A general long-shaft rotor core stacking fixture and stacking method

Abstract

This invention belongs to the field of power tool technology, specifically a universal long-shaft rotor core stacking fixture and method. The proposed solution includes, from bottom to top, a base plate, an AS pad, bolts, a dummy shaft, a positioning key, a flat pressure ring, silicon steel sheets, a perforated pressure ring, a grooved bar, a BS pad, a top plate, a screw, a nut, a dummy shaft lowering fixture, a tripod base, a shaft, a core key, and a retaining ring. The stacking method includes the following steps: Step one, first, place the circular base plate of the dummy shaft on a horizontal pressing platform, then sequentially insert the flat pressure ring, silicon steel sheets, perforated pressure ring, BS pad, and top plate into the dummy shaft and stack them. This invention improves the utilization rate of the hydraulic press, increases the safety factor during the rotor core stacking process, reduces the stacking time, and improves production efficiency.

Description

Technical Field

[0001] This invention relates to the field of power tool technology, and in particular to a general-purpose long-shaft rotor core stacking fixture and stacking method. Background Technology

[0002] Traditionally, the rotor core of medium and large generators is stacked by placing the shaft drive end downwards on a movable base next to a press, and then passing silicon steel sheets through a ladder at height. The silicon steel sheets are then placed onto the rotor core from top to bottom through shaft holes on the non-drive end of the shaft. After stacking, a pressure ring is placed in the core, and a hydraulic press is used to apply pressure according to a pre-designed pressure, causing the retaining ring to expand and contract into its groove. This stacking method consumes a significant amount of manpower and time in transferring the silicon steel sheets, requires the shaft and silicon steel sheets to be in place simultaneously for production to begin, poses safety hazards, severely reduces press operating time, and decreases the production efficiency of motor manufacturing. Summary of the Invention

[0003] Based on the technical problems raised in the background art, this invention proposes a universal long-shaft rotor core stacking fixture and stacking method, which solves the safety hazards and low utilization rate of the press in the existing high-altitude lamination.

[0004] This invention proposes a universal long-shaft rotor core stacking fixture, comprising, from bottom to top, a base plate, an AS pad, bolts, a dummy shaft, a positioning key, a flat pressure ring, silicon steel sheets, a plum blossom pressure ring, a grooved bar, a BS pad, a top plate, a screw, a nut, a dummy shaft dropping fixture, a tripod base, a shaft, a core key, and a retaining ring. A circular steel plate is welded to the lower surface of the base plate, and several U-shaped sections are cut at equal intervals on the outer circumference of the base plate. The dummy shaft is welded from a cylindrical shaft, four reinforcing ribs, and a circular plate base. The outer circumference of the dummy shaft mates with the shaft hole of the silicon steel sheet. The positioning key mates with the dummy shaft to form a single unit. One end of the screw is fastened to a horseshoe nut and welded firmly, then machined flat. The other end of the screw is inserted into the top plate, and a nut is screwed onto the other end of the screw. The base of the tripod base supports the heated core workpiece. The shaft passes through the center hole of the circular plate of the tripod base and extends into the pit below the hydraulic press. A retaining ring is placed on the circular plate of the tripod base.

[0005] Preferably, the base plate and the AS pad are cut into semicircles and staggered in a cross shape, and the base plate and the AS pad are fastened together by bolts.

[0006] Preferably, the keyway width and depth of the dummy shaft are manufactured according to standards, and the keyway length of the dummy shaft covers the longest main rotor core length of the same series of products.

[0007] Preferably, the outer diameter, inner diameter, thickness, and U-shaped hole specifications of the top plate are the same as those of the bottom plate.

[0008] Preferably, the inner diameter hole of the AS pad is matched with the rotor core flat pressure ring, the thickness of the AS pad is the same as the thickness of the flat pressure ring, and the outer diameter of the AS pad is the same as the outer diameter of the silicon steel sheet.

[0009] This invention also proposes a stacking method for a universal long-shaft rotor core stacking fixture, comprising the following steps:

[0010] Step 1: First, place the dummy shaft circular base plate on the horizontal pressing platform, and then insert the flat pressure ring, silicon steel sheet, plum blossom pressure ring, BS pad, and top plate into the dummy shaft in sequence. During the stacking of silicon steel sheets, the slot bar needs to be driven into the rotor core slot shape formed by stacking silicon steel sheets in a cross-shaped staggered manner.

[0011] Step 2: Place the fastened base plate and AS pad horizontally on the moving platform of the hydraulic press, and use the overhead crane to pass the stacked iron core workpiece through the base plate and AS pad and place it on the moving platform of the hydraulic press;

[0012] Step 3: Insert several screws from the outside to the inside into the U-shaped grooves of the bottom and top plates and secure them with double nuts, but do not tighten them completely, ensuring that the screws are vertical;

[0013] Step 4: Place the pressure cylinder on top of the workpiece, push it into the pressing position of the hydraulic press, apply pressure according to the designed pressure, and tighten the screw and nut;

[0014] Step 5: Push out the workpiece, press out the dummy shaft, and use a crane to flip the workpiece so that its AS end faces upward;

[0015] Step Six: Place the workpiece into the drying oven. After the oven temperature reaches °, keep it at that temperature for hours.

[0016] Step 7: Insert the iron core into the shaft. Use a copper rod to drive the iron core key into the keyway of the pre-machined shaft, so that it fits snugly against the shaft and is installed in place.

[0017] Step 8: Place the stretched retaining ring on the tripod base in advance, then place the heated iron core workpiece on the tripod base feet, insert the shaft BS end downward into the iron core, and send it into the press.

[0018] Step 9: Pressurize to the designed pressure, depressurize, install the retaining ring, remove the screw, push out the trolley, exit the press, and remove the tooling.

[0019] The beneficial effects of this invention are as follows:

[0020] This invention improves the utilization rate of the hydraulic press, increases the safety factor in the process of stacking rotor cores, reduces the stacking time, and improves production efficiency. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the present invention;

[0022] Figure 2 This is a diagram showing the fit between the base plate and the AS pad of this invention;

[0023] Figure 3 This is a schematic diagram of the stacked rotor silicon steel sheet driven into the slotted sample bar structure of the present invention;

[0024] Figure 4 This is a schematic diagram of the dummy shaft tooling structure of the present invention;

[0025] Figure 5 This is a schematic diagram of the three-legged base structure of the present invention;

[0026] Figure 6 This is a schematic diagram of the shaft-driven rotor structure of the present invention.

[0027] In the diagram: 1. Base plate; 2. AS pad; 3. Bolt; 4. Dummy shaft; 5. Locating key; 6. Flat pressure ring; 7. Silicon steel sheet; 8. Plum blossom pressure ring; 9. Groove bar; 10. BS pad; 11. Top plate; 12. Screw; 13. Nut; 14. Dummy shaft dropping fixture; 15. Tripod base; 16. Shaft; 17. Iron core key; 18. Retaining ring. Detailed Implementation

[0028] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0029] Reference Figure 1-6A general-purpose long-shaft rotor core stacking fixture, from bottom to top, consists of: base plate 1, AS pad 2, bolt 3, dummy shaft 4, locating key 5, flat pressure ring 6, silicon steel sheet 7, plum blossom pressure ring 8, grooved bar 9, BS pad 10, top plate 11, screw 12, nut 13, dummy shaft dropping fixture 14, tripod base 15, shaft 16, core key 17, and retaining ring 18. Base plate 1 and AS pad 2 are both annular. The inner diameter hole of AS pad 2 mates with the rotor core flat pressure ring 6. The thickness of AS pad 2 is the same as the thickness of flat pressure ring 6. The outer diameter of AS pad 2 is the same as the outer diameter of silicon steel sheet 7. The upper surface of base plate 1 has a stop with a depth of 2-5mm that mates with the outer diameter of AS pad 2. The diameter of the inner diameter hole of the base plate 1 needs to take into account the size of the base of the dummy shaft 4 and the diameter of the shoulder on the left side of the iron core stop of shaft 15 to ensure smooth passage. A circular steel plate is welded around the lower surface of the base plate 1. These circular steel plates serve two purposes: first, to support the base plate 1 so that the horseshoe-shaped screw 12 can be easily installed and disassembled; second, to ensure that these protruding circular steel plates fit snugly against the inner diameter of the cylinder of the dummy shaft fixture 14, making the pressing process of the dummy shaft 4 safer and more reliable. Several U-shaped holes are evenly distributed on the outer circle of the base plate 1. These U-shaped holes mate with the horseshoe-shaped nut fixed at one end of the screw 12. The U-shaped holes have a certain depth of stop cut according to the size of the horseshoe-shaped nut to position the horseshoe-shaped nut of the screw 12. The base plate 1 and AS pad 2 needs to be fastened into a whole with bolts 3 before rotor stacking. The dummy shaft 4 is welded from a cylindrical shaft, 4 ribs and a circular plate base. After welding, the outer circle of the ribs matches the shaft hole of the silicon steel sheet 7. The keyway width and depth of the dummy shaft 4 are produced according to standards. The keyway length of the dummy shaft can cover the longest main rotor core length of the same series of products. The positioning key 5 is installed as a whole with the dummy shaft 4. BS pad 10 and top plate 11 are both annular. The inner diameter hole of BS pad 10 matches the rotor core plum blossom pressure ring 8. The thickness of BS pad 10 is the same as the thickness of plum blossom pressure ring 8. The outer diameter of BS pad 10 is the same as the outer diameter of silicon steel sheet 7. The outer diameter, inner diameter, thickness and U of top plate 11 and bottom plate 1 are the same. With the same hole shape, one end of the screw 12 is fastened to the horseshoe nut and welded firmly and machined flat, while the other end has a certain depth of thread. After pressing the iron core, it is fastened with double nuts 13. The grooved rod 9 is made into a plate of a certain length according to the groove shape. Generally, at least 4 pieces need to be prepared. The grooved rod 9 plays the role of positioning the silicon steel sheet 7 when it is stacked. The grooved rod 9 plays the role of fixing the silicon steel sheet when the rotor workpiece is rotated and heated. The bottom foot of the tripod base 15 is to support the iron core workpiece after heating. The center hole of the circular plate of the tripod base allows the shaft to pass through and extend into the pit under the hydraulic press. The pre-opened retaining ring 18 is placed on the circular plate of the tripod base to facilitate the installation of the retaining ring 18 after the shaft 16 is pressed in.

[0030] A method for stacking and forming a large long-shaft rotor core includes the following steps:

[0031] First, place the circular base plate of the dummy shaft 4 on the horizontal pressing platform, and then insert the flat pressure ring 6, silicon steel sheet 7, plum blossom pressure ring 8, BS pad 10, and top plate 11 into the dummy shaft 4 in sequence. During the stacking of silicon steel sheet 7, the slot rod 9 needs to be driven into the rotor core slot of the silicon steel sheet 7 in a cross-shaped staggered manner.

[0032] Step 2: Place the fastened base plate 1 and AS pad 2 horizontally on the movable platform of the hydraulic press, and use the overhead crane to pass the stacked iron core workpiece through the base plate 1 and AS pad 2 and place it on the movable platform of the hydraulic press.

[0033] The third step is to insert several screws 12 from the outside to the inside into the U-shaped grooves of the bottom plate 1 and the top plate 11 and fix them with double nuts 13 without tightening them, so as to ensure that the screws 12 are vertical.

[0034] Step 4: Place the pressure cylinder on top of the workpiece, push it into the pressing position of the hydraulic press, apply pressure according to the designed pressure, and tighten the screw 12 and nut 13.

[0035] Step 5: Push out the workpiece, press out the dummy shaft 4, and use a crane to flip the workpiece so that its AS end faces upward.

[0036] Step 6: Place the workpiece into the drying oven. After the oven temperature reaches 180°C, keep it at that temperature for 2 hours.

[0037] Step 7: Insert the iron core through the shaft 16. Use a copper rod to drive the iron core key 17 into the keyway of the pre-machined shaft 16, so that it fits snugly against the shaft 16 and is installed in place.

[0038] Step 8: Place the stretched retaining ring 18 on the tripod base 15 beforehand, then place the heated iron core workpiece on the tripod base 15, insert the shaft 16BS end downward into the iron core, and feed it into the press.

[0039] Step 9: Pressurize according to the designed pressure, release the pressure, install the retaining ring 18, remove the screw 12, push out the trolley, exit the press, and remove the tooling.

[0040] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A general-purpose long-shaft rotor core stacking fixture, comprising, from bottom to top, a base plate (1), an AS pad (2), bolts (3), a dummy shaft (4), a positioning key (5), a flat pressure ring (6), a silicon steel sheet (7), a plum blossom pressure ring (8), a grooved bar (9), a BS pad (10), a top plate (11), a screw (12), a nut (13), a dummy shaft lowering fixture (14), a tripod base (15), a shaft (16), a core key (17), and a retaining ring (18), characterized in that, A circular steel plate is welded to the lower surface of the base plate (1). Several U-shaped sections are opened at equal intervals on the outer circle of the base plate (1). The dummy shaft (4) is welded from a cylindrical shaft, four ribs and a circular plate base. The outer circle of the dummy shaft (4) is fitted with the shaft hole of the silicon steel sheet (7). The positioning key (5) is fitted with the dummy shaft (4) to form a whole. One end of the screw (12) is fastened to the horseshoe nut and welded firmly and machined flat. The other end of the screw (12) is inserted into the top plate (11), and the other end of the screw (12) is screwed with a nut (13). The base of the tripod (15) supports the hot-baked iron core workpiece. The shaft (16) passes through the center hole of the circular plate of the tripod (15) and extends into the pit under the hydraulic press. A retaining ring (18) is placed on the circular plate of the tripod (15).

2. The universal long-shaft rotor core stacking fixture according to claim 1, characterized in that, The base plate (1) and the AS pad (2) are cut into semicircles and staggered in a cross shape, and the base plate (1) and the AS pad (2) are fastened by bolts (3).

3. The universal long-shaft rotor core stacking fixture according to claim 1, characterized in that, The keyway width and depth of the dummy shaft (4) are manufactured according to standards, and the keyway length of the dummy shaft (4) covers the longest main rotor core length of the same series of products.

4. The universal long-shaft rotor core stacking fixture according to claim 1, characterized in that, The outer diameter, inner diameter, thickness, and U-shaped hole specifications of the top plate (11) are the same as those of the bottom plate (1).

5. A universal long-shaft rotor core stacking fixture according to claim 1, characterized in that, The inner diameter hole of the AS pad (2) is matched with the rotor core flat pressure ring (6). The thickness of the AS pad (2) is the same as the thickness of the flat pressure ring (6). The outer diameter of the AS pad (6) is the same as the outer diameter of the silicon steel sheet (7).

6. The stacking method of a universal long-shaft rotor core stacking fixture according to claim 1, characterized in that, Includes the following steps: Step 1: First, place the circular base plate of the dummy shaft (4) on the horizontal pressing platform, and then insert the flat pressure ring (6), silicon steel sheet (7), plum blossom pressure ring (8), BS pad (10), and top plate (11) into the dummy shaft (4) and stack them. During the stacking process of silicon steel sheet (7), the slot rod (9) needs to be driven into the rotor core slot of the silicon steel sheet (7) in a cross-shaped staggered manner. Step 2: Place the fastened base plate (1) and AS pad (2) horizontally on the moving platform of the hydraulic press, and use a crane to pass the stacked iron core workpiece through the base plate (1) and AS pad (2) and place it on the moving platform of the hydraulic press. Step 3: Insert several screws (12) from the outside to the inside into the U-shaped grooves of the bottom plate (1) and the top plate (11) and fix them with double nuts (13) without tightening them, to ensure that the screws (12) are vertical; Step 4: Place the pressure cylinder on top of the workpiece, push it into the pressing position of the hydraulic press, apply pressure according to the designed pressure, and tighten the screw (12) and nut (13); Step 5: Push out the workpiece, press out the dummy shaft (4), and use a crane to flip the workpiece so that its AS end faces upward; Step 6: Place the workpiece into the drying oven. After the oven temperature reaches 180°C, keep it at that temperature for 2 hours. Step 7: Insert the iron core through the shaft (16). Use a copper rod to drive the iron core key (17) into the keyway of the pre-machined shaft (16) so that it fits snugly against the shaft (16) and is installed in place. Step 8: Place the stretched retaining ring (18) on the tripod base (15) beforehand, then place the heated iron core workpiece on the tripod base (15), insert the shaft (16) with the BS end facing down into the iron core, and send it into the press. Step 9: Pressurize according to the designed pressure, release the pressure, install the retaining ring (18), remove the screw (12), push out the trolley, exit the press, and remove the tooling.

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