Tool and method for fixing rotor core and magnetic steel, motor and vehicle

Abstract

The invention belongs to the technical field of motors, and discloses a tool and method for fixing a rotor core and magnetic steel, a motor and a vehicle, and the tool comprises a tray, a magnetic steel positioning plate, a press fitting upper die, and a magnetic steel profiling block. The magnetic steel positioning plate is provided with guiding characteristic holes which are arranged in one-to-one correspondence with magnetic steel grooves of a rotor core, and the press-fitting upper die is provided with loading characteristic bosses which are arranged in one-to-one correspondence with the guiding characteristic holes. And the tray is provided with characteristic holes / grooves which are arranged in one-to-one correspondence with the guide characteristic holes and are used for accommodating the magnetic steel profiling blocks. The device is not only simple in structure, but also capable of eliminating scratches on the surface of the mechanically fixed magnetic steel of the rotor core.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a tool, method, motor and vehicle for fixing a rotor core and magnetic steel. Background Art

[0002] With the vigorous development of the new energy vehicle industry, the performance optimization and cost control of electric drive systems have become the focus of the industry. As one of the core components of the new energy electric drive assembly system, the design and assembly quality of the rotor directly affects the overall performance and service life of the motor. In the manufacturing process of the rotor, the fixing method of the magnetic steel has undergone a technical evolution from bonding to mechanical fixing.

[0003] The introduction of the mechanical fixing solution for magnetic steel is based on the consideration of reducing manufacturing costs. The traditional bonding and fixing process requires the use of special adhesives, which not only has high material costs, but also takes a long time to cure, affecting production efficiency. The mechanical fixing solution uses a specially designed spring structure to fix the magnetic steel, which greatly reduces material costs and avoids processes such as adhesive curing, which can theoretically improve production efficiency.

[0004] However, the mechanical fixing solution exposes several technical difficulties in actual production: First, due to the strong magnetism of permanent magnets, it is difficult for operators to accurately control the movement trajectory of the magnet during manual assembly, which makes it easy for the magnet to collide with the rotor slot body; second, the existence of strong magnetic force makes it easy for the magnet to shift during the slot insertion process, affecting the assembly accuracy; third, although the spring structure can realize the mechanical fixing function, its sharp edges can easily scratch the coating on the surface of the magnet during the assembly process, causing the corrosion resistance of the magnet to decrease.

[0005] These problems are particularly prominent in mass production: operators need to pay more attention to ensure assembly quality, resulting in a significant reduction in assembly efficiency; inaccurate positioning of the magnet into the slot can easily cause deviations in the dynamic balance performance of the rotor; uneven press-fitting may lead to uneven air gaps, affecting the stability of the motor operation; and scratches on the magnet coating by spring clips not only affect the product appearance, but may also cause the magnet to rust during use, thus affecting the product's reliability and service life.

[0006] Therefore, how to solve the technical problems in the existing assembly process while maintaining the cost advantage of the mechanical fixing solution has become a key issue that needs to be solved urgently. This is not only related to the improvement of product quality, but also directly affects the manufacturing efficiency and product competitiveness of the electric drive system of new energy vehicles. Summary of the invention

[0007] In order to solve or partially solve the problems existing in the related art, the purpose of the present invention is to provide a tooling, method, motor and vehicle for fixing the rotor core and magnetic steel, which pre-shapes the fixing spring pieces in the slot by means of a magnetic steel profiling block before the magnetic steel is pressed into the core, to ensure that when the magnetic steel is subsequently pressed into the magnetic steel slot of the core, the spring pieces in the magnetic steel slot will not scratch the surface coating of the magnetic steel, thereby achieving the effect of eliminating scratches on the surface of the mechanically fixed magnetic steel of the rotor core.

[0008] The present invention discloses a tool for fixing a rotor core and a magnetic steel, which comprises a tray for positioning the rotor core; a magnetic steel positioning plate for guiding the magnetic steel so that it can be inserted into the rotor core; a press-fit upper die for loading the magnetic steel so that it can be inserted into the rotor core; a magnetic steel profiling block for positioning and shaping the spring pieces inside the magnetic steel slot of the rotor core before the magnetic steel is inserted into the rotor core; the magnetic steel positioning plate is provided with guide feature holes arranged in a one-to-one correspondence with the magnetic steel slot of the rotor core, the press-fit upper die is provided with loading feature bosses arranged in a one-to-one correspondence with the guide feature holes, and the tray is provided with feature holes / slots arranged in a one-to-one correspondence with the guide feature holes for accommodating the magnetic steel profiling blocks.

[0009] In a preferred embodiment of the present invention, the axial depth of the guide feature hole is greater than the axial height of the magnetic steel profiling block.

[0010] In a preferred embodiment of the present invention, the axial height of the loading feature boss corresponds to the axial depth of the guiding feature hole.

[0011] In a preferred embodiment of the present invention, the tray and / or the magnetic steel positioning plate are provided with positioning features that cooperate with flat key features of the center hole on the rotor core to achieve positioning thereof.

[0012] In a preferred embodiment of the present invention, the positioning feature comprises two arc-shaped bosses arranged in mirror symmetry and at intervals, and the circumferential spacing between the end faces of the two arc-shaped bosses corresponds to the circumferential size of the flat key feature of the center hole on the rotor core.

[0013] In a preferred embodiment of the present invention, a center positioning hole is provided on the magnetic steel positioning plate, and a center positioning boss coaxially arranged with the center positioning hole is provided on the press-fitting upper die.

[0014] In a preferred embodiment of the present invention, the shape of the magnetic steel profiling block corresponds to the shape of the magnetic steel, and the dimensional tolerance of the magnetic steel profiling block is smaller than the dimensional tolerance of the magnetic steel.

[0015] The present invention also discloses a method for assembling a rotor core and magnetic steel using a tooling, wherein a magnetic steel profiling block and a magnetic steel are sequentially installed into the guide characteristic holes on each magnetic steel positioning plate, the upper die is pressed downward, and the loading characteristic boss is used to load the magnetic steel. The magnetic steel profiling block first enters the magnetic steel slot of the rotor core to bend and shape the spring sheet inside the magnetic steel. After the shaping is completed, the magnetic steel profiling block falls into the characteristic hole / slot in the tray, and the magnetic steel and the magnetic steel slot of the rotor core are assembled.

[0016] The present invention also discloses a motor, comprising a rotor core and magnetic steel, wherein the rotor core and the steel are assembled by a tooling for fixing the rotor core and the magnetic steel.

[0017] The invention also discloses a vehicle, which comprises a motor.

[0018] The beneficial effect of the present invention is as follows: the present invention provides a solution that can improve the scratching of the magnetic steel and the misalignment of the magnetic steel in the slot during the auxiliary guidance and press-fitting process of the magnetic steel into the magnetic steel slot of the iron core when the iron core is assembled. Before the magnetic steel is pressed into the iron core, the fixed spring piece in the slot is pre-shaped by the magnetic steel profiling block to ensure that when the magnetic steel is subsequently pressed into the magnetic steel slot of the iron core, the spring piece in the magnetic steel slot will not scratch the surface coating of the magnetic steel, thereby achieving the effect of eliminating the scratching of the surface of the mechanically fixed magnetic steel of the rotor iron core.

[0019] First, the present invention realizes the pre-shaping of the spring pieces inside the rotor core by innovatively designing the structure of the magnetic steel profiling block and the magnetic steel positioning plate. Since the dimensional tolerance of the magnetic steel profiling block is smaller than the dimensional tolerance of the magnetic steel, the spring pieces can be bent and positioned more accurately, effectively avoiding the problem of the magnetic steel being scratched by the spring pieces during assembly, and significantly improving product quality and reliability.

[0020] Secondly, the present invention uses a precise matching method among the guide characteristic hole, the loading characteristic boss and the characteristic hole / slot to construct a complete magnetic steel assembly guide system. This structural design ensures that the magnetic steel always maintains the correct posture and position during the assembly process, greatly improves the alignment accuracy of the magnetic steel into the slot, and solves the problem of easy displacement of the magnetic steel in traditional manual assembly.

[0021] Thirdly, the precise positioning of the rotor core is achieved by setting the positioning features on the tray and the magnetic steel positioning plate, especially the design of two mirror-symmetrical arc-shaped bosses cooperating with the flat key features of the rotor core center hole. This positioning method is not only simple and fast to operate, but also can ensure the relative position accuracy of each magnetic steel slot, laying the foundation for the subsequent uniform distribution of magnetic steel.

[0022] Fourth, the depth matching design of the magnetic steel profiling block and the guide characteristic hole of the present invention ensures the continuity and reliability of the shaping and assembly process. By making the axial depth of the guide characteristic hole greater than the axial height of the magnetic steel profiling block, after the spring piece is shaped, the magnetic steel profiling block can be smoothly detached without affecting the assembly of the magnetic steel, thereby improving the assembly efficiency.

[0023] Fifth, the tooling design of the present invention realizes the semi-automatic process of magnetic steel assembly, which significantly reduces the labor intensity of operators. Through a single downward movement of the press-fit upper die, the two processes of spring shaping and magnetic steel assembly can be completed, which not only improves production efficiency but also ensures the consistency of assembly quality.

[0024] Finally, the tooling of the present invention has a simple structure, is easy to manufacture and maintain, and has strong versatility and expansibility. By replacing magnetic steel profiling blocks of different specifications and corresponding guides, the tooling can be applied to the assembly of rotors of different models, and has good economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments disclosed in the present invention, the drawings of the embodiments will be briefly introduced below. These drawings are only used for illustrative purposes and are not intended to limit the protection scope of the present invention.

[0026] Figure 1 is a schematic diagram of a rotor core of the present invention;

[0027] Figure 2 is a schematic diagram of a rotor core of the present invention;

[0028] Figure 3 It is a general schematic diagram of a tooling for fixing a rotor core and magnetic steel of the present invention;

[0029] Figure 4 It is a schematic diagram of a press-fit upper die of a tooling for fixing a rotor core and magnetic steel of the present invention;

[0030] Figure 5 It is a schematic diagram of a magnetic steel positioning plate of a tooling for fixing a rotor core and magnetic steel of the present invention;

[0031] Figure 6 It is a top view of a magnetic steel positioning plate of a tooling for fixing a rotor core and magnetic steel of the present invention;

[0032] Figure 7 It is a side view of a magnetic steel positioning plate of a tooling for fixing a rotor core and magnetic steel of the present invention;

[0033] Figure 8 It is a front view of a magnetic steel positioning plate of a tooling for fixing a rotor core and magnetic steel of the present invention;

[0034] Fig. 9 It is a schematic diagram of a tray of a tooling for fixing a rotor core and magnetic steel of the present invention;

[0035] Fig.10 It is a top view of a tray of a tooling for fixing a rotor core and magnetic steel according to the present invention. DETAILED DESCRIPTION

[0036] The technical solution of the present invention (including the preferred technical solution) is further described in detail below by means of the accompanying drawings and by listing some optional embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. 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.

[0037] Embodiment 1

[0038] This embodiment provides a tool for fixing the rotor core and the magnetic steel, such as Figure 3-10 As shown, the tooling mainly includes a press-fit upper die 1, a magnetic steel 2, a magnetic steel profiling block 3, a magnetic steel positioning plate 4, a rotor core 5 and a tray 6. Among them, the press-fit upper die 1 is arranged at the top to provide the pressure required for assembly; the tray 6 is arranged at the bottom to support and position the rotor core 5; the magnetic steel positioning plate 4 is arranged between the press-fit upper die 1 and the tray 6 to achieve precise guidance of the magnetic steel 2.

[0039] The core innovation of this tooling is the design of the key component, the magnetic steel profiling block 3. The shape of the magnetic steel profiling block 3 completely corresponds to the shape of the magnetic steel 2, but its dimensional tolerance is specifically controlled to be within a smaller range than that of the magnetic steel 2. This design ensures that the magnetic steel profiling block 3 can enter the magnetic steel slot of the rotor core 5 more accurately, thereby realizing accurate shaping of the internal spring sheet 5.1. At the same time, since the dimensional tolerance of the magnetic steel profiling block 3 is small, it can effectively avoid excessive deformation or damage to the spring sheet during the shaping process.

[0040] The magnetic steel positioning plate 4 is provided with a plurality of guide characteristic holes 4.1, and the arrangement of these holes corresponds to the magnetic steel slots on the rotor core 5. The axial depth of each guide characteristic hole 4.1 is greater than the axial height of the magnetic steel profiling block 3. This depth difference design ensures that the magnetic steel profiling block 3 can be smoothly separated from the magnetic steel slot after the shaping is completed. The loading characteristic boss 1.1 provided on the press-fitting upper die 1 also corresponds to the guide characteristic hole 4.1 one by one, and its axial height matches the depth of the guide characteristic hole 4.1, ensuring the stability and controllability of the press-fitting process.

[0041] In order to achieve accurate positioning of the rotor core 5, the tooling is designed with a unique positioning feature on the tray 6. Specifically, the positioning feature is composed of two arc-shaped bosses 7 arranged in mirror symmetry, and the circumferential spacing between the end faces of the two bosses accurately corresponds to the circumferential size of the flat key feature 5.2 on the center hole of the rotor core 5. This positioning method not only ensures the circumferential positioning accuracy of the rotor core 5, but also facilitates the operator to quickly complete the clamping and positioning.

[0042] In addition, in order to ensure the coaxiality between the press-fit upper die 1 and the magnetic steel positioning plate 4, a center positioning hole 4.2 is provided on the magnetic steel positioning plate 4, and a center positioning boss 1.2 coaxial therewith is correspondingly provided on the press-fit upper die 1. This structural design ensures that the components always maintain coaxial movement during the press-fitting process, effectively preventing problems that may be caused by eccentric assembly.

[0043] Embodiment 2

[0044] This embodiment describes in detail the specific process flow of assembling the rotor core and magnetic steel using the above-mentioned tooling. The entire assembly process can be divided into the following key steps:

[0045] First, the operator needs to sequentially install the magnetic steel profiling block 3 and the magnetic steel 2 in each guide characteristic hole 4.1 of the magnetic steel positioning plate 4. When installing, it is necessary to maintain the correct direction to ensure that the magnetic steel profiling block 3 is located below the magnetic steel 2. Since the magnetic steel 2 has strong magnetism, the guiding effect of the guide characteristic hole 4.1 should be used during the installation process to avoid collision between the magnetic steel 2 and the surrounding structure.

[0046] Secondly, the press-fitting equipment is started, and the press-fitting upper die 1 starts to move downward. In this process, the loading feature boss 1.1 will apply uniform pressure to the magnetic steel 2. Since the loading feature boss 1.1 corresponds precisely to the guide feature hole 4.1, the direction of the pressure action is completely consistent with the axial direction of the magnetic steel slot.

[0047] Subsequently, under the action of pressure, the magnetic steel profiling block 3 first enters the magnetic steel slot of the rotor core 5. At this time, the magnetic steel profiling block 3 will pre-press and shape the spring piece 5.1 in the magnetic steel slot. Since the dimensional accuracy of the magnetic steel profiling block 3 is higher than that of the magnetic steel 2, this shaping process can accurately control the deformation of the spring piece 5.1, creating ideal conditions for the subsequent installation of the magnetic steel 2.

[0048] When the shaping is completed, the magnetic steel profiling block 3 will fall into the pre-set characteristic hole / slot 6.1 on the tray 6 under the action of continued downward pressure. At the same time, the magnetic steel 2 following it will be accurately installed in the magnetic steel slot that has been shaped. This continuous action design ensures the smoothness of the entire assembly process and avoids possible interference or jamming in the intermediate links.

[0049] Finally, when the press-fit upper die 1 reaches the set limit position, the entire assembly process is completed. At this time, all the magnetic steels 2 have been firmly installed in the magnetic steel slots of the rotor core 5, and the magnetic steel profiling blocks 3 have all fallen into the characteristic holes / slots 6.1 of the tray 6, which are convenient for recycling.

[0050] Embodiment 3

[0051] This embodiment focuses on the optimization design and extended application of the tooling in practical applications. According to different specifications of the magnetic steel 2 and the rotor core 5, the assembly effect can be optimized by adjusting the key parameters of the magnetic steel profiling block 3.

[0052] Specifically, the thickness and tolerance of the magnetic steel profiling block 3 are two key design parameters. For thicker magnetic steel 2, the thickness of the magnetic steel profiling block 3 can be increased accordingly to ensure sufficient shaping force on the spring sheet 5.1; for thinner magnetic steel 2, the thickness of the magnetic steel profiling block 3 can be reduced to avoid excessive deformation of the spring sheet 5.1. Similarly, for fixed spring sheets of different lengths, the size parameters of the magnetic steel profiling block 3 also need to be adjusted accordingly.

[0053] In actual production, it is recommended to prepare corresponding sets of magnetic steel profiling blocks 3 for different specifications of magnetic steel 2. Each set of magnetic steel profiling blocks 3 should be optimized according to the specific size of magnetic steel 2 and the characteristics of spring 5.1 to obtain the best shaping effect. This modular design concept not only improves the versatility of tooling, but also facilitates the rapid switching of different product models on the production line.

[0054] The tooling of the present invention can also be further extended to other types of motor products. For example, by adjusting the positioning features of the tray 6 and the layout of the guide feature holes 4.1 of the magnetic steel positioning plate 4, the tooling can be applied to the assembly of motor rotors with different pole numbers. At the same time, by optimizing the structure of the press-fit upper die 1, multi-station synchronous assembly can also be achieved, further improving production efficiency.

[0055] It is worth noting that the tooling adopts a purely mechanical method to solve the scratch problem in the assembly process of the magnetic steel 2. This solution is not only highly reliable but also has low maintenance costs. Especially in mass production, this mechanical solution has obvious economic advantages over other solutions.

[0056] Those skilled in the art will readily appreciate that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, replacements, improvements, etc. made within the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A tool for fixing a rotor core and a magnetic steel, characterized in that: include A tray (6) for positioning the rotor core (5); A magnetic steel positioning plate (4) for guiding the magnetic steel (2) so that it can be inserted into the rotor core (5); A press-fit upper die (1) is used to load the magnetic steel (2) so that it can be inserted into the rotor core (5); A magnetic steel profiling block (3) is used to position and shape the spring piece (5.1) inside the magnetic steel slot of the rotor core (5) before the magnetic steel (2) is inserted into the rotor core (5); The magnetic steel positioning plate (4) is provided with guide feature holes (4.1) arranged in one-to-one correspondence with the magnetic steel slots of the rotor core (5), the press-fitting upper die (1) is provided with loading feature bosses (1.1) arranged in one-to-one correspondence with the guide feature holes (4.1), and the tray (6) is provided with feature holes / slots (6.1) arranged in one-to-one correspondence with the guide feature holes (4.1) for accommodating the magnetic steel profiling blocks (3).

2. The tooling for fixing the rotor core and the magnetic steel according to claim 1, characterized in that: The axial depth of the guide characteristic hole (4.1) is greater than the axial height of the magnetic steel profiling block (3).

3. The tooling for fixing the rotor core and the magnetic steel according to claim 1, characterized in that: The axial height of the loading feature boss (1.1) corresponds to the axial depth of the guiding feature hole (4.1).

4. The tooling for fixing the rotor core and the magnetic steel according to claim 1, characterized in that: The tray (6) and / or the magnetic steel positioning plate (4) are provided with positioning features that cooperate with the flat key features (5.2) of the center hole on the rotor core (5) to achieve positioning thereof.

5. The tooling for fixing the rotor core and the magnetic steel according to claim 4, characterized in that: The positioning feature comprises two arc-shaped bosses (7) arranged in a mirror-symmetrical manner, and the circumferential spacing between the end faces of the two arc-shaped bosses (7) corresponds to the circumferential size of the flat key feature (5.2) of the center hole on the rotor core (5).

6. The tooling for fixing the rotor core and the magnetic steel according to claim 1, characterized in that: The magnetic steel positioning plate (4) is provided with a central positioning hole (4.2), and the press-fitting upper die (1) is provided with a central positioning boss (1.2) coaxially arranged with the central positioning hole (4.2).

7. The tooling for fixing the rotor core and the magnetic steel according to claim 1, characterized in that: The shape of the magnetic steel profiling block (3) corresponds to the shape of the magnetic steel (2), and the dimensional tolerance of the magnetic steel profiling block (3) is smaller than the dimensional tolerance of the magnetic steel (2).

8. A method for assembling a rotor core and magnetic steel using the tooling as claimed in any one of claims 1 to 7, characterized in that: The magnetic steel profiling block (3) and the magnetic steel (2) are sequentially installed into the guide characteristic holes (4.1) on the magnetic steel positioning plates (4), and the upper press mold (1) is moved downward, and the loading characteristic boss (1.1) loads the magnetic steel (2). The magnetic steel profiling block (3) first enters the magnetic steel slot of the rotor core (5) to bend and shape the spring sheet (5.1) inside the magnetic steel profiling block (3). After the shaping is completed, the magnetic steel profiling block (3) falls into the characteristic hole / slot (6.1) in the tray (6), and the magnetic steel (2) and the magnetic steel slot of the rotor core (5) are assembled.

9. A motor, comprising a rotor core (5) and a magnetic steel (2), characterized in that: The rotor core (5) and the steel (2) are assembled by means of a tool for fixing the rotor core and the magnetic steel as described in any one of claims 1 to 8.

10. A vehicle, characterized in that: Comprising the motor as claimed in claim 9.

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