High-pressure cast aluminum rotor production process and production device

Abstract

The invention discloses a high-pressure casting aluminum rotor production process and a production device, and belongs to the technical field of aluminum casting rotor production. The production process comprises the following steps: S1, iron core preparation and aluminum melting preparation; s2, high-pressure casting; s3, slag ladles are cut off; s4, heat treatment: carrying out heat preservation on the rotor; s5, shaft entering; s6, turning an outer circle: turning and finishing the rotor by using turning equipment, and cleaning; s7, size detection: detecting the outer diameter of the iron core, the outer diameter runout of the iron core, the radial runout of a bearing circle, the runout of the end surface of the bearing retainer and the distance of the bearing retainer, performing dynamic balance detection, rotating the product, punching according to a rotating result, performing rotation measurement again after punching, and repeating the steps until the unbalance amount of the product is qualified; and S8, the product is soaked in anti-rust oil, oil draining is conducted after oil soaking, and packaging is conducted when the anti-rust oil does not flow down in strands any more. The technical problem that noise and vibration generated in the rotor operation process are large is solved.

Description

Technical Field

[0001] The invention relates to the technical field of aluminum casting rotor production, and in particular to a high-pressure aluminum casting rotor production process and a production device. Background Art

[0002] The motor consists of a stator and a rotor, where the rotor is the rotating part of the motor. The working principle of the motor rotor is based on the principles of electromagnetic induction and electromagnetic force. When the stator is energized to generate a rotating magnetic field, the conductors (windings or squirrel cage bars) in the rotor induce currents in the magnetic field. These induced currents interact with the stator magnetic field to generate electromagnetic torque, which causes the rotor to start rotating.

[0003] In the process of research, development and improvement of motors, reducing the vibration and noise of motors has always been the pursuit of researchers. Since the rotor shaft and the rotor core are designed as separate parts, vibration and noise are easily generated at the connection between the two. Therefore, a process is proposed to reduce the noise and vibration generated during the operation of the rotor. Summary of the invention

[0004] The main purpose of the present invention is to provide a high-pressure cast aluminum rotor production process and a production device, aiming to reduce the noise and vibration generated during the operation of the rotor.

[0005] To achieve the above object, the high pressure cast aluminum rotor production process proposed in the present invention comprises: S1. Preparation of iron core and molten aluminum; S2, high pressure casting, the iron core is placed in the high pressure cast aluminum rotor production device for mold casting. During the casting process, the aluminum liquid enters the mold at a predetermined pressure; S3, remove the slag bag; S4, heat treatment, keep the rotor warm for ≥2h; S5, insert the shaft, put the shaft into the upper and lower centers of the shaft inserting equipment, move the upper and lower centers downward until the shaft is completely pressed into the iron core, the lower center continues to move downward, the lower end of the shaft releases force, and the upper end maintains pressure for a predetermined time; S6, turning the outer circle, using turning equipment to turn and trim the rotor, and clean it; S7, Dimension detection, detection of core outer diameter, core outer diameter runout, bearing radial runout, bearing stop end face runout, bearing stop distance, Dynamic balancing test: the product is rotated and holes are punched according to the rotation results. After punching, the product is rotated again for measurement. The above steps are repeated until the product imbalance is qualified. S8. Soak the product in anti-rust oil, drain the oil after soaking, and package it when the anti-rust oil no longer flows down in strands.

[0006] Optionally, in an embodiment of the present invention, step S1 includes: S11, iron core preparation, select the iron core, and perform weight detection and blockage detection on the iron core. After passing the detection, preheat the iron core; S12, aluminum melting preparation, preheating and drying the aluminum material, preheating the smelting furnace, placing the aluminum material into the smelting furnace for smelting, deslagging and degassing the aluminum liquid after smelting, and transferring the aluminum liquid to a holding furnace for standby use after deslagging and degassing.

[0007] Optionally, in an embodiment of the present invention, step S3 further includes: after the slag bag is removed, the casting quality is inspected.

[0008] Optionally, in one embodiment of the present invention, in step S3, the quality of the end rings and guide bars of the rotor is inspected, and samples are randomly cut along the axis of the rotor to check whether the filling is full and whether there are thin bars.

[0009] To achieve the above object, the present invention further provides a high pressure cast aluminum rotor production device, which is applied to the production process described above, and the production device comprises: A fixed mold unit, wherein the fixed mold unit is provided with a casting liquid pipeline and a diverter plate, and the casting liquid pipeline is connected to the diverter plate; A movable mold unit, wherein the movable mold unit is provided with a clamping mechanism and an ejector plate, the fixed mold unit and the movable mold unit are buckled together to form a casting cavity, and the diverter plate, the clamping mechanism and the ejector plate are located in the casting cavity; The anti-bumping plate is respectively located on the fixed mold unit and the movable mold unit, and has continuous corrugated protrusions. The anti-bumping plate is also provided with an overflow hole, and the overflow hole is provided at one end of the anti-bumping plate close to the casting cavity.

[0010] Optionally, in one embodiment of the present invention, the clamping mechanism includes: A fixed supporting block, wherein the fixed supporting block has a supporting arc surface; A sliding clamping block, wherein the sliding clamping block is symmetrically arranged on both sides of the fixed supporting block, and the sliding clamping block includes a track block, a slider, a connecting block, a clamping block, a coupling and a hydraulic cylinder. The clamping block cooperates with the fixed supporting block to clamp the iron core. The track blocks are slidably connected on both sides of the slider. The hydraulic cylinder drives the connecting block through the coupling, and the clamping block is connected to the connecting block.

[0011] Optionally, in one embodiment of the present invention, the production device is further provided with a heating pipeline and a heat preservation pipeline. The medium in the heating pipeline is oil, and the medium in the insulation pipeline is water; One of the heat preservation pipelines surrounds the manifold, and the other is arranged on the movable mold unit; One of the heating pipelines is adjacent to the casting liquid pipeline, and the other leads to the ejector plate.

[0012] Optionally, in one embodiment of the present invention, the fixed mold unit and the movable mold unit are both provided with overflow grooves, and a plurality of the overflow grooves are arranged on the periphery of the casting cavity.

[0013] Optionally, in one embodiment of the present invention, the diverter plate is provided with an overflow groove.

[0014] Optionally, in one embodiment of the present invention, the movable mold unit is provided with a vacuum pipe, one end of the vacuum pipe is connected to a negative pressure machine, and the other end of the vacuum pipe is connected to the casting cavity.

[0015] Compared with the prior art, the present invention can at least achieve the following beneficial effects.

[0016] During the production process of the rotor, an aluminum casting process needs to be carried out on the iron core. Aluminum bars are cast on the iron core. The aluminum bars are the conductor material in the rotor and are responsible for transmitting current. When current passes through the aluminum bars, it interacts with the electromagnetic field to generate electromagnetic force, thereby causing the rotor to rotate.

[0017] Before casting begins, the aluminum and iron core are screened and qualified aluminum and iron core are selected. The aluminum melts at high temperature to become aluminum liquid, the iron core is placed in the casting mold, and the aluminum liquid is pressed into the casting mold at a predetermined pressure to complete the aluminum bar casting. After the high-pressure aluminum liquid enters the casting mold, it has a faster flow speed, and the cavity in the mold can be completely filled, thereby improving the molding accuracy of the casting. In addition, the casting accuracy of the casting is also higher than that of conventional casting, reducing subsequent polishing.

[0018] After the casting is cut, the slag bag is removed. After the slag bag is removed, the casting is subjected to heat preservation treatment to slowly cool down within the predetermined temperature range to prevent excessive temperature changes from causing thermal stress and cracks.

[0019] After the casting temperature drops to room temperature, the casting is put into the shaft using a shaft-inserting machine. When the shaft is completely pressed into the core, the upper end is pressed against the shaft for a certain period of time to ensure a firm connection between the shaft and the core. This prevents the rotor from shaking between the core and the shaft during operation, which can cause vibration and noise in the motor.

[0020] The products after entering the shaft are trimmed and then inspected for size. Products with qualified size are inspected for dynamic balance and punched to meet the dynamic balance standard.

[0021] Finally, the product is treated with rust-proofing and packaged. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0023] Figure 1 It is a structural schematic diagram of an embodiment of a high pressure cast aluminum rotor production device of the present invention; Figure 2 It is a structural schematic diagram of the high-pressure cast aluminum rotor production device of the present invention from another perspective; Figure 3 A side view of a high pressure cast aluminum rotor production device according to the present invention; Figure 4 A perspective view of a first fixed die plate in a high pressure cast aluminum rotor production device of the present invention; Figure 5 A perspective view of a second fixed die plate in a high pressure cast aluminum rotor production device of the present invention; Figure 6 A perspective view of a first movable platen in a high pressure cast aluminum rotor production device of the present invention; Figure 7 A perspective view of a second movable platen in a high pressure cast aluminum rotor production device of the present invention; Figure 8 A perspective view of a third movable die plate in the high pressure cast aluminum rotor production device of the present invention; Fig. 9 It is a front view of the first moving platen in the high pressure cast aluminum rotor production device of the present invention; Fig.10 for Fig. 9 A partial enlarged view of the middle A; Fig.11 It is a stereoscopic view of the fixed mold unit in the high-pressure cast aluminum rotor production device of the present invention.

[0024] Description of Figure Numbers: 100, fixed mold unit; 110, positioning groove; 120, locking groove; 130, first fixed mold plate; 131, No. 3 heating pipeline; 132, No. 5 heating pipeline; 133, No. 4 insulation pipeline; 140, second fixed mold plate; 141, No. 1 heating pipeline; 142, No. 2 heating pipeline; 143, No. 12 heating pipeline; 150, casting liquid pipeline; 200, movable mold unit; 210, positioning rod; 220, clamping mechanism; 221, fixed support block; 222, sliding clamping block; 223, Clamping block; 224, locking block; 225, positioning protrusion; 226, positioning groove; 227, overflow half groove; 228, coupling; 230, first movable plate; 231, No. 8 heating pipeline; 240, second movable plate; 241, ejector plate; 242, No. 6 heating pipeline; 243, No. 7 heating pipeline; 250, third movable plate; 251, No. 11 insulation pipeline; 310, anti-burst plate; 320, diverter plate; 321, overflow groove; 400, vacuum pipeline; 500, overflow hole; The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0025] 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 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.

[0026] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0027] In the present invention, unless otherwise clearly specified and limited, the terms "connection", "fixation", etc. should be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0028] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the meaning of "and / or" appearing in the full text includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme that satisfies both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in the field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0029] The present invention provides a high-pressure aluminum casting rotor production process, comprising: S1. Preparation of iron core and molten aluminum; S2, high pressure casting, the iron core is placed in the high pressure cast aluminum rotor production device for mold casting. During the casting process, the aluminum liquid enters the mold at a predetermined pressure; S3, remove the slag bag; S4, heat treatment, keep the rotor warm for ≥2h; S5, insert the shaft, put the shaft into the upper and lower centers of the shaft inserting equipment, move the upper and lower centers downward until the shaft is completely pressed into the iron core, the lower center continues to move downward, the lower end of the shaft releases force, and the upper end maintains pressure for a predetermined time; S6, turning the outer circle, using turning equipment to turn and trim the rotor, and clean it; S7, Dimension detection, detection of core outer diameter, core outer diameter runout, bearing radial runout, bearing stop end face runout, bearing stop distance, Dynamic balancing test: the product is rotated and holes are punched according to the rotation results. After punching, the product is rotated again for measurement. The above steps are repeated until the product imbalance is qualified. S8. Soak the product in anti-rust oil, drain the oil after soaking, and package it when the anti-rust oil no longer flows down in strands.

[0030] During the production process of the rotor, an aluminum casting process needs to be carried out on the iron core. Aluminum bars are cast on the iron core. The aluminum bars are the conductor material in the rotor and are responsible for transmitting current. When current passes through the aluminum bars, it interacts with the electromagnetic field to generate electromagnetic force, thereby causing the rotor to rotate.

[0031] Before casting begins, the aluminum and iron core are screened and qualified aluminum and iron core are selected. The aluminum melts at high temperature to become aluminum liquid, the iron core is placed in the casting mold, and the aluminum liquid is pressed into the casting mold at a predetermined pressure to complete the aluminum bar casting. After the high-pressure aluminum liquid enters the casting mold, it has a faster flow speed, and the cavity in the mold can be completely filled, thereby improving the molding accuracy of the casting. In addition, the casting accuracy of the casting is also higher than that of conventional casting, reducing subsequent polishing.

[0032] Specifically, when casting, it is necessary to check the parameters of the casting device first. After waiting for the parameters of the equipment to be in place, the robot will put the preheated iron core into the casting mold for mold closing and casting. After casting and cooling are completed, the robot will take out the product and check the appearance and size of the rotor.

[0033] After the casting is cut, the slag bag is removed. After the slag bag is removed, the casting is subjected to heat preservation treatment, so that it is slowly cooled within the predetermined temperature range to prevent excessive temperature changes from causing thermal stress and cracks. The heat preservation time is not less than two hours. After the heat preservation is completed, the rotor is taken out by the robot and marked on the rotor surface to indicate that the heat preservation treatment has been completed.

[0034] After the temperature of the casting drops to room temperature, the casting is put into the shaft. The robot grabs the casting and places it on the shaft-inserting machine. The robot grabs the shaft, scans the code on the shaft, and places the shaft into the upper and lower centers of the shaft-inserting machine. The upper and lower centers move down to insert the shaft. When the shaft is completely pressed into the iron core, the upper end maintains pressure on the shaft for a certain period of time, and the lower center continues to move down. The lower end of the shaft is no longer under force, ensuring a firm connection between the shaft and the iron core. Prevent the rotor from shaking between the iron core and the shaft during operation, thereby causing vibration and noise in the motor. After the shaft is inserted, the robot grabs the rotor and puts it on the AGV turnover tray. It should be noted that when the shaft is inserted, it is in a normal temperature environment. Inserting the shaft in this environment can avoid thermal stress caused by temperature changes after the shaft is inserted or deformation of the product due to thermal expansion and contraction.

[0035] After the product is put into the shaft, the manipulator is used to place the product from the turnover tray into the fixture of the turning equipment, and the product is rough-processed and fine-processed in turn to make the product size meet the requirements. After turning, the product is sent to the cleaning station for cleaning. After turning, the product is dimensional measured, and the outer diameter of the core, the outer diameter runout of the core, the radial runout of the bearing circle, the end face runout of the bearing stop, the distance of the bearing stop, etc. are fully inspected by the detection device, and qualified products and unqualified products are classified and placed. In addition to the above-mentioned tests, tea farmers are also required to conduct broken bar detection and impedance detection.

[0036] Finally, the product is tested for dynamic balancing. First, the product is placed in the test fixture, and the product is rotated to complete the initial imbalance measurement. According to the measurement results, holes are punched at the corresponding positions of the rotor. After the holes are punched, the measurement is performed again. The steps of drilling and measuring are repeated until the imbalance of the product is qualified. At the same time, each measurement data and punching data are bound and uploaded with the product.

[0037] Finally, the product is treated with rust prevention and packaged. First, take a CCD photo of the product appearance, save it and upload it to the system, then soak the product in anti-rust oil, drain the oil after soaking for a period of time, and when the anti-rust oil no longer flows down in strands, put the product in a packaging box and add a desiccant to complete the packaging.

[0038] Furthermore, when the core is screened, it is subjected to quality inspection and blockage inspection. Before the core is placed in the casting mold, it is also necessary to preheat the core. The preheating treatment can not only remove the residual oil and water on the core, but also reduce the temperature difference between it and the aluminum liquid, thereby reducing the stress caused by the temperature difference.

[0039] When preheating the iron core, you can choose to use a tunnel furnace. Tunnel furnace heating can not only ensure the continuity of the process, but also heat a large number of iron cores simultaneously and heat the iron cores completely.

[0040] Before aluminum melting, the chemical composition and mechanical properties of aluminum are tested, and a QR code is affixed to each batch of aluminum that passes the test. Before aluminum is used, the QR code is scanned, weighed, and the data is recorded and uploaded for subsequent traceability.

[0041] When melting aluminum, first preheat the aluminum material and remove the remaining moisture on the aluminum material. After the melting furnace is heated, put the aluminum material into the melting furnace. After the aluminum material is melted, the aluminum liquid is deslagging and degassing. Confirm the degassing parameters (such as speed, gas, air pressure, flow, preheating time, degassing time, standing time, etc.). After the graphene rod of the degasser is preheated, the degassing operation is carried out. After the degassing is completed, it is left to stand for a period of time for slagging. After the slagging is completed, the aluminum liquid is measured for density, composition, mechanical properties, etc. to ensure the quality of the aluminum liquid.

[0042] After the aluminum liquid has completed the quality inspection, it is transferred to the insulation furnace next to the casting mold for insulation and standby. Multiple insulation furnaces can be set up next to the casting mold and used alternately. When the aluminum liquid in one insulation furnace is used up, it is switched to other insulation furnaces for use. When the insulation furnace is in use, the temperature is controlled at 700~730℃. If the insulation furnace is not used for more than two hours, the temperature of the insulation furnace is reduced to 690℃ for insulation. If the aluminum liquid is not used up for more than six hours, the chemical composition of the aluminum liquid needs to be retested.

[0043] Furthermore, after casting, the slag bag of the casting is cut off and the casting is inspected for quality. Specifically, when inspecting the quality of the casting, the end rings and guide bars (aluminum bars) of the rotor are inspected for quality. In addition, it is also necessary to conduct a cross-section inspection of the overall quality of the rotor by sampling, and to perform an inclined cutting along the axis of the rotor to produce a larger cross section, and to check whether the aluminum bars are fully filled in the iron core through the cross section.

[0044] Reference Figure 1 to Figure 11 The present invention also provides a high-pressure cast aluminum rotor production device, including a fixed mold unit 100 and a movable mold unit 200, the fixed mold unit 100 and the movable mold unit 200 are covered to form a casting cavity, and the casting liquid pipeline in the fixed mold unit 100 is connected to the casting cavity.

[0045] Since the present solution is mold-closing casting, the accuracy of the fastening between the fixed mold unit 100 and the movable mold unit 200 will also affect the final casting quality. To ensure the accuracy of mold closing, positioning grooves 110 and positioning rods 210 are respectively provided in the fixed mold unit 100 and the movable mold unit 200. Specifically, positioning grooves 110 are provided at the four corners of the fixed mold unit 100, and positioning rods 210 are provided at the four corners of the movable mold unit 200. During the mold closing process, the positioning rods 210 gradually extend into the positioning grooves 110. After the positioning rods 210 extend into the positioning grooves 110, the small deviation of the mold closing trajectory will be corrected to ensure that the mold can be accurately closed in the end.

[0046] Reference Figure 9~Figure 10 The aluminum strip is cast directly into the iron core by casting aluminum liquid, so the stability and accuracy of the clamping mechanism 220 for the iron core will also affect the final casting quality. In the first embodiment of this scheme, the clamping structure includes a fixed support block 221 and a sliding clamping block 222, and the fixed support block 221 and the clamping block 223 cooperate to clamp the iron core.

[0047] The number of sliding clamping blocks 222 can be 2n, where n is an integer. In a preferred embodiment, two sliding clamping blocks 222 are provided, and the two sliding clamping blocks 222 are symmetrically arranged on both sides of the fixed supporting block 221. The fixed supporting block 221 is a non-moving component, so when the iron core is placed on the fixed supporting block 221, the fixed supporting block 221 will provide support for the lower area of ​​the iron core. If the iron core is clamped on both horizontal sides of the iron core at this moment, the position of the iron core on the fixed supporting block 221 may be moved. For this reason, the two sliding clamping blocks 222 are arranged obliquely to a certain extent. When the oblique sliding clamping block 222 generates an extrusion force on the iron core, the fixed supporting block 221 can generate a support force in the opposite direction of the extrusion force of the sliding clamping block 222 to avoid position displacement of the iron core. To further ensure that the clamping blocks 223 on both sides are precisely enclosed, a positioning protrusion 225 is provided on one of the two clamping blocks 223, and a positioning groove 226 is provided on the other. When the positioning protrusion 225 is fully extended into the positioning groove 226, the two clamping blocks 223 are completely enclosed.

[0048] In addition, the hydraulic cylinder (not shown) drives the clamp block 223 via the coupling 228 , which can compensate for the alignment error and further improve the movement accuracy of the clamp block 223 .

[0049] In order to improve the clamping stability of the clamping mechanism 220 on the iron core, the sliding clamping block 222 is also provided with a locking block 224, and the fixed mold unit 100 is provided with a locking groove 120. The locking block 224 is a component of the sliding clamping block 222, so the locking block 224 is driven by the hydraulic cylinder and also has a clamping position and a material discharge position. In order to prevent the sliding clamping block 222 from moving during the casting process and causing the clamping to loosen, a locking groove 120 is provided on the fixed mold unit 100, and the position of the locking groove 120 corresponds to when the locking block 224 is in the clamping position. That is, when the locking block 224 extends into the locking groove 120, the locking groove 120 locks the locking block 224, and the sliding clamping block 222 cannot move, ensuring that the clamping mechanism 220 stably clamps the iron core during the casting process.

[0050] Furthermore, when the core is cast with aluminum bars, the aluminum liquid has a certain pressure when entering the casting cavity, and the pressure is used to achieve rapid filling of the aluminum liquid in the casting cavity, thereby improving the compactness. In addition, during the casting process, more aluminum liquid than required will be pressed in (for example, if 50 kg of aluminum liquid is required for casting, more than 50 kg of aluminum liquid will be pressed into the casting cavity). Therefore, the remaining aluminum liquid needs to be processed, and it is necessary to prevent the high-temperature aluminum liquid from overflowing and spurting out of the gap between the two molds due to high pressure. In view of the above problems, an anti-burst plate 310 is provided, and the anti-burst plate 310 has continuous corrugated protrusions. When the aluminum liquid overflows to the anti-burst plate 310 and contacts the corrugated protrusions, the flow rate will be greatly reduced, making it difficult for the aluminum liquid to pass through multiple corrugated protrusions and flow to the outside of the mold.

[0051] Reference Figure 6 and Fig.11 For the excess aluminum liquid flowing out of the casting cavity, an overflow groove and an overflow hole 500 are provided on the periphery of the casting cavity. The overflow groove provides a path and guide for the flow of the excess aluminum liquid, and the excess aluminum liquid flows to a specific area through the overflow hole 500 for processing. Furthermore, since the flow rate of the aluminum liquid will be greatly reduced after flowing through the first corrugated protrusion after flowing to the anti-burst plate 310, this part of the aluminum liquid is not collected, and an overflow hole 500 is also provided at one end of the anti-burst plate 310 close to the casting cavity.

[0052] In addition, after the aluminum liquid enters the casting cavity, it is diverted by the diverter plate 320. To facilitate the excess aluminum liquid to flow out, the diverter plate 320 is provided with an overflow groove 321. The clamping block 223 is also provided with an overflow half groove 227. After the two clamping blocks 223 are enclosed, the overflow half groove 227 is synchronously enclosed to allow the excess aluminum liquid to pass through.

[0053] In the step of preparing for melting aluminum, the aluminum material is melted into molten aluminum and transferred to a holding furnace. The holding temperature of the holding furnace is usually around 700°C, while the solidification temperature of the molten aluminum is 660°C. The difference between the two is small, so the molten aluminum solidifies faster after casting. In order to prevent the molten aluminum from solidifying before completely filling the casting cavity, a heating pipeline is set. In order to prevent the molten aluminum from being too high and causing overheating of the production device, a holding pipeline is set to control the temperature of the production device.

[0054] Reference Figure 3~Figure 8 The fixed mold unit 100 is formed by stacking the first fixed mold plate 130 and the second fixed mold plate 140 in sequence, and the movable mold unit 200 is formed by stacking the first movable mold plate 230, the second movable mold plate 240 and the third movable mold plate 250 in sequence. The pipelines in each mold plate are described below.

[0055] The first fixed template 130 is provided with a diverter plate 320 and a casting liquid pipeline 150. During casting, the aluminum liquid flows from the casting liquid pipeline 150 to the diverter plate 320. After passing through the diverter plate 320, the aluminum liquid flows into various positions in the casting cavity in different directions. Since the overall temperature of the first fixed template 130 has a great influence on the temperature of the casting cavity, a No. 3 heating pipeline 131 is arranged in a cross structure to form a heating surface arranged in the first fixed template 130 to achieve overall heating of the first fixed template 130. In addition, a No. 5 heating pipeline 132 is also provided. The No. 5 heating pipeline 132 is close to the casting liquid pipeline 150 and mainly realizes heating of the casting liquid pipeline 150. The diverter plate 320 is the first component that contacts the aluminum liquid after the aluminum liquid flows out of the casting liquid pipeline 150. During the entire casting process, the contact time between the diverter plate 320 and the aluminum liquid is extremely long. In order to prevent the diverter plate 320 from being deformed or damaged due to high temperature, a No. 4 insulation pipeline 133 is provided to regulate the temperature of the diverter plate 320.

[0056] Three heating pipelines are arranged in the second fixed mold plate 140, wherein the first heating pipeline 141 is arranged in a surrounding configuration to heat the surface of the second fixed mold plate 140. In addition, a heating cavity is formed between the first fixed mold plate 130 and the second fixed mold plate 140 by covering, and the second heating pipeline 142 is connected to the heating cavity, and the heating cavity forms a preheating for the entire fixed mold unit 100. The casting liquid pipeline 150 is provided with a casting liquid inlet in the second fixed mold plate 140, and therefore, the twelfth heating pipeline 143 is arranged at the casting liquid inlet to ensure that the temperature of the casting liquid does not drop significantly when the casting liquid enters the casting liquid pipeline 150.

[0057] An eighth heating pipeline 231 is disposed in the first movable platen 230 . The eighth heating pipeline 231 is connected to the fixed supporting block 221 to preheat the fixed supporting block 221 .

[0058] The second movable plate 240 is provided with an ejector plate 241, and the ejector plate 241 is provided with an ejector hole along its circumferential direction so that the ejector can pass through to discharge the casting. Compared with low temperature, it is easier to demould the casting in a high temperature environment, so a No. 7 heating pipeline 243 is provided to heat the ejector plate 241 to facilitate subsequent demoulding. In addition, a No. 6 heating pipeline 242 is also provided in the second movable plate 240, which is in a surrounding configuration to heat the second movable plate 240 as a whole.

[0059] An eleventh heat preservation pipeline 251 is arranged in the third movable mold plate 250 to control the temperature of the movable mold unit 200 to prevent the mold from overheating and affecting its use.

[0060] Reference Figure 6 In addition to the heating pipeline and the insulation pipeline, the production device is also provided with a vacuum pipeline 400, which connects the casting cavity with the external environment. Before the aluminum liquid enters the casting cavity, the casting cavity is first subjected to negative pressure treatment to reduce the gas content in the casting cavity. Casting under negative pressure conditions can reduce the gas involved in the aluminum liquid during mold filling and increase the density of the casting. In addition, it can also reduce the oxidized slag generated by the oxidation of oxygen and aluminum liquid in the mold.

[0061] The above are only optional embodiments of the present invention, and are not intended to limit the patent scope of the present invention. All equivalent structural changes made using the contents of the present invention's specification and drawings, or directly / indirectly applied in other related technical fields, are included in the patent protection scope of the present invention.

Claims

1. A high pressure cast aluminum rotor production process, characterized in that: include: S1. Preparation of iron core and molten aluminum; S2, high pressure casting, the iron core is placed in the high pressure cast aluminum rotor production device for mold casting. During the casting process, the aluminum liquid enters the mold at a predetermined pressure; S3, remove the slag bag; S4, heat treatment, keep the rotor warm for ≥2h; S5, insert the shaft, put the shaft into the upper and lower centers of the shaft inserting equipment, move the upper and lower centers downward until the shaft is completely pressed into the iron core, the lower center continues to move downward, the lower end of the shaft releases force, and the upper end maintains pressure for a predetermined time; S6, turning the outer circle, using turning equipment to turn and trim the rotor, and clean it; S7, Dimension detection, detection of core outer diameter, core outer diameter runout, bearing radial runout, bearing stop end face runout, bearing stop distance, Dynamic balancing test: the product is rotated and holes are punched according to the rotation results. After punching, the product is rotated again for measurement. The above steps are repeated until the product imbalance is qualified. S8. Soak the product in anti-rust oil, drain the oil after soaking, and package it when the anti-rust oil no longer flows down in strands.

2. The high pressure cast aluminum rotor production process according to claim 1, characterized in that: Step S1 includes: S11, iron core preparation, select the iron core, and perform weight detection and blockage detection on the iron core. After passing the detection, preheat the iron core; S12, aluminum melting preparation, preheating and drying the aluminum material, preheating the smelting furnace, placing the aluminum material into the smelting furnace for smelting, deslagging and degassing the aluminum liquid after smelting, and transferring the aluminum liquid to a holding furnace for standby use after deslagging and degassing.

3. The high pressure cast aluminum rotor production process according to claim 1, characterized in that: Step S3 also includes: after the slag bag is removed, the casting quality is inspected.

4. The high pressure cast aluminum rotor production process according to claim 3, characterized in that: In step S3, the quality of the end rings and guide bars of the rotor is checked, and samples are randomly cut along the axis of the rotor to check whether the filling is full and whether there are thin bars.

5. A high pressure cast aluminum rotor production device, applied to the production process according to any one of claims 1 to 4, characterized in that: include: A fixed mold unit, wherein the fixed mold unit is provided with a casting liquid pipeline and a diverter plate, and the casting liquid pipeline is connected to the diverter plate; A movable mold unit, wherein the movable mold unit is provided with a clamping mechanism and an ejector plate, the fixed mold unit and the movable mold unit are buckled together to form a casting cavity, and the diverter plate, the clamping mechanism and the ejector plate are located in the casting cavity; The anti-bumping plate is respectively located on the fixed mold unit and the movable mold unit, and has continuous corrugated protrusions. The anti-bumping plate is also provided with an overflow hole, and the overflow hole is provided at one end of the anti-bumping plate close to the casting cavity.

6. The high pressure cast aluminum rotor production device according to claim 5, characterized in that: The clamping mechanism comprises: A fixed supporting block, wherein the fixed supporting block has a supporting arc surface; A sliding clamping block, wherein the sliding clamping block is symmetrically arranged on both sides of the fixed supporting block, and the sliding clamping block includes a track block, a slider, a connecting block, a clamping block, a coupling and a hydraulic cylinder. The clamping block cooperates with the fixed supporting block to clamp the iron core. The track blocks are slidably connected on both sides of the slider. The hydraulic cylinder drives the connecting block through the coupling, and the clamping block is connected to the connecting block.

7. The high pressure cast aluminum rotor production device according to claim 5, characterized in that: The production device is also provided with a heating pipeline and a heat preservation pipeline. The medium in the heating pipeline is oil, and the medium in the insulation pipeline is water; One of the heat preservation pipelines surrounds the manifold, and the other is arranged on the movable mold unit; One of the heating pipelines is adjacent to the casting liquid pipeline, and the other leads to the ejector plate.

8. The high pressure cast aluminum rotor production device according to claim 5, characterized in that: The fixed mold unit and the movable mold unit are both provided with overflow grooves, and a plurality of the overflow grooves are arranged on the outer periphery of the casting cavity.

9. The high pressure cast aluminum rotor production device according to claim 5, characterized in that: The diverter plate is provided with an overflow groove.

10. The high pressure cast aluminum rotor production device according to claim 5, characterized in that: The movable mold unit is provided with a vacuum pipeline, one end of which is connected to a negative pressure machine, and the other end of which is connected to the casting cavity.

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