Stator core manufacturing process and device and stator core

Abstract

The invention relates to the technical field of axial flux motors, in particular to a stator core manufacturing process and equipment and a stator core, and aims to solve the problem of poor insulation performance between core layers of an existing stator core. The stator iron core manufacturing process provided by the invention comprises the following steps: a strip is wound into a ring shape after being soaked in insulating glue, and then the stator iron core is cut on the ring-shaped strip. According to the stator core manufacturing process, the stator core is manufactured in a strip winding mode, specifically, a strip is driven by a reel and wound into a ring shape, then the stator core is cut on the ring-shaped strip, and the axis of the ring-shaped strip is the axis of the stator. Before winding, the strip is soaked in insulation glue to ensure full glue dipping. Compared with a stator core formed by stacking a laminated structure, the manufacturing process provided by the invention has the advantages that the problem of poor insulation effect caused by the fact that glue cannot enter the space between the laminated layers is solved, so that the loss of the stator core is extremely low, and the layers are bonded more firmly.

Description

Technical Field

[0001] The present invention relates to the technical field of axial flux motors, and in particular to a stator core manufacturing process, equipment and a stator core. Background Art

[0002] The existing stator core is made of tens of thousands of layers of high-magnetic conductivity materials stacked together, and the manufacturing process is relatively complicated. During the manufacturing process, each layer of high-magnetic conductivity sheet needs to be bonded with high-insulation, high-viscosity, high-temperature resistant high-quality glue. When the glue penetrates between the layers, it is difficult to avoid areas where the glue cannot reach. Therefore, it is easy to cause poor insulation between the layers of the high-magnetic conductivity sheet, resulting in short circuits and eddy current losses when installed in the motor and running. Summary of the invention

[0003] The object of the present invention is to provide a stator core manufacturing process, equipment and stator core to solve the problem of poor insulation performance between existing stator core sheets.

[0004] In order to solve the above technical problems, the technical solution provided by the present invention is:

[0005] A stator core manufacturing process comprises the following steps:

[0006] The strip is soaked in insulating glue and then wound into a ring shape, and then the stator core is cut out from the ring strip.

[0007] Furthermore, after the strip leaves the insulating glue, the excess glue is scraped off by a scraper to ensure that the thickness of the glue layer does not exceed 0.02 mm.

[0008] Furthermore, the insulating glue is epoxy resin glue, and the insulating glue needs to be heated and vacuumed.

[0009] Furthermore, the stator core is cut out by a wire cutting machine, each layer of the stator core is in an I-shape, and each layer of the annular strip corresponds to a layer of the stator core.

[0010] Furthermore, the strip thickness is 0.012-0.025 mm, and the strip material is an iron-based nanocrystalline alloy or an iron-based amorphous alloy.

[0011] Furthermore, the axis of the annular strip is coaxial with the axis of the stator.

[0012] On the other hand, the present invention provides a stator core manufacturing device, which adopts the above-mentioned stator core manufacturing process, including a main reel, a glue dipping roller, and a glue pool, wherein the glue pool contains insulating glue, and the glue dipping roller is partially or completely immersed in the insulating glue. The main reel is connected to the end of the strip and rotates around its own axis to drive the strip through the glue pool and the glue dipping roller and wind it into a ring.

[0013] Furthermore, the stator core manufacturing equipment also includes a cutting machine, which is used to cut the stator core from the annular strip.

[0014] Furthermore, the stator core manufacturing equipment also includes a scraper plate, which is arranged between the main reel and the dipping roller and is used to scrape off excess insulating glue on the strip.

[0015] A third aspect of the present invention provides a stator core manufactured using the above-mentioned stator core manufacturing process.

[0016] Based on the above technical solutions, the technical effects that can be achieved by the present invention are:

[0017] The manufacturing process of the stator core provided by the present invention comprises the following steps: a strip is soaked in insulating glue and then wound into a ring shape, and then the stator core is cut out from the ring-shaped strip.

[0018] The stator core manufacturing process provided by the present invention adopts a strip winding method to manufacture the stator core. Specifically, the strip is driven by a reel and wound into a ring shape, and then the stator core is cut on the ring-shaped strip, and the axis of the ring-shaped strip is the axis of the stator. Before winding, the strip is soaked in insulating glue to ensure sufficient impregnation. Compared with the stator core formed by stacking a laminar structure, the manufacturing process of the present invention will not have the problem of glue not being able to enter between the laminae, resulting in poor insulation effect. Therefore, the loss of the stator core is extremely low and the bonding between the layers is more firm.

[0019] The winding method can maintain appropriate pressure between layers with a certain preload force according to the structural and design requirements. During the winding process, each layer can be preloaded and the pressure between the layers is more uniform, thereby ensuring the dimensional stability of the stator core, and preventing uneven force and uneven gaps between the layers when pressing the sheets. Therefore, the stator core manufacturing process provided by the present invention enables the stator core to have a higher stacking coefficient, and the magnetic permeability can reach above 0.99. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0021] Figure 1 A schematic structural diagram of a stator core manufacturing device provided in an embodiment of the present invention;

[0022] Figure 2 Schematic diagram of cutting of annular strip;

[0023] Figure 3 It is a structural schematic diagram of the stator core;

[0024] Figure 4 It is the front view of the stator core;

[0025] Figure 5 This is the rear view of the stator core.

[0026] Icons: 100, main reel; 200, glue-dipping roller; 300, glue pool; 400, glue scraper. DETAILED DESCRIPTION

[0027] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0028] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0029] Some embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0030] The existing stator core is made of tens of thousands of layers of high-magnetic conductivity materials stacked together, and the manufacturing process is relatively complicated. During the manufacturing process, each layer of high-magnetic conductivity sheet needs to be bonded with high-insulation, high-viscosity, high-temperature resistant high-quality glue. When the glue penetrates between the layers, it is difficult to avoid areas where the glue cannot reach. Therefore, it is easy to cause poor insulation between the layers of the high-magnetic conductivity sheet, resulting in short circuits and eddy current losses when installed in the motor and running.

[0031] In view of this, the present invention provides a stator core manufacturing process, comprising the following steps: a strip is soaked in insulating glue and then wound into a ring shape, and then the stator core is cut from the ring-shaped strip.

[0032] The stator core manufacturing process provided by the present invention adopts a strip winding method to manufacture the stator core. Specifically, the strip is driven by a reel and wound into a ring shape, and then the stator core is cut on the ring-shaped strip, and the axis of the ring-shaped strip is the axis of the stator. Before winding, the strip is soaked in insulating glue to ensure sufficient impregnation. Compared with the stator core formed by stacking a laminar structure, the manufacturing process of the present invention will not have the problem of glue not being able to enter between the laminae, resulting in poor insulation effect. Therefore, the loss of the stator core is extremely low and the bonding between the layers is more firm.

[0033] The winding method can maintain appropriate pressure between layers with a certain preload force according to the structural and design requirements. During the winding process, each layer can be preloaded and the pressure between the layers is more uniform, thereby ensuring the dimensional stability of the stator core, and preventing uneven force and uneven gaps between the layers when the layers are stacked and then pressed. Therefore, the stator core manufacturing process provided by the present invention enables the stator core to have a higher stacking coefficient, and the magnetic permeability can reach above 0.99.

[0034] The following combination Figure 1-Figure 5 The stator core manufacturing process provided in this embodiment is described in detail:

[0035] In this embodiment, one end of the strip is connected to the main reel 100 and is wound into a ring shape to a set thickness under the drive of the main reel 100. The axis of the ring strip is coaxial with the axis of the stator. Before winding, the strip is soaked in the glue pool 300 to fully contact with the insulating glue, ensuring that the surface of the strip is covered with insulating glue. Figure 1 The tension of the strip can be controlled by a damping device to ensure the preload and preload between the layers, so as to better control the interlayer spacing and the radial dimension of the stator core. The axial dimension of the stator core is controlled by the strip width and can be processed later to ensure accuracy.

[0036] After winding, high-precision high-speed wire cutting machine is used for cutting to ensure processing accuracy, such as Figure 2 As shown, firstly, a fan-shaped section is cut on the annular strip with a plane passing through the axis of the annular strip to obtain a fan-shaped block, and then the fan-shaped block is processed as shown in FIG. Figure 4 , Figure 5 The stator core is obtained by an I-shaped cross section as shown, each layer is I-shaped, each layer of the annular strip corresponds to a layer of the stator core, and the I-shaped structure enlarges the pole shoe range at both ends of the stator core, which is beneficial to improve the magnetic field distribution. Specifically, the layers of the stator core are arranged along the radial direction of the stator, such as Figure 2 shown.

[0037] In this embodiment, after the strip leaves the insulating glue, the scraper 400 scrapes off the excess glue to ensure that the thickness of the glue layer does not exceed 0.02 mm. Specifically, the scraper 400 is provided on both the upper and lower sides of the strip.

[0038] In this embodiment, epoxy resin glue is selected as the insulating glue, and the insulating glue needs to be heated and evacuated to eliminate the gas in the glue to ensure the bonding quality and insulation effect.

[0039] In this embodiment, the strip thickness is 0.012-0.025 mm, and the strip material is an iron-based nanocrystalline alloy or an iron-based amorphous alloy.

[0040] The manufacturing process of a single iron core is relatively complicated. From the cross-section, it is made up of tens of thousands of layers of high magnetic flux materials stacked together. After stacking, each layer of high magnetic permeability sheet needs to be bonded with high-insulation, high-viscosity, high-temperature resistant high-quality glue. Therefore, it is easy to cause poor insulation between layers of high magnetic permeability sheets, resulting in short circuits and eddy current losses when installed in the motor for operation.

[0041] The iron core manufacturing process provided in this embodiment realizes interlayer glue dipping by passing the strip through the glue pool 300. Compared with the method of pressurized glue dipping after stacking the layers, the bonding is more firm, the glue is more uniform, the insulation is good, the heat generation and loss are small, and the magnetic conductivity is high. In the existing method of pressurized glue dipping in the glue pool 300 after stacking the layers, the glue is not easy to penetrate between the layers because the layers are pressed tightly after stacking. In addition, in order to make it easier for the glue to enter between the layers to ensure the bonding effect and insulation quality, the glue used is relatively thin, resulting in weak bonding and poor insulation effect. The process adopted in this embodiment can use relatively thick glue to ensure the stability of the glue during the winding process, and at the same time has better bonding and insulation effects.

[0042] At the same time, the stacking molding method is not easy to control the molding size, while the winding method can better control the size of the stator core after molding, and there will be no dimensional changes along the stacking direction after superposition and pressurization, and the size of the stator core is more accurate. Specifically, the width dimension of the strip is the dimension of the stator core along the stator axis direction, and the thickness of the strip winding is the dimension of the stator core along the stator radial direction. The existing stacking method causes the size to be compressed after stacking molding due to pressurization, and it is difficult to control the size of the stator core along the stator radial direction. Therefore, the process provided in this embodiment has good dimensional accuracy after winding molding, and the stator core obtained by high-precision high-speed wire cutting, and the molding accuracy can reach ±0.01mm. After the molding size accuracy is improved, it is easier to assemble, and the stator core is easier to match with the positioning groove on the housing.

[0043] The stator core manufacturing process provided in this embodiment realizes high-precision winding of thin strips after being evenly soaked in glue during the core manufacturing process, achieving high insulation between the layers, thereby achieving the effects of low heat generation, low loss, and high magnetic conductivity. That is, a high-quality ultra-high magnetic permeability core with negligible loss is obtained. Because the strip is evenly soaked in insulating glue and a higher concentration of glue can be used, the overall firmness of the stator core is greatly improved. And the molding method of strip winding makes the dimensional accuracy of the stator core controllable, the dimensional accuracy is greatly improved, and the magnetic conductivity effect is further guaranteed. In addition, since no mold is required and the strip winding method can realize assembly line operation, the production cost is reduced and the production efficiency is significantly improved while improving product quality.

[0044] Based on the stator core manufacturing process provided in this embodiment, a stator core manufacturing device is proposed, which adopts the above-mentioned stator core manufacturing process, including a main reel 100, a glue dipping roller 200, a glue pool 300 and a cutting machine, such as Figure 1 As shown. Among them, the glue pool 300 contains insulating glue, and the dipping roller 200 is partially or completely immersed in the insulating glue; the main reel 100 is connected to the end of the strip and rotates around its own axis to drive the strip to pass through the glue pool 300 and the dipping roller 200 and wind it into a ring; the cutting machine is used to cut the stator core on the ring strip. The strip can be fed by an I-shaped wheel, that is, the two ends of the strip are respectively connected to the main reel 100 and the I-shaped wheel and the strip is wound and stored on the I-shaped wheel. When in use, the main reel 100 drives the I-shaped wheel to rotate through the strip to release the strip. In addition, a damping device such as a damper can be set on the I-shaped wheel to control the tension of the strip to ensure that there is sufficient pre-pressure between each layer, so that each layer is tightly bonded and the forming size is accurate. Among them, the damping device is a conventional device and will not be described here.

[0045] In this embodiment, three dipping rollers 200 are arranged in a triangle to change the winding path of the strip, so that both sides of the strip are immersed in the glue pool 300 to ensure that both sides are coated with glue. Furthermore, the dipping rollers 200 are threaded and the threads of adjacent dipping rollers 200 are in opposite directions, so that the glue is distributed more evenly and thinner on the strip through the thread design.

[0046] In this embodiment, the cutting machine is a high-precision high-speed wire cutting machine, and molybdenum wire is used for cutting.

[0047] To further ensure the uniformity and size control of the insulating glue, a scraper 400 is provided between the main reel 100 and the dipping roller 200 to scrape off excess insulating glue on the strip. Specifically, scrapers 400 are provided on both the upper and lower sides of the strip to control the thickness of the insulating glue on the strip to not exceed 0.02 mm, thereby ensuring the uniformity of each layer and the uniform distribution of the glue on the strip, making it easier to control the size of the stator core.

[0048] It should be noted that due to the pressure between the layers during winding, some glue will be squeezed out after the strip is wound into a ring, but it will not affect the uniformity of the glue, the insulation effect and the bonding strength, and will make the size after molding more stable.

[0049] Based on the stator core manufacturing process provided in this embodiment, a stator core is proposed, which is manufactured using the above-mentioned stator core manufacturing process.

[0050] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A stator core manufacturing process, characterized in that: The steps include: The strip is soaked in insulating glue and then wound into a ring shape, and then the stator core is cut out from the ring strip.

2. The stator core manufacturing process according to claim 1, characterized in that: After the strip leaves the insulating glue, the scraper (400) scrapes off the excess glue to ensure that the thickness of the glue layer does not exceed 0.02 mm.

3. The stator core manufacturing process according to claim 1, characterized in that: The insulating glue is epoxy resin glue, and the insulating glue needs to be heated and vacuumed.

4. The stator core manufacturing process according to claim 1, characterized in that: The stator core is cut out by a wire cutting machine. Each layer of the stator core is in an I-shape, and each layer of the annular strip corresponds to a layer of the stator core.

5. The stator core manufacturing process according to claim 1, characterized in that: The strip thickness is 0.012-0.025 mm, and the strip material is an iron-based nanocrystalline alloy or an iron-based amorphous alloy.

6. The stator core manufacturing process according to claim 1, characterized in that: The axis of the annular strip is coaxial with the axis of the stator.

7. A stator core manufacturing device, using the stator core manufacturing process according to any one of claims 1 to 6, characterized in that: The invention comprises a main reel (100), a glue dipping roller (200), and a glue pool (300), wherein the glue pool (300) contains insulating glue, the glue dipping roller (200) is partially or completely immersed in the insulating glue, and the main reel (100) is connected to the end of the strip and rotates around its own axis to drive the strip to pass through the glue pool (300) and the glue dipping roller (200) and be wound into a ring shape.

8. The stator core manufacturing equipment according to claim 7, characterized in that: The invention also comprises a cutting machine, wherein the cutting machine is used for cutting the stator core from the annular strip.

9. The stator core manufacturing equipment according to claim 7, characterized in that: It also comprises a scraper plate (400), which is arranged between the main reel (100) and the glue dipping roller (200) and is used for scraping off excess insulating glue on the strip.

10. A stator core, characterized in that: The stator core is manufactured by the stator core manufacturing process as described in any one of claims 1 to 6.

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