Manufacturing method of fanning strip rotor asynchronous motor

Abstract

The invention discloses a fanning strip rotor asynchronous motor manufacturing method, and belongs to the technical field of motor manufacturing, and the fanning strip rotor asynchronous motor manufacturing method comprises the steps: S100, machining a motor shaft, and checking the quality of the motor shaft; s200, laminating the rotor iron core, and installing a taper key to tension the rotor iron core; s300, a machine base is manufactured; s400, performing stator core lamination by using a stator core lamination tool, and mounting a stator core protection frame after the stator core lamination is completed; step S500, vertically hoisting the engine base by using a crane, and sleeving the engine base on the outer side of the stator inserted line; and S600, installing the rotor, using a jack to assist in hoisting the installed rotor, assembling a sliding bearing of the motor, and completing manufacturing of the motor. The manufacturing quality of the fanning strip rotor asynchronous motor is improved, the residual stress of motor parts is reduced or eliminated, and deformation of the motor parts is reduced or avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of motor manufacturing, and in particular to a method for manufacturing a sector-shaped rotor asynchronous motor. Background Art

[0002] High-power asynchronous motors are widely used and can usually provide higher power output. In the design and manufacturing process of high-power asynchronous motors, due to the size limitations of silicon steel sheets, the stator and rotor cores usually adopt a sector-shaped structure. Accordingly, this type of motor with a sector-shaped rotor structure is also usually called a sector-shaped rotor asynchronous motor. However, as the power of the sector-shaped rotor asynchronous motor increases, the volume of the sector-shaped rotor asynchronous motor also increases, which also makes the sector-shaped rotor asynchronous motor face many new technical challenges in design and manufacturing.

[0003] Firstly, due to the high linear speed and large centrifugal force of the rotor, the rotor is prone to blade shedding when running at high speed, which not only affects the stability of the sector-segment rotor asynchronous motor, but also generates large electromagnetic noise, causing the sector-segment rotor asynchronous motor to run unsteadily; in addition, the stator frame, stator core, rotor core and other components of the sector-segment rotor asynchronous motor are larger in size and weaker in rigidity than those of conventional motors. The large size and weak rigidity make it very easy for these components to generate residual internal stress during the manufacturing process, resulting in unbalanced load and vibration during the operation of the sector rotor asynchronous motor. If these residual internal stresses are not effectively eliminated, they will gradually accumulate during the normal use of the sector rotor asynchronous motor, affecting the overall performance of the sector rotor asynchronous motor and even causing failure of the sector rotor asynchronous motor, thereby shortening the service life of the sector rotor asynchronous motor. In addition, in the manufacturing process of the sector rotor asynchronous motor, the inaccuracy of the lamination process and the fixing process, especially improper operation during the manufacturing process, often leads to deformation of the components. The deformation of these components may aggravate the vibration and noise of the sector rotor asynchronous motor during operation, affecting the working efficiency and reliability of the sector rotor asynchronous motor, and even to the service life and operating cost of the sector rotor asynchronous motor.

[0004] Therefore, how to effectively control the manufacturing process of sector-shaped rotor asynchronous motors during the production process, optimize and improve the manufacturing quality of sector-shaped rotor asynchronous motors, reduce or eliminate residual stress, reduce or avoid component deformation, and improve the accuracy of the lamination process and fixing process has become a technical problem that motor manufacturers urgently need to solve. Summary of the invention

[0005] The purpose of the present invention is to provide a method for manufacturing a sector-shaped rotor asynchronous motor to partially or completely solve the problems existing in the above-mentioned prior art. To achieve the above-mentioned purpose, the technical solution adopted by the present invention is:

[0006] A method for manufacturing a sector rotor asynchronous motor, comprising:

[0007] Step S100: machining the motor shaft and inspecting the quality of the motor shaft; wherein the process of machining the motor shaft includes: rough turning - rough milling - quenching and tempering - semi-finishing turning - stress relief annealing - semi-finishing milling - finishing turning - grinding - finishing milling - dynamic balancing, and inspecting the quality of the motor shaft includes: using the rotor punching sheet to compare with the pigeon tail of the motor shaft after machining to inspect the machining quality of the motor shaft;

[0008] Step S200: stacking the rotor core, adjusting the stacking quality of the rotor core using the tie rod hole positioning rod and the slot positioning rod, applying molybdenum disulfide lubricant to the sliding surface of the helical key, and installing the helical key by a three-step keying method of cold-hot-cold-tack to tighten the rotor core;

[0009] Step S300: manufacturing the machine base, performing annealing heat treatment after welding the machine base, and using a sling to turn the machine base over on a soft turning platform; during the machine base processing, fixing the bottom and the middle of the machine base;

[0010] Step S400: stacking the stator core using a stator core stacking tool, and installing a stator core protection frame after the stator core stacking is completed;

[0011] Step S500: The combined bracket is fixed on the platform, the stator wire in a vertical state is placed in the combined bracket, the straightness of the stator core is checked and confirmed by a knife edge ruler, the machine base is vertically lifted by a crane, and the machine base is mounted on the outside of the stator wire;

[0012] Step S600: Install the rotor, use a jack to assist in lifting the installed rotor, assemble the sliding bearings of the motor, and complete the manufacture of the motor.

[0013] Optionally, in step S200, the rotor punching is provided with a pull rod hole and a slot, and the pull rod hole positioning rod is inserted into the pull rod hole. For every 250mm of rotor core laminations, the operator lifts the pull rod hole positioning rod to complete the arrangement of the slot shape once; at the same time, the slot positioning rod is used, and the slot positioning rod is arranged and installed along the outer circle of the rotor in eight equal parts. The slot positioning rod positions multiple rotor punchings, and the slot positioning rod is inserted into the slot. The rotor core is pre-pressed once for every 500mm of rotor core laminations.

[0014] Optionally, in step S400, the stator core lamination tooling includes vertical ribs, positioning ribs, tightening screws and positioning screws, the vertical ribs are provided with installation grooves, the positioning screws position the vertical ribs and the positioning ribs, the positioning ribs are guided to move relative to the installation grooves to adjust the radial distance between the positioning ribs and the vertical ribs, and the tightening screws connect the vertical ribs and the positioning ribs; when the positioning screws move along the radial direction of the rotor, the positioning ribs are guided to move relative to the installation grooves, and after the positioning screws adjust and position the radial distance between the positioning ribs and the vertical ribs, the tightening screws connect the vertical ribs and the positioning ribs, thereby completing the installation of the positioning ribs; the stator core lamination tooling is used to perform stator core lamination, and the stator core is pre-pressed once each time the stack reaches a height of 500 mm.

[0015] Optionally, in step S400, after the stator core is stacked, the positioning screws are loosened first, and then the tensioning screws are tightened, so that the outer circle of the entire stator core stacking tooling will be reduced, and the stator core and the stator core stacking tooling can be safely separated.

[0016] Optionally, in step S400, after the stator cores are stacked, a stator core protection frame is installed, and the stator core protection frame includes an end plate with a stop groove to prevent the stator cores from falling off.

[0017] Optionally, in step S500, the combined corbel includes a corbel and a ring, and the combined corbel is fixed on a platform for placing the stator wire in a vertical state. A knife edge ruler is used to detect the straightness of the outer circle of the stator core. After confirming that it meets the technical requirements, a crane is used to vertically lift the machine base.

[0018] Optionally, in step S600, the rotor needs to be lifted again when installing the lower bushing of the sliding bearing. A jack needs to be used to support the motor shaft before lifting. After the sliding bearing is installed, the position of the lower bushing of the sliding bearing is adjusted by rotating the rotor.

[0019] The beneficial effects brought about by the technical solution provided by the present invention application include at least:

[0020] Firstly, in the rotor core lamination process and the stator core lamination process, the rotor core lamination is carried out by adopting the method of segmented pre-pressing and multiple positioning, the fan-shaped rotor punching is fixed, and the cold-hot-cold three-time keying method is used to install the oblique key in place to fully tighten the rotor core, ensure the quality of rotor core lamination, and improve the rotor operation stability; in the stator core lamination process, the stator core is laminated by adopting the method of segmented pre-pressing, and the detachable stator core lamination tooling is used to realize the safe separation of the tooling and the stator core; in addition, starting from the motor manufacturing process, anti-deformation measures for the motor shaft, stator core and rotor are formulated to ensure that the deformation of the above-mentioned parts is small during the circulation and operation process, thereby improving the quality of the above-mentioned motor parts and improving the stability of the operation of each part when the motor is running; in addition, in the stator set process, the combined bracket tooling is designed to ensure the safety of the stator wire embedding and the base set, strengthen the management of the heavy motor assembly process, reduce the potential damage to the parts caused by the intermediate matching process, and improve the overall operation stability of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0022] Figure 1 It is a structural schematic diagram of the sector rotor asynchronous motor applied for by the present invention;

[0023] Figure 2 It is a schematic diagram of the structure of the motor shaft and the rotor core of the present invention;

[0024] Figure 3 It is a schematic diagram of the structure of the motor shaft and rotor punching sheet of the present invention;

[0025] Figure 4 It is a structural schematic diagram of the tie rod hole positioning rod of the present invention;

[0026] Figure 5 It is a structural schematic diagram of the notch positioning rod of the present invention;

[0027] Figure 6 This is a schematic diagram of the structure of the stator core stacking of the present invention. Figure 1 ;

[0028] Figure 7 This is a schematic diagram of the structure of the stator core stacking of the present invention. Figure 2 ;

[0029] Figure 8 It is a structural schematic diagram of the stator core protection frame applied for by the present invention;

[0030] Fig. 9It is a schematic diagram of the structure of the end plate of the present invention;

[0031] Fig.10 It is a structural schematic diagram of the stator set applied for by the present invention;

[0032] Fig.11 It is a structural schematic diagram of the combined corbel applied in the present invention. DETAILED DESCRIPTION

[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the 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 in 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.

[0034] Among them, the same parts are represented by the same figure marks. It should be noted that the words "front", "rear", "left", "right", "up" and "down" used in the following description refer to the directions in the drawings of the present application specification, and the words "bottom surface" and "top surface", "inside" and "outside" refer to the direction towards or away from a specific component, respectively. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present application specification, the meaning of "multiple" is two or more.

[0035] The present invention provides a method for manufacturing a sector-shaped rotor asynchronous motor, comprising:

[0036] Step S100: machining the motor shaft and inspecting the quality of the motor shaft; wherein the process of machining the motor shaft includes: rough turning - rough milling - quenching and tempering - semi-finishing turning - stress relief annealing - semi-finishing milling - finishing turning - grinding - finishing milling - dynamic balancing, and inspecting the quality of the motor shaft includes: using the rotor punching sheet to compare with the pigeon tail of the motor shaft after machining to inspect the machining quality of the motor shaft;

[0037] In some embodiments, according to the characteristics of the shaft forging being heavy and long and prone to stress deformation during processing, the process of processing the motor shaft 1 includes: rough turning - rough milling - quenching and tempering - semi-finishing turning - stress relief annealing - semi-finishing milling - finishing turning - grinding - finishing milling - dynamic balancing. Two heat treatment processes are used in the processing of the motor shaft 1: quenching and tempering and stress relief annealing. First, quenching and tempering can significantly increase the strength of the motor shaft, so that the motor shaft has a higher ability to resist deformation; quenching and tempering form a uniform hardness distribution through the process of heating and quenching, improve the mechanical properties of the motor shaft, especially improve the ability to resist compression, tension and torsion, so that the motor shaft can better withstand the high load generated during operation and extend the service life of the motor shaft; secondly, the stress relief annealing process helps to reduce the internal stress generated by the motor shaft during the processing, thereby effectively preventing deformation caused by stress. During the processing, due to mechanical rough turning, rough milling, semi-finishing turning and other operations, residual stress is easily generated inside the motor shaft. If these stresses are not effectively released, the motor shaft may be deformed or affect the accuracy in subsequent use. Stress relief annealing can reduce or eliminate these residual stresses through proper heating and slow cooling, ensure the dimensional stability of the motor shaft, and improve the machining accuracy and durability of the motor shaft. Therefore, the combination of the two heat treatment processes of the motor shaft 1 can not only improve the mechanical properties of the motor shaft 1, but also improve the reliability and long life of the motor shaft 1 under high-load working environments.

[0038] In some embodiments, after the motor shaft 1 is ground, it is necessary to form the motor shaft dove tail 2. The processing of the dove tail 2 is the most difficult part of the motor shaft processing procedure. During the processing, the chord distance and straightness of the dove tail need to be ensured at the same time. During the dove tail processing, the rotor punching sheet is used to compare with the processed motor shaft dove tail at any time to check the processing quality of the motor shaft. The parameters to be checked include: the chord distance of the dove tail.

[0039] In some embodiments, due to strict requirements on the roughness control of the bearing gear of the motor shaft 1, a suitable processing allowance needs to be left after the motor shaft 1 is ground during the process of processing the motor shaft 1. In this way, the bearing gear of the motor shaft can be processed by Hawke energy to reduce the surface roughness of the bearing gear, increase the surface hardness of the bearing gear, reduce the surface stress of the motor shaft 1, and increase the fatigue strength of the motor shaft 1. Finally, the processed motor shaft needs to be dynamically balanced once separately to ensure the vibration performance of the motor.

[0040] Step S200: stacking the rotor core 6, adjusting the stacking quality of the rotor core using the tie rod hole positioning rod 4 and the slot positioning rod 5, applying molybdenum disulfide lubricant to the sliding surface of the helical key, and installing the helical key by a three-step keying method of cold-hot-cold-tack to tighten the rotor core;

[0041] In some embodiments, the rotor cores are stacked in a vertical state. Considering the long length of the rotor, a rotor core stacking operation platform needs to be built to ensure the safety of the rotor core stacking operation.

[0042] In some embodiments, in order to ensure the lamination quality of the rotor core, during the lamination process of the rotor core 6, the rotor punching 3 is provided with a pull rod hole 41 and a slot 51. The rotor punching 3 and the dove tail 2 need to fit tightly, and the pull rod hole positioning rod 4 is inserted into the pull rod hole 41. For every 250mm of rotor core lamination, the operator lifts the pull rod hole positioning rod 4 to complete the slot shape adjustment once; at the same time, in order to prevent the subsequent lamination and pre-pressing of the rotor core 6 from having an adverse effect on the slot shape, a slot positioning rod 5 can be used. The slot positioning rod 5 is arranged and installed along the outer circle of the rotor in eight equal parts. The slot positioning rod 5 positions multiple rotor punchings 3, and the slot positioning rod 5 is inserted into the slot 51. The rotor core is pre-pressed once for every 500mm height of the rotor core lamination to reduce the generation of core waviness.

[0043] In some embodiments, after the rotor core is laminated, the guide bars are first installed vertically. When the inclined key is installed, the sliding surface of the inclined key is made of molybdenum disulfide MoS 2 Lubricate the bevel key to ensure that the bevel key slides more smoothly and is tightened more fully. Tightening the bevel key is very important. Use the three-step keying method of cold punching-hot punching-cold punching to install the bevel key to tighten the rotor core. Specifically, after the guide bar is inserted into the rotor core, first, the bevel key is cold punched for the first time, and the bevel key enters the keyway 31 of the rotor punching sheet 3 and the dove tail 2; then, the rotor core is heated as a whole, and after heating, the bevel key is hot punched to make the dove tail 2 of the motor shaft more closely contact the rotor punching sheet 3, and the tightening of the rotor core is more reliable; finally, after the rotor core is cooled as a whole, the bevel key is cold punched for the second time. After the bevel key is installed in place, the rotor core is also fully tightened.

[0044] In some embodiments, the rotor end ring is welded by medium frequency welding, which can appropriately reduce the welding heat affected zone and avoid cracks and pores. The specifications of the rotor end ring are too large, and the medium frequency welding time is long. When using medium frequency welding, it is necessary to strictly control the welding parameters to prevent the hardness of the end ring from decreasing after welding. After welding, soak it in citric acid water while it is hot, use a wire brush to brush off the surface flux and oxides, and manually sandblast the surface of the end ring. After sandblasting, check whether there are welding defects on the weld surface. In addition, when the rotor end ring is welded by medium frequency, it is necessary to pay attention to the protection of the rotor punching insulation and the pull rod insulation to prevent the insulation from being damaged and the rotor iron loss from increasing.

[0045] Step S300: manufacturing the machine base, performing annealing heat treatment after welding the machine base, and using a sling to turn the machine base over on a soft turning platform; during the machine base processing, fixing the bottom and the middle of the machine base;

[0046] In some embodiments, since the base of a high-power asynchronous motor is usually large in size and heavy in weight, the base has relatively poor deformation resistance. In particular, during the manufacturing process, due to the high temperature of the welding process, the base will produce large welding internal stresses, which will cause the base to deform during use, thereby affecting the operating accuracy and reliability of the motor. In order to reduce this adverse effect, a post-weld annealing process is usually used to effectively reduce the internal stress of the base. In the annealing heat treatment after the base is welded, the welded base is heated to a certain temperature and maintained for a certain period of time, so that the internal stress generated during the welding process is released, the hardness and toughness of the base are balanced, the deformation resistance and mechanical properties are improved, and the overall quality and performance of the motor are improved.

[0047] In some embodiments, considering that the machine base is large in size and heavy in weight, if there is no proper support and control during the turning process, it may cause damage to the surface of the machine base or internal stress concentration, thereby affecting the structural stability of the machine base. Therefore, a sling can be used during the turning process of the machine base, and the operation can be performed on a soft turning platform to effectively reduce the impact force during the turning process.

[0048] In some embodiments, the lifting device may include a bridge crane, a gantry crane, etc. The lifting device can evenly distribute the weight of the machine base, avoid eccentric loading during the turning process, and reduce the risk of deformation of the machine base. The lifting center of the lifting device and the center of gravity of the machine base are on the same line, ensuring that the lifting device can accurately control the turning angle and speed of the machine base, thereby avoiding damage to the machine base due to unbalanced force.

[0049] In some embodiments, when the base is turned over, the soft turning platform can be made of soft materials (such as rubber or synthetic cushions or wood) to bear the weight of the base and absorb the impact force generated during the turning process. These soft materials can effectively buffer the collision between the base and the platform during turning over, avoid scratches and dents on the surface of the base, help to smoothly achieve the turning transition of the base, reduce vibration, and thus reduce the stress shock that may occur during the turning process.

[0050] In some embodiments, during the turning process, first, the machine base is lifted by a sling to ensure that the connection between the sling and the machine base is firm and balanced; then, the machine base is slowly turned over to the desired position using a soft turning platform. During the turning process, the operator needs to monitor the stability of the sling and the platform at all times to ensure that the turning action is smooth and avoid sudden rotation or uneven force. After the turning is completed, check whether the machine base is deformed or damaged, and ensure that the welding parts and connection points of the machine base are not subjected to excessive impact.

[0051] In some embodiments, since the matching tolerance between the inner circle of the machine base and the stator core is only 0.1mm, and the length of the machine base is too long, the processing difficulty of the machine base is very large, and the risk of uneven force and large deformation of the machine base during the processing of the machine base is also high. Therefore, in order to ensure the processing accuracy of the machine base and avoid subsequent poor matching due to deformation during the processing, first of all, the deformation position of the machine base that may occur during the processing can be analyzed, and additional fixing points are designed at the bottom and middle positions of the machine base to fix the bottom and middle of the machine base to avoid deformation caused by excessive weight of the machine base and external forces generated during the processing, improve the ability of the machine base to resist external forces during the processing, and improve the rigidity of the machine base during the processing.

[0052] In some embodiments, in order to prevent the uneven deformation of the shape of the machine base due to the internal stress generated by excessive machining feed, the machining feed of the machine base must be strictly controlled. During the machining process of the machine base, a step-by-step cutting method is adopted according to the characteristics of the machine base material and the geometric shape of the workpiece to avoid excessive cutting at one time. By accurately controlling the amount of feed each time, the internal stress concentration caused by excessive cutting force can be effectively avoided, and the warping and deformation during the machining of the machine base can be reduced; at the same time, during the machining process of the machine base, deformation may also occur due to improper gear adjustment. The operator can monitor the machining status at all times, adjust the machining gear as needed, and strictly control the various machining parameters. By finely adjusting the gear during the machining process, the deformation of the machine base that may occur during the machining process can be effectively reduced, and the machining accuracy and quality of the machine base can be ensured.

[0053] Therefore, by taking control of these operations, the accuracy of the base processing can be improved, ensuring that the matching tolerance between the base and the stator core meets the design requirements, avoiding quality problems caused by deformation during the base processing process, and thus improving the overall performance and service life of the motor.

[0054] Step S400: stacking the stator core 7 using a stator core stacking tool, and installing the stator core protection frame 8 after the stator core stacking is completed.

[0055] In some embodiments, the stator core lamination tooling includes a vertical rib 71, a positioning rib 72, a tightening screw 73, a positioning screw 74 and a reinforcing rib, the vertical rib 71 is provided with a mounting groove, the positioning screw 74 positions the vertical rib 71 and the positioning rib 72, the positioning rib 72 moves relative to the mounting groove guide to adjust the radial distance between the positioning rib 72 and the vertical rib 71, and the tightening screw 73 connects the vertical rib 71 and the positioning rib 72. When the positioning screw 74 moves along the radial direction of the rotor, the positioning rib 72 moves relative to the mounting groove guide, and the positioning screw 74 adjusts and positions the radial distance between the positioning rib 72 and the vertical rib 71, the tightening screw 73 can connect the vertical rib 71 and the positioning rib 72, thereby completing the installation of the positioning rib 72, and also achieving the outer circle size of the stator core lamination tooling 7 can be adjusted according to the actual size of the stator core 7. The stator core lamination tooling can be firstly locked according to the relevant size requirements of the drawing, and then the tightening screw is locked, and then processed to the size required by the drawing to obtain the core lamination tooling.

[0056] In some embodiments, before the stator core is stacked, it is necessary to ensure that the verticality of the stator core stacking tooling is no more than 0.1 mm after installation. The stator core stacking tooling is used to stack the stator core. The stator core is pre-stressed each time the stacking reaches a height of 500 mm. At the same time, it is necessary to monitor the verticality of the outer circle of the stator core and the symmetrical 4-point stator core length parameters. If any unreasonableness is found, timely adjustments should be made. After the stator core is stacked in place, the rib plate welding and the yoke screw installation are completed under the pressure maintaining state.

[0057] In some embodiments, after the stator core is stacked, the positioning screw 74 is loosened first, and then the tensioning screw 73 is tightened. The outer circle of the entire stator core stacking tooling will be reduced, and the stator core 7 and the stator core stacking tooling can be safely separated subsequently. When the stator core is separated from the stator core stacking tooling, it is necessary to avoid damaging the stator core.

[0058] In some embodiments, after the stator core is stacked, a stator core protection frame 8 is installed. The stator core protection frame 8 can increase the rigidity of the stator core. The stator core protection frame 8 can be used in the entire stator manufacturing and transfer process. The stator core protection frame 8 includes an end plate 81 with a stop groove. The end plate 81 with a stop groove can prevent the stator core from falling off when the motor is subsequently lifted. The strength of the stator protection frame 8 needs to be verified by computer simulation to meet the use strength.

[0059] Step S500: The combined bracket is fixed on the platform, the stator wire in a vertical state is placed in the combined bracket, the straightness of the stator core is checked and confirmed by a knife edge ruler, the machine base is vertically lifted by a crane, and the machine base is mounted on the outside of the stator wire.

[0060] In some embodiments, the stator is mounted on the base and the stator is embedded in the stator. The total height of the stator is more than 9m. Once an abnormal jam occurs during the stator mounting process and cannot be corrected, the loss will be huge. During the stator mounting process, lifting the base and placing the stator embedding wire vertically are key, which can be achieved by combining brackets.

[0061] In some embodiments, the combined corbel includes a corbel 91 and a ring 92. The combined corbel 9 is fixed on a platform to place the stator wire in a vertical state. A knife-edge ruler is used to detect the straightness of the outer circle of the stator core. Only after confirming that it meets the technical requirements can it be installed. A crane is arranged on one side of the machine base (for example, on the driving side of the motor). The crane lifts the machine base vertically or horizontally. When the machine base is lifted, a level ruler is placed to check again to ensure that the machine base is lifted vertically. In the process of combining the machine base and the stator wire, the crane should work slowly and steadily. After the machine base slides into the outer circle of the stator wire, the machine base is released evenly, and the machine base is installed on the outside of the stator wire to complete the stator installation.

[0062] Step S600: Install the rotor, use a jack to assist in lifting the installed rotor, assemble the sliding bearings of the motor, and complete the manufacture of the motor.

[0063] In some embodiments, the bearing and the rotor are matched and ground, and the contact surface of the bearing is scraped in advance. After the contact surface of the bearing meets the requirements, the motor rotor is installed using lifting equipment. The weight of the motor is close to 100 tons, the weight of the motor rotor is 35 tons, and the air gap of the motor is small. Pay attention to the balance of the lifting during installation. During the motor assembly process, pay attention to adding a soft protective plate between the stator and the rotor to prevent the stator and rotor from being scratched during the installation process. After the stator and rotor are combined, the soft protective plate can also relieve the pressure of the rotor's own weight on the stator core and reduce the risk of stator pressure breaking.

[0064] In some embodiments, when installing the lower bearing of the sliding bearing, it is necessary to lift the rotor again. Before lifting, a jack is needed to support the motor shaft to prevent the center of gravity of the rotor from deviating to one side at the moment of lifting, which would cause excessive pressure and damage at the part where the rotor core and the stator core are finally separated. After the sliding bearing is installed, the position of the lower bearing in the sliding bearing needs to be adjusted by rotating the rotor to prevent the sliding bearing from holding back and causing the bearing to burn out.

[0065] In the present invention application, the following auxiliary measures can also be adopted in the motor process to reduce or avoid damage and deformation of the workpiece and improve the manufacturing quality of the motor product.

[0066] In some embodiments, after the motor shaft is processed, a bearing stop protection hoop is installed and is not removed until the motor is assembled. The bearing stop is not allowed to be exposed during the entire manufacturing process to prevent damage to the bearing stop during rotor processing, transportation, and placement.

[0067] In some embodiments, after the rotor core is stacked, it does not touch the ground during the entire rotor circulation process, and is transported using tooling. This can prevent the rotor from being placed for a long time and the core from being crushed due to the rotor's own weight, and can also prevent the rotor's center of gravity from shifting to one side at the moment of lifting, resulting in damage caused by excessive pressure at the part where the rotor core is last separated from the ground.

[0068] In some embodiments, screw holes need to be added to both ends of the motor shaft to install lifting tools, so that the motor shaft and rotor can be turned over in the air to avoid the impact force during conventional turning over on the ground. The stator should be turned over using a turning tool and on a soft platform to reduce deformation caused by the turning impact force.

[0069] In the manufacturing method of the asynchronous motor with a sector-shaped rotor applied in the present invention, firstly, in the rotor core lamination process and the stator core lamination process, the rotor core lamination is carried out by adopting the method of segmented pre-pressing and multiple positioning, the sector-shaped rotor punching is fixed, and the cold-hot-cold three-time keying method is adopted to install the oblique key in place to fully tighten the rotor core, ensure the lamination quality of the rotor core, and improve the rotor operation stability; in the stator core lamination process, the stator core is laminated by adopting the method of segmented pre-pressing, and the separable stator core lamination tooling is used to realize the safe separation of the tooling and the stator core; in addition, starting from the motor manufacturing process, anti-deformation measures for the motor shaft, stator core and rotor are formulated to ensure that the deformation of the above-mentioned components is small during the circulation and operation process, thereby improving the quality of the above-mentioned components and improving the operation stability of each component when the motor is running; in addition, in the stator set process, a combined bracket tooling is designed to ensure the safety of the stator wire embedding and the base set, strengthen the management of the heavy motor assembly process, reduce the potential damage to the components caused by the intermediate matching process, and improve the overall operation stability of the motor.

[0070] In the embodiments disclosed in the present application, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; "connected" can be a direct connection or an indirect connection through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments disclosed in the present application can be understood according to specific circumstances.

[0071] The above is only a preferred implementation of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for manufacturing a sector rotor asynchronous motor, characterized in that: include: Step S100: machining the motor shaft and inspecting the quality of the motor shaft; wherein the process of machining the motor shaft includes: rough turning - rough milling - quenching and tempering - semi-finishing turning - stress relief annealing - semi-finishing milling - finishing turning - grinding - finishing milling - dynamic balancing, and inspecting the quality of the motor shaft includes: using the rotor punching sheet to compare with the pigeon tail of the motor shaft after machining to inspect the machining quality of the motor shaft; Step S200: stacking the rotor core, adjusting the stacking quality of the rotor core using the tie rod hole positioning rod and the slot positioning rod, applying molybdenum disulfide lubricant to the sliding surface of the helical key, and installing the helical key by a three-step keying method of cold-hot-cold-tack to tighten the rotor core; Step S300: manufacturing the machine base, performing annealing heat treatment after welding the machine base, and using a sling to turn the machine base over on a soft turning platform; during the machine base processing, fixing the bottom and the middle of the machine base; Step S400: stacking the stator core using a stator core stacking tool, and installing a stator core protection frame after the stator core stacking is completed; Step S500: The combined bracket is fixed on the platform, the stator wire in a vertical state is placed in the combined bracket, the straightness of the stator core is checked and confirmed by a knife edge ruler, the machine base is vertically lifted by a crane, and the machine base is mounted on the outside of the stator wire; Step S600: Install the rotor, use a jack to assist in lifting the installed rotor, assemble the sliding bearings of the motor, and complete the manufacture of the motor.

2. The method for manufacturing a sector rotor asynchronous motor according to claim 1, characterized in that: In step S200, the rotor punching is provided with a pull rod hole and a slot, and the pull rod hole positioning rod is inserted into the pull rod hole. For every 250mm of rotor core laminations, the operator lifts the pull rod hole positioning rod to complete the slot shape adjustment once; at the same time, the slot positioning rod is used, and the slot positioning rod is arranged and installed along the outer circle of the rotor in eight equal parts. The slot positioning rod positions multiple rotor punchings, and the slot positioning rod is inserted into the slot. The rotor core is pre-pressed once for every 500mm of rotor core laminations.

3. The method for manufacturing a sector rotor asynchronous motor according to claim 2, characterized in that: In step S400, the stator core lamination tooling includes vertical ribs, positioning ribs, tightening screws and positioning screws. The vertical ribs are provided with installation grooves. The positioning screws position the vertical ribs and the positioning ribs. The positioning ribs are guided to move relative to the installation grooves to adjust the radial distance between the positioning ribs and the vertical ribs. The tightening screws connect the vertical ribs and the positioning ribs. When the positioning screws move along the radial direction of the rotor, the positioning ribs are guided to move relative to the installation grooves. After the positioning screws adjust and position the radial distance between the positioning ribs and the vertical ribs, the tightening screws connect the vertical ribs and the positioning ribs, thereby completing the installation of the positioning ribs. The stator core lamination tooling is used to perform stator core lamination, and the stator core is pre-pressed once each time the stack reaches a height of 500 mm.

4. The method for manufacturing a sector rotor asynchronous motor according to claim 3, characterized in that: In step S400, after the stator core is stacked, the positioning screws are loosened first, and then the tensioning screws are tightened. The outer circle of the entire stator core stacking tooling will be reduced, and the stator core and the stator core stacking tooling are safely separated.

5. The method for manufacturing a sector rotor asynchronous motor according to claim 4, characterized in that: In step S400, after the stator cores are stacked, a stator core protection frame is installed. The stator core protection frame includes an end plate with a stop groove to prevent the stator cores from falling off.

6. The method for manufacturing a sector rotor asynchronous motor according to claim 5, characterized in that: In step S500, the combined corbel includes a corbel and a ring. The combined corbel is fixed on a platform for placing the stator wire in a vertical state. A knife edge ruler is used to detect the straightness of the outer circle of the stator core. After confirming that it meets the technical requirements, a crane is used to vertically lift the machine base.

7. The method for manufacturing a sector rotor asynchronous motor according to claim 6, characterized in that: In step S600, the rotor needs to be lifted again when installing the lower bushing of the sliding bearing. Before lifting, a jack needs to be used to support the motor shaft. After the sliding bearing is installed, the position of the lower bushing of the sliding bearing is adjusted by rotating the rotor.

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