Structural design and processing method of motor end cover

Abstract

The invention provides a motor end cover structure design and processing method, and belongs to the technical field of component processing, and the method comprises the steps: determining the shape of a motor end cover according to the size specification of a motor, and creating a model of the end cover; picking up the front and rear end faces of the model and processing a bottom plate and a top plate with the same structure by taking the end faces as references; the powder is filled between the bottom plate and the top plate, and the bottom plate, the top plate and the powder are preliminarily solidified into an integrated structure through extrusion forming and sintering and serve as a test component. Testing the structural strength and toughness of the test component, and adjusting the bottom plate, the top plate and the powder according to a test result; and after adjustment is completed, the to-be-machined component is redesigned and machined, and high current is applied to multiple positions of the to-be-machined component to enable powder to be hot-melted so as to complete connection between the to-be-machined component and the bottom plate and the top plate. According to the motor end cover structure design and the processing method thereof provided by the invention, the normal service life of the end cover can be ensured, more importantly, the process required by processing is simplified, the production efficiency is improved, and the cost is greatly reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of component processing, and more specifically, relates to the structural design of a motor end cover and a processing method thereof. Background Art

[0002] Motor refers to mechanical equipment that realizes different forms of energy conversion. Motors are widely used in industrial and agricultural production, national defense, science and technology, and daily life. Usually, the two ends of the motor are the front cover and the rear cover, which play the role of supporting the rotor, stator, rectifier and brush assembly. The performance of the motor end cover has a great influence on its normal operation and its service life. Therefore, this requires that the motor end cover not only has good mechanical properties and mechanical properties, but also has good temperature resistance, corrosion resistance, etc.

[0003] Since the production of motor end covers involves multiple processes, manual loading and unloading is required on different equipment, which makes the efficiency of processing parts low and the labor intensity high. The overall processing efficiency of the end cover is low, and more steps are required to process the finished product, resulting in high costs and inability to produce quickly and in batches. Summary of the invention

[0004] The purpose of the present invention is to provide a motor end cover structure design and a processing method thereof, aiming to solve the problem that the end cover processing has low production efficiency, many steps and high cost.

[0005] To achieve the above purpose, the technical solution adopted by the present invention is: to provide a motor end cover structure design and a processing method thereof, including: Determine the shape of the motor end cover according to the size specifications of the motor and create a model of the end cover; Pick up the front and rear end faces of the model and process the bottom plate and top plate of the same structure based on the end faces; Filling powder between the bottom plate and the top plate, and preliminarily solidifying the bottom plate, the top plate and the powder into an integrated structure through extrusion shaping and sintering as a test component; The structural strength and toughness of the test component are tested, and the bottom plate, the top plate and the powder are adjusted according to the test results; after the adjustment is completed, the component to be processed is redesigned and processed, and high current is applied to multiple locations of the component to be processed to heat-melt the powder to complete the connection with the bottom plate and the top plate.

[0006] In a possible implementation, determining the shape of the motor end cover according to the size specifications of the motor and creating a model of the end cover includes: The load and working environment of the motor are preliminarily determined to predict the physical properties required for the end cover, and a shape that meets the requirements is designed based on the predicted results and the model is preliminarily created.

[0007] In a possible implementation, picking up the front and rear end faces of the model and processing the bottom plate and the top plate of the same structure based on the end faces includes: Picking up the shapes of the outer side and the inner side of the model and then preparing a mold of the same shape; The shapes of the bottom plate and the top plate are respectively the same as the outer side surface and the inner side surface of the model through stamping and forming.

[0008] In a possible implementation, the stamping process is used to make the shapes of the bottom plate and the top plate the same as the outer side surface and the inner side surface of the model, respectively, including: Surface treatment is performed on the sheet materials used for stamping so that their surface quality meets the requirements; During the stamping process, the plate is plastically deformed to eliminate the stress on the bottom plate and the top plate; during the stamping process, holes are punched at positions corresponding to the bottom plate and the top plate.

[0009] In a possible implementation, picking up the front and rear end faces of the model and processing the bottom plate and the top plate of the same structure based on the end faces includes: The bottom plate is engaged with the top plate to ensure that the openings on the bottom plate and the top plate are coaxially arranged.

[0010] In a possible implementation, filling the powder between the bottom plate and the top plate includes: First, the top plate is positioned, and then the powder is sprayed on the top surface of the top plate to ensure that the thickness of the powder at each location meets the requirements; After the powder spraying is completed, the base plate is clamped and subsequently extruded and formed.

[0011] In a possible implementation, filling the powder between the bottom plate and the top plate includes: Firstly, a bottom film is laid, and after the bottom film is laid, the powder is sprayed, and after the powder is sprayed, a top film is laid and then extruded and formed; After shaping is completed, quality inspection is performed, and the stability of the powder structure is ensured by the bottom film and the top film.

[0012] In a possible implementation manner, after the stability of the powder structure is ensured by the bottom film and the top film, the method further includes: The powder together with the bottom film and the top film are positioned between the bottom plate and the top plate. During the subsequent sintering process, the bottom film and the top film fill the gap between the bottom plate, the top plate and the powder while achieving bonding and fastening of the two.

[0013] In a possible implementation, adjusting the bottom plate, the top plate, and the powder according to the test results includes: Adjust the material of the bottom plate and the top plate according to the test results; adjust the thickness of the bottom plate, the top plate and the powder layer; If the test shows that the bearing capacity of the position is insufficient and deformation occurs, the thickness of the bottom plate and the top plate in the deformation area is increased, or a reinforcing structure is fixed on the bottom plate and the top plate before positioning the powder.

[0014] In a possible implementation, applying high current to multiple locations of the component to be processed to heat-melt the powder so as to complete the connection with the bottom plate and the top plate includes: A high voltage is applied between the bottom plate and the top plate, so that a current is formed between the bottom plate and the top plate, and the current causes the bottom plate, the top plate and the powder in the corresponding area to melt and form an integrated structure after cooling.

[0015] The motor end cover structure design and processing method provided by the present invention have the following beneficial effects: Compared with the prior art, the motor end cover structure design and processing method provided by the present invention first determine the shape of the motor end cover according to the size specifications of the motor and create a model of the end cover. Pick up the front and rear end faces of the model and process the bottom plate and top plate of the same structure based on the end faces. Fill the powder between the bottom plate and the top plate, and preliminarily solidify the bottom plate, top plate and powder into an integrated structure through extrusion shaping and sintering to serve as a test component.

[0016] After the test component is processed, its structural strength and toughness are tested, and then the bottom plate, top plate and powder are adjusted according to the results. Finally, in order to further improve the stability, high current is applied to multiple parts of the component to be processed to melt the powder and complete the connection with the bottom plate and top plate. This application discloses the design and processing flow of the motor end cover, which can ensure the normal service life of the end cover. More importantly, it simplifies the process required for processing, improves production efficiency and greatly reduces costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0018] Figure 1 A flow chart of the motor end cover structure design and its processing method provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0019] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0020] See also Figure 1 The motor end cover structure design and processing method provided by the present invention are now described. The motor end cover structure design and processing method include: Determine the shape of the motor end shield according to the size specifications of the motor and create a model of the end shield.

[0021] Pick up the front and rear end faces of the model and use the end faces as a reference to machine the bottom plate and top plate of the same structure.

[0022] The powder is filled between the bottom plate and the top plate, and the bottom plate, the top plate and the powder are initially solidified into an integrated structure through extrusion shaping and sintering and used as a test component.

[0023] The structural strength and toughness of the test component are tested, and the bottom plate, top plate and powder are adjusted according to the test results. After the adjustment is completed, the component to be processed is redesigned and processed, and high current is applied to multiple locations of the component to be processed to heat-melt the powder to complete the connection with the bottom plate and top plate.

[0024] The motor end cover structure design and processing method provided by the present invention have the following beneficial effects: Compared with the prior art, the motor end cover structure design and processing method provided by the present invention first determine the shape of the motor end cover according to the size specifications of the motor and create a model of the end cover. Pick up the front and rear end faces of the model and process the bottom plate and top plate of the same structure based on the end faces. Fill the powder between the bottom plate and the top plate, and preliminarily solidify the bottom plate, top plate and powder into an integrated structure through extrusion shaping and sintering to serve as a test component.

[0025] After the test component is processed, its structural strength and toughness are tested, and then the bottom plate, top plate and powder are adjusted according to the results. Finally, in order to further improve the stability, high current is applied to multiple parts of the component to be processed to melt the powder and complete the connection with the bottom plate and top plate. This application discloses the design and processing flow of the motor end cover, which can ensure the normal service life of the end cover. More importantly, it simplifies the process required for processing, improves production efficiency and greatly reduces costs.

[0026] In some embodiments of the motor end cover structure design and processing method provided in the present application, determining the shape of the motor end cover according to the size specifications of the motor and creating a model of the end cover includes: Preliminary judgment is made on the motor load and working environment to predict the physical properties required for the end cover. Based on the predicted results, a shape that meets the requirements is designed and a preliminary model is created.

[0027] Powder metallurgy is a process technology that uses metal powder as raw material, and after shaping and sintering, manufactures metal materials, composite materials and various types of products. It is a processing method that makes various products through pressing and sintering. The raw material of powder metallurgy is metal powder, which is mainly a powder composed of various metal raw materials decomposed into fine particles and mixed. Due to the different processes of powder metallurgy and casting, metal powder is often difficult to fuse well, so sintering is required after extrusion and shaping.

[0028] The purpose of the present application is to provide a method for processing a motor end cover, which is based on powder metallurgy and improves the production of the end cover on this basis, ultimately being able to improve the production efficiency of the end cover, increase its service life, and reduce the maintenance rate.

[0029] In some embodiments of the motor end cover structure design and processing method provided in the present application, picking up the front and rear end faces of the model and processing the bottom plate and top plate of the same structure as the end faces as a reference includes: Pick up the shape of the outer and inner sides of the model and then prepare a mold of the same shape.

[0030] The shapes of the bottom plate and the top plate are respectively the same as the outer side and the inner side of the model through stamping and forming.

[0031] The motor end cover is an important part in motor production. At present, the motor end cover processing method generally goes through the processes of loading, clamping, rough turning, punching, fine turning, inspection, etc. The loading and clamping process needs to be done manually, which is labor-intensive and inefficient. After the rough turning is completed, the workpiece is manually removed to the punching equipment for punching. After the holes are punched, it is manually transferred to the lathe equipment for fine turning. After fine turning, it is removed and measured to obtain the various dimensions of the motor end cover, and then the processing of the end cover parts is completed.

[0032] When the motor end cover is working, especially when the load is complex and the rotation is high-speed, it will be subjected to great centrifugal force, impact and vibration, and generate a lot of heat. The combined effect of force and heat will cause the end cover structure to change, and in severe cases it will cause burns and fractures, thus placing high process requirements on the motor end cover.

[0033] This application optimizes the production steps of the end covers by replanning the processing route of the end covers, and ultimately achieves high-quality and efficient production of the end covers through sheet metal stamping and powder metallurgy, thereby greatly reducing production costs.

[0034] In some embodiments of the motor end cover structure design and processing method provided in the present application, the shapes of the bottom plate and the top plate are respectively the same as the outer side and the inner side of the model through stamping and forming, which includes: The sheet materials used for stamping are subjected to surface treatment so that their surface quality meets the requirements.

[0035] During the stamping process, the plate is deformed to eliminate the stress on the bottom plate and the top plate; during the stamping process, holes are punched at corresponding positions of the bottom plate and the top plate.

[0036] Traditional end covers use lathes, drilling machines and other equipment in the production process. Each step takes a certain amount of processing time and requires deburring and other finishing. The entire processing process is relatively cumbersome. At the same time, during the processing, it is inevitable that a series of problems such as cracks will appear inside the material, which is difficult to detect and greatly affects the service life. More importantly, the structure of some motor end covers is relatively complex, and there are many grooves and other structures for avoidance on the inside and outside of the end covers, which puts forward many requirements for the processing technology.

[0037] In the present application, the bottom plate and the top plate for forming the end cover are first processed by stamping. The bottom plate and the top plate cooperate with each other, and there is a gap in the middle for metallurgy. The direct stamping of materials such as steel plates can greatly improve the production efficiency, and the stamping surface error is small and smooth, which can greatly reduce the cost of subsequent processing.

[0038] In some embodiments of the motor end cover structure design and processing method provided in the present application, picking up the front and rear end faces of the model and processing the bottom plate and top plate of the same structure as the end faces as a reference includes: The bottom plate is snap-fitted with the top plate to ensure that the openings on the bottom plate and the top plate are coaxially arranged.

[0039] In order to explain in more detail, we first need to build a model of the motor end cover. After the entire model is created, we need to determine the application scenario of the end cover and the external force it is subjected to based on the motor's operating conditions and corresponding operating conditions. Usually, it is necessary to simulate the working conditions through simulation and finite element analysis. The ultimate goal is to determine the external force the motor is subjected to during operation. The purpose of simulating the above situation is to perform the same working condition test on the final end cover after processing it, and finally determine the thickness of the bottom plate and the top plate and the corresponding material, and at the same time determine the gap between the bottom plate and the top plate.

[0040] During actual processing, the bottom plate and the top plate are stamped in sequence. At this time, in order to facilitate positioning, sockets and plug rods can be set at corresponding positions of the bottom plate and the top plate, and the bottom plate and the top plate are ultimately positioned accurately through snap-fitting.

[0041] In some embodiments of the motor end cover structure design and processing method provided in the present application, filling powder between the bottom plate and the top plate includes: First, position the top plate, then spray powder on the top surface of the top plate to ensure that the thickness of the powder at each location meets the requirements; After the powder coating is completed, the base plate is clamped and then extruded and formed.

[0042] When the usage scenarios are different, the corresponding parameters such as the thickness of the bottom plate and the top plate will be different. One embodiment is that when the size of the motor is large and the operating power is large, the force on the end cover during operation is large, so the end cover needs to have sufficient structural strength. In order to meet the above situation, it is necessary to appropriately increase the thickness of the bottom plate and the top plate. At this time, by selecting the appropriate thickness and material to ensure that the outer surface of the end cover has sufficient ability to resist external deformation, the gap between the two plates can be reduced accordingly.

[0043] If the size of the motor is small and the corresponding operating power is also small, then the thickness of the bottom plate and the top plate can be appropriately reduced. As the thickness of the plate is reduced, the difficulty of stamping will be reduced accordingly, which will make it easier to improve processing efficiency and reduce processing difficulty. At this time, the gap between the two can be appropriately increased to reserve enough space for processes similar to powder metallurgy.

[0044] In some embodiments of the motor end cover structure design and processing method provided in the present application, filling powder between the bottom plate and the top plate includes: First, lay the bottom film, spray the powder after the bottom film is laid, and after the powder spraying is completed, lay the top film and then extrude it to shape.

[0045] After the shaping is completed, the quality inspection is carried out, and the stability of the powder structure is ensured by the bottom film and the top film.

[0046] To explain in more detail, the bottom plate and top plate are first processed by stamping equipment, and then the bottom plate is placed on the lower mold. After positioning is completed, powder is sprayed on the top surface of the bottom plate. At this time, it is necessary to ensure that there is no external wind. More importantly, it is necessary to ensure that the thickness of the powder in each place meets the specified requirements. In some cases, a certain amount of adhesive can be added during the powder spraying process. The adhesive comes into contact with the moving powder being sprayed, and finally the powder can be positioned on the base plate with the help of the adhesive. The adhesive can ensure the stability of the powder position and prevent the powder from shifting during the metallurgical process due to gravity and other reasons, resulting in the powder thickness in some positions not meeting the requirements.

[0047] After the powder spraying is completed, powder metallurgy operations need to be performed. At this time, the top plate can be placed on the sprayed powder according to the actual situation, and then extruded together and subsequently sintered to complete the processing of the end cover.

[0048] In some embodiments of the motor end cover structure design and processing method provided in the present application, after ensuring the stability of the powder structure by the bottom film and the top film, the following is also included: The powder together with the bottom film and the top film are positioned between the bottom plate and the top plate. During the subsequent sintering process, the bottom film and the top film fill the gap between the bottom plate, the top plate and the powder and realize the bonding and fastening of the two.

[0049] It should be pointed out that after the base plate is initially positioned and then sprayed with powder, due to vibration and uneven powder thickness, the structural strength of the end cover will be different from the design. At this time, it needs to be re-sprayed or scrapped, which will eventually make subsequent processing and production impossible, affecting construction efficiency.

[0050] In order to improve efficiency and reduce errors caused by spraying, in this application, the initial extrusion of the powder can be carried out on the remaining extruders to complete the shaping. After shaping, the thickness of each part is tested. When it is qualified, it can be placed between the bottom plate and the top plate, and then the bottom plate, the top plate and the initially shaped powder are squeezed into an integrated structure through extrusion again.

[0051] The above method can quickly and efficiently complete the shaping of the powder, and after shaping, it can be sintered to finally form an integrated structure.

[0052] In some embodiments of the motor end cover structure design and processing method provided in the present application, adjusting the bottom plate, the top plate and the powder according to the test results includes: Adjust the material of the bottom plate and top plate according to the test results; adjust the thickness of the bottom plate, top plate and powder layer; If the test shows that the position has insufficient bearing capacity and deformation occurs, the thickness of the bottom plate and the top plate in the deformation area is increased, or a reinforcing structure is fixed to the bottom plate and the top plate before positioning the powder.

[0053] In order to further reduce the gap between the bottom plate and the top plate, so that there is no gap between the bottom plate and the top plate, thereby increasing the ability of the entire end cap to resist deformation and external impact, and more importantly, to avoid the falling of the initially shaped powder and the incompleteness of its own structure. It is for the above reasons that in this application, the bottom film is first laid on the extrusion die, and after the bottom film is laid, the powder is sprayed and the subsequent initial extrusion is finalized. When the above conditions are confirmed, the top film is laid.

[0054] It should be pointed out that the surface of the bottom film and the top film itself has a certain viscosity, and the viscosity can be set to ensure the adsorption force with the powder. More importantly, the bottom film and the top film themselves will be in a liquid state after being heated and high temperature. When the bottom plate and the top plate clamp and shape the bottom film and the top film by extrusion, due to the large extrusion force, this will cause the bottom film and the top film to have a certain deformation. The deformed bottom film and the top film will initially fill the pits involved in the bottom plate and the top plate, and then sintering will be carried out. During the sintering process, the bottom film and the top film melt, and the powder is bonded to the bottom plate and the top plate as an integrated structure, thereby ensuring the structural stability of the entire end cover.

[0055] In some embodiments of the motor end cover structure design and processing method provided in the present application, applying high current to multiple locations of the component to be processed to heat-melt the powder to complete the connection with the bottom plate and the top plate includes: A high voltage is applied between the bottom plate and the top plate, so that a current is formed between the bottom plate and the top plate. The current causes the bottom plate, the top plate and the powder in the area to melt and form an integrated structure after cooling.

[0056] Traditional powder metallurgy can only complete the processing and manufacturing of parts through extrusion and sintering. However, since the present application uses a bottom plate and a top plate, if only extrusion and sintering are used, gaps may still be generated at the interface between the front top plate and the powder due to insufficient material filling. At this time, even if the sintering temperature is increased, the generation of gaps cannot be avoided.

[0057] In order to solve this problem, after sintering is completed, a certain voltage can be applied between the bottom plate and the top plate. Due to the existence of voltage, a large current will exist between the bottom plate and the top plate, and this current will melt the powder and cause it to fuse into one with the bottom plate and the top plate. By applying voltage to the end cover multiple times, multiple melting points can be formed between the bottom plate and the top plate. The existence of these melting points improves the connection reliability between the powder layer and the front top plate, and improves the stability of the integrated structure.

[0058] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. The motor end cover structure design and processing method thereof are characterized in that: include: Determine the shape of the motor end cover according to the size specifications of the motor and create a model of the end cover; Pick up the front and rear end faces of the model and process the bottom plate and top plate of the same structure based on the end faces; Filling powder between the bottom plate and the top plate, and preliminarily solidifying the bottom plate, the top plate and the powder into an integrated structure through extrusion shaping and sintering as a test component; The structural strength and toughness of the test component are tested, and the bottom plate, the top plate and the powder are adjusted according to the test results; after the adjustment is completed, the component to be processed is redesigned and processed, and high current is applied to multiple locations of the component to be processed to heat-melt the powder to complete the connection with the bottom plate and the top plate.

2. The motor end cover structure design and processing method thereof as claimed in claim 1, characterized in that: Determining the shape of the motor end cover according to the size specifications of the motor and creating a model of the end cover includes: The load and working environment of the motor are preliminarily determined to predict the physical properties required for the end cover, and a shape that meets the requirements is designed based on the predicted results and the model is preliminarily created.

3. The motor end cover structure design and processing method thereof as claimed in claim 1, characterized in that: The method of picking up the front and rear end faces of the model and processing the bottom plate and the top plate of the same structure based on the end faces comprises: Picking up the shapes of the outer side and the inner side of the model and then preparing a mold of the same shape; The shapes of the bottom plate and the top plate are respectively the same as the outer side surface and the inner side surface of the model through stamping and forming.

4. The motor end cover structure design and processing method thereof as claimed in claim 3, characterized in that: The method of making the shapes of the bottom plate and the top plate the same as the outer side surface and the inner side surface of the model respectively by stamping and forming comprises: Surface treatment is performed on the sheet materials used for stamping so that their surface quality meets the requirements; During the stamping process, the plate is plastically deformed to eliminate the stress on the bottom plate and the top plate; during the stamping process, holes are punched at positions corresponding to the bottom plate and the top plate.

5. The motor end cover structure design and processing method thereof as claimed in claim 4, characterized in that: The method of picking up the front and rear end faces of the model and processing the bottom plate and the top plate of the same structure based on the end faces comprises: The bottom plate is engaged with the top plate to ensure that the openings on the bottom plate and the top plate are coaxially arranged.

6. The motor end cover structure design and processing method as claimed in claim 1, characterized in that: The filling of powder between the bottom plate and the top plate comprises: First, the top plate is positioned, and then the powder is sprayed on the top surface of the top plate to ensure that the thickness of the powder at each location meets the requirements; After the powder spraying is completed, the base plate is clamped and subsequently extruded and formed.

7. The motor end cover structure design and processing method as claimed in claim 1, characterized in that: The filling of powder between the bottom plate and the top plate comprises: Firstly, a bottom film is laid, and after the bottom film is laid, the powder is sprayed, and after the powder is sprayed, a top film is laid and then extruded and formed; After shaping is completed, quality inspection is performed, and the stability of the powder structure is ensured by the bottom film and the top film.

8. The motor end cover structure design and processing method thereof as claimed in claim 7, characterized in that: After the stability of the powder structure is ensured by the bottom film and the top film, the method further comprises: The powder together with the bottom film and the top film are positioned between the bottom plate and the top plate. During the subsequent sintering process, the bottom film and the top film fill the gap between the bottom plate, the top plate and the powder while achieving bonding and fastening of the two.

9. The motor end cover structure design and processing method thereof according to claim 1, characterized in that: The adjusting the bottom plate, the top plate and the powder according to the test results comprises: Adjust the material of the bottom plate and the top plate according to the test results; adjust the thickness of the bottom plate, the top plate and the powder layer; If the test shows that the position has insufficient bearing capacity and deformation occurs, the thickness of the bottom plate and the top plate in the deformation area is increased, or a reinforcing structure is fixed on the bottom plate and the top plate before positioning the powder.

10. The motor end cover structure design and processing method thereof according to claim 1, characterized in that: The step of applying high current at multiple locations of the component to be processed to heat-melt the powder so as to complete the connection with the bottom plate and the top plate comprises: A high voltage is applied between the bottom plate and the top plate, so that a current is formed between the bottom plate and the top plate, and the current causes the bottom plate, the top plate and the powder in the corresponding area to melt and form an integrated structure after cooling.

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