Iron core single sheet, stator iron core, motor, processing equipment and processing method

Abstract

The invention relates to an iron core single sheet, a stator core, a motor, a processing device and a processing method, the iron core single sheet comprises a first alloy area and a second alloy area, the first alloy area is provided with a tooth part and a first yoke part, and the first yoke part is arranged at the periphery of the tooth part; the second alloy area is provided with a second yoke part, the second yoke part is arranged on the periphery of the first yoke part, the second alloy area comprises a plurality of atoms arranged in a disordered state, and the magnetic conductivity of the first alloy area is larger than that of the second alloy area. The magnetic conductivity of the first alloy area in the iron core single piece is larger than that of the second alloy area, the first alloy area can be made of an annealed emerging soft magnetic material, and the second alloy area comprises the multiple atoms in the disordered arrangement state, so that the periphery of the first alloy area can be protected, and the service life of the first alloy area is prolonged. The iron core single sheets and the periphery of the stator iron core can disperse and resist stress more effectively under the action of external force, and the structural strength and the processing performance of the iron core single sheets can be improved.

Description

Technical Field

[0001] The present application relates to the field of motor technology, and in particular to a single iron core, a stator iron core, a motor, a processing device and a processing method. Background Art

[0002] With the development of modernization, motors have been widely used in various technical fields. During the use of motors, motor losses mainly include iron loss and copper loss. Iron loss is caused by the motor core. When the motor structure is certain, iron loss is mainly determined by the properties of the soft magnetic material that constitutes the core, while copper loss is caused by the motor winding and is also affected by the magnetic permeability of the core material.

[0003] In order to improve the magnetic permeability of the core material, the existing technology often uses the annealing process to manufacture emerging soft magnetic materials such as nanocrystals, whose magnetic permeability is greatly improved compared with conventional electrical steel, and their iron loss can be reduced by more than 50% compared with electrical steel. However, materials such as nanocrystalline alloys will become brittle after annealing, and the process performance is poor. They are easily damaged during production, storage and transportation, and the interference fit method cannot be used for assembly, resulting in the difficulty of popularizing and applying emerging soft magnetic materials with low iron loss and high magnetic permeability. Summary of the invention

[0004] The present application provides a core monolithic sheet, a stator core, a motor, a processing device and a processing method to solve the technical problem in the prior art that emerging soft magnetic materials become brittle and easily damaged due to annealing.

[0005] In a first aspect, the present application provides a core monolithic chip, comprising:

[0006] A first alloy region, the first alloy region having a tooth portion and a first yoke portion, wherein the first yoke portion is disposed on the outer periphery of the tooth portion;

[0007] The second alloy region has a second yoke, the second yoke is arranged on the periphery of the first yoke, the second alloy region includes a plurality of atoms arranged in a disordered state, and the magnetic permeability of the first alloy region is greater than the magnetic permeability of the second alloy region.

[0008] Optionally, the first alloy region includes a plurality of crystal grains in an orderly arrangement state, and the size of the crystal grains is less than 20 nanometers.

[0009] Optionally, in the first direction, the size of the first yoke is W1, the size of the second yoke is W2, and the ratio range of W1 to W2 satisfies 1≤W1 / W2≤4.

[0010] Optionally, the maximum outer diameter of the core monolith is d, the first direction is the radial direction of the core monolith, and the sum of the size W1 of the first yoke and the size W2 of the second yoke satisfies d / 18≤W1+W2≤d / 10.

[0011] Optionally, the material of the first alloy region is a nanocrystalline alloy, and the material of the second alloy region is an amorphous alloy.

[0012] Optionally, the material of the amorphous alloy is Fe-Si-B-Nb-Cu system, Fe-Co-Si-B-Nb-Cu system, Fe-Si-BP-Cu system, Fe-Co-Si-BP-Cu system, Fe-Zr-B-Cu system or Fe-Co-Zr-B-Cu system.

[0013] In a second aspect, the present application provides a stator core, including the core monolith provided in the first aspect of the present application, wherein the number of the core monoliths is multiple, the multiple core monoliths are stacked, and an insulating layer is provided between two adjacent core monoliths.

[0014] In a third aspect, the present application provides a motor, comprising the stator core provided in the second aspect of the present application.

[0015] Optionally, in the first direction, the size of the first yoke is W1, and the size of the second yoke is W2;

[0016] When the motor frequency of the motor is below the preset frequency threshold, the ratio range of W1 to W2 satisfies 2≤W1 / W2≤4;

[0017] When the motor frequency of the motor is greater than the preset frequency threshold, the ratio range of W1 to W2 satisfies 1≤W1 / W2≤3.

[0018] In a fourth aspect, the present application provides a processing device for manufacturing the stator core provided in the second aspect of the present application, comprising a heating component and a cooling component, wherein the heating component is arranged corresponding to the first alloy zone, and the cooling component is arranged corresponding to the second alloy zone.

[0019] Optionally, the heating assembly includes a heating element, a central portion of the first alloy zone has an accommodating space for accommodating the heating element, an axis of the heating element coincides with an axis of the stator core, and an outer periphery of the second alloy zone is arranged in contact with the cooling assembly.

[0020] Optionally, the cooling assembly includes an annular cooling tooling, a cooling channel is provided inside the annular cooling tooling, and the cooling channel extends along the circumference of the annular cooling tooling.

[0021] Optionally, the cooling flow channel includes a plurality of annular flow channels, and the plurality of annular flow channels are sequentially arranged along the axial direction of the stator core.

[0022] As another optional technical solution, the cooling channel is a spiral channel, and the spiral channel extends along the axial direction of the stator core.

[0023] Optionally, the processing equipment further comprises a temperature detection component, which is used to measure the temperature of the first alloy zone and the second alloy zone; the temperature detection component is signal-connected to the heating component.

[0024] In a fifth aspect, the present application provides a processing method, which uses the processing equipment provided in the fourth aspect of the present application and is used for the stator core provided in the second aspect of the present application, comprising the following steps:

[0025] preparing a plurality of iron core monolithic bodies on the second alloy strip;

[0026] A plurality of core monolithic bodies are stacked to form a stator core block, a heating assembly is arranged in the middle of the stator core block, and a cooling assembly is arranged on the periphery of the stator core block;

[0027] The heating component and the cooling component are turned on to form a first alloy zone in the middle of the stator core block through crystallization annealing.

[0028] The above technical solution provided by the embodiment of the present application has the following advantages compared with the prior art:

[0029] The core monolith provided in the embodiment of the present application includes a first alloy region and a second alloy region, wherein the magnetic permeability of the first alloy region is greater than that of the second alloy region, and the material thereof may be an emerging soft magnetic material after annealing, and the second alloy region includes a plurality of atoms in a disordered arrangement state. When the second alloy region is located outside the first alloy region, the periphery of the first alloy region may be protected. Since the atoms in the second alloy region are arranged in a disordered state, the periphery of the core monolith and the stator core may be more effectively dispersed and resisted stress when subjected to external forces, thereby improving the structural strength and process performance of the core monolith, and preventing the core monolith and the stator core from being damaged during production, storage, transportation and assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the present application.

[0031] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0032] One or more embodiments are exemplarily described by pictures in the corresponding drawings, and these exemplified descriptions do not constitute limitations on the embodiments. Elements with the same reference numerals in the drawings represent similar elements, and unless otherwise stated, the figures in the drawings do not constitute proportional limitations.

[0033] Figure 1 A top view of a single core piece provided in an embodiment of the present application;

[0034] Figure 2 Provided in the embodiments of this application Figure 1 A magnified view of the details of part A;

[0035] Figure 3 A schematic diagram of a partial structure of a motor provided in an embodiment of the present application;

[0036] Figure 4 Provided in the embodiments of this application Figure 3 A partial cross-sectional view of

[0037] Figure 5 A partial cross-sectional view of a stator core provided in an embodiment of the present application;

[0038] Figure 6 A processing schematic diagram of a processing device provided in an embodiment of the present application;

[0039] Figure 7 The embodiment of the present application provides Figure 6 Cross-sectional view of the middle BB;

[0040] Figure 8 Provided in the embodiments of this application Figure 7 A detailed enlarged view of part C in the middle;

[0041] Fig. 9 Provided in the embodiments of this application Figure 7 A magnified detail of section D.

[0042] Description of reference numerals:

[0043] 1. Iron core monolithic; 11. First alloy region; 111. Tooth portion; 112. First yoke portion; 12. Second alloy region; 121. Second yoke portion; 13. Accommodation space; 14. Stator slot;

[0044] 2. Insulation layer;

[0045] 3. Insulation frame;

[0046] 4. Slot insulation paper;

[0047] 5. Winding; 51. Lead wire;

[0048] 6. Heating assembly; 61. Heating element; 62. Wire;

[0049] 7. Cooling assembly; 71. Annular cooling tool; 72. Cooling channel; 721. First annular channel; 722. Second annular channel; 723. Third annular channel; 724. Input pipeline; 725. Output pipeline;

[0050] 8. Temperature detection component; 81. First detection component; 82. Second detection component. DETAILED DESCRIPTION

[0051] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0052] The disclosure below provides many different embodiments or examples to implement the different structures of the present application. In order to simplify the disclosure of the present application, the parts and settings of specific examples are described below. Of course, they are only examples, and the purpose is not to limit the present application. In addition, the present application can repeat reference numbers and / or letters in different examples. This repetition is for the purpose of simplification and clarity, and does not itself indicate the relationship between the various embodiments and / or settings discussed.

[0053] For ease of description, spatial relative terms may be used herein to describe the relative positional relationship or movement of one element or feature relative to another element or feature as shown in the figure, such as "inside", "outside", "inner side", "outer side", "below", "below", "above", "above", "front", "back", etc. Such spatial relative terms are intended to include different orientations of the device in use or operation in addition to the orientation depicted in the figure. For example, if the device in the figure undergoes a position flip or a posture change or a motion state change, then these directional indications also change accordingly, for example: an element described as "below other elements or features" or "below other elements or features" will subsequently be oriented as "above other elements or features" or "above other elements or features". Therefore, the example term "below..." may include both upper and lower orientations. The device may be otherwise oriented (rotated 90 degrees or in other directions) and the spatial relative descriptors used herein are interpreted accordingly.

[0054] In order to solve the technical problem in the prior art that the emerging soft magnetic materials become brittle and easy to be damaged due to annealing, the present application provides a core monolith 1, a stator core, a motor, a processing equipment and a processing method. The core monolith 1 includes a first alloy zone 11 and a second alloy zone 12, wherein the magnetic permeability of the first alloy zone 11 is greater than the magnetic permeability of the second alloy zone 12, and its material can be the emerging soft magnetic material after annealing, and the second alloy zone 12 includes a plurality of atoms in a disordered arrangement state. When the second alloy zone 12 is located at the periphery of the first alloy zone 11, the periphery of the first alloy zone 11 can be protected. Since the atoms in the second alloy zone 12 are arranged in a disordered state, the second alloy zone 12 (i.e., the periphery of the core monolith 1 and the stator core) can be more effectively dispersed and resisted stress when subjected to external force, thereby improving the structural strength and process performance of the core monolith 1, and avoiding damage to the core monolith 1 and the stator core during production, storage, transportation and assembly.

[0055] See also Figures 1 to 9 In a first aspect, an embodiment of the present application provides a core monolithic sheet 1, comprising a first alloy region 11 and a second alloy region 12, such as Figure 1 As shown (the dotted line in the figure represents the boundary between the first alloy zone 11 and the second alloy zone 12).

[0056] The first alloy region 11 has a tooth portion 111 and a first yoke portion 112, and the first yoke portion 112 is arranged on the outer periphery of the tooth portion 111; the tooth portion 111 includes a plurality of stator teeth, and a stator slot 14 is formed between two adjacent stator teeth, which can be used to realize the assembly of the winding 5. The plurality of stator teeth are sequentially arranged along the circumference of the first yoke portion 112, and the shape and number of the stator teeth can be designed as required, which is not limited here.

[0057] The second alloy zone 12 has a second yoke 121, which is arranged on the outer periphery of the first yoke 112, so that the first yoke 112 and the second yoke 121 are connected to form the yoke of the core monolith 1, wherein the first yoke 112 is the inner side of the yoke and the second yoke 121 is the outer side of the yoke.

[0058] During operation of the motor, the magnetic circuit mainly passes through the tooth portion 111 and the first yoke portion 112 (i.e., the inner side of the yoke portion). Therefore, the magnetic permeability of the first alloy region 11 is greater than that of the second alloy region 12. This ensures that the area through which the magnetic circuit passes (i.e., the first alloy region 11) has a high magnetic permeability, thereby reducing the iron loss of the stator core.

[0059] The second alloy region 12 includes a plurality of atoms arranged in a disordered state. When the core monolith 1 or the periphery of the stator core is subjected to external force, the atoms arranged in a disordered state in the second alloy region 12 can more effectively disperse and resist stress, so that the second alloy region 12 has high-strength characteristics, which is beneficial to improving the structural strength and process performance of the core monolith 1, and avoiding damage to the core monolith 1 and the stator core during production, storage, transportation and assembly.

[0060] It should be noted that the material of the first alloy zone 11 can be a new type of soft magnetic material with high magnetic permeability in the prior art, such as nanocrystalline alloy, iron-silicon-aluminum alloy, high magnetic permeability iron-nickel soft magnetic alloy, etc., and the material of the second alloy zone 12 can be a soft magnetic material with good magnetic permeability and process performance in the prior art, such as amorphous alloy, iron-silicon alloy, etc.

[0061] In some preferred embodiments of the present application, the material of the first alloy zone 11 is a nanocrystalline alloy, and the material of the second alloy zone 12 is an amorphous alloy. Since the saturation magnetic induction intensity of the nanocrystalline alloy is usually higher than the saturation magnetic induction intensity of the amorphous alloy, the nanocrystalline alloy is more suitable for the teeth 111 and the first yoke 112 where the magnetic circuit passes densely, which is conducive to reducing the iron loss of the core monolith 1 and the stator core. During the annealing process of the amorphous alloy, crystallization occurs, that is, the amorphous phase gradually transforms into a crystalline phase to form a nanocrystalline alloy. Therefore, the nanocrystalline alloy in the first alloy zone 11 can be made by annealing the amorphous alloy, while the amorphous alloy in the second alloy zone 12 is still in an unannealed state and will not be embrittled, which can take into account the high magnetic permeability performance and high structural strength performance (i.e., process performance) of the core monolith 1. In addition, since the magnetic permeabilities of the amorphous alloy and the nanocrystalline alloy are both very high and are almost unaffected by the excitation frequency, the high-frequency copper loss of the motor will not be greatly increased.

[0062] In some embodiments of the present application, the first alloy region 11 includes a plurality of grains in an orderly arrangement state, and the size of the grains is below 20 nanometers (nm), which can increase the solubility of boron atoms (B atoms) in the first alloy region 11, thereby increasing the initial relative magnetic permeability of the nanocrystalline alloy to above 20,000, and reducing the coercive force to below 5 A / m. By reducing the coercive force, the BH curve (magnetization curve) is narrowed, thereby greatly reducing the hysteresis loss in the iron loss.

[0063] In the above embodiment, the division of the first alloy region 11 and the second alloy region 12 can be designed according to the shape and size of the core monolith 1, so that the first alloy region 11 covers the area where the magnetic circuit passes.

[0064] In some embodiments of this application, please refer to Figure 1 and Figure 2, in the first direction, the size of the first yoke 112 is W1, and the size of the second yoke 121 is W2, and the ratio range of W1 to W2 satisfies 1≤W1 / W2≤4. Among them, W1 is the width of the magnetic circuit passing through the yoke, which is the width area that needs to have excellent magnetic properties, and W2 is the width of the yoke that the magnetic circuit does not pass through, which is the part that needs to have good processability in the transportation, winding, assembly and other processes. The first direction is the width direction of the yoke. When the total width of the yoke of the core monolithic 1 is certain, if the ratio of W1 to W2 is less than 1, the width area with excellent magnetic properties in the yoke will be smaller, which is difficult to meet the design requirements of the magnetic circuit width. When the ratio of W1 to W2 is greater than 4, the width of the second alloy zone 12 will be limited, and it will not be able to play an effective peripheral protection role.

[0065] In some embodiments of this application, please refer to Figure 1 , when the core monolith 1 is a circular structure, the maximum outer diameter of the core monolith 1 is d, the first direction is the radial direction of the core monolith 1, and the sum of the size W1 of the first yoke 112 and the size W2 of the second yoke 121 satisfies d / 18≤W1+W2≤d / 10. The heavier the motor working condition, the larger the required diameter d of the core monolith 1. In order to ensure the magnetic circuit width and the process performance of the core monolith 1, the larger the overall width W1+W2 of the yoke is, and the relationship between the width and the diameter d is proportional. When W1+W2 is less than d / 18, the total width of the yoke will be small, which will lead to the small width of the first yoke 112 and the second yoke 121, and the width of the magnetic circuit passed by the first yoke 112 and the process performance of the second yoke 121 cannot be guaranteed. When W1+W2 is greater than d / 10, the yoke will account for too large a proportion, which will lead to an increase in the material and volume of the core monolith 1 and the stator core, which will not only increase the manufacturing cost, but also increase the iron loss of the stator core, thereby causing the motor efficiency to decrease. Therefore, the present application preferably selects d / 18≤W1+W2≤d / 10, which can not only ensure the magnetic circuit width and process performance of the stator core, but also ensure the motor efficiency.

[0066] In some embodiments of the present application, the material of the amorphous alloy is Fe-Si-B-Nb-Cu system, Fe-Co-Si-B-Nb-Cu system, Fe-Si-BP-Cu system, Fe-Co-Si-BP-Cu system, Fe-Zr-B-Cu system or Fe-Co-Zr-B-Cu system, all of which have excellent magnetic and mechanical properties, which can not only avoid the adverse effects of the second alloy zone 12 on the magnetic circuit of the stator core, but also improve the structural strength and process performance of the core monolithic sheet 1 and the stator core.

[0067] Among them, Fe-Si-B-Nb-Cu amorphous alloys have excellent soft magnetic properties and good thermal stability, and are expected to become near-room temperature magnetic refrigeration materials. Fe-Co-Si-B-Nb-Cu amorphous alloys have good high-frequency performance and high corrosion resistance, are suitable for high-frequency electronic applications, and can maintain stable performance in harsh environments. Fe-Si-BP-Cu amorphous alloys have structural density, which helps to improve the magnetic and mechanical properties of amorphous alloys. Fe-Co-Si-BP-Cu amorphous alloys have excellent magnetic properties, high-frequency performance and corrosion resistance, and are suitable for high-performance electronic components, high-frequency transformers, and application scenarios requiring high corrosion resistance. Fe-Zr-B-Cu amorphous alloys have good strength and toughness, so that the second alloy zone 12 has better mechanical properties. Fe-Co-Zr-B-Cu amorphous alloys combine the advantages of cobalt and zirconium, have excellent magnetic properties, high strength and high hardness, and have significant advantages in applications that need to withstand high stress and high impact.

[0068] See also Figures 1 to 9 In a second aspect of an embodiment of the present application, a stator core is provided, comprising a core monolith 1 in the above embodiment, wherein the number of the core monolith 1 is multiple, the multiple core monoliths 1 are stacked, and an insulating layer 2 is provided between two adjacent core monoliths 1, and interlayer insulation between two adjacent core monoliths 1 is achieved by the insulating layer 2, such as Figure 5 As shown, the normal use of the stator core is guaranteed.

[0069] In some embodiments of the present application, in the second direction, the thickness H2 of the insulating layer 2 is 0.3-1.0 microns (μm). This is because the insulating layer 2 is formed by impregnating the stator core block with insulating glue. When the insulating glue liquid material is solidified between adjacent core monoliths 1 to form an insulating layer 2 with a thickness of less than 0.3 microns, the burrs of the core monolith 1 itself can easily pierce the insulating layer 2, resulting in the insulating layer 2 being unable to meet the interlayer insulation requirements; and when the thickness of the insulating layer 2 is greater than 1 micron, the lamination factor of the stator core will be too low, resulting in a reduction in the effective cross-sectional area of ​​the stator core.

[0070] In the above embodiments, the second direction is the axial direction of the stator core, and the insulating layer 2 can be made by curing the insulating varnish in the prior art, which can achieve the purpose of the present application.

[0071] As a preferred embodiment of the present application, the insulating layer 2 is made of epoxy resin, so that the insulating layer 2 not only has good insulation properties, but also has good bonding properties and chemical stability. It can tightly fit adjacent core monoliths 1 and resist corrosion from various chemical substances, so that the stator core will not loosen, disintegrate or fail during the operation of the motor.

[0072] See also Figures 1 to 9 The present application embodiment provides a motor, including the stator core in the above embodiment, and also includes an insulating frame 3, slot insulating paper 4 and a winding 5. The assembly relationship between the components can be set with reference to the prior art, so that a motor with an amorphous nanocrystalline alloy stator core can be made, such as Figure 3 and Figure 4 The lead wire 51 of the winding 5 can be used to transmit three-phase current to the motor, so that the motor rotor generates a rotating magnetic field, thereby driving the motor to operate.

[0073] It should be noted that since the stator core has excellent magnetic properties and process performance, the motor provided in this application can be used not only in low-power equipment such as household appliances, but also in high-power equipment such as new energy vehicles and production equipment. The specifications of the stator core and battery core can be designed according to power requirements and are not limited here.

[0074] The frequently used operating frequency of the motor is f, and the number of pole pairs of the stator core is n, then f×n represents the motor frequency of the motor. The larger the motor frequency, the heavier the working condition of the motor. At this time, the maximum outer diameter d of the stator core is also larger. Correspondingly, the sizes of the first yoke 112 and the second yoke 121 also need to be set according to the working condition of the motor.

[0075] In some embodiments of the present application, when the motor frequency of the motor is below the preset frequency threshold, the ratio range of W1 to W2 satisfies 2≤W1 / W2≤4; this is because when the motor frequency is low, the skin effect in the stator core is not obvious, and the actual width of the magnetic circuit in the stator core is large, requiring the first yoke 112 to account for a large proportion of the overall width of the yoke. If W1 / W2 < 2, it will cause material waste and increase iron loss. If W1 / W2 > 4, it will cause the magnetic properties of the partial width through which the magnetic circuit passes to decrease, thereby reducing the efficiency of the motor.

[0076] In some preferred embodiments of the present application, when the stator core adopts a larger width assembly method such as shrink fitting that generates greater stress and affects the magnetic properties of the yoke, it is appropriate to adopt a design where W1 / W2 is close to 2 to prevent the width of the magnetic circuit from being affected.

[0077] In other preferred embodiments of the present application, when the stator core adopts an assembly method such as structural locking that has less impact on the yoke, the width ratio of the second yoke 121 can be appropriately reduced, and the stator core is suitable for adopting a design in which W1 / W2 is close to 4 to reduce material costs and reduce iron losses.

[0078] In other embodiments of the present application, when the motor frequency of the motor is greater than the preset frequency threshold, the ratio range of W1 to W2 satisfies 1≤W1 / W2≤3. This is because when the motor frequency is high, the skin effect inside the stator core is more obvious, resulting in a narrower actual width of the magnetic circuit, and the width of the first yoke 112 and the second yoke 121 can be appropriately reduced. If W1 / W2 < 1, it will cause material waste and increase iron loss. If W1 / W2 > 3, it will cause the magnetic properties of the partial width of the magnetic circuit to decrease, resulting in reduced motor efficiency.

[0079] In some preferred embodiments of the present application, when the stator core is assembled in a manner that has a greater impact on the yoke, it is appropriate to adopt a design in which W1 / W2 is close to 1, thereby increasing the proportion of the second yoke 121 to improve the structural strength and process performance of the outer periphery of the stator core.

[0080] In other preferred embodiments of the present application, when the stator core is assembled in a manner that has less impact on the yoke, it is appropriate to adopt a design in which W1 / W2 is close to 3, which can appropriately reduce the width proportion of the second yoke 121 in the yoke, reduce material waste, and reduce manufacturing costs.

[0081] In the above embodiment, the frequency preset threshold can be set according to the motor usage scenario. In the present application, the frequency preset threshold is set to 400 Hz, because below 400 Hz is the low frequency range used by general household appliance motors, and above 400 Hz is the high frequency range used by general new energy vehicle drive motors. The area division of the first alloy zone 11 and the second alloy zone 12 can be designed according to the motor usage conditions, so that the motor meets the magnetic circuit design and process performance requirements under different working conditions.

[0082] As a specific embodiment of the present application, when the maximum outer diameter d of the core monolith 1 (i.e., the maximum outer diameter of the stator core) is 111.76 mm, the design range of the sum of the radial dimensions W1+W2 of the first yoke 112 and the second yoke 121 in the core monolith 1 is limited to between 6.21-11.18 mm.

[0083] The frequently used working frequency of the motor is 60Hz, and the number of pole pairs n of the stator core of the motor is 3 pairs. At this time, the motor frequency is below 400Hz. When the stator core is assembled by shrink-fitting, W1 / W2=2.5 is selected, W1 is designed to be 5mm, and W2 is designed to be 2mm. Compared with the motor core made of 35W300 electrical steel in the prior art and applied to the same working condition, the amorphous nanocrystalline alloy stator core made in this embodiment can reduce the iron loss by more than 40% compared with the prior art under the conditions of motor frequency of 180Hz and magnetic induction intensity of 1.5T.

[0084] See also Figures 1 to 9In order to prepare the first alloy zone 11 and the second alloy zone 12 on the core monolith 1 of the stator core to form an amorphous nanocrystalline alloy stator core with material transition, the fourth aspect of the embodiment of the present application provides a processing device for manufacturing the stator core in the above embodiment, including a heating component 6 and a cooling component 7. The heating component 6 is arranged corresponding to the first alloy zone 11, so that the central area of ​​the core monolith 1 can undergo crystallization annealing during the heat treatment process, thereby generating a nanocrystalline alloy. The cooling component 7 is arranged corresponding to the second alloy zone 12, so that the temperature of the second alloy zone 12 can be reduced to avoid crystallization annealing of the second alloy zone 12 during the heat treatment process, and to avoid embrittlement of the second alloy zone 12 due to annealing, which affects the structural strength and process performance of the second alloy zone 12 (i.e., the second yoke 121). Figure 6 and Figure 7 shown.

[0085] It should be noted that in this application, the core monolithic sheet 1 before heat treatment is recorded as the core monolithic sheet body, and the core monolithic sheet body has been processed by punching and other processing methods to achieve the preparation of the tooth portion 111 and the yoke portion, and its shape is as follows: Figure 1 and Figure 6 As shown. The material of the core monolithic body is preferably an amorphous alloy. When the heating component 6 heats the central area of ​​the stator core, the temperature of the core monolithic 1 gradually decreases from the center to the edge area, so that the amorphous alloy in the central area of ​​the core monolithic body undergoes crystallization annealing, thereby forming a first alloy zone 11 having a nanocrystalline alloy; and the cooling component 7 is arranged on the periphery of the stator core, which can prevent the temperature of the amorphous alloy on the periphery of the core monolithic body from reaching the annealing temperature, so that the amorphous alloy on the periphery of the core monolithic body is always kept in an unannealed state and amorphous alloy that has not been embrittled, that is, the second alloy zone 12.

[0086] By cooperating with the heating component 6 and the cooling component 7 in the partitioning of the stator core, limited area heating can be achieved, so that the inner area where the magnetic circuit of the stator core is concentrated (i.e., the tooth portion 111 and the first yoke portion 112) is transformed into a nanocrystalline alloy with excellent magnetic properties, while the outer area (i.e., the second yoke portion 121) through which the magnetic circuit basically does not pass remains an amorphous alloy in an unannealed state and has not undergone embrittlement, thereby improving the process performance of the outer periphery of the stator core.

[0087] In some embodiments of this application, please refer to Figure 6 and Figure 7The heating assembly 6 includes a heating element 61. The middle part of the first alloy zone 11 has an accommodating space 13 for accommodating the heating element 61. The axis of the heating element 61 coincides with the axis of the stator core, so that the temperature of the heating element 61 can be uniformly radiated to the tooth portion 111 and the first yoke portion 112, and the stator core can undergo a material transition along its radial direction, so that the material of the tooth portion 111 and the first yoke portion 112 is transitioned from an amorphous alloy with good processability to a nanocrystalline alloy with excellent magnetic properties. The periphery of the second alloy zone 12 is arranged in contact with the cooling component 7, and the second alloy zone 12 (i.e., the second yoke 121) can be cooled by contact heat exchange, so that the peripheral temperature of the stator core is significantly lower than the temperature of the middle part of the stator core, and crystallization annealing in a limited area is achieved, so that the radially continuous core monolithic sheet 1 has different materials in different parts, and only the tooth part 111 and the inner side of the yoke part (i.e., the first yoke part 112) where the magnetic circuit of the stator core is concentrated produce nanocrystals due to crystallization annealing, thereby achieving an increase in magnetic permeability; and the outer side of the yoke part (i.e., the second yoke part 121) through which the magnetic circuit basically does not pass will not become brittle due to crystallization annealing, and still has good processability, which can prevent the periphery of the stator core from being damaged during production, storage, transportation and assembly.

[0088] In some embodiments of the present application, the heating assembly 6 also includes a wire 62, through which current can be transmitted to the heating element 61, so that the heating element 61 performs crystallization annealing on the tooth portion 111 and the inner side of the yoke (i.e., the first yoke 112) of the stator core block in an unbonded state (i.e., a state in which the insulating layer 2 has not yet been prepared) by resistance heating or induction heating.

[0089] In some embodiments of this application, please refer to Figure 6 The cooling assembly 7 includes an annular cooling fixture 71, and a cooling channel 72 is opened inside the annular cooling fixture 71. The cooling channel 72 extends along the circumference of the annular cooling fixture 71. When the cooling channel 72 flows in the annular cooling fixture 71, uniform cooling of the stator core in the circumference can be achieved, thereby avoiding deviations in the formation distribution of the first alloy zone 11 and the second alloy zone 12 in the stator core due to uneven cooling.

[0090] In the above embodiment, in order to improve the heat treatment efficiency, multiple core monolithic bodies are stacked into a stator core block, thereby realizing simultaneous heat treatment of multiple core monolithic bodies. Therefore, it is necessary not only to achieve uniform cooling of the outer periphery of the stator core block, but also to achieve uniform cooling of the axial direction of the stator core block.

[0091] In order to solve the above problems, in some embodiments of the present application, please refer to Figure 7The cooling channel 72 includes a plurality of annular channels, which are sequentially arranged along the axial direction of the stator core, and are respectively recorded as the first annular channel 721, the second annular channel 722 and the third annular channel 723, so as to realize uniform cooling of the stator core block in the axial direction and ensure the consistency of the heat treatment effect of the plurality of core monolithic bodies. Each annular channel is correspondingly provided with an input pipeline 724 and an output pipeline 725, so as to continuously input cooling water to the plurality of annular channels and ensure the cooling effect of the cooling assembly 7.

[0092] In some other embodiments of the present application, the cooling channel 72 is a spiral channel, which extends axially along the stator core. Uniform axial and circumferential cooling of the stator core block can be achieved through the same spiral channel. An input pipeline 724 is provided at one end of the spiral channel, and an output pipeline 725 is provided at the other end. The input pipeline 724 and the output pipeline 725 are respectively located at the two ends of the stator core block in the axial direction.

[0093] In the above embodiment, the cooling channel 72 can make the temperature of the annular cooling fixture 71 lower than 80°C, and through the contact heat exchange between the annular cooling fixture 71 and the outer periphery of the stator core block, the temperature of the second yoke 121 can be made lower than 250°C, which is lower than the crystallization annealing temperature of the amorphous alloy, so that the amorphous alloy of the second yoke 121 will not undergo crystallization annealing.

[0094] In some embodiments of this application, please refer to Figure 7 The processing equipment also includes a temperature detection component 8, which is used to measure the temperature of the first alloy zone 11 and the second alloy zone 12; the temperature detection component 8 is connected to the heating component 6 by signal, and can be used to control the temperature during the annealing process to ensure the heat treatment effect of the stator core block.

[0095] In some embodiments of the present application, the temperature detection assembly 8 includes a first detection member 81 and a second detection member 82, wherein the first detection member 81 is used to measure the temperature inside the tooth portion 111. Figure 8 The second detection member 82 is used to measure the temperature of the second yoke 121, such as Fig. 9 When the temperature detection component 8 detects that the temperature inside the tooth portion 111 is higher than 550°C or the temperature of the second yoke portion 121 is higher than 200°C, the power of the heating component 6 is reduced or heating is stopped to avoid excessive grain growth of the tooth portion 111 and crystallization annealing of the second yoke portion 121.

[0096] In some embodiments of the present application, the first detection member 81 and the second detection member 82 are both thermocouples, which can directly perform contact measurement with the tooth portion 111 or the second yoke portion 121, thereby improving the temperature measurement accuracy and better achieving temperature control during the annealing process.

[0097] See also Figures 1 to 9 The fifth aspect of the embodiment of the present application provides a processing method, which uses the processing equipment in the above embodiment to manufacture the stator core in the above embodiment, including the following steps:

[0098] Step 1: Use a rapid quenching process to produce an amorphous alloy strip so that the amorphous alloy strip has lower eddy current loss and better mechanical properties.

[0099] It should be noted that the thickness of the amorphous alloy strip is preferably 18-36 microns. This is because the thickness of the amorphous alloy strip is the same as the thickness H1 of the iron core monolith 1. If the thickness of the amorphous alloy strip is less than 18 microns, the prepared iron core monolith body will not meet the mechanical performance requirements during subsequent processing and transportation; and when the thickness of the amorphous alloy strip is greater than 36 microns, it is difficult to produce it through the existing smelting, casting, and rolling processes. The thickness of the crystalline alloy strip is preferably 18-36 microns in this application, which can reduce the difficulty of making the amorphous alloy strip and ensure the mechanical properties of the iron core monolith 1 produced by the amorphous alloy strip.

[0100] Step 2: Prepare a plurality of iron core monolithic bodies on the second alloy strip.

[0101] It should be noted that the preparation of multiple iron core monolithic bodies can be carried out in a variety of ways. Multiple iron core monolithic bodies can be punched out one by one on the amorphous alloy strip, or multiple amorphous alloy strips can be stacked into blocks and then multiple iron core monolithic bodies of the same shape can be cut out at one time by wire cutting. Both methods can achieve the purpose of the present application.

[0102] Step three: stack multiple single-piece core bodies into a stator core block, set the heating component 6 in the middle of the stator core block, so that the axis of the heating element 61 coincides with the axis of the stator core block; set the cooling component 7 on the outer periphery of the stator core block so that the second yoke 121 and the annular cooling tooling 71 are evenly contacted.

[0103] Step 4: Turn on the heating component 6 and the cooling component 7 to form a first alloy zone 11 in the middle of the stator core block through crystallization annealing. Under the cooling effect of the cooling component 7, the outer periphery of the stator core block keeps the amorphous alloy in the second alloy zone 12 outside the first alloy zone 11 in an unannealed and unbrittle state.

[0104] In some embodiments of the present application, the annealing temperature of the crystallization annealing is 450-600°C, and the annealing time is 30-60min. Conventional amorphous alloy annealing in the prior art generally adopts an annealing process of keeping warm below 250°C for more than 2 hours to achieve the effect of eliminating stress. The present application uses a higher annealing temperature and a shorter annealing time to enable the amorphous alloy corresponding to the first alloy zone 11 to produce nano-sized grains, thereby transforming the material of the first alloy zone 11 into a nanocrystalline alloy, which has the effect of greatly improving the magnetic permeability and coercive force.

[0105] In some preferred embodiments of the present application, the cooling assembly 7 can make the temperature of the second yoke 121 at the periphery of the stator core block lower than 100° C. during the crystallization annealing process, thereby avoiding crystallization annealing of the amorphous alloy in the second yoke 121 .

[0106] In some embodiments of the present application, since the distance between the tooth portion 111 and the heating element 61 is smaller than the distance between the first yoke portion 112 and the heating element 61, grain growth will occur in the tooth portion 111, thereby causing the grain size in the tooth portion 111 to be larger than the grain size in the first yoke portion 112. However, when the grain size of the first yoke portion 112 is approximately 5-10 nanometers, the grain size of the tooth portion 111 can still be maintained at 14-18 nanometers, which can still significantly improve the solubility of B atoms, thereby significantly improving the magnetic permeability of the first yoke portion 112 and the tooth portion 111.

[0107] Step 5: Immerse the stator core blocks that have undergone crystallization annealing in the insulating glue curing liquid to form an insulating layer 2 between the core monoliths 1. By applying pressure in the thickness direction (i.e., axial direction) of the unbonded stator core blocks, the thickness of the insulating layer 2 is controlled to be 0.3-1 microns to form an amorphous nanocrystalline alloy stator core.

[0108] It should be understood that the terms used herein are only for the purpose of describing specific example embodiments and are not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms "one", "an" and "said" as used herein may also be meant to include plural forms. The terms "include", "comprise", "contain", and "have" are inclusive, and therefore specify the existence of stated features, steps, operations, elements and / or parts, but do not exclude the existence or addition of one or more other features, steps, operations, elements, parts, and / or combinations thereof. The method steps, processes, and operations described herein are not interpreted as necessarily requiring them to be performed in the specific order described or illustrated, unless the execution order is clearly indicated. It should also be understood that additional or alternative steps may be used.

[0109] Although the terms first, second, third, etc. can be used in the text to describe multiple elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or section from another region, layer or section. Unless the context clearly indicates, terms such as "first", "second" and other numerical terms do not imply order or sequence when used in the text. Therefore, the first element, component, region, layer or section discussed below can be referred to as the second element, component, region, layer or section without departing from the teaching of the example embodiments.

[0110] The above description is only a specific implementation of the present application, so that those skilled in the art can understand or implement the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest range consistent with the principles and novel features applied for herein.

Claims

1. A core monolithic chip (1), characterized in that: include: A first alloy region (11), the first alloy region (11) having a tooth portion (111) and a first yoke portion (112), the first yoke portion (112) being arranged on the outer periphery of the tooth portion (111); A second alloy region (12), wherein the second alloy region (12) has a second yoke (121), the second yoke (121) is arranged on the periphery of the first yoke (112), the second alloy region (12) includes a plurality of atoms arranged in a disordered state, and the magnetic permeability of the first alloy region (11) is greater than the magnetic permeability of the second alloy region (12).

2. The core monolithic piece (1) according to claim 1, characterized in that: The first alloy region (11) comprises a plurality of crystal grains in an orderly arrangement state, and the size of the crystal grains is less than 20 nanometers.

3. The core monolithic piece (1) according to claim 1, characterized in that: In the first direction, the size of the first yoke (112) is W1, the size of the second yoke (121) is W2, and the ratio range of W1 to W2 satisfies 1≤W1 / W2≤4.

4. The core monolithic piece (1) according to claim 3, characterized in that: The maximum outer diameter of the core monolith (1) is d, the first direction is the radial direction of the core monolith (1), and the sum of the size W1 of the first yoke (112) and the size W2 of the second yoke (121) satisfies d / 18≤W1+W2≤d / 10.

5. The core monolith (1) according to any one of claims 1 to 4, characterized in that: The material of the first alloy region (11) is a nanocrystalline alloy, and the material of the second alloy region (12) is an amorphous alloy.

6. The core monolith (1) according to claim 5, characterized in that: The material of the amorphous alloy is Fe-Si-B-Nb-Cu system, Fe-Co-Si-B-Nb-Cu system, Fe-Si-BP-Cu system, Fe-Co-Si-BP-Cu system, Fe-Zr-B-Cu system or Fe-Co-Zr-B-Cu system.

7. A stator core, characterized in that: It comprises the core monolith (1) as claimed in any one of claims 1 to 6, wherein the number of the core monoliths (1) is multiple, the multiple core monoliths (1) are stacked, and an insulating layer (2) is provided between two adjacent core monoliths (1).

8. A motor, characterized in that: Comprising the stator core as claimed in claim 7.

9. The motor according to claim 8, characterized in that In a first direction, the size of the first yoke (112) is W1, and the size of the second yoke (121) is W2; When the motor frequency of the motor is below the preset frequency threshold, the ratio range of W1 to W2 satisfies 2≤W1 / W2≤4; When the motor frequency of the motor is greater than a preset frequency threshold, the ratio range of W1 to W2 satisfies 1≤W1 / W2≤3.

10. A processing equipment, characterized in that: Used to manufacture the stator core as claimed in claim 7, comprising a heating component (6) and a cooling component (7), wherein the heating component (6) is arranged corresponding to the first alloy zone (11), and the cooling component (7) is arranged corresponding to the second alloy zone (12).

11. The processing equipment according to claim 10, characterized in that The heating assembly (6) comprises a heating element (61), the middle of the first alloy zone (11) comprises a containing space (13) for accommodating the heating element (61), the axis of the heating element (61) coincides with the axis of the stator core, and the outer periphery of the second alloy zone (12) is arranged in contact with the cooling assembly (7).

12. The processing equipment according to claim 10, characterized in that: The cooling assembly (7) comprises an annular cooling fixture (71), a cooling channel (72) is provided inside the annular cooling fixture (71), and the cooling channel (72) extends along the circumference of the annular cooling fixture (71).

13. The processing equipment according to claim 12, characterized in that: The cooling flow channel (72) comprises a plurality of annular flow channels, and the plurality of annular flow channels are arranged in sequence along the axial direction of the stator core.

14. The processing equipment according to claim 12, characterized in that: The cooling channel (72) is a spiral channel, and the spiral channel extends along the axial direction of the stator core.

15. The processing equipment according to any one of claims 11 to 14, characterized in that: It also comprises a temperature detection component (8), wherein the temperature detection component (8) is used to measure the temperature of the first alloy zone (11) and the second alloy zone (12); the temperature detection component (8) is connected to the heating component (6) by signal.

16. A processing method, characterized in that: The processing equipment according to any one of claims 10 to 15 is used to manufacture the stator core according to claim 7, comprising the following steps: preparing a plurality of iron core monolithic bodies on the second alloy strip; A plurality of single-piece iron core bodies are stacked to form a stator iron core block, the heating component (6) is arranged in the middle of the stator iron core block, and the cooling component (7) is arranged on the periphery of the stator iron core block; The heating component (6) and the cooling component (7) are turned on to form the first alloy region (11) in the middle of the stator core block through crystallization annealing.

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