Iron core single piece, stator core, motor, processing device and processing method

Abstract

The application relates to a core single piece, a stator core, a motor, a processing device and a processing method. The core single piece comprises a first alloy area and a second alloy area. The first alloy area has a tooth part and a first yoke part. The first yoke part is arranged at the outer periphery of the tooth part. The second alloy area has a second yoke part. The second yoke part is arranged at the outer periphery of the first yoke part. The second alloy area comprises a plurality of atoms arranged in a disordered state. The magnetic permeability of the first alloy area is greater than that of the second alloy area. The magnetic permeability of the first alloy area in the core single piece provided by the application is greater than that of the second alloy area. The material can be a new soft magnetic material after annealing. Since the second alloy area comprises a plurality of atoms arranged in a disordered state, the periphery of the first alloy area can be protected. When the outer periphery of the core single piece and the stator core is subjected to external force, the stress can be more effectively dispersed and resisted, and the structural strength and process performance of the core single piece can be improved.

Description

Technical Field

[0001] This application relates to the field of motor technology, and in particular to a single iron core, a stator core, a motor, processing equipment, and processing method. Background Technology

[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 losses and copper losses. Iron losses are generated by the motor core. When the motor structure is fixed, iron losses are mainly determined by the characteristics of the soft magnetic materials that make up the core. Copper losses are generated by the motor windings and are also affected by the permeability of the core material.

[0003] To improve the magnetic permeability of core materials, existing technologies often employ annealing processes to manufacture emerging soft magnetic materials such as nanocrystalline alloys. These materials exhibit significantly higher permeability compared to conventional electrical steel, and their iron loss can be reduced by more than 50%. However, nanocrystalline alloys and similar materials become brittle after annealing, resulting in poor processing performance. They are easily damaged during production, storage, and transportation, and interference fits cannot be used for assembly. This hinders the widespread application of these emerging soft magnetic materials with low iron loss and high permeability. Summary of the Invention

[0004] This application provides a single core wafer, a stator core, a motor, processing equipment, and a processing method to solve the technical problem that emerging soft magnetic materials in the prior art become brittle and easily damaged due to annealing.

[0005] In a first aspect, this application provides a single iron core wafer, comprising:

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

[0007] The second alloy region has a second yoke, which is disposed on the outer 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 that of the second alloy region.

[0008] Optionally, the first alloy region includes multiple grains arranged in an ordered manner, with the grain size being 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 of W1 to W2 satisfies 1≤W1 / W2≤4.

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

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

[0012] Optionally, the amorphous alloy can be made of Fe-Si-B-Nb-Cu, Fe-Co-Si-B-Nb-Cu, Fe-Si-BP-Cu, Fe-Co-Si-BP-Cu, Fe-Zr-B-Cu, or Fe-Co-Zr-B-Cu.

[0013] Secondly, this application provides a stator core, including the core wafers provided in the first aspect of this application. The number of core wafers is multiple, and the multiple core wafers are stacked and arranged in layers, with an insulating layer between two adjacent core wafers.

[0014] Thirdly, this application provides an electric motor, including the stator core provided in the second aspect of this 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 is below the preset frequency threshold, the ratio of W1 to W2 satisfies 2≤W1 / W2≤4.

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

[0018] Fourthly, this application provides a processing apparatus for manufacturing the stator core provided in the second aspect of this application, including a heating assembly and a cooling assembly, wherein the heating assembly is disposed corresponding to a first alloy region and the cooling assembly is disposed corresponding to a second alloy region.

[0019] Optionally, the heating assembly includes a heating element, a first alloy region having a accommodating space in the middle for accommodating the heating element, the axis of the heating element coinciding with the axis of the stator core, and the outer periphery of the second alloy region being in contact with the cooling assembly.

[0020] Optionally, the cooling assembly includes an annular cooling fixture with cooling channels inside, the cooling channels extending circumferentially along the annular cooling fixture.

[0021] Optionally, the cooling channel includes multiple annular channels, which are arranged sequentially along the axial direction of the stator core.

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

[0023] Optionally, the processing equipment also includes a temperature detection component for measuring the temperature of the first alloy zone and the second alloy zone; the temperature detection component is signal-connected to the heating component.

[0024] Fifthly, this application provides a processing method using the processing equipment provided in the fourth aspect of this application for the stator core provided in the second aspect of this application, comprising the following steps:

[0025] Multiple iron core monoliths were fabricated on the second alloy strip;

[0026] Multiple iron core monoliths are stacked to form a stator iron core block. The heating component is placed in the middle of the stator iron core block, and the cooling component is placed on the outer periphery of the stator iron core block.

[0027] The heating and cooling components are turned on, allowing the first alloy zone to be formed in the middle of the stator core block through crystallization annealing.

[0028] The technical solutions provided in this application have the following advantages compared with the prior art:

[0029] The core wafer provided in this application includes a first alloy region and a second alloy region. The magnetic permeability of the first alloy region is greater than that of the second alloy region. Its material can be an annealed emerging soft magnetic material. The second alloy region includes multiple atoms arranged in a disordered state. When the second alloy region is located outside the first alloy region, it can protect the periphery of the first alloy region. Since the atoms in the second alloy region are arranged in a disordered state, the outer periphery of the core wafer and the stator core can more effectively disperse and resist stress when subjected to external forces. This can improve the structural strength and process performance of the core wafer and prevent damage to the core wafer and the stator core during production, storage, transportation and assembly. Attached Figure Description

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

[0031] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0033] Figure 1 A top view of a single core sheet provided in an embodiment of this application;

[0034] Figure 2 Provided for the embodiments of this application Figure 1 Enlarged detail of section A;

[0035] Figure 3 A partial structural schematic diagram of the motor provided in an embodiment of this application;

[0036] Figure 4 Provided for the embodiments of this application Figure 3 A partial sectional view;

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

[0038] Figure 6 This is a schematic diagram of the processing equipment provided in the embodiments of this application;

[0039] Figure 7 The following are provided for the embodiments of this application: Figure 6 Sectional view of BB;

[0040] Figure 8 Provided for the embodiments of this application Figure 7 Enlarged detail of section C;

[0041] Figure 9 Provided for the embodiments of this application Figure 7 A magnified view of the details in section D.

[0042] Explanation of reference numerals in the attached figures:

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

[0044] 2. Insulation layer;

[0045] 3. Insulating frame;

[0046] 4. Groove insulating paper;

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

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

[0049] 7. Cooling assembly; 71. Annular cooling fixture; 72. Cooling channel; 721. First annular channel; 722. Second annular channel; 723. Third annular channel; 724. Inlet pipe; 725. Outlet pipe;

[0050] 8. Temperature detection component; 81. First detection element; 82. Second detection element. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0052] The following disclosure provides numerous different embodiments or examples for implementing various structures of this application. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0053] For ease of description, spatial relative terms may be used in the text to describe the relative position or movement of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "inside," "outside," "middle," "outer," "below," "below," "above," "front," "back," etc. Such spatial relative terms are intended to include different orientations of the device in use or operation, other than those depicted in the figure. For example, if the device in the figure undergoes a positional flip, orientation change, or change of motion, these directional indications will change accordingly. For instance, an element described as "below other elements or features" or "below other elements or features" will subsequently be oriented "above other elements or features" or "above other elements or features." Therefore, the example term "below" can 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 in the text will be interpreted accordingly.

[0054] To address the technical problem of embrittlement and easy damage of emerging soft magnetic materials due to annealing in existing technologies, this application provides a core monolith 1, a stator core, a motor, processing equipment, and a processing method. The core monolith 1 includes a first alloy region 11 and a second alloy region 12, wherein the permeability of the first alloy region 11 is greater than that of the second alloy region 12, and its material can be an annealed emerging soft magnetic material. The second alloy region 12 includes multiple atoms arranged in a disordered state. When the second alloy region 12 is located on the periphery of the first alloy region 11, it can protect the periphery of the first alloy region 11. Since the atoms in the second alloy region 12 are arranged in a disordered state, the second alloy region 12 (i.e., the outer periphery of the core monolith 1 and the stator core) can more effectively disperse and resist stress when subjected to external forces, thereby improving the structural strength and process performance of the core monolith 1 and preventing damage to the core monolith 1 and the stator core during production, storage, transportation, and assembly.

[0055] Please see Figures 1 to 9 The first aspect of this application provides a core monolith 1, including a first alloy region 11 and a second alloy region 12, such as... Figure 1 As shown in the attached figure (the dashed line represents the boundary between the first alloy region 11 and the second alloy region 12).

[0056] The first alloy region 11 has a toothed portion 111 and a first yoke portion 112, with the first yoke portion 112 disposed on the outer periphery of the toothed portion 111. The toothed portion 111 includes a plurality of stator teeth, with stator slots 14 formed between adjacent stator teeth for assembling the winding 5. The plurality of stator teeth are arranged sequentially along the circumference of the first yoke portion 112, and the shape and number of the stator teeth can be designed as needed and are not limited here.

[0057] The second alloy region 12 has a second yoke 121, which is disposed on the outer periphery of the first yoke 112, such that the first yoke 112 and the second yoke 121 are connected to form the yoke of the iron 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] Since the magnetic circuit mainly passes through the tooth section 111 and the first yoke section 112 (i.e., the inner side of the yoke section) during the operation of the motor, the 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 high permeability, thereby reducing the iron loss of the stator core.

[0059] The second alloy region 12 includes multiple atoms arranged in a disordered state. When the outer periphery of the core sheet 1 or 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 the stress, giving the second alloy region 12 high strength characteristics. This is beneficial to improving the structural strength and process performance of the core sheet 1 and preventing damage to the core sheet 1 and the stator core during production, storage, transportation and assembly.

[0060] It should be noted that the material of the first alloy region 11 can be a novel 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., while the material of the second alloy region 12 can be a soft magnetic material with both good magnetic permeability and processing performance in the prior art, such as amorphous alloy, iron-silicon alloy, etc.

[0061] In some preferred embodiments of this application, the first alloy region 11 is made of a nanocrystalline alloy, and the second alloy region 12 is made of an amorphous alloy. Since the saturation magnetic induction intensity of nanocrystalline alloys is generally higher than that of amorphous alloys, nanocrystalline alloys are more suitable for the densely packed magnetic circuits of the tooth section 111 and the first yoke section 112, which helps reduce iron losses in the core wafer 1 and the stator core. During the annealing process of the amorphous alloy, crystallization occurs, that is, the amorphous phase gradually transforms into the crystalline phase, forming a nanocrystalline alloy. Therefore, the nanocrystalline alloy in the first alloy region 11 can be made by annealing the amorphous alloy, while the amorphous alloy in the second alloy region 12 remains in an unannealed state and will not become embrittled. This balances the high permeability and high structural strength (i.e., processability) of the core wafer 1. Furthermore, since both amorphous and nanocrystalline alloys have high permeability and are almost unaffected by the excitation frequency, they will not cause a significant increase in high-frequency copper losses in the motor.

[0062] In some embodiments of this application, the first alloy region 11 includes a plurality of grains arranged in an ordered state, and the size of the grains is less than 20 nanometers (nm). This can increase the solubility of boron atoms (B atoms) in the first alloy region 11, thereby increasing the initial relative permeability of the nanocrystalline alloy to more than 20,000 and reducing the coercivity to less than 5 A / m. By reducing the coercivity, the BH curve (magnetization curve) is narrowed, which greatly reduces the hysteresis loss in iron loss.

[0063] In the above embodiments, 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 iron core sheet 1, so that the first alloy region 11 covers the area through which the magnetic circuit passes.

[0064] In some embodiments of this application, please refer to Figure 1 and Figure 2In the first direction, the dimension of the first yoke 112 is W1, and the dimension of the second yoke 121 is W2. The ratio of W1 to W2 satisfies 1 ≤ W1 / W2 ≤ 4. Here, W1 is the width of the magnetic circuit passing through the yoke, which is the width region requiring excellent magnetic properties, while W2 is the width of the yoke not traversed by the magnetic circuit, which is the part requiring good manufacturability during transportation, winding, and assembly. The first direction is the width direction of the yoke. When the total width of the yoke of the core piece 1 is constant, if the ratio of W1 to W2 is less than 1, the width region with excellent magnetic properties in the yoke will be small, making it difficult to meet the design requirements for the magnetic circuit width. Conversely, if the ratio of W1 to W2 is greater than 4, the width of the second alloy region 12 will be limited, failing to provide effective external protection.

[0065] In some embodiments of this application, please refer to Figure 1 When the core piece 1 is circular, its maximum outer diameter is d, and the first direction is the radial direction of the core piece 1. The sum of the dimensions W1 of the first yoke 112 and W2 of the second yoke 121 satisfies d / 18 ≤ W1 + W2 ≤ d / 10. The heavier the motor's operating conditions, the larger the required diameter d of the core piece 1. To ensure the magnetic circuit width and the manufacturing performance of the core piece 1, the overall width W1 + W2 of the yoke is also larger, directly proportional to the diameter d. When W1 + W2 is less than d / 18, the total width of the yoke becomes smaller, resulting in smaller widths for both the first yoke 112 and the second yoke 121. This makes it impossible to guarantee the magnetic circuit width traversed by the first yoke 112 and the manufacturing performance of the second yoke 121. However, when W1+W2 is greater than d / 10, the yoke portion becomes too large, leading to increased material and volume in both the core sheet 1 and the stator core. This not only increases manufacturing costs but also increases iron losses in the stator core, resulting in decreased motor efficiency. Therefore, this application preferably uses d / 18≤W1+W2≤d / 10, which ensures both the magnetic circuit width and manufacturing performance of the stator core, as well as motor efficiency.

[0066] In some embodiments of this application, the amorphous alloy is made of 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. This can avoid the adverse effects of the second alloy region 12 on the magnetic circuit of the stator core, and can also improve the structural strength and processability of the core wafer 1 and the stator core.

[0067] Among them, Fe-Si-B-Nb-Cu amorphous alloys possess excellent soft magnetic properties and good thermal stability, making them promising near-room temperature magnetic refrigeration materials. Fe-Co-Si-B-Nb-Cu amorphous alloys exhibit good high-frequency performance and high corrosion resistance, making them suitable for high-frequency electronic applications and maintaining stable performance even in harsh environments. Fe-Si-BP-Cu amorphous alloys have a dense structure, which helps improve the magnetic and mechanical properties of amorphous alloys. Fe-Co-Si-BP-Cu amorphous alloys possess excellent magnetic properties, high-frequency performance, and corrosion resistance, making them suitable for high-performance electronic components, high-frequency transformers, and applications requiring high corrosion resistance. Fe-Zr-B-Cu amorphous alloys have good strength and toughness, resulting in better mechanical properties in the second alloy region 12. Fe-Co-Zr-B-Cu amorphous alloys combine the advantages of cobalt and zirconium, possessing excellent magnetic properties, high strength, and high hardness, offering significant advantages in applications requiring high stress and high impact resistance.

[0068] Please see Figures 1 to 9 The second aspect of this application provides a stator core, including the core wafer 1 described in the above embodiments. Multiple core wafers 1 are stacked, and an insulating layer 2 is provided between adjacent core wafers 1. The insulating layer 2 achieves interlayer insulation between adjacent core wafers 1. Figure 5 As shown, this ensures the normal use of the stator core.

[0069] In some embodiments of this application, in the second direction, the thickness H2 of the insulating layer 2 is 0.3-1.0 micrometers (μm). This is because the insulating layer 2 is formed by impregnating the stator core block with insulating adhesive. When the thickness of the insulating layer 2 formed by the curing of the liquid insulating adhesive between adjacent core sheets 1 is less than 0.3 micrometers, the burrs of the core sheet 1 itself can easily puncture the insulating layer 2, thus causing the insulating layer 2 to fail to meet the interlayer insulation requirements. When the thickness of the insulating layer 2 is greater than 1 micrometer, it will cause the lamination factor of the stator core to be too low, thereby reducing 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 insulating varnish in the prior art, which can achieve the purpose of this application.

[0071] As a preferred embodiment of this application, the insulating layer 2 is made of epoxy resin, which not only has good insulation performance, but also good adhesion performance and chemical stability performance. It can tightly bond adjacent iron core pieces 1 and resist the corrosion of various chemical substances, so that the stator iron core will not loosen, disintegrate or fail during the operation of the motor.

[0072] Please see Figures 1 to 9 This application provides a motor, including the stator core described in the above embodiments, and further including an insulating frame 3, slot insulating paper 4, and windings 5. The assembly relationship between the components can be set with reference to existing technology, thus producing a motor with an amorphous nanocrystalline alloy stator core. Figure 3 and Figure 4 As shown. The lead wire 51 of 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 run.

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

[0074] If the frequency of frequent use of the motor is f and the number of pole pairs of the stator core is n, then f×n represents the motor frequency. The higher the motor frequency, the heavier the motor's operating conditions. At this time, the maximum outer diameter d of the stator core is also larger. Correspondingly, the dimensions of the first yoke 112 and the second yoke 121 also need to be set according to the motor's operating conditions.

[0075] In some embodiments of this application, when the motor frequency is below a preset frequency threshold, the ratio 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 significant, and the actual width of the magnetic circuit in the stator core is larger, requiring the first yoke 112 to account for a larger proportion of the total width of the yoke. If W1 / W2 < 2, it will result in material waste and increased iron loss; if W1 / W2 > 4, it will lead to a decrease in the magnetic properties of the portion of the magnetic circuit that passes through, thereby reducing motor efficiency.

[0076] In some preferred embodiments of this application, when the stator core adopts an assembly method with a large width that generates high stress and affects the magnetic properties of the yoke, such as a heat-shrinkable assembly, 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 some other preferred embodiments of this application, when the stator core adopts an assembly method that has little impact on the yoke, such as structural clamping, the width ratio of the second yoke 121 can be appropriately reduced, and the stator core is suitable for a design where W1 / W2 is close to 4, in order to reduce material costs and reduce iron loss.

[0078] In some other embodiments of this application, when the motor frequency is greater than a preset frequency threshold, the ratio 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 pronounced, resulting in a narrower actual width of the magnetic circuit. Therefore, the widths of the first yoke 112 and the second yoke 121 can be appropriately reduced. If W1 / W2 < 1, it will cause material waste and increased iron loss. If W1 / W2 > 3, it will lead to a decrease in the magnetic properties of the portion of the magnetic circuit that passes through, resulting in reduced motor efficiency.

[0079] In some preferred embodiments of this application, when the stator core adopts an assembly method that has a significant impact on the yoke, it is appropriate to adopt a design where 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 stator core's outer periphery.

[0080] In some other preferred embodiments of this application, when the stator core adopts an assembly method that has little impact on the yoke, it is appropriate to adopt a design where W1 / W2 is close to 3, which can appropriately reduce the width ratio of the second yoke 121 in the yoke, reduce material waste, and lower manufacturing costs.

[0081] In the above embodiments, the preset frequency threshold can be set according to the motor's usage scenario. In this application, the preset frequency threshold is set to 400Hz. This is because below 400Hz is the low-frequency range used by motors in general household appliances, while above 400Hz is the high-frequency range used by drive motors in general new energy vehicles. The regional division of the first alloy region 11 and the second alloy region 12 can be designed according to the motor's operating conditions, so that the motor meets the magnetic circuit design and process performance requirements under different operating conditions.

[0082] As a specific embodiment of this application, when the maximum outer diameter d of the core piece 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 of the core piece 1 is limited to 6.21-11.18 mm.

[0083] The motor is frequently used at a frequency of 60Hz, and the stator core has 3 pole pairs (n). At this frequency, the motor frequency is below 400Hz. When the stator core is assembled using a heat-shrink method, W1 / W2 = 2.5 is selected, with W1 designed to be 5mm and W2 2mm. Compared to existing motor cores made of 35W300 electrical steel used under the same operating conditions, the amorphous nanocrystalline alloy stator core fabricated in this embodiment reduces iron loss by more than 40% under conditions of a motor frequency of 180Hz and a magnetic induction intensity of 1.5T.

[0084] Please see Figures 1 to 9To prepare a first alloy region 11 and a second alloy region 12 on the core wafer 1 of the stator core, forming an amorphous nanocrystalline alloy stator core with a material transition, a fourth aspect of this application provides a processing apparatus for manufacturing the stator core in the above embodiment. The apparatus includes a heating component 6 and a cooling component 7. The heating component 6 is correspondingly arranged to the first alloy region 11, allowing the central region of the core wafer 1 to undergo crystallization annealing during heat treatment, thereby generating a nanocrystalline alloy. The cooling component 7 is correspondingly arranged to the second alloy region 12, reducing the temperature of the second alloy region 12 and preventing crystallization annealing during heat treatment. This avoids embrittlement of the second alloy region 12 due to annealing, which would affect the structural strength and processing performance of the second alloy region 12 (i.e., the second yoke 121). Figure 6 and Figure 7 As shown.

[0085] It should be noted that in this application, the iron core sheet 1 before heat treatment is referred to as the iron core sheet body. The iron core sheet body has already had the teeth 111 and the yoke prepared by means of punching and other processing methods, and its shape is as follows. Figure 1 and Figure 6 As shown. The material of the core monolith is preferably an amorphous alloy. When the heating component 6 heats the central area of ​​the stator core, the temperature of the core monolith 1 gradually decreases from the center to the edge, causing the amorphous alloy in the central area of ​​the core monolith to undergo crystallization annealing, thereby forming the first alloy region 11 with nanocrystalline alloy. The cooling component 7 is located on the outer periphery of the stator core, which can prevent the temperature of the amorphous alloy on the outer periphery of the core monolith from reaching the annealing temperature, so that the amorphous alloy on the outer periphery of the core monolith always remains in an unannealed state and does not become embrittled, which is the second alloy region 12.

[0086] By coordinating the heating component 6 and the cooling component 7 with the stator core in a partitioned manner, heating of a limited area can be achieved. This transforms the inner region of the stator core where the magnetic circuit is concentrated (i.e., the tooth 111 and the first yoke 112) into a nanocrystalline alloy with excellent magnetic properties, while the outer region through which the magnetic circuit is basically not passed (i.e., the second yoke 121) remains an unannealed amorphous alloy that has not become embrittled, thus improving the processing 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 first alloy region 11 has a accommodating space 13 in the middle 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 111 and the first yoke 112, and the stator core undergoes a material transition along its radial direction, so that the material of the tooth 111 and the first yoke 112 is transitioned from an amorphous alloy with good processability to a nanocrystalline alloy with excellent magnetic properties. The outer periphery of the second alloy region 12 is in contact with the cooling assembly 7, and the second alloy region 12 (i.e., the second yoke 121) can be cooled through contact heat exchange, so that the temperature of the outer periphery of the stator core is significantly lower than that of the middle part of the stator core. This achieves crystallization annealing in a limited area, so that the radially continuous core sheet 1 has different materials in different parts. Only the toothed part 111 and the inner side of the yoke (i.e., the first yoke 112) where the magnetic circuit of the stator core is concentrated produce nanocrystals due to crystallization annealing, thereby improving the magnetic permeability. The outer side of the yoke (i.e., the second yoke 121) where the magnetic circuit basically does not pass will not become brittle due to crystallization annealing, and still has good processability, which can prevent damage to the outer periphery of the stator core during production, storage, transportation and assembly.

[0088] In some embodiments of this application, the heating assembly 6 further includes a wire 62, through which current is supplied to the heating element 61, thereby enabling the heating element 61 to perform crystallization annealing on the teeth 111 and the inner side of the yoke (i.e., the first yoke 112) of the unbonded stator core block (i.e., the state before the insulation layer 2 is 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 provided inside the annular cooling fixture 71. The cooling channel 72 extends circumferentially along the annular cooling fixture 71. When the cooling channel 72 flows in the annular cooling fixture 71, it can achieve uniform cooling of the stator core circumferentially, and avoid deviations in the formation and distribution of the first alloy region 11 and the second alloy region 12 in the stator core due to uneven cooling.

[0090] In the above embodiments, in order to improve the heat treatment efficiency, multiple core monoliths are stacked into a stator core block, thereby achieving synchronous heat treatment of multiple core monoliths. 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] To address the aforementioned issues, please refer to some embodiments of this application. Figure 7The cooling channel 72 includes multiple annular channels arranged sequentially along the axial direction of the stator core, designated as the first annular channel 721, the second annular channel 722, and the third annular channel 723. These channels provide uniform axial cooling of the stator core blocks, ensuring consistent heat treatment performance across multiple core segments. Each annular channel is equipped with an input pipe 724 and an output pipe 725 to continuously supply cooling water to the multiple annular channels, ensuring the effective cooling of the cooling assembly 7.

[0092] In some other embodiments of this application, the cooling channel 72 is a spiral channel that extends along the axial direction of the stator core. The stator core block can be uniformly cooled in both the axial and circumferential directions through the same spiral channel. One end of the spiral channel is provided with an input pipe 724 and the other end is provided with an output pipe 725. The input pipe 724 and the output pipe 725 are located at the two ends of the stator core block in the axial direction, respectively.

[0093] In the above embodiment, the cooling channel 72 can keep the temperature of the annular cooling fixture 71 below 80°C. By exchanging heat with the outer periphery of the stator core block through contact, the temperature of the second yoke 121 can be kept below 250°C, which is below 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 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 this application, the temperature detection component 8 includes a first detection element 81 and a second detection element 82, wherein the first detection element 81 is used to measure the temperature of the inner side of the tooth 111, such as... Figure 8 As shown; the second detection element 82 is used to measure the temperature of the second yoke 121, such as... Figure 9 As shown. When the temperature detection component 8 detects that the temperature inside the tooth 111 is higher than 550°C or the temperature of the second yoke 121 is higher than 200°C, it reduces the power of the heating component 6 or stops heating to prevent the grains in the tooth 111 from growing too large and to prevent the second yoke 121 from undergoing crystallization annealing.

[0096] In some embodiments of this application, the first detection element 81 and the second detection element 82 are both thermocouples, which can directly contact the tooth 111 or the second yoke 121 for measurement, thereby improving the accuracy of temperature measurement and enabling better temperature control during the annealing process.

[0097] Please see Figures 1 to 9 The fifth aspect of this application provides a processing method using the processing equipment described in the above embodiments to manufacture the stator core described in the above embodiments, comprising the following steps:

[0098] Step 1: Use rapid quenching process to produce amorphous alloy strips, so that the amorphous alloy strips have lower eddy current losses and better mechanical properties.

[0099] It should be noted that the thickness of the amorphous alloy strip is preferably 18-36 micrometers. This is because the thickness of the amorphous alloy strip is the same as the thickness H1 of the iron core sheet 1. If the thickness of the amorphous alloy strip is less than 18 micrometers, the resulting iron core sheet body will not meet the mechanical performance requirements during subsequent processing and transportation. Conversely, if the thickness of the amorphous alloy strip is greater than 36 micrometers, it is difficult to manufacture using existing smelting, casting, and rolling processes. This application specifies that the thickness of the amorphous alloy strip is preferably 18-36 micrometers, which reduces the manufacturing difficulty of the amorphous alloy strip while ensuring the mechanical properties of the iron core sheet 1 produced from it.

[0100] Step 2: Prepare multiple iron core monoliths on the second alloy strip.

[0101] It should be noted that multiple core monoliths can be prepared in various ways. They can be cut out one by one from an amorphous alloy strip, or multiple amorphous alloy strips can be stacked into a block and then cut out multiple core monoliths of the same shape at once by wire cutting. Both methods can achieve the purpose of this application.

[0102] Step 3: Stack multiple iron core monoliths to form a stator iron core block. Place the heating component 6 in the middle of the stator iron core block, so that the axis of the heating component 61 coincides with the axis of the stator iron core block. Place the cooling component 7 on the outer periphery of the stator iron core block, so that the second yoke 121 and the annular cooling fixture 71 are in uniform contact.

[0103] Step 4: Turn on the heating component 6 and the cooling component 7, so that the middle part of the stator core block forms the first alloy region 11 through crystallization annealing. Under the cooling effect of the cooling component 7, the amorphous alloy in the second alloy region 12 on the outer periphery of the stator core block remains in an unannealed and unembrittled state.

[0104] In some embodiments of this application, the annealing temperature for crystallization annealing is 450-600℃ and the annealing time is 30-60min. Conventional amorphous alloy annealing in the prior art generally adopts an annealing process of holding at below 250℃ for more than 2 hours to achieve the effect of stress elimination. This application, through a higher annealing temperature and a shorter annealing time, enables the amorphous alloy corresponding to the first alloy region 11 to produce nano-sized grains, thereby transforming the material of the first alloy region 11 into a nanocrystalline alloy, which has the effect of significantly improving magnetic permeability and coercivity.

[0105] In some preferred embodiments of this application, the cooling component 7 can keep the temperature of the second yoke 121 on the outer periphery of the stator core block below 100°C during the crystallization annealing process, thereby preventing the amorphous alloy in the second yoke 121 from undergoing crystallization annealing.

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

[0107] Step 5: Immerse the crystallized annealed stator core block in the insulating adhesive curing liquid to form an insulating layer 2 between the core pieces 1. By applying pressure to the thickness direction (i.e., axial direction) of the unbonded stator core block, control the thickness of the insulating layer 2 to be 0.3-1 micrometers to produce an amorphous nanocrystalline alloy stator core.

[0108] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “described” as used herein may also include the plural forms. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore indicate the presence of the stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein are not construed as requiring them to be performed in a particular order described or illustrated unless the order of performance is explicitly indicated. It should also be understood that additional or alternative steps may be used.

[0109] Although terms such as first, second, third, etc., may be used in this document to describe multiple elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence. Therefore, the first element, component, region, layer, or segment discussed below may be referred to as the second element, component, region, layer, or segment without departing from the teachings of the exemplary embodiments.

[0110] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A single iron core piece (1) disposed in the stator core of an electric motor, characterized in that, include: A first alloy region (11) has a toothed portion (111) and a first yoke portion (112), the first yoke portion (112) being disposed on the outer periphery of the toothed portion (111); The second alloy region (12) is located around the first alloy region (11) and is used to protect the periphery of the first alloy region (11). The second alloy region (12) has a second yoke (121) which is disposed on the outer 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 that of the second alloy region (12). The first alloy region (11) is made of nanocrystalline alloy, and the second alloy region (12) is made of amorphous alloy. In the radial direction of the iron core monolith (1), the size of the first yoke (112) is W1, and the size of the second yoke (121) is W2. The ratio of W1 to W2 is 1≤W1 / W2≤4. When the motor frequency of the motor is below the preset frequency threshold, the ratio of W1 to W2 is 2≤W1 / W2≤4. When the motor frequency of the motor is above the preset frequency threshold, the ratio of W1 to W2 is 1≤W1 / W2≤3. The maximum outer diameter of the core piece (1) is d, and the sum of the dimensions W1 of the first yoke (112) and W2 of the second yoke (121) satisfies d / 18≤W1+W2≤d / 10.

2. The iron core monolith (1) according to claim 1, characterized in that, The first alloy region (11) includes a plurality of grains arranged in an ordered manner, the size of which is less than 20 nanometers.

3. The iron core monolith (1) according to claim 1, characterized in that, The amorphous alloy is made of Fe-Si-B-Nb-Cu, Fe-Co-Si-B-Nb-Cu, Fe-Si-BP-Cu, Fe-Co-Si-BP-Cu, Fe-Zr-B-Cu, or Fe-Co-Zr-B-Cu.

4. A stator core, characterized in that, Includes a core sheet (1) as described in any one of claims 1 to 3, wherein there are multiple core sheets (1), the multiple core sheets (1) are stacked, and an insulating layer (2) is provided between two adjacent core sheets (1).

5. An electric motor, characterized in that, Including the stator core as described in claim 4.

6. A processing device, characterized in that, For manufacturing the stator core as described in claim 4, a heating assembly (6) and a cooling assembly (7) are provided, wherein the heating assembly (6) is disposed corresponding to the first alloy region (11) and the cooling assembly (7) is disposed corresponding to the second alloy region (12).

7. The processing equipment according to claim 6, characterized in that, The heating assembly (6) includes a heating element (61), and the first alloy region (11) has a accommodating space (13) in the middle 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 region (12) is in contact with the cooling assembly (7).

8. The processing equipment according to claim 6, characterized in that, The cooling assembly (7) includes an annular cooling fixture (71), and a cooling channel (72) is provided inside the annular cooling fixture (71), which extends circumferentially along the annular cooling fixture (71).

9. The processing equipment according to claim 8, characterized in that, The cooling channel (72) includes multiple annular channels, which are arranged sequentially along the axial direction of the stator core.

10. The processing equipment according to claim 8, characterized in that, The cooling channel (72) is a spiral channel that extends along the axial direction of the stator core.

11. The processing equipment according to any one of claims 6 to 10, characterized in that, It also includes a temperature detection component (8), which is used to measure the temperature of the first alloy region (11) and the second alloy region (12); the temperature detection component (8) is signal connected to the heating component (6).

12. A processing method, characterized in that, The manufacturing of the stator core as described in claim 4, using the processing equipment as described in any one of claims 6 to 11, includes the following steps: Multiple iron core monoliths were fabricated on the second alloy strip; Multiple iron core monoliths are stacked to form a stator iron core block. The heating component (6) is placed in the middle of the stator iron core block, and the cooling component (7) is placed on the outer periphery of the stator iron core block. Turn on the heating component (6) and the cooling component (7) so that the first alloy region (11) is formed in the middle of the stator core block through crystallization annealing.

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