A double-spliced welded cast aluminum rotor and its manufacturing process

Abstract

The present invention discloses a double-jointed welded cast aluminum rotor, comprising two short iron-core cast aluminum rotors, both ends of each short iron-core cast aluminum rotor are coaxially integrated with annular end plates, and the end faces of the two annular end plates are vertically connected to a plurality of rectangular blades distributed in a circumferential array; a part of each of the two coaxial short iron-core cast aluminum rotors close to each other is cut off at one end and then coaxially spliced, and the connection is welded on the basis of the axial splicing to form a double-jointed welded cast aluminum rotor; the long cast aluminum rotor of the present invention is formed by coaxially welding two short finished cast aluminum rotors after cutting, and there is no need to die-cast a cast aluminum rotor with a too long iron core, thereby avoiding the problem of air being more likely to be unable to be discharged in time inside the cast aluminum rotor due to the iron core being too long during die-casting.

Description

Technical Field

[0001] The present invention belongs to the field of cast aluminum rotors. Background Art

[0002] The working principle of casting aluminum for the rotor core is that pressure injects the melted aluminum liquid into the cavity, and waits for it to cool and solidify into a casting. Its characteristics are as follows:

[0003] (1) Throughout the die-casting process, pressure plays a major role.

[0004] (2) During die-casting, when the molten metal is in the process of high-speed filling the mold cavity, if the gas in the cavity cannot be discharged in time, it will be involved in the metal to generate pores.

[0005] (3) Since the molten metal is under pressure during the filling process of the mold cavity, the rotor core can be die-cast in the cold state.

[0006] In order to improve the product competitiveness, motor manufacturers often design higher-power motors in a smaller-sized frame, or increase the power of motors of a certain frame number by several levels; this results in a very long rotor core in the motor design and insufficient dimensions of the cast aluminum mold;

[0007] At the same time, if the cast aluminum rotor has a too long core during die-casting, it is easier for air inside to not be discharged in time, and the manufacturing quality cannot be guaranteed, affecting the efficiency, power factor, starting, running and other performances of the motor. Summary of the Invention

[0008] Object of the Invention: In order to overcome the deficiencies in the prior art, the present invention provides a double-piece welded cast aluminum rotor and its manufacturing process, which solves the problem that when die-casting a long-strip cast aluminum rotor, it is easier for air inside not to be discharged in time due to the too long core.

[0009] Technical Solution: To achieve the above object, a double-piece welded cast aluminum rotor of the present invention includes two short-core cast aluminum rotors. At both ends of each short-core cast aluminum rotor, there is an annular end plate integrated coaxially, and a plurality of rectangular blades distributed in a circumferential array are vertically connected to the end faces of the two annular end plates; one end of the two coaxially short-core cast aluminum rotors close to each other is cut off a part and then spliced coaxially, and on the basis of the coaxial splicing, it is welded and connected to form a double-piece welded cast aluminum rotor.

[0010] Further, the annular end plates at one end of the two coaxially short-core cast aluminum rotors close to each other are cut off a part along the radial direction and then spliced coaxially, and the annular splicing seam of the coaxial splicing is welded and connected to form a double-piece welded cast aluminum rotor.

[0011] Further, a manufacturing process of a double-piece welded cast aluminum rotor:

[0012] Step 1: Prepare two existing short-core cast aluminum rotors, and denote the two prepared short-core cast aluminum rotors as the first short-core cast aluminum rotor and the second short-core cast aluminum rotor respectively; denote the annular end plate at the end of the first short-core cast aluminum rotor as the first annular end plate; denote the annular end plate at the end of the second short-core cast aluminum rotor as the second annular end plate;

[0013] Step 2: Cut the first annular end plate at one end of the first short-core cast aluminum rotor along the radial direction, and denote the remaining part of the first annular end plate after being cut as the first welding disk to be welded;

[0014] Cut the second annular end plate at one end of the second short-core cast aluminum rotor along the radial direction, and denote the remaining part of the second annular end plate after being cut as the second welding disk to be welded;

[0015] Step 3: Align and fit the first welding disk to be welded of the first short-core cast aluminum rotor and the second welding disk to be welded of the second short-core cast aluminum rotor coaxially through a tooling fixture or a manipulator, so as to form a circle of welding seams to be welded on the outer periphery of the joint surface of the first welding disk to be welded and the second welding disk to be welded;

[0016] Step 4: The welding device completely welds the circle of the welding seams, so that the first short-core cast aluminum rotor and the second short-core cast aluminum rotor are joined together to form a double-piece welded cast aluminum rotor.

[0017] Optionally, each rectangular blade at the mutually approaching ends of the two coaxially short-core cast aluminum rotors is cut and spliced, and on the basis of the axial splicing, they are welded and connected to form a double-piece welded cast aluminum rotor.

[0018] Further, the two coaxially short-core cast aluminum rotors are denoted as the first short-core cast aluminum rotor and the second short-core cast aluminum rotor respectively;

[0019] Denote the annular end plate and the rectangular blades at the end of the first short-core cast aluminum rotor close to the second short-core cast aluminum rotor as the first annular end plate and the first rectangular blades respectively; the part of each first rectangular blade remaining on the first annular end plate after being truncated is denoted as the first broken blade;

[0020] Denote the annular end plate and the rectangular blades at the end of the second short-core cast aluminum rotor close to the first short-core cast aluminum rotor as the second annular end plate and the second rectangular blades respectively; the part of each second rectangular blade remaining on the second annular end plate after being truncated is denoted as the second broken blade;

[0021] When the first short-core cast aluminum rotor and the second short-core cast aluminum rotor are in the state of axial splicing, each first broken blade corresponds to each second broken blade one by one;

[0022] In the axial view of the first short-core cast aluminum rotor / second short-core cast aluminum rotor, the midlines of the first broken blade and the second broken blade both extend along the radial direction of the first short-core cast aluminum rotor / second short-core cast aluminum rotor;

[0023] At one end close to the axis of the first short-core cast aluminum rotor / second short-core cast aluminum rotor, any corresponding first broken blade and second broken blade are in line contact with each other, so that a molten solder filling pool with a pointed bottom is formed between the corresponding first broken blade and the second broken blade. After the molten solder filled in the molten solder filling pool solidifies, a welding sandwich layer sandwiched between the first broken blade and the second broken blade is formed; thus, the first short-core cast aluminum rotor and the second short-core cast aluminum rotor together constitute a double-piece welded cast aluminum rotor.

[0024] Further, the corresponding first broken blade, second broken blade and welding sandwich layer together constitute an integral centrifugal blade.

[0025] Further, a centrifugal air duct is formed between any two adjacent integral centrifugal blades on the double-piece welded cast aluminum rotor.

[0026] Further, a manufacturing process of a double-piece welded cast aluminum rotor:

[0027] Step 1, prepare two existing short-core cast aluminum rotors, and respectively denote the two prepared short-core cast aluminum rotors as the first short-core cast aluminum rotor and the second short-core cast aluminum rotor;

[0028] Denote the annular end plate and the rectangular blade on the first short-core cast aluminum rotor as the first annular end plate and the first rectangular blade respectively; denote the annular end plate and the rectangular blade on the second short-core cast aluminum rotor as the second annular end plate and the second rectangular blade respectively;

[0029] Step 2, use a cutting device to cut off the same length of all the first rectangular blades at one end of the first short-core cast aluminum rotor; the part of each first rectangular blade remaining on the first annular end plate after cutting is denoted as the first broken blade;

[0030] Use a cutting device to cut off the same length of all the second rectangular blades at one end of the second short-core cast aluminum rotor; the part of each second rectangular blade remaining on the second annular end plate after cutting is denoted as the second broken blade;

[0031] Each first broken blade corresponds to each second broken blade one by one;

[0032] Step 3, use two three-jaw chucks arranged coaxially and oppositely to clamp the first short-core cast aluminum rotor and the second short-core cast aluminum rotor respectively, so that the first short-core cast aluminum rotor and the second short-core cast aluminum rotor are coaxially arranged, and one end of the first short-core cast aluminum rotor with several first broken blades is opposite to one end of the second short-core cast aluminum rotor with several second broken blades;

[0033] Step 4: Rotate one of the two three-jaw chucks alone along the axis to rotate the clamped first short-core cast-aluminum rotor or the second short-core cast-aluminum rotor alone until several first broken blades on the first short-core cast-aluminum rotor are staggered from several second broken blades on the second short-core cast-aluminum rotor in the axial view.

[0034] Step 5: Control the two three-jaw chucks to move closer to each other along the axis direction, so that the first short-core cast-aluminum rotor and the second short-core cast-aluminum rotor approach each other along the axis direction until the ends of the first broken blades on the first short-core cast-aluminum rotor contact the end face of the second annular end plate on the second short-core cast-aluminum rotor, and the ends of the second broken blades on the second short-core cast-aluminum rotor contact the end face of the first annular end plate on the first short-core cast-aluminum rotor.

[0035] Step 6: Rotate one of the two three-jaw chucks alone along the axis to rotate the clamped first short-core cast-aluminum rotor or the second short-core cast-aluminum rotor alone, so that the first short-core cast-aluminum rotor and the second short-core cast-aluminum rotor rotate relatively along the axis direction until any corresponding first broken blade and second broken blade are in line contact at one end close to the axis of the first short-core cast-aluminum rotor / the second short-core cast-aluminum rotor, thereby forming a molten solder filling pool with a pointed bottom between any corresponding first broken blade and second broken blade. At this time, it enters the splicing completion state.

[0036] Step 7: Synchronously control the two three-jaw chucks to rotate synchronously along the axis, so that the splicing structure composed of the first short-core cast-aluminum rotor and the second short-core cast-aluminum rotor rotates synchronously along the axis until the first molten solder filling pool among several circumferentially arrayed molten solder filling pools has its pool mouth facing up, then synchronously control the two three-jaw chucks to pause; then inject molten solder into the first molten solder filling pool with the pool mouth facing up. After the molten solder filled in the molten solder filling pool quickly solidifies, a welding sandwich layer is formed between the first broken blade and the second broken blade; the corresponding first broken blade, second broken blade, and welding sandwich layer together form an integral centrifugal blade.

[0037] Step 8: Synchronously control the two three-jaw chucks to rotate synchronously along the axis, so that the splicing structure composed of the first short-core cast-aluminum rotor and the second short-core cast-aluminum rotor rotates synchronously along the axis until the pool mouth of another molten solder filling pool faces up, then synchronously control the two three-jaw chucks to pause; then inject molten solder into the molten solder filling pool with the pool mouth facing up, thereby obtaining another integral centrifugal blade.

[0038] Step nine, continuously repeating the process of "step eight" until all the welding liquid filling pools are finally filled with welding liquid; finally, the first short iron core cast aluminum rotor and the second short iron core cast aluminum rotor together form a double-jointed welded cast aluminum rotor; a centrifugal air duct is formed between any two adjacent integral centrifugal blades on the double-jointed welded cast aluminum rotor.

[0039] Beneficial effects: The long cast aluminum rotor of the present invention is made by coaxially welding two short finished cast aluminum rotors after cutting. There is no need to die-cast a cast aluminum rotor with a too long iron core, thereby avoiding the problem of air not being able to be discharged from the inside of the cast aluminum rotor due to the iron core being too long during die-casting. At the same time, in the "second embodiment", the problem of uneven heat dissipation of the long iron core is solved while ensuring the connection strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 This is a schematic diagram of the existing short iron core cast aluminum rotor structure;

[0041] Figure 2 This is a schematic diagram of the cutting process in "Step 2" of the "First Embodiment";

[0042] Figure 3 This is a schematic diagram of the completion of the cutting in "Step 2" of the "First Embodiment";

[0043] Figure 4 This is a schematic diagram of the double-jointed welded cast aluminum rotor structure obtained after welding is completed in the "first embodiment";

[0044] Figure 5 Schematic diagram of the first short iron-core cast aluminum rotor and the second short iron-core cast aluminum rotor prepared for the "Second Embodiment";

[0045] Figure 6 This is a schematic diagram of the blade after being cut off at the end of "Step 2" of "Second Embodiment";

[0046] Figure 7 This is a schematic diagram at the end of "Step 5" of "Second Embodiment";

[0047] Figure 8 for Figure 7 A-direction sectional view;

[0048] Figure 9 This is a schematic diagram at the end of "Step 6" of "Second Embodiment";

[0049] Figure 10 for Figure 9 B-direction sectional view;

[0050] Figure 11 for Figure 10 An enlarged schematic diagram of the mark 14;

[0051] Figure 12 Schematic diagram after injecting welding fluid into the welding fluid filling pool on the basis of Figure 11 , see Step 7. Specific Embodiments

[0052] The present invention will be further described below with reference to the accompanying drawings.

[0053] As shown in the attached Figures 1 to 12 A double - spliced welded cast aluminum rotor, as Figure 1 , includes two existing short - core cast aluminum rotors 1. The aspect ratio of the short - core cast aluminum rotor 1 is approximately 5:4. At both ends of each short - core cast aluminum rotor 1, there are annular end plates 7 integrated coaxially. And on the end faces of the two annular end plates 7, there are several rectangular blades 2 distributed in a circumferential array perpendicular to the connection; An axial hole seat 5 is integrally arranged inside the short - core cast aluminum rotor 1. There is an axial hole 5 in the center of the axial hole seat 5 for the rotor shaft to pass through. There is a keyway or other synchronization structures, such as welding, etc. in the axial hole 5 for synchronization with the rotor shaft. There are ventilation holes 6 at the edge of the axial hole seat 5; One end of the two coaxially - arranged short - core cast aluminum rotors 1 that are close to each other is cut off a part and then spliced coaxially, and on the basis of the axial splicing, they are welded together to form a double - spliced welded cast aluminum rotor 1. The long cast aluminum rotor of the present invention is obtained by cutting two short finished cast aluminum rotors and then welding them coaxially. There is no need to cast a cast aluminum rotor with a too - long iron core, thus avoiding the problem that when casting the cast aluminum rotor, due to the too - long iron core, it is easier for air inside not to be discharged in time.

[0054] Specifically, it includes the following two embodiments.

[0055] The First Embodiment:

[0056] As shown in Figure 2 , 3 , 4, the annular end plates 7 at one end of the two coaxially - arranged short - core cast aluminum rotors 1 that are close to each other are cut off a part along the radial direction and then spliced coaxially. The annular splicing seam of the coaxial splicing is connected by welding to form a double - spliced welded cast aluminum rotor 1c.

[0057] Manufacturing process of the double - spliced welded cast aluminum rotor in the first embodiment:

[0058] Step 1: Prepare two existing short - core cast aluminum rotors 1, and respectively denote the two prepared short - core cast aluminum rotors 1 as the first short - core cast aluminum rotor 1a and the second short - core cast aluminum rotor 1b; Denote the annular end plate 7 at the end of the first short - core cast aluminum rotor 1a as the first annular end plate 7a; Denote the annular end plate 7 at the end of the second short - core cast aluminum rotor 1b as the second annular end plate 7b;

[0059] Step 2: Cut the first annular end plate 7a at one end of the first short - core cast aluminum rotor 1a along the radial direction. The remaining part after the first annular end plate 7a is cut off is denoted as the first welding - to - be - welded plate 7.1a;

[0060] Cut the second annular end plate 7b at one end of the second short-core cast aluminum rotor 1b in the radial direction. The remaining part of the second annular end plate 7b after being cut is denoted as the second welding plate to be welded 7.1b;

[0061] The thickness of the first welding plate to be welded 7.1a and the second welding plate to be welded 7.1b is 10 - 15 mm;

[0062] Step 3: Align and fit the first welding plate to be welded 7.1a of the first short-core cast aluminum rotor 1a and the second welding plate to be welded 7.1b of the second short-core cast aluminum rotor 1b coaxially through a tooling fixture or a manipulator, so that a welding seam 41 to be welded is formed in a circle on the outer periphery of the joint surface of the first welding plate to be welded 7.1a and the second welding plate to be welded 7.1b;

[0063] Step 4: The welding device completely welds the welding seam 41 in a circle, so that the first short-core cast aluminum rotor 1a and the second short-core cast aluminum rotor 1b are joined together to form a double-spliced welded cast aluminum rotor 1c.

[0064] Since the length of this double-spliced welded cast aluminum rotor 1c is almost doubled compared with the short-core cast aluminum rotor 1, the axial length of the stator winding of the motor matching it is also doubled, and the middle section of the stator winding is too far from the heat dissipation fins at both ends of the rotor, thus causing the problem of poor heat dissipation of the stator winding matching it.

[0065] Second Embodiment:

[0066] As Figures 5 to 12 shown, the rectangular blades 2 at the mutually approaching ends of the two coaxial short-core cast aluminum rotors 1 are all cut and spliced, and are welded and connected on the basis of the axial center splicing to form a double-spliced welded cast aluminum rotor 1c; the two coaxial short-core cast aluminum rotors 1 are respectively denoted as the first short-core cast aluminum rotor 1a and the second short-core cast aluminum rotor 1b;

[0067] The annular end plate 7 and the rectangular blade 2 at one end of the first short-core cast aluminum rotor 1a close to the second short-core cast aluminum rotor 1b are respectively denoted as the first annular end plate 7a and the first rectangular blade 2a; the part of each first rectangular blade 2a remaining on the first annular end plate 7a after being truncated is denoted as the first broken blade 2.1a;

[0068] The annular end plate 7 and the rectangular blade 2 at one end of the second short-core cast aluminum rotor 1b close to the first short-core cast aluminum rotor 1a are respectively denoted as the second annular end plate 7b and the second rectangular blade 2b; the part of each second rectangular blade 2b remaining on the second annular end plate 7b after being truncated is denoted as the second broken blade 2.1b;

[0069] When the first short-core cast aluminum rotor 1a and the second short-core cast aluminum rotor 1b are spliced coaxially, each first broken blade 2.1a corresponds to each second broken blade 2.1b one by one;

[0070] From the axial view of the first short-core cast aluminum rotor 1a / the second short-core cast aluminum rotor 1b, the midlines 33 of the first broken blade 2.1a and the second broken blade 2.1b both extend along the radial direction of the first short-core cast aluminum rotor 1a / the second short-core cast aluminum rotor 1b;

[0071] One end of any corresponding first broken blade 2.1a and second broken blade 2.1b that is close to the axis of the first short-core cast aluminum rotor 1a / the second short-core cast aluminum rotor 1b is in line contact 32 with each other, so that a molten solder filling pool 8 with a pointed bottom is formed between the corresponding first broken blade 2.1a and second broken blade 2.1b. After the molten solder filled in the molten solder filling pool 8 solidifies, a welded interlayer 12 sandwiched between the first broken blade 2.1a and the second broken blade 2.1b is formed; thus, the first short-core cast aluminum rotor 1a and the second short-core cast aluminum rotor 1b jointly constitute a double-spliced welded cast aluminum rotor 1c.

[0072] The corresponding first broken blade 2.1a, second broken blade 2.1b and welded interlayer 12 together constitute an integral centrifugal blade 13; thus, a centrifugal air duct 9 is formed between any two adjacent integral centrifugal blades 13 on the double-spliced welded cast aluminum rotor 1c.

[0073] Manufacturing process of the double-spliced welded cast aluminum rotor of the second embodiment:

[0074] Step 1, prepare two existing short-core cast aluminum rotors 1, and mark the two prepared short-core cast aluminum rotors 1 as the first short-core cast aluminum rotor 1a and the second short-core cast aluminum rotor 1b respectively;

[0075] Mark the annular end plate 7 and the rectangular blade 2 on the first short-core cast aluminum rotor 1a as the first annular end plate 7a and the first rectangular blade 2a respectively; mark the annular end plate 7 and the rectangular blade 2 on the second short-core cast aluminum rotor 1b as the second annular end plate 7b and the second rectangular blade 2b respectively;

[0076] Step 2, use a cutting device to cut off the same length from all the first rectangular blades 2a at one end of the first short-core cast aluminum rotor 1a; the part of each first rectangular blade 2a remaining on the first annular end plate 7a after cutting is marked as the first broken blade 2.1a;

[0077] Use a cutting device to cut off the same length from all the second rectangular blades 2b at one end of the second short-core cast aluminum rotor 1b; the part of each second rectangular blade 2b remaining on the second annular end plate 7b after cutting is marked as the second broken blade 2.1b;

[0078] Each first broken blade 2.1a corresponds to each second broken blade 2.1b one by one;

[0079] Step 3: Clamp the first short iron-core cast aluminum rotor 1a and the second short iron-core cast aluminum rotor 1b respectively using two coaxially opposed three-jaw chucks, so that the first short iron-core cast aluminum rotor 1a and the second short iron-core cast aluminum rotor 1b are coaxially arranged, and one end of the first short iron-core cast aluminum rotor 1a having the plurality of first broken blades 2.1a is opposite to one end of the second short iron-core cast aluminum rotor 1b having the plurality of second broken blades 2.1b;

[0080] Step 4: By controlling one of the two three-jaw chucks to rotate along the axis, the clamped first short iron-core cast aluminum rotor 1a or the second short iron-core cast aluminum rotor 1b is rotated separately until the first broken blades 2.1a on the first short iron-core cast aluminum rotor 1a and the second broken blades 2.1b on the second short iron-core cast aluminum rotor 1b are offset from each other in the axial direction;

[0081] Step 5: By controlling the two three-jaw chucks to move closer to each other along the axial direction, the first short iron core cast aluminum rotor 1a and the second short iron core cast aluminum rotor 1b are moved closer to each other along the axial direction until the ends of the first broken blades 2.1a on the first short iron core cast aluminum rotor 1a contact the end surface of the second annular end plate 7b on the second short iron core cast aluminum rotor 1b, and the ends of the second broken blades 2.1b on the second short iron core cast aluminum rotor 1b contact the end surface of the first annular end plate 7a on the first short iron core cast aluminum rotor 1a; if the first short iron core cast aluminum rotor 1a and the second short iron core cast aluminum rotor 1b are to be moved closer together in this state, The cast aluminum rotor 1b is welded into one piece. Since the conditions for continuous welding are not met in this state, the ends of each second segmented blade 2.1b and the first annular end disc 7a, as well as the ends of each first segmented blade 2.1a and the second annular end disc 7b can only be combined by unstable spot welding. Since the joint area of the spot welding is very small, such unstable discrete spot welding will easily fall off one by one in the later stage, especially due to the problem of thermal expansion and contraction. The unstable spot welding will further cause the risk of separation of the first short iron core cast aluminum rotor 1a and the second short iron core cast aluminum rotor 1b during the operation of the motor. Therefore, the following process needs to be introduced:

[0082] Step 6: By controlling one of the two three-jaw chucks to rotate along the axis alone, the clamped first short iron-core cast aluminum rotor 1a or the second short iron-core cast aluminum rotor 1b is rotated alone, thereby causing the first short iron-core cast aluminum rotor 1a and the second short iron-core cast aluminum rotor 1b to rotate relative to each other along the axis until any corresponding first broken blade 2.1a and the second broken blade 2.1b are in line contact 32 with each other at one end close to the axis of the first short iron-core cast aluminum rotor 1a / the second short iron-core cast aluminum rotor 1b, thereby forming a welding liquid filling pool 8 with a pointed bottom between any corresponding first broken blade 2.1a and the second broken blade 2.1b, and the splicing is now completed;

[0083] Step 7: Synchronously control the two three-jaw chucks to rotate synchronously along the axis, so that the splicing structure composed of the first short-core cast aluminum rotor 1a and the second short-core cast aluminum rotor 1b rotates synchronously along the axis. When the orifice of the first solder filling pool 8 among several solder filling pools 8 arranged in a circular array faces upward, synchronously control the two three-jaw chucks to pause; then inject solder (such as molten aluminum, etc.) into the solder filling pool 8 with the upward-facing orifice. After the solder filled in the solder filling pool 8 quickly solidifies, a welding interlayer 12 sandwiched between the first broken blade 2.1a and the second broken blade 2.1b is formed; correspondingly, the first broken blade 2.1a, the second broken blade 2.1b and the welding interlayer 12 together constitute an integral centrifugal blade 13;

[0084] Step 8: Synchronously control the two three-jaw chucks to rotate synchronously along the axis, so that the splicing structure composed of the first short-core cast aluminum rotor 1a and the second short-core cast aluminum rotor 1b rotates synchronously along the axis. When the orifice of another solder filling pool 8 faces upward, synchronously control the two three-jaw chucks to pause; then inject solder into the solder filling pool 8 with the upward-facing orifice, thereby obtaining another integral centrifugal blade 13;

[0085] Step 9: Continuously repeat the process of "Step 8" until all the solder filling pools 8 are filled with solder once; finally, the first short-core cast aluminum rotor 1a and the second short-core cast aluminum rotor 1b together form a double-spliced welded cast aluminum rotor 1c; a centrifugal air duct 9 is formed between any two adjacent integral centrifugal blades 13 on the double-spliced welded cast aluminum rotor 1c.

[0086] When this double-spliced welded cast aluminum rotor 1c with double the length cooperates with a long-sized stator winding, during the high-speed rotation of the double-spliced welded cast aluminum rotor 1c, the air in the centrifugal air duct 9 formed between any two adjacent integral centrifugal blades 13 is continuously thrown outwards by the centrifugal force to the middle area of the long-sized stator winding, and then diffuses towards both ends through the stator-rotor air gap, thereby promoting the heat dissipation of the middle section of the long-sized stator winding; at the same time, the air at both ends of the stator-rotor cavity is continuously supplemented to the middle position inside the double-spliced welded cast aluminum rotor 1c through the ventilation holes 6 at both ends of the double-spliced welded cast aluminum rotor 1c and is continuously thrown out through the centrifugal air duct 9, thereby forming a continuous gas internal circulation inside the stator-rotor cavity and avoiding the formation of a high-temperature environment that is difficult to diffuse locally inside the stator-rotor cavity.

[0087] The above is only the preferred embodiment of the present invention. It should be pointed out that: for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and retouches can be made, and these improvements and retouches should also be regarded as the protection scope of the present invention.

Claims

1. A double-jointed welded cast aluminum rotor, characterized in that: The invention comprises two short iron core cast aluminum rotors (1), both ends of each short iron core cast aluminum rotor (1) are coaxially integrated with an annular end disk (7), and the end surfaces of the two annular end disks (7) are vertically connected with a plurality of rectangular blades (2) distributed in a circumferential array; a portion of each of the two coaxial short iron core cast aluminum rotors (1) is cut off at one end close to each other, and then the ends are coaxially spliced, and the axial splicing is welded to form a double-jointed welded cast aluminum rotor (1); The rectangular blades (2) of the two coaxial short iron core cast aluminum rotors (1) close to one end are cut and then spliced, and then welded together on the basis of the axial splicing to form a double-joined welded cast aluminum rotor (1c); Two coaxial short iron-core cast aluminum rotors (1) are respectively denoted as a first short iron-core cast aluminum rotor (1a) and a second short iron-core cast aluminum rotor (1b); The annular end disc (7) and the rectangular blade (2) of the first short iron core cast aluminum rotor (1a) close to one end of the second short iron core cast aluminum rotor (1b) are respectively recorded as the first annular end disc (7a) and the first rectangular blade (2a); the portion of each first rectangular blade (2a) remaining on the first annular end disc (7a) after being cut off is recorded as the first broken blade (2.1a); The annular end disc (7) and the rectangular blade (2) of the second short iron core cast aluminum rotor (1b) close to one end of the first short iron core cast aluminum rotor (1a) are respectively recorded as the second annular end disc (7b) and the second rectangular blade (2b); the portion of each second rectangular blade (2b) remaining on the second annular end disc (7b) after being cut off is recorded as the second broken blade (2.1b); The first short iron core cast aluminum rotor (1a) and the second short iron core cast aluminum rotor (1b) are coaxially spliced, and each first broken blade (2.1a) corresponds to each second broken blade (2.1b) one by one; From an axial perspective of the first short iron-core cast aluminum rotor (1a) / the second short iron-core cast aluminum rotor (1b), the center lines (33) of the first broken blade (2.1a) and the second broken blade (2.1b) both extend in the radial direction of the first short iron-core cast aluminum rotor (1a) / the second short iron-core cast aluminum rotor (1b); Any corresponding first broken blade (2.1a) and second broken blade (2.1b) are in line contact (32) with each other at one end close to the axis of the first short iron core cast aluminum rotor (1a) / the second short iron core cast aluminum rotor (1b), so that a welding liquid filling pool (8) with a pointed bottom is formed between the corresponding first broken blade (2.1a) and the second broken blade (2.1b), and the welding liquid filled in the welding liquid filling pool (8) solidifies to form a welding interlayer (12) sandwiched between the first broken blade (2.1a) and the second broken blade (2.1b); thereby, the first short iron core cast aluminum rotor (1a) and the second short iron core cast aluminum rotor (1b) together constitute a double-jointed welded cast aluminum rotor (1c).

2. A double-spliced welded cast aluminum rotor according to claim 1, characterized in that: The corresponding first broken blade (2.1a), the second broken blade (2.1b) and the welded interlayer (12) together form an integrated centrifugal blade (13).

3. A double-spliced welded cast aluminum rotor according to claim 2, characterized in that: A centrifugal air duct (9) is formed between any two adjacent integral centrifugal blades (13) on the double-jointed welded cast aluminum rotor (1c).

4. The manufacturing process of a double-jointed welded cast aluminum rotor according to claim 3, characterized in that: Step 1: prepare two existing short iron-core cast aluminum rotors (1), and respectively record the two prepared short iron-core cast aluminum rotors (1) as a first short iron-core cast aluminum rotor (1a) and a second short iron-core cast aluminum rotor (1b); The annular end disc (7) and the rectangular blade (2) on the first short iron core cast aluminum rotor (1a) are respectively recorded as the first annular end disc (7a) and the first rectangular blade (2a); the annular end disc (7) and the rectangular blade (2) on the second short iron core cast aluminum rotor (1b) are respectively recorded as the second annular end disc (7b) and the second rectangular blade (2b); Step 2: Using a cutting device, all first rectangular blades (2a) at one end of the first short iron core cast aluminum rotor (1a) are cut off by the same length; the portion of each first rectangular blade (2a) remaining on the first annular end plate (7a) after being cut off is recorded as a first broken blade (2.1a); All second rectangular blades (2b) at one end of the second short iron core cast aluminum rotor (1b) are cut off by a cutting device to the same length; the portion of each second rectangular blade (2b) remaining on the second annular end disc (7b) after being cut off is recorded as a second broken blade (2.1b); Each first broken blade (2.1a) corresponds to each second broken blade (2.1b) one by one; Step 3: clamping the first short iron-core cast aluminum rotor (1a) and the second short iron-core cast aluminum rotor (1b) respectively by two coaxially oppositely arranged three-jaw chucks, so that the first short iron-core cast aluminum rotor (1a) and the second short iron-core cast aluminum rotor (1b) are coaxially arranged, and one end of the first short iron-core cast aluminum rotor (1a) having the plurality of first broken blades (2.1a) is opposite to one end of the second short iron-core cast aluminum rotor (1b) having the plurality of second broken blades (2.1b); Step 4: by controlling one of the two three-jaw chucks to rotate independently along the axis, the clamped first short iron-core cast aluminum rotor (1a) or the second short iron-core cast aluminum rotor (1b) is rotated independently until the plurality of first broken blades (2.1a) on the first short iron-core cast aluminum rotor (1a) and the plurality of second broken blades (2.1b) on the second short iron-core cast aluminum rotor (1b) are staggered in an axial perspective; Step 5: By controlling the two three-jaw chucks to move closer to each other along the axial direction, the first short iron-core cast aluminum rotor (1a) and the second short iron-core cast aluminum rotor (1b) are moved closer to each other along the axial direction until the ends of the first broken blades (2.1a) on the first short iron-core cast aluminum rotor (1a) contact the end surface of the second annular end disk (7b) on the second short iron-core cast aluminum rotor (1b), and the ends of the second broken blades (2.1b) on the second short iron-core cast aluminum rotor (1b) contact the end surface of the first annular end disk (7a) on the first short iron-core cast aluminum rotor (1a): Step six, by controlling one of the two three-jaw chucks to rotate along the axis alone, the clamped first short iron core cast aluminum rotor (1a) or the second short iron core cast aluminum rotor (1b) is rotated alone, thereby causing the first short iron core cast aluminum rotor (1a) and the second short iron core cast aluminum rotor (1b) to rotate relative to each other along the axis direction, until any corresponding first broken blade (2.1a) and the second broken blade (2.1b) are in line contact (32) with each other at one end close to the axis of the first short iron core cast aluminum rotor (1a) / the second short iron core cast aluminum rotor (1b), thereby forming a welding liquid filling pool (8) with a pointed bottom between any corresponding first broken blade (2.1a) and the second broken blade (2.1b), and the splicing is now completed; Step seven, by synchronously controlling the two three-jaw chucks to rotate synchronously along the axis, the spliced structure formed by the first short iron core cast aluminum rotor (1a) and the second short iron core cast aluminum rotor (1b) is synchronously rotated along the axis until the pool opening of the first welding liquid filling pool (8) in a plurality of welding liquid filling pools (8) distributed in a circumferential array faces upward, and then the two three-jaw chucks are synchronously controlled to pause; then, welding liquid is injected into the welding liquid filling pool (8) with the pool opening facing upward, and the welding liquid filled in the welding liquid filling pool (8) quickly solidifies to form a welding interlayer (12) sandwiched between the first broken blade (2.1a) and the second broken blade (2.1b); the corresponding first broken blade (2.1a), the second broken blade (2.1b) and the welding interlayer (12) together constitute an integrated centrifugal blade (13); Step eight, by synchronously controlling the two three-jaw chucks to rotate synchronously along the axis, the spliced structure formed by the first short iron core cast aluminum rotor (1a) and the second short iron core cast aluminum rotor (1b) is synchronously rotated along the axis until the pool opening of the other welding liquid filling pool (8) is facing upward, and then the two three-jaw chucks are synchronously controlled to pause; then, welding liquid is injected into the welding liquid filling pool (8) with the pool opening facing upward, thereby obtaining another integrated centrifugal blade (13); Step nine, continuously repeating the process of "step eight" until all the welding liquid filling pools (8) are finally filled with welding liquid; finally, the first short iron core cast aluminum rotor (1a) and the second short iron core cast aluminum rotor (1b) together form a double-jointed welded cast aluminum rotor (1c); and a centrifugal air duct (9) is formed between any two adjacent integral centrifugal blades (13) on the double-jointed welded cast aluminum rotor (1c).

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