Manufacturing method of motor rotor

Abstract

The invention discloses a manufacturing method of a motor rotor, which belongs to the technical field of motor rotor production, and comprises the following steps of: 1, manufacturing a rotor iron core; 2, assembling a rotor iron core accessory; thirdly, an end ring blank is manufactured and assembled; 4, heating the rotor end ring; 5, the rotor end ring is extruded; step 6, rotor blanking; vII, adjusting the dynamic balance of the rotor. The method can achieve the purposes of eliminating air bubbles and air holes in the end ring of the rotor, improving the production efficiency, improving the yield of the rotor and ensuring the product quality of the motor rotor.

Description

Technical Field

[0001] The invention belongs to the technical field of motor rotor production, and in particular relates to a method for manufacturing a motor rotor. Background Art

[0002] The invention patent with the publication (announcement) number CN115313710A discloses a high-speed asynchronous motor cast aluminum rotor and a manufacturing method thereof, wherein the manufacturing method of the high-speed asynchronous motor cast aluminum rotor is: first prepare the rotor core, then insert the copper bars and weld the copper rings, then put it into the cavity of the aluminum casting mold and inject the aluminum liquid, and cast the aluminum bars and end rings at one time. The motor rotor made by the above method can reduce the skin effect generated when the motor is running at variable frequency, improve the structural strength and reliability of the rotor at high speed, reduce the resistance of the rotor bars and end rings, improve the motor operation efficiency and stability, and the manufacturing process is relatively simple.

[0003] However, the applicant of this application discovered during the actual production and use process that the aluminum rotor end ring would have pores and bubbles inside, which on the one hand would make the manufacturing process of the motor rotor substandard, and on the other hand would cause the dynamic imbalance of the rotor to exceed the standard in the circumferential direction, affecting the quality and use of the motor rotor, and ultimately affecting the working performance and service life of the engine. Summary of the invention

[0004] The purpose of the present invention is to overcome the technical problems in the prior art that bubbles and pores exist inside the aluminum rotor end ring, affecting the quality of the rotor, and to provide a method for manufacturing a motor rotor that can eliminate bubbles and pores inside the aluminum rotor end ring to ensure the quality of the rotor.

[0005] In order to solve the above technical problems, the present invention provides a method for manufacturing a motor rotor, the manufacturing method comprising the following steps: Step 1: Make the rotor core, select silicon steel sheets as raw materials, place the silicon steel sheets in a punching machine for punching, form rotor punching sheets, stack the rotor punching sheets in sequence and press them to make the rotor core; Step 2: Assemble the rotor core accessories, install the rotating shaft in the shaft groove that penetrates axially in the center of the rotor core, insert the guide bars in turn in the rotor grooves that penetrate axially formed in the circumferential direction of the rotor core, and make the rotor, wherein the guide bars are made of copper material, and the length of the guide bars is the same as the length of the rotor groove; Step 3: Make and assemble the end ring blank, select aluminum plate as the raw material, place the aluminum plate in a punching machine for punching, form a circular end ring blank, and install the end ring blank at both ends of the rotor. The diameter of the end ring blank is larger than the diameter of the finished end ring; Step 4: Heat the rotor end ring. Move the rotor into the steel magnetic conductive material cavity wrapped by the high-frequency heating ring to heat the rotor end ring. The heating time is set to 3-8 minutes and the heating temperature is set to 400-650°C to make the rotor end ring in a molten state. Step 5: Extruding the rotor end ring, transferring the heated rotor in step 4 into the extruder, and driving the first driving mechanism, the first shaping die presses the rotor end ring, and extrude and shape the rotor end ring in a molten state, the pressure of the first shaping die is set to 20-40T, and the bubbles in the rotor end ring are discharged through the exhaust channel of the first shaping die; Step 6: Remove the rotor from the extruder, and remove the rotor burrs after the rotor end ring cools and sets; Step 7: Adjust the dynamic balance of the rotor. Place the rotor in step 6 in a balancing machine for testing. Correct the imbalance of the rotor based on the data measured by the balancing machine to reduce the vibration generated when the rotor rotates to within the allowable range, thus completing the manufacturing of the entire motor rotor product.

[0006] As a further improvement measure of the present invention, the first shaping mold in the above-mentioned step five is respectively provided with a groove corresponding to the end ring, and a through hole connected to the groove, the inner wall of the groove is provided with a first exhaust hole along its own axial direction, the inner wall of the through hole is provided with a second exhaust hole along the circumferential direction, the first exhaust hole is connected with the second exhaust hole, and an exhaust channel is formed between the first exhaust hole and the second exhaust hole.

[0007] As a further improvement measure of the present invention, in the above step four, the lower end ring of the rotor is placed in a second shaping mold, and under the drive of a second driving mechanism, the rotor is transferred to a high-frequency heating ring to heat the upper end ring of the rotor to put it in a molten state.

[0008] As a further improvement measure of the present invention, in the above-mentioned step five, under the drive of the third driving mechanism, the second shaping mold drives the rotor to move into the extruder, and under the drive of the first driving mechanism, the first shaping mold presses the upper end ring of the rotor, extrude and shape the upper end ring of the rotor in a molten state, and discharges the pores and bubbles in the upper end ring of the rotor.

[0009] As a further improvement measure of the present invention, in the above-mentioned step six, the rotor is taken out from the extruder by a manipulator, and the rotor is turned 180°, and the upper end ring of the rotor that has been shaped, exhausted and cooled and finalized is placed in a second shaping mold. Under the drive of the second driving mechanism, the rotor is transferred to the high-frequency heating circle again, and the lower end ring of the rotor is heated to be in a molten state. Under the drive of the third driving mechanism, the second shaping mold drives the rotor to move into the extruder. Under the drive of the first driving mechanism, the first shaping mold presses the lower end ring of the rotor, extrude and shape the lower end ring of the rotor in a molten state, and discharges the bubbles in the lower end ring of the rotor.

[0010] As a further improvement measure of the present invention, in the above step 1, the rotor punchings are fixed by welding after being pressed.

[0011] As a further improvement measure of the present invention, in the above-mentioned step, the rotor punching is fixed by nailing after being compressed.

[0012] Compared with the prior art, the beneficial effect of the present invention is that: the present invention heats the rotor end ring and shapes and extrude the rotor end ring in a molten state through a first shaping mold, so that the bubbles and pores inside the rotor end ring are discharged from the exhaust channel of the first shaping mold during the extrusion process, so as to achieve the purpose of eliminating the bubbles and pores inside the aluminum rotor end ring, improving production efficiency, increasing the rotor yield, and ensuring the product quality of the motor rotor. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a flow chart of the present invention.

[0014] Figure 2 It is a three-dimensional diagram of the first shaping mold in the present invention.

[0015] Figure 3 It is a bottom view of the first shaping mold in the present invention.

[0016] Figure 4 yes Figure 3 AA section view.

[0017] Description of the accompanying drawings: 1-first shaping mold, 2-groove, 3-through hole, 4-first exhaust hole, 5-second exhaust hole, 6-exhaust channel. DETAILED DESCRIPTION

[0018] The present invention will be further described below in conjunction with the accompanying drawings.

[0019] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0020] On the contrary, the present invention covers any substitution, modification, equivalent method and scheme made on the essence and scope of the present invention as defined by the claims. Further, in order to make the public have a better understanding of the present invention, some specific details are described in detail in the detailed description of the present invention below. Those skilled in the art can fully understand the present invention without the description of these details.

[0021] like Figure 1 A method for manufacturing a motor rotor is shown, and the manufacturing method includes the following steps: first, a rotor core is made. Silicon steel sheets are selected as raw materials, and the silicon steel sheets are placed in a punching machine for punching to form rotor punching sheets, and the rotor punching sheets are stacked and pressed and fixed in sequence to form a rotor core. The initial stacking height of the rotor punching sheets can be 1.1 or 1.2 times the height of the finished product, so that after being pressed and fixed, the height of the motor rotor can be guaranteed to meet the product requirements. The fixing method of the rotor punching sheets can be selected by welding with a welding gun or by connecting with nails, and the welding can be argon arc welding or laser welding.

[0022] Secondly, assembling accessories in the manufactured rotor core, that is, installing the rotating shaft in the axial slot extending axially through the center of the rotor core, and inserting guide bars in sequence into the axially extending rotor slots formed in the circumferential direction of the rotor core to manufacture the rotor. The guide bars are made of copper material, and the length of the guide bars is the same as the length of the rotor slots.

[0023] Afterwards, the end ring blank is manufactured and assembled. Aluminum plate is selected as the raw material, and the aluminum plate is placed in a punching machine for punching to form a circular end ring blank. The end ring blank is installed at both ends of the rotor. The diameter of the end ring blank is larger than the diameter of the finished end ring.

[0024] Since there are many pores and bubbles in the aluminum plate, there will also be many pores and bubbles in the end ring made of it, which makes the quality of the end ring poor. If it is not processed, it will affect the use of the motor rotor. Therefore, it needs to be vented.

[0025] like Figure 1 and Figure 2As shown, the first step of the exhaust step is to heat the rotor end ring, and transfer the rotor to a steel magnetic conductive material cavity wrapped by a high-frequency heating ring to heat the rotor end ring. The heating time is set to 4 minutes, and the heating temperature can be set to 450°C, 500°C or 650°C, so that the rotor end ring is in a molten state; the second step of the exhaust step is to extrude the rotor end ring, and transfer the heated rotor to an extruder. Under the drive of the first driving mechanism, the first shaping mold 1 presses the rotor end ring to extrude and shape the rotor end ring in a molten state. The pressure of the first shaping mold 1 can be adjusted to 20T, 35T or 40T according to the actual end ring size.

[0026] like Figures 2 to 4 As shown, the first shaping die 1 is provided with grooves 2 corresponding to the end rings and through holes 3 connected to the grooves 2, and the shaft can pass through the through holes 3. The inner wall of the groove 2 is provided with first exhaust holes 4 along its axial direction, and the inner wall of the through hole 3 is provided with second exhaust holes 5 along the circumferential direction. The first exhaust holes 4 are connected to the second exhaust holes 5, and an exhaust channel 6 is formed between the first exhaust holes 4 and the second exhaust holes 5. During the extrusion process of the first shaping die 1, the bubbles in the rotor end ring can be discharged through the exhaust channel 6.

[0027] The rotor that has been shaped, extruded and exhausted is taken out of the extruder, and the burrs of the rotor are removed after the rotor end ring is cooled and shaped.

[0028] As a solution, the end rings at both ends of the rotor can be heated and extruded at the same time, that is, the rotor core part is clamped by a robot, and the rotor is transferred to a high-frequency heating circle for synchronous heating of the end rings at both ends, and then transferred to the extruder. The first shaping mold 1 is set in two, and under the drive of the first driving mechanism, the end rings at both ends of the rotor are synchronously pressed, and the two end rings are extruded, shaped and exhausted.

[0029] As another solution, the end rings at both ends of the rotor need to be heated and extruded separately. First, the lower end ring of the rotor is placed in the second shaping mold. Under the drive of the second driving mechanism, the rotor is transferred to the high-frequency heating circle, and the upper end ring of the rotor is heated to make it in a molten state. Then, under the drive of the third driving mechanism, the second shaping mold drives the rotor to move into the extruder. Under the drive of the first driving mechanism, the first shaping mold 1 presses the upper end ring of the rotor, extrude and shape the upper end ring of the rotor in a molten state, and discharges the pores and bubbles in the upper end ring of the rotor.

[0030] Afterwards, the rotor is taken out of the extruder by a robot, and the rotor is turned 180° to exchange the positions of the upper and lower end rings of the rotor. The upper end ring of the rotor that has been shaped, exhausted and cooled and finalized is placed in the second shaping mold, and the above steps are repeated, that is, under the drive of the second driving mechanism, the rotor is transferred to the high-frequency heating circle again, and the lower end ring of the rotor is heated to be in a molten state. Under the drive of the third driving mechanism, the second shaping mold drives the rotor to move into the extruder. Under the drive of the first driving mechanism, the first shaping mold 1 presses the lower end ring of the rotor, extrude and shape the lower end ring of the rotor in a molten state, and discharges the bubbles in the lower end ring of the rotor.

[0031] like Figure 1 As shown in the figure, after the motor rotor is manufactured, the dynamic balance of the rotor needs to be adjusted. The rotor is placed in a balancing machine for testing. The unbalance of the rotor is corrected according to the data measured by the balancing machine, so that the vibration generated when the rotor rotates is reduced to within the allowable range, and the manufacturing of the entire motor rotor is completed. The correction method can be the weight reduction method, which uses a drill to drill holes in the rotor end ring of the out-of-tolerance part to reduce the offset and reach the balance value.

[0032] The above describes the embodiments of the present invention in detail in conjunction with the accompanying drawings, but the present invention is not limited to the above embodiments. For ordinary technicians in this field, several modifications and improvements can be made without departing from the present invention, and these should also be regarded as belonging to the protection scope of the present invention.

Claims

1. A method for manufacturing a motor rotor, characterized in that: The manufacturing method comprises the following steps: Step 1: Make the rotor core, select silicon steel sheets as raw materials, place the silicon steel sheets in a punching machine for punching, form rotor punching sheets, stack the rotor punching sheets in sequence and press them to make the rotor core; Step 2: Assemble the rotor core accessories, install the rotating shaft in the shaft groove that penetrates axially in the center of the rotor core, insert the guide bars in turn in the rotor grooves that penetrate axially formed in the circumferential direction of the rotor core, and make the rotor, wherein the guide bars are made of copper material, and the length of the guide bars is the same as the length of the rotor groove; Step 3: Make and assemble the end ring blank, select aluminum plate as the raw material, place the aluminum plate in a punching machine for punching, form a circular end ring blank, and install the end ring blank at both ends of the rotor. The diameter of the end ring blank is larger than the diameter of the finished end ring; Step 4: Heat the rotor end ring. Move the rotor into the steel magnetic conductive material cavity wrapped by the high-frequency heating ring to heat the rotor end ring. The heating time is set to 3-8 minutes and the heating temperature is set to 400-650°C to make the rotor end ring in a molten state. Step 5: Extruding the rotor end ring, transferring the rotor heated in step 4 into an extruder, and under the drive of the first drive mechanism, the first shaping die (1) presses the rotor end ring to extrude and shape the rotor end ring in a molten state, the pressure of the first shaping die (1) being set at 20-40T, and the bubbles in the rotor end ring are discharged through the exhaust channel (6) of the first shaping die (1); Step 6: Remove the rotor from the extruder, and remove the rotor burrs after the rotor end ring cools and sets; Step 7: Adjust the dynamic balance of the rotor. Place the rotor in step 6 in a balancing machine for testing. Correct the imbalance of the rotor based on the data measured by the balancing machine to reduce the vibration generated when the rotor rotates to within the allowable range, thus completing the manufacturing of the entire motor rotor product.

2. The method for manufacturing a motor rotor according to claim 1, characterized in that: The first shaping mold (1) in step five is provided with a groove (2) corresponding to the end ring and a through hole (3) connected to the groove (2); the inner wall of the groove (2) is provided with a first exhaust hole (4) along its axial direction; the inner wall of the through hole (3) is provided with a second exhaust hole (5) along the circumferential direction; the first exhaust hole (4) is connected to the second exhaust hole (5), and an exhaust channel (6) is formed between the first exhaust hole (4) and the second exhaust hole (5).

3. The method for manufacturing a motor rotor according to claim 1, characterized in that: In the step 4, the lower end ring of the rotor is placed in the second shaping mold, and the rotor is moved into the high-frequency heating ring under the drive of the second driving mechanism to heat the upper end ring of the rotor to put it in a molten state.

4. The method for manufacturing a motor rotor according to claim 3, characterized in that: In step five, the second shaping die drives the rotor to move into the extruder under the drive of the third driving mechanism, and the first shaping die (1) presses the upper end ring of the rotor under the drive of the first driving mechanism, extrude and shape the upper end ring of the rotor in a molten state, and discharges pores and bubbles in the upper end ring of the rotor.

5. The method for manufacturing a motor rotor according to claim 4, characterized in that: In step six, the rotor is taken out of the extruder by a robot and turned 180 degrees. The upper end ring of the rotor that has been shaped, exhausted and cooled and fixed is placed in a second shaping die. Under the drive of the second driving mechanism, the rotor is transferred to the high-frequency heating circle again to heat the lower end ring of the rotor so that it is in a molten state. Under the drive of the third driving mechanism, the second shaping die drives the rotor to move into the extruder. Under the drive of the first driving mechanism, the first shaping die (1) presses the lower end ring of the rotor to extrude and shape the lower end ring of the rotor in a molten state, and discharges the bubbles in the lower end ring of the rotor.

6. The method for manufacturing a motor rotor according to claim 1, characterized in that: In step 1, the rotor punching is fixed by welding after being pressed.

7. The method for manufacturing a motor rotor according to claim 1, characterized in that: Step 1: After the rotor punching is compressed, it is fixed by nailing.

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