a physical or chemical method so that the liquid resin reaches a semi-cured state.

[0013] In at least one embodiment, the material or chemical method comprises at least one of the following methods: heating, light radiation, and applying a catalyst.

[0014] In at least one embodiment, during the winding process of each layer, the winding speed satisfies:

[0015] When the winding of the present layer is completed, the resin in the winding completion section of the present layer is all in a semi-cured state.

[0016] In at least one embodiment, during the multi-layer winding of the fiber tape, the liquid resin is applied continuously or intermittently, and the fiber tape is wound at a constant speed or at a variable speed.

[0017] In at least one embodiment, the process of treating the wound completed section to which the liquid resin has been applied by a physical or chemical method is performed continuously or intermittently.

[0018] In at least one embodiment, the amount of resin applied to the fiber tapes in different layers is not exactly the same.

[0019] In at least one embodiment, the amount of resin applied to the bottommost fiber tape is greater than the amount of resin applied to the fiber tape in the middle layer, and / or the amount of resin applied to the surfacemost fiber tape is greater than the amount of resin applied to the fiber tape in the middle layer.

[0020] The rotor fiber sheath winding method according to the present invention breaks through the limitation of the original wet winding glue supply method, so that the application of resin for each winding layer is located after the fiber squeezing winding step, so that the resin distribution in the overlapping area and the non-overlapping area is uniform, and the fiber sheath has a uniform thickness and a flat surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 is a schematic diagram of a winding process of a rotor fiber sheath according to the first embodiment of the present application.

[0022] Figure 2 It is a schematic diagram of a method for applying glue to a rotor fiber sheath during the winding process according to the first embodiment of the present application.

[0023] Figure 3 It is a schematic diagram of another sizing method during the winding process of the rotor fiber sheath according to the first embodiment of the present application.

[0024] Figure 4 It is a partially enlarged schematic diagram of the rotor fiber sheath during the winding process according to the first embodiment of the present application.

[0025] Figure 5 is a schematic diagram of a winding process of a rotor fiber sheath according to a second embodiment of the present application.

[0026] Figure 6 is a schematic diagram of a winding process of a rotor fiber sheath according to a third embodiment of the present application.

[0027] Figure 7 yes Figure 6 Top view of the .

[0028] Description of reference numerals:

[0029] 10 iron core; 20 fiber belt; 30 gluing device; 40 heating device;

[0030] D Overlap area; A Winding completion section. DETAILED DESCRIPTION

[0031] The exemplary embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are only used to teach those skilled in the art how to implement the present invention, and are not intended to exhaust all possible modes of the present invention, nor to limit the scope of the present invention.

[0032] First embodiment

[0033] Reference Figures 1 to 4 , a method for winding a rotor fiber sheath according to an embodiment of the present application is introduced.

[0034] The fiber sheath is formed by winding a plurality of layers of fiber tapes 20 impregnated with resin around the outer circumference of the core 10 and after the resin is cured.

[0035] The fiber tape 20 is composed of a plurality of (usually tens of thousands of) fiber filaments. In the present invention, the fiber tape 20 is not pre-impregnated with resin. The application of resin is performed layer by layer during the winding process.

[0036] Each layer of the fiber sheath is formed by spirally winding a fiber band 20. Two adjacent turns of the spirally wound fiber band 20 form a spiral ring-shaped overlapping area. For example, Figure 4 The figure shows the state of the fiber tape 20 during the winding process, and the shaded part in the figure is the overlapping area D.

[0037] The following introduction to the sheath winding method takes the winding of one layer of the sheath as an example unless otherwise specified. In each layer of winding, the fiber band section that has been wound to a certain position on the periphery of the core 10 and will no longer be covered by adjacent turns of the same layer is defined as the winding completion section A. The axial forward direction of the winding of this layer is defined as the front, and the frontmost portion of the fiber band in the winding process of this layer does not belong to the winding completion section A, because in the subsequent winding process, the next turn of the fiber band will partially cover the portion of the fiber band currently located at the front end. In the prior art of wet fiber winding, because the fiber band is pre-soaked with liquid resin, the overlapping areas that are continuously formed during the winding process cause the fiber bands to squeeze each other, resulting in uneven distribution of the resin in the fiber band.

[0038] In this embodiment, after each layer of the fiber tape 20 is wound halfway or when each layer is wound close to the last few turns, the glue applying device 30 begins to apply resin to the wound section A of the layer. The glue applying device 30 is, for example, a nozzle or a brush, that is, the glue application method can be spraying or brushing. The glue application progress lags behind the winding progress to avoid applying resin to the non-wound section of the layer, thereby avoiding causing the newly formed overlapping area D to squeeze the resin already applied to the fiber tape 20. The resin is applied evenly in the glue application area.

[0039] It can be understood that in this embodiment, the application of resin is intermittent. In the early stage of each layer of fiber winding, the glue applying device 30 does not work. In the middle and late stages of each layer of fiber winding, after the glue applying device 30 starts to work, the glue applying direction of the glue applying device 30 in the axial direction of the core can be from one end to the other end of the axial direction, for example Figure 2 The axial glue application direction shown in FIG. is from left to right. It can also be from the axial center to both sides of the axial direction, for example Figure 3 The present application does not impose any restrictions on the specific gluing path and gluing speed, and only needs to satisfy the following conditions: when the winding of the current layer is completed, the winding completion section A of the current layer has completely completed the application of the resin, and the resin is evenly distributed.

[0040] The last area of ​​each layer to be glued is usually the front end of the winding, and in the winding of the next layer, the fiber tape usually covers the last area of ​​the previous layer to be glued first. Therefore, after each layer of glue is completed, the winding can be paused for a short period of time, such as a few seconds, so that the glue in the last area to be glued has a certain amount of time to solidify or semi-solidify.

[0041] Optionally, since the resin is applied layer by layer, the resin content of each layer can be precisely controlled. For example, the resin content of different layers can be different. In one possible embodiment, the initial P-layer fiber layer is called the bottom fiber, and the resin content applied to each bottom fiber is M; the last Q-layer fiber layer is called the surface fiber, and the resin content applied to each surface fiber is N; the remaining middle layer fiber layer is called the middle layer fiber, and the resin content applied to each middle layer fiber is L; wherein M>L, N>L, P is, for example, an integer from 1 to 3, and Q is, for example, an integer from 1 to 3. In other words, in this embodiment, the resin content of the bottom fiber and the surface fiber is greater than that of the middle layer fiber. This is because the bottom layer fibers are expected to have a higher bonding strength with the metal surface of the rotor core, so the amount of resin applied to the bottom layer fibers is set higher; the surface layer fibers are expected to have higher density and smoothness to avoid defects such as tiny air gaps in the surface resin, which may cause cracking of the fiber sheath after the resin is cured; in addition, the front and back sides of the middle layer fibers can be infiltrated by the resin from the surface and bottom layers respectively, so the amount of resin applied to the middle layer fibers can be controlled to be less.

[0042] It should be understood that after the entire fiber sheath is wound, it is generally necessary to place the rotor together with the fiber sheath in an oven for heating so that the resin in the fiber sheath is completely cured.

[0043] Second embodiment

[0044] Reference Figure 5 The second embodiment of the present application is introduced. The second embodiment is a modification of the first embodiment, and components having the same or similar structures or functions as those in the first embodiment are marked with the same reference numerals, and detailed descriptions of these components are omitted.

[0045] The main difference between this embodiment and the first embodiment is that a heating device 40 is also used during the winding process of the sheath. The heating device 40 is, for example, a hot air blower or a heating wire, that is, the heating method can be heat convection or heat radiation. The heating device 40 is used to make the liquid resin applied to the winding completion section A reach a semi-cured state, so that when the next layer of fiber tape 20 is wound, the next layer of fiber tape 20 will not squeeze and deform the resin attached to the previous layer of fiber tape 20, resulting in uneven distribution.

[0046] In other possible implementations, depending on the type of resin used, ultraviolet rays may be used, for example, to achieve semi-curing of the resin. Alternatively, chemical methods, such as applying an additional catalyst, may be used to accelerate the semi-curing process of the resin.

[0047] Third embodiment

[0048] Reference Figure 6 and Figure 7 The third embodiment of the present application is introduced. The third embodiment is another variation of the first embodiment.

[0049] The main difference between this embodiment and the first embodiment is that, during each layer of winding, the interval between the start time of gluing and the start time of winding is very short, for example, the gluing operation starts after the first 2 to 3 turns of winding are completed; and in the subsequent gluing process of the layer, the gluing speed is almost the same as the winding speed, but there is a phase difference in position. The principle followed by the entire gluing process is still that the gluing area is the surface of the winding section of the layer, and the glue is evenly distributed in the gluing area.

[0050] It should be understood that the above-mentioned embodiments and some aspects or features thereof may be appropriately combined.

[0051] The present invention has at least one of the following advantages:

[0052] (i) The present application innovatively improves the wet winding of carbon fiber so that the fibers are not attached with liquid resin before winding, but the resin is applied dynamically layer by layer in the winding completion section, so that the resin in the overlapping area and the resin in the non-overlapping area of ​​each layer of fiber tape are evenly distributed, and the carbon fiber sheath finally formed has uniform thickness and smooth surface.

[0053] (ii) During the winding process of each layer, the glue application area can be semi-cured in time to further avoid uneven distribution of resin due to interlayer extrusion of the fiber tape.

[0054] Of course, the present invention is not limited to the above embodiments, and those skilled in the art can make various modifications to the above embodiments of the present invention under the guidance of the present invention without departing from the scope of the present invention. For example, the fiber sheath of the present application is not limited to carbon fiber, and the fiber used can also be other fibers, such as glass fiber.

Claims

1. A method for winding a rotor fiber sheath, the method being used for winding a fiber tape (20) onto the outer periphery of an iron core (10) of a motor rotor to form a sheath, characterized in that: The fiber tape (20) is spirally wound around the outer circumference of the iron core (10) layer by layer, and a spiral overlapping area (D) is formed between two adjacent turns of the fiber tape (20) in each layer of the sheath. During the winding process of each layer, the fiber band section that has been wound to a certain position on the outer periphery of the iron core (10) and will no longer be covered by the fiber band (20) of the adjacent turn in the same layer forms a winding completion section (A), and the fiber band section at the front end of the winding process of the layer does not belong to the winding completion section (A). The fiber tape (20) has no resin attached to its surface before winding, but during the winding process of each layer, liquid resin is evenly applied to the surface of the winding completed section (A) of the current layer. The amount of resin applied to the fiber tapes (20) of different layers is not exactly the same, and the amount of resin applied to the fiber tape (20) of the bottom layer is greater than the amount of resin applied to the fiber tape (20) of the middle layer.

2. The method for winding a rotor fiber sheath according to claim 1, characterized in that: The liquid resin is applied to the winding completion section (A) by spraying or brushing.

3. The method for winding a rotor fiber sheath according to claim 1, characterized in that: During the winding process of each layer, the winding speed satisfies: When the winding of the present layer is completed, the application of resin to the winding completion section (A) of the present layer is completely completed.

4. The method for winding a rotor fiber sheath according to claim 1, characterized in that: During each layer of winding, the winding completion section (A) to which the liquid resin has been applied is treated by physical or chemical methods so that the liquid resin reaches a semi-cured state.

5. The method for winding a rotor fiber sheath according to claim 4, characterized in that: The physical or chemical method includes at least one of the following methods: heating, light irradiation, and applying a catalyst.

6. The method for winding a rotor fiber sheath according to claim 4, characterized in that: During the winding process of each layer, the winding speed satisfies: When the winding of this layer is completed, the resin in the winding completion section (A) of this layer has all reached a semi-cured state.

7. The method for winding a rotor fiber sheath according to any one of claims 1 to 6, characterized in that: During the multi-layer winding of the fiber tape (20), the application process of the liquid resin is performed continuously or intermittently, and the winding of the fiber tape (20) is performed at a uniform speed or at a variable speed.

8. The method for winding a rotor fiber sheath according to any one of claims 4 to 6, characterized in that: The process of treating the winding completed section to which the liquid resin has been applied by a physical or chemical method is carried out continuously or intermittently.

9. The method for winding a rotor fiber sheath according to any one of claims 1 to 6, characterized in that: The amount of resin applied to the fiber tape (20) of the outermost layer is greater than the amount of resin applied to the fiber tape (20) of the middle layer.

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