Novel amorphous alloy permanent magnet synchronous motor applied to belt conveyor driving system

Abstract

The invention provides a novel amorphous alloy permanent magnet synchronous motor applied to a novel belt conveyor driving system, which comprises a stator iron core, a stator winding and a rotor, and is characterized in that the stator iron core comprises a silicon steel laminated iron core section a1 formed by laminating a plurality of silicon steel sheets and an iron-based amorphous alloy section a2 formed by mutually laminating a plurality of iron-based non-alloy sheets; the stator winding is a three-phase connected hairpin type winding, the rotor comprises a silicon steel iron core formed by laminating a plurality of silicon steel sheets and a permanent magnet adopting a V-type structure, in the stator iron core, the iron-based amorphous alloy iron core section a2 accounts for 40-50% of the stator iron core by volume, and the silicon steel laminated iron core sections a1 are arranged at the two ends of the stator iron core. According to the invention, the performance and efficiency of the permanent magnet synchronous motor can be effectively improved by utilizing the iron-based amorphous alloy and the hairpin winding while the silicon steel sheets detached from the original permanent magnet synchronous motor are fully utilized.

Description

Technical Field

[0001] The invention relates to the technical field of motor equipment, and in particular to a novel amorphous alloy permanent magnet synchronous motor applied to a novel belt conveyor drive system. Background Art

[0002] As the most important conveying equipment for coal in coal mines, belt conveyors are developing towards high efficiency, high power, fast belt speed, large transport capacity and long conveying distance. The efficient and stable operation of coal mine belt conveyors is a necessary guarantee for efficient coal production.

[0003] At present, coal mines generally use asynchronous motors in series with reducers, hydraulic couplings and other transmission mechanisms to drive belt conveyors. Asynchronous motors have slip loss and harmonic loss. This inevitable loss makes the efficiency of asynchronous motors generally hover between 0.7-0.9; and the efficiency and power factor of asynchronous motors are determined by the load. When the load range is within 0.7, its efficiency and power factor drop rapidly; when using asynchronous motors to drive coal mine belt conveyors, the rated power of the motor should be selected according to the maximum load of the conveyor. However, in coal mines, the load of belt conveyors during normal operation is usually between 0.3-0.5, so asynchronous motors are in an inefficient operating state for a long time, wasting a lot of electricity.

[0004] Amorphous materials are a new type of soft magnetic material that has been developed recently. Compared with silicon steel sheets, they have higher resistivity and magnetic permeability, and lower coercivity and core loss. Therefore, the use of amorphous materials and silicon steel sheets can produce low-loss, high-efficiency stator and rotor motor cores, saving resources. In addition, the silicon steel sheets of old motors can be reused, which can effectively reduce motor costs and reduce resource waste.

[0005] Amorphous alloy has superior soft magnetic properties. Its magnetic permeability and resistance are higher than silicon steel, and its coercive force and iron loss are lower than silicon steel, among which the iron loss is only about 25% of that of silicon steel. However, since the saturation magnetic flux density of amorphous alloy is lower than that of ordinary silicon steel, if the silicon steel core is directly replaced with amorphous alloy material, although the motor loss is reduced, it will cause the motor torque to decrease. This does not meet the requirements of belt conveyor drive motors. In view of this situation, a new type of amorphous alloy permanent magnet synchronous motor for belt conveyor drive system is proposed. Summary of the invention

[0006] The purpose of the present invention is to provide a new type of amorphous alloy permanent magnet synchronous motor with high power density for use in a belt conveyor drive system, which can fully utilize the silicon steel sheets disassembled from the original permanent magnet synchronous motor while effectively improving the power density and efficiency of the permanent magnet synchronous motor.

[0007] To achieve the above-mentioned purpose, the present invention provides a new type of amorphous alloy permanent magnet synchronous motor applied to a belt conveyor drive system, comprising a stator core and a rotor core, wherein the stator core structure comprises a silicon steel laminated core segment a1 formed by stacking a plurality of silicon steel sheets, and an iron-based amorphous alloy core segment a2 formed by stacking a plurality of iron-based amorphous alloy sheets; the rotor core is a silicon steel laminated core formed by stacking a plurality of silicon steel sheets; the silicon steel laminated core segment a1 is arranged at both ends of the stator core; in the stator core, the volume fraction of the iron-based amorphous alloy core segment a2 in the stator core is 40%-50%.

[0008] Preferably, the silicon steel laminated core segment and the iron-based amorphous alloy core segment are both annular segments, and the axial lengths of the annular segments are equal.

[0009] Preferably, the thickness of each silicon steel sheet in the silicon steel laminated core segment is 0.2 mm, and the thickness of each iron-based amorphous alloy sheet in the iron-based amorphous alloy core segment is 0.02 mm.

[0010] Furthermore, ordinary silicon steel sheets from waste asynchronous motors are flattened, pickled or physically treated to remove surface coatings; stress relief annealing is performed at a temperature of 950°C for 4 hours with nitrogen as the protective gas; the sheets are cooled to room temperature with the furnace, and then cut and formed and re-coated with a new coating to complete the processing, thereby remanufacturing the silicon steel sheets.

[0011] Preferably, the stator winding is a three-phase hairpin winding.

[0012] Preferably, the rotor permanent magnet structure is of "V-" type.

[0013] Preferably, the production of the iron-based amorphous alloy core segment comprises the following steps: Step 1: Determine the basic Fe-based amorphous alloy parameters for adding elements; Step 2: According to the parameters of the iron-based amorphous alloy, determine the factors that affect the saturation magnetic induction intensity and coercivity of the amorphous alloy through computational material science analysis, and establish a database; Step 3: Select the element composition added to the iron-based amorphous alloy, simulate it through software, and obtain the composition ratio of the iron-based amorphous alloy with a saturation magnetic induction intensity close to that of silicon steel and a coercive force lower than that of silicon steel; the basic data of the iron-based amorphous alloy include the composition ratio of the original constituent elements of the iron-based amorphous alloy, the saturation magnetic induction intensity, and the coercive force; Step 4: Optimize the element ratio based on machine learning to obtain the final iron-based amorphous alloy molecular formula. Multiple iron-based amorphous alloy sheets are stacked on each other to form an iron-based amorphous alloy block. The iron-based amorphous alloy block is wire-cut into an iron-based amorphous alloy core segment.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0015] 1. Due to the lower core loss and saturation flux density of amorphous alloys, for remanufactured motors whose stator and rotor cores have a design value of magnetic flux density lower than the saturation flux density of amorphous alloys, the present invention replaces the silicon steel stator and rotor cores of disassembled scrap motors with laminated stator and rotor cores. The stator and rotor core losses at rated speed are 40%-60% of the original, and the energy-saving effect is more obvious as the speed increases, so that the efficiency of the remanufactured motor is increased by about 2%. For remanufactured motors whose stator and rotor cores have a design value of magnetic flux density higher than the saturation flux density of amorphous alloys, the laminated stator core reduces the torque contraction caused by direct replacement with amorphous alloys and improves the motor efficiency.

[0016] 2. In the present invention, the laminated stator core is arranged at the axial outermost end as old silicon steel laminated segments, which are evenly spaced and effectively avoid the problems caused by thin and brittle amorphous alloy laminates, effectively protect the amorphous alloy segment core, and effectively improve the lamination coefficient of the amorphous alloy.

[0017] 3. The present invention not only significantly improves the energy efficiency and performance of the original motor, but also makes full use of the components of the old motor.

[0018] 4. The present invention utilizes computational materials science and deep learning to design iron-based amorphous alloys, thereby reducing the research and development costs of iron-based amorphous alloy materials, while avoiding the large errors in estimating the performance of amorphous alloys based on experience. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 The schematic diagram of the structure of the novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system of the present invention; in the figure, a is the stator core, b is the rotor core, 1 is the stator winding, and 2 is the rotor permanent magnet.

[0020] Figure 2 This is a structural diagram of the stator core of the novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system of the present invention; in the figure, a1 is a silicon steel laminated core segment, a2 is an iron-based amorphous alloy core segment, and 3 is an amorphous alloy permanent magnet synchronous motor stator slot.

[0021] Figure 3 This is a cross-sectional view of the rotor core structure of the novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system of the present invention; b in the figure is the silicon steel laminated rotor core, and 2 is the amorphous alloy permanent magnet synchronous motor rotor permanent magnet.

[0022] Figure 4 The figure is a schematic diagram of the process of designing an iron-based amorphous alloy by using computational materials science according to the present invention.

[0023] FIG5 is a graph showing the external characteristic curves of the novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system of the present invention, wherein (a) is the speed-torque characteristic curve, and (b) is the speed-power characteristic curve.

[0024] FIG6 is a comparison diagram of the total loss curves of the original permanent magnet synchronous motor and the new amorphous alloy permanent magnet synchronous motor of the present invention applied to the belt conveyor drive system, wherein (a) is the original permanent magnet synchronous motor and (b) is the permanent magnet synchronous motor of the present invention. DETAILED DESCRIPTION

[0025] The present invention provides a novel amorphous alloy permanent magnet synchronous motor for use in a belt conveyor drive system. Figure 1 6 is a detailed description of the novel amorphous alloy permanent magnet synchronous motor used in the belt conveyor drive system of the present invention.

[0026] like Figure 1 As shown in FIG. 6 , the novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system of the present invention comprises a stator core a and a rotor core b. The stator core a is formed by laminating silicon steel lamination core segments of disassembled waste motors and amorphous alloy core segments in the axial direction with spacing therebetween. The rotor core b is formed by laminating silicon steel laminations of disassembled waste motors.

[0027] like Figure 2 As shown, the stator core a includes a silicon steel laminated core segment a1 formed by stacking multiple silicon steel sheets, and an iron-based amorphous alloy core segment a2 formed by stacking multiple iron-based amorphous alloy sheets. The silicon steel laminated core segment a1 and the iron-based amorphous alloy core segment a2 are stacked together to form the stator core (the core silicon steel sheets refer to the silicon steel sheets in the silicon steel core of the disassembled scrap motor).

[0028] like Figure 3 As shown, the rotor core b is a silicon steel laminated core formed by laminating a plurality of silicon steel sheets.

[0029] The stator core a is respectively provided with silicon steel laminated core segments a1 at both ends. Since the iron-based amorphous alloy laminated material is thin, hard and brittle, the iron-based amorphous core has a low lamination coefficient and is prone to breakage and peeling. The two ends of the stator core a are provided with silicon steel laminated core segments a1, which can protect the amorphous alloy material and improve the lamination coefficient of the iron-based amorphous alloy core segment a2.

[0030] In the stator core a, the volume fraction of the iron-based amorphous alloy core segment a2 is 40%-50% of the stator core a. One of the main purposes of remanufacturing is to save materials. In order to recycle the old silicon steel sheets in large quantities, the lower limit of the volume fraction of the silicon steel laminated core segment a1 is 50%. Although the loss of iron-based amorphous alloy material is only about 25% of the loss of silicon steel material, its low saturation magnetic flux density will cause the motor torque to decrease. In order to reduce the torque reduction of the remanufactured motor and improve the motor efficiency, the upper limit of the volume fraction of the iron-based amorphous alloy core segment a2 is 50%.

[0031] The silicon steel laminated core segment and the iron-based amorphous alloy core segment are both annular segments, and the axial lengths of the annular segments are equal. Due to the different magnetization characteristics of the two soft magnetic materials, the magnetic field distributions of the core segments and air gaps of different materials are different. In order to ensure the symmetry of the axial magnetic field of the iron core motor and eliminate the asymmetry of the axial magnetic field in the motor caused by different materials, the axial length of each stator core segment is set to be equal.

[0032] The thickness of each silicon steel sheet in the silicon steel laminated core segment a1 in the stator core a is set to be 0.2 mm, and the thickness of each iron-based amorphous alloy sheet in the iron-based amorphous alloy core segment a2 is set to be 0.02 mm.

[0033] The stator winding is a three-phase hairpin winding, and the stator slot type is parallel slot.

[0034] The thickness of each silicon steel sheet in the rotor core b is set to 0.2 mm.

[0035] The rotor permanent magnet is set to be N48UH sintered NdFeB permanent magnet with a "V-" structure.

[0036] On the one hand, the present invention makes full use of the old motor silicon steel sheets, and on the other hand, due to the excellent low-loss characteristics of the iron-based amorphous alloy, the laminated stator core loss is 40%-60% of the original stator core loss, so that the motor efficiency after remanufacturing is improved by about 2%.

[0037] The silicon steel sheet of the present invention is made from ordinary silicon steel sheets in waste permanent magnet synchronous motors, which are flattened, pickled or physically treated to remove surface coatings; stress relief annealing is performed at a temperature of 950°C, the heat preservation time is 4 hours, and the protective gas is nitrogen; the sheet is cooled to room temperature with the furnace, and then cut and formed and re-coated with a new coating to complete the treatment.

[0038] like Figure 4 As shown, the iron-based amorphous alloy core segment of the present invention is designed by using computational materials science and deep learning to select five elements of Fe, Si, B, P, and C to design an iron-based amorphous alloy with a saturation magnetic induction intensity close to that of silicon steel materials and a coercive force lower than that of silicon steel materials. The preparation thereof includes the following steps: Step 1: Determine the basic Fe-based amorphous alloy parameters for adding elements; Step 2: According to the parameters of the iron-based amorphous alloy, determine the factors that affect the saturation magnetic induction intensity and coercivity of the amorphous alloy through computational material science analysis, and establish a database; Step 3: Select the element composition added to the iron-based amorphous alloy, simulate it through software, and obtain the composition ratio of the iron-based amorphous alloy with a saturation magnetic induction intensity close to that of silicon steel and a coercive force lower than that of silicon steel; the basic data of the iron-based amorphous alloy include the composition ratio of the original constituent elements of the iron-based amorphous alloy, the saturation magnetic induction intensity, and the coercive force; Step 4: Optimize the element ratio based on machine learning to obtain the final iron-based amorphous alloy molecular formula. Multiple iron-based amorphous alloy sheets are stacked on each other to form an iron-based amorphous alloy block. The iron-based amorphous alloy block is wire-cut into an iron-based amorphous alloy core segment.

[0039] The number of segments of the laminated stator core depends on the design value of the magnetic flux density of the remanufactured motor stator core, and the optimal number of segments is achieved with the goal of improving motor efficiency and meeting torque requirements. In addition, the iron-based amorphous alloy core can also be replaced with other soft magnetic materials with superior performance.

[0040] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A novel amorphous alloy permanent magnet synchronous motor applied to a belt conveyor drive system, comprising a stator core, a stator winding and a rotor, characterized in that: The stator core structure comprises a silicon steel laminated core segment a1 formed by laminating a plurality of silicon steel sheets, and an iron-based amorphous alloy core segment a2 formed by laminating a plurality of iron-based amorphous alloy sheets. The stator winding is a three-phase connected hairpin winding; The rotor comprises a silicon steel laminated rotor core formed by laminating a plurality of silicon steel sheets and a N48UH sintered NdFeB permanent magnet with a "V-" structure; The silicon steel laminated core segment a1 is arranged at both ends of the stator core; In the stator core, the volume fraction of the iron-based amorphous alloy core segment a2 in the stator core is 40%-50%.

2. The novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system according to claim 1 is characterized in that: The stator core silicon steel laminated core segment and the iron-based amorphous alloy core segment are both annular segments, and the axial lengths of the annular segments are equal.

3. The novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system according to claim 1 or 2, characterized in that: The thickness of each silicon steel sheet in the silicon steel laminated core segment is 0.2 mm, and the thickness of each iron-based amorphous alloy sheet in the iron-based amorphous alloy core segment is 0.02 mm.

4. The novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system according to claim 1 is characterized in that: Ordinary silicon steel sheets from waste permanent magnet synchronous motors are flattened, pickled or physically treated to remove surface coatings; stress relief annealing is performed at a temperature of 950° C. for 4 hours with nitrogen as the protective gas; the sheets are cooled to room temperature with the furnace, and then cut and formed and re-coated with a new coating to complete the treatment, thereby remanufacturing the silicon steel sheets.

5. The novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system according to claim 1 is characterized in that: The stator winding is of three-phase hairpin type, and the stator winding slot type is parallel slot.

6. The novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system according to claim 1 is characterized in that: The thickness of each silicon steel sheet in the rotor silicon steel laminated core is 0.2 mm, and the rotor permanent magnet is installed in a "V-" style.

7. The novel amorphous alloy permanent magnet synchronous motor applied to the belt conveyor drive system according to claim 1 is characterized in that: The production of the iron-based amorphous alloy core segment comprises the following steps: Step 1: Determine the basic Fe-based amorphous alloy parameters for adding elements; Step 2: According to the parameters of the iron-based amorphous alloy, determine the factors that affect the saturation magnetic induction intensity and coercivity of the amorphous alloy through computational material science analysis, and establish a database; Step 3: Select the element composition added to the iron-based amorphous alloy, simulate it through software, and obtain the composition ratio of the iron-based amorphous alloy with a saturation magnetic induction intensity close to that of silicon steel and a coercive force lower than that of silicon steel; the basic data of the iron-based amorphous alloy include the composition ratio of the original constituent elements of the iron-based amorphous alloy, the saturation magnetic induction intensity, and the coercive force; Step 4: Optimize the element ratio based on machine learning to obtain the final iron-based amorphous alloy molecular formula. Multiple iron-based amorphous alloy sheets are stacked on each other to form an iron-based amorphous alloy block. The iron-based amorphous alloy block is wire-cut into an iron-based amorphous alloy core segment.

Images