A new motor rotor sheath winding system

Abstract

The present invention discloses a novel motor rotor sheath winding system, which belongs to the technical field of motor rotor winding molding process, including a prepreg unwinding device, a drive rewinding device, a tension control device, a film unwinding device, a motor rotor winding platform, a loading and unloading manipulator, and a curing oven. The present invention addresses the problems of existing winding devices being complex and poorly adaptable, not matching the winding process, high resin waste rate, and low fiber tension, and simultaneously achieves efficient and environmentally friendly high-tension precision winding. By adopting a guide wheel made of non-stick material, the risk of friction and fuzzing of the prepreg is reduced. By using a folding unwinding control structure, the width of the prepreg is stabilized. By using a drive rewinding structure and a tension control structure, the prepreg can be wound onto the motor rotor at high speed and with ultra-high constant tension.

Description

Technical Field

[0001] The present invention relates to the technical field of motor rotor winding forming technology, and more particularly to a novel motor rotor sheath winding system. Background Art

[0002] Winding is a process used to manufacture fiber-reinforced composites, typically used to produce cylindrical structural components. The core of the winding process involves wrapping fiber material around a mold in a specific pattern to form composite components, such as motor winding rotors, pressure cylinders, and composite pipes. These components are widely used in aerospace, automotive, sports equipment, wind power generation, and other new energy applications.

[0003] The traditional manufacturing process for motor rotors involves individually winding, drying, demolding, and processing the outer surface carbon fiber sheath into components. The formed carbon fiber sheath is then placed over the motor rotor. This method is complex, polluting, and requires high precision when assembling the formed sheath to the motor rotor, leading to significant damage to the sheath during installation. This leads to high costs and reduced strength for the finished motor rotor sheath. A new manufacturing process for motor rotors involves directly wrapping carbon fiber around the rotor to form the motor rotor carbon fiber sheath.

[0004] The existing technology is a wet winding process, in which the fiber is released through a creel, enters an impregnation device, and then is wound on a motor rotor, and finally heated and cured. Although the existing method has largely solved the problem of high installation accuracy of the sheath and the motor rotor in the traditional process, the fiber is easily brought out with the resin after entering the impregnation device, resulting in resin waste. Therefore, the winding speed is generally slow. At the same time, the solvent or low-boiling point component in the resin system is prone to form defects such as bubbles and voids during curing, affecting the molding quality and the performance of the final product. In addition, it also has an adverse effect on personnel health, equipment maintenance and environmental protection. In the existing winding process, since the resin content of the product is difficult to control and inspect during the winding process, the tension applied to the fiber is also difficult to control. Since the motor rotor sheath requires high strength, this method is not easy to achieve the tension value required for the production of the motor rotor. In order to solve the shortcomings of traditional processes and existing processes, the present invention designs a new winding method for a sheathed motor rotor. Summary of the Invention

[0005] Technical problems to be solved

[0006] To address the challenges of the prior art, the present invention aims to provide a novel motor rotor sheath winding system. This system addresses the complex and poorly adapted winding devices, mismatched winding processes, high resin waste, and low fiber tension, while simultaneously achieving efficient, environmentally friendly, and high-tension precision winding. The use of a guide pulley made of a non-stick material reduces the risk of friction and fuzzing of the prepreg tape. A folding and unwinding control structure stabilizes the prepreg tape's width. By driving the rewinding mechanism and tension control structure, the prepreg tape can be wound onto the motor rotor at high speed and with ultra-high, constant tension.

[0007] Technical Solution

[0008] In order to solve the above problems, the present invention adopts the following technical solutions:

[0009] A novel motor rotor sheath winding system includes a prepreg unwinding device, a drive rewinding device, a tension control device, a film unwinding device, a motor rotor winding platform, a loading and unloading robot and a curing oven. Aluminum alloy doors and windows are arranged on the outside of the prepreg unwinding device. The prepreg unwinding device is arranged on the right side of the film unwinding device, the drive rewinding device is arranged on the upper side of the film unwinding device, the tension control device is arranged on the left side of the drive rewinding device, the motor rotor winding platform is arranged on the left side of the tension control device, and the loading and unloading robot is arranged on the outside of the motor rotor winding platform. The prepreg unwinding device, the drive rewinding device, the tension control device, the film unwinding device, the motor rotor winding platform, the loading and unloading robot and the curing oven are all arranged inside the aluminum alloy doors and windows.

[0010] As a preferred solution of the present invention, the prepreg unwinding device includes an unwinding spindle, a spindle tensioning rubber ring, a friction disk, a spindle fixed shaft, a friction belt, a tension spring and an adjusting screw. The unwinding spindle, the spindle tensioning rubber ring and the friction disk are all installed on the spindle fixed shaft, the friction belt is installed on the friction disk, and the tension spring and the adjusting screw are both connected to the friction belt.

[0011] As a preferred solution of the present invention, the drive rewinding device includes a drive roller, a drive roller mounting seat, a synchronous gear, a drive motor, a passive roller, a spherical flange seat and a wire bundle, the drive roller is mounted on the drive roller mounting seat, the synchronous gear is mounted on the drive roller mounting seat, the passive roller is arranged on the right side of the drive roller, the wire bundle is wound around the drive roller and the passive roller, the spherical flange seat is mounted on the upper side of the passive roller, and the synchronous gear is mounted on the output end of the drive motor.

[0012] As a preferred solution of the present invention, the tension control device includes a motor rotor, a pneumatic tailstock, a pneumatic claw, a rotor drive motor, a front end winding reciprocating motor and a front end winding connecting plate. The motor rotor, pneumatic tailstock, pneumatic claw, rotor drive motor, front end winding reciprocating motor and front end winding connecting plate are all arranged in aluminum alloy doors and windows, the motor rotor is arranged between the pneumatic tailstock and the pneumatic claw, the front end winding reciprocating motor is connected to the front end winding connecting plate, and the rotor drive motor is connected to the belt.

[0013] As a preferred solution of the present invention, a front-end winding assembly fixing frame is provided on the outside of the prepreg tape unwinding device, and the prepreg tape unwinding device, drive rewinding device, tension control device and film unwinding device are all installed on the front-end winding assembly fixing frame.

[0014] As a preferred solution of the present invention, a floating control screen is installed on the aluminum alloy doors and windows.

[0015] As a preferred solution of the present invention, the prepreg unwinding device adopts a folding unwinding structure.

[0016] Beneficial effects

[0017] Compared with the prior art, the advantages of the present invention are:

[0018] (1) In this solution, the new sheath winding machine is a single-spindle prepreg winding machine, which includes the winding function of the prepreg and film to the motor rotor, as well as the automatic disassembly and assembly after the motor rotor is formed, and the heating and curing function, which can realize the continuous production of motor rotor sheath winding molding as a whole. The modified equipment can achieve a maximum of 120KG constant tension winding and 80m / min high-speed winding, and the prepreg tension and wire width are always kept constant, without sliding friction and fuzzing, and the maximum speed is 80m / min. It provides a guarantee for the continuous, automated and stable production of high-tension, high-speed motor rotors.

[0019] (2) In this proposal, in order to address the shortcomings of traditional and existing processes, a new winding method for sheathed motor rotors is designed. This method prepares prepreg tapes in advance and then directly winds the prepreg tapes onto the motor sleeve rotor. Since the prepreg tapes are professionally produced, the resin content and thus the quality of the prepreg yarn can be precisely controlled, and the mechanical properties of the cured product have a smaller variation. Compared with existing processes, this winding method can achieve a higher winding speed, improve the production efficiency of components, and the winding speed can reach up to 100m / min. The working environment is clean and tidy, there is no resin flow and waste, and the operator can reduce the inhalation of toxic substances in the environment. At the same time, the quality and performance of the molded products can be better guaranteed.

[0020] (3) In this scheme, the selection of winding molding process parameters has a great influence on the performance of composite products. In order to improve the performance of winding molding composite materials, it is particularly important to optimize its main process parameters. The control of winding tension is an important process parameter in the winding process. The purpose is to make the fibers neatly and evenly wound onto the core mold, thereby ensuring the uniformity of tension between each fiber and each winding layer, and giving full play to the strength of carbon fiber. This winding method can increase higher tension, with a maximum tension of up to 120KG, thereby improving the strength of the motor rotor.

[0021] (4) This solution addresses the problems of existing winding devices, such as complexity and poor adaptability, mismatch with winding processes, high resin waste rate, and low fiber tension, while achieving efficient and environmentally friendly high-tension precision winding. By using a guide wheel made of non-stick material, the risk of friction and fuzzing of the prepreg tape is reduced. By using a folding and releasing wire control structure, the width of the prepreg tape is stabilized. By driving the rewinding structure and tension control structure, the prepreg tape can be wound onto the motor rotor at high speed and with ultra-high constant tension. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0023] Figure 2 Schematic diagram of a curing oven according to the present invention;

[0024] Figure 3 This is a schematic structural diagram of the prepreg unwinding device of the present invention;

[0025] Figure 4 Schematic diagram of the structure of the driving rewinding device of the present invention;

[0026] Figure 5 is a first schematic diagram of the tension control device of the present invention;

[0027] Figure 6 This is a second schematic diagram of the tension control device of the present invention.

[0028] Description of the numbers in the figure:

[0029] 1. Prepreg unwinding device; 101. Unwinding spindle; 102. Spindle tensioning rubber ring; 103. Friction disc; 104. Spindle fixing shaft; 105. Friction belt; 106. Tension spring; 107. Adjusting screw; 2. Drive rewinding device; 201. Drive roller; 202. Drive roller mounting seat; 203. Synchronous gear; 204. Drive motor; 205. Passive roller; 206. Spherical flange seat; 207. Fiber bundle; 3. Tension control device; 301. Motor rotor; 302. Pneumatic tailstock; 303. Pneumatic clamping claw; 304. Rotor drive motor; 305. Front-end winding reciprocating motor; 306. Front-end winding connecting plate; 4. Film unwinding device; 5. Motor rotor winding platform; 6. Loading and unloading robot; 7. Curing oven; 8. Suspended control panel; 9. Aluminum alloy doors and windows; 10. Front-end winding component fixing frame. DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are also within the scope of protection of the present invention.

[0031] Example:

[0032] See also Figure 1-6 A new type of motor rotor sheath winding system includes a prepreg unwinding device 1, a drive rewinding device 2, a tension control device 3, a film unwinding device 4, a motor rotor winding platform 5, a loading and unloading robot 6 and a curing oven 7. Aluminum alloy doors and windows 9 are arranged on the outside of the prepreg unwinding device 1. The prepreg unwinding device 1 is arranged on the right side of the film unwinding device 4, the drive rewinding device 2 is arranged on the upper side of the film unwinding device 4, the tension control device 3 is arranged on the left side of the drive rewinding device 2, the motor rotor winding platform 5 is arranged on the left side of the tension control device 3, and the loading and unloading robot 6 is arranged on the outside of the motor rotor winding platform 5. The prepreg unwinding device 1, the drive rewinding device 2, the tension control device 3, the film unwinding device 4, the motor rotor winding platform 5, the loading and unloading robot 6 and the curing oven 7 are all arranged in the aluminum alloy doors and windows 9.

[0033] In this embodiment, the sheath motor rotor winding system is composed of a prepreg unwinding device, a drive rewinding device, a tension control device, a film unwinding device, a motor rotor winding platform, a loading and unloading robot, and a curing oven. The prepreg unwinding device includes a unwinding spindle and a friction belt. The friction belt provides initial tension during the prepreg unwinding process; the drive rewinding device includes a set of driving rollers, a set of passive rollers, etc., which are used to provide driving force for the filament bundle to move forward and give the filament bundle an increased tension value; the tension control device is composed of a weighing sensor and a guide wheel to control the tension value of the filament bundle winding process; the film unwinding device includes a unwinding spindle and a friction belt. The friction belt provides initial tension during the film unwinding process; the motor rotor winding platform includes an electronic rotor fixing and rotating device and a reciprocating drive device of the front-end winding assembly; the loading and unloading robot is composed of a robot and a robot moving guide rail. The robot is used for automatic loading and unloading of the motor rotor, and the robot moving guide rail transfers the formed motor rotor to the curing oven; the curing oven is used for heating and curing the motor rotor sheath after forming;

[0034] Furthermore, the prepreg unwinding device adopts a folding unwinding structure, with the unwinding axis parallel to the wire path. This allows the tow to offset the reciprocating movement during the unwinding process, reducing friction and fuzzing of the prepreg and ensuring uniform wire width throughout the unwinding process.

[0035] Furthermore, the curing oven can store multiple groups of wound motor sheath rotors at the same time, with a uniform and adjustable temperature to complete the heating and curing of the motor rotor sheath;

[0036] Furthermore, the front-end winding assembly and the motor rotor winding platform are installed on an integral frame. The frame adopts an aluminum alloy glass door and window structure to facilitate personnel observation. At the same time, it forms a closed structure to isolate the possible carbon fiber dust from damaging human health.

[0037] Furthermore, the reciprocating drive device of the front-end winding assembly connects the winding assembly consisting of the front-end prepreg tape unwinding device, the drive rewinding device, the tension control device, and the film unwinding yarn rack to the motor rotor winding platform, thereby completing the horizontal winding of the prepreg tape and the film on the motor rotor.

[0038] Specifically, the prepreg unwinding device 1 includes an unwinding spindle 101, a spindle tensioning rubber ring 102, a friction disk 103, a spindle fixing shaft 104, a friction belt 105, a tension spring 106 and an adjusting screw 107. The unwinding spindle 101, the spindle tensioning rubber ring 102 and the friction disk 103 are all installed on the spindle fixing shaft 104, the friction belt 105 is installed on the friction disk 103, and the tension spring 106 and the adjusting screw 107 are both connected to the friction belt 105.

[0039] In this embodiment, the friction disc 103 generates mutual friction with the friction belt 105 to give the prepreg an initial tension. By adjusting the screw 107, the tension spring 106 generates different tensions, so that the friction force between the friction disc 103 and the friction belt 105 changes, thereby adjusting the tension value of the prepreg.

[0040] Specifically, the drive rewinding device 2 includes a drive roller 201, a drive roller mounting seat 202, a synchronous gear 203, a drive motor 204, a passive roller 205, a spherical flange seat 206 and a filament bundle 207. The drive roller 201 is installed on the drive roller mounting seat 202, the synchronous gear 203 is installed on the drive roller mounting seat 202, the passive roller 205 is arranged on the right side of the drive roller 201, the filament bundle 207 is wound on the drive roller 201 and the passive roller 205, the spherical flange seat 206 is installed on the upper side of the passive roller 205, and the synchronous gear 203 is installed at the output end of the drive motor 204.

[0041] In this embodiment, the tow 207 is wound back and forth between the driving roller 201 and the passive roller 205 to obtain a high tension value. The driving roller 201 is mounted on the driving roller mounting seat 202 and rotated by the synchronous gear 203 and the driving motor 204. The passive roller 205 is mounted on the spherical flange seat 206. The spherical flange seat 206 can form a fixed angle between the passive roller 205 and the driving roller 201. This angle allows the tow 207 to wind back and forth between the two rollers to maintain a stable path.

[0042] Furthermore, the tow is wound back and forth between the driving roller and the passive roller, and the tow will obtain a larger tension. The tension range of the tow can be controlled by controlling the number of winding turns.

[0043] Furthermore, the driving roller and the passive roller are coated with Teflon anti-stick coating to prevent the prepreg tape from sticking to the roller surface;

[0044] Furthermore, a load cell detects the current tension of the tow and works in conjunction with the motor's rotor fixing and rotating mechanism to precisely control the tow tension. The detected tension value is displayed as a curve on the screen, allowing tension fluctuations to be observed.

[0045] Specifically, the tension control device 3 includes a motor rotor 301, a pneumatic tailstock 302, a pneumatic clamping claw 303, a rotor driving motor 304, a front end winding reciprocating motor 305 and a front end winding connecting plate 306. The motor rotor 301, the pneumatic tailstock 302, the pneumatic clamping claw 303, the rotor driving motor 304, the front end winding reciprocating motor 305 and the front end winding connecting plate 306 are all arranged in the aluminum alloy door and window 9. The motor rotor 301 is arranged between the pneumatic tailstock 302 and the pneumatic clamping claw 303, the front end winding reciprocating motor 305 is connected to the front end winding connecting plate 306, and the rotor driving motor 304 is connected to the belt.

[0046] In this embodiment, after the loading and unloading robot 6 clamps the motor rotor 301 to the position shown in the figure, the pneumatic tailstock 302 and the pneumatic clamping claw 303 are tightened at the same time to complete the fixation of the motor rotor 301. The motor rotor 301 fixing device is connected to the rotor drive motor 304 through a belt, which drives the rewinding device 2 to rotate and drive the motor rotor 301 to rotate axially;

[0047] The prepreg unwinding device 1, the drive rewinding device 2, the tension control device 3 and the film unwinding device 4 are all installed on the front winding assembly fixed frame 10, and the front winding assembly fixed frame 10 is further connected to the front winding reciprocating motor 305 through the front winding connecting plate 306;

[0048] The entire winding equipment forms an integrated structure. The front-end winding reciprocating motor 305 controls the horizontal movement of the entire front-end winding system;

[0049] Furthermore, the motor rotor fixing device is used to fix the motor rotor during the winding process, with a pneumatic clamping claw on one side and a pneumatic tailstock on the other side. The pneumatic control system completes the automatic installation, fixation and disassembly of the motor rotor.

[0050] Furthermore, the motor rotor rotating device is used for axial rotation of the motor rotor during the winding process, and adopts a servo system to accurately control the rotation speed of the rotor.

[0051] Specifically, a front-end winding assembly fixed frame 10 is provided on the outside of the prepreg tape unwinding device 1, and the prepreg tape unwinding device 1, the drive rewinding device 2, the tension control device 3 and the film unwinding device 4 are all installed on the front-end winding assembly fixed frame 10.

[0052] In this embodiment, a front-end winding assembly fixed frame 10 is provided on the outside of the prepreg tape unwinding device 1, and the prepreg tape unwinding device 1, the drive rewinding device 2, the tension control device 3 and the film unwinding device 4 are all installed on the front-end winding assembly fixed frame 10, so that the entire winding equipment forms an integrated structure, and the front-end winding reciprocating motor 305 controls the horizontal movement of the entire front-end winding system.

[0053] Specifically, a floating control screen 8 is installed on the aluminum alloy door and window 9.

[0054] In this embodiment, a floating control screen 8 is installed on the aluminum alloy door and window 9.

[0055] Specifically, the prepreg unwinding device 1 adopts a folding unwinding structure.

[0056] In this embodiment, the prepreg unwinding device 1 adopts a folding unwinding structure.

[0057] Working Principle: To address the shortcomings of traditional and existing processes, a novel winding method for sheathed motor rotors has been designed. This method utilizes prepreg tape, which is then directly wound onto the motor sleeve rotor. Because the prepreg tape is professionally manufactured, the resin content and, consequently, the quality of the prepreg yarn, can be precisely controlled, resulting in minimal variation in the mechanical properties of the cured product. Compared to existing processes, this winding method achieves higher winding speeds, up to 100 m / min, improving component production efficiency. The work environment is clean and tidy, with no resin waste, reducing operator exposure to toxic substances. Furthermore, the quality and performance of the finished product are better guaranteed. The new sheath winding machine utilizes a single spindle for prepreg winding, integrating prepreg tape and film onto the motor rotor, as well as automated assembly and disassembly after rotor formation, and heating and curing functions, enabling continuous production of motor rotor sheath winding. The modified equipment can achieve a maximum winding speed of 80 m / min, with a maximum tension of 120 kg and a maximum winding speed of 80 m / min. The prepreg tension and yarn width remain constant, eliminating friction and fuzzing. It provides a guarantee for the continuous, automated and stable production of high-tension and high-speed motor rotors.

[0058] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes based on the technical solutions and improved concepts of the present invention within the technical scope disclosed by the present invention, and these changes should be covered by the scope of protection of the present invention.

Claims

1. A novel motor rotor sheath winding system, comprising a prepreg unwinding device (1), a drive rewinding device (2), a tension control device (3), a film unwinding device (4), a motor rotor winding platform (5), a loading and unloading manipulator (6) and a curing oven (7), characterized in that: An aluminum alloy door and window (9) is provided on the outside of the prepreg tape unwinding device (1); the prepreg tape unwinding device (1) is provided on the right side of the film unwinding device (4); the drive rewinding device (2) is provided on the upper side of the film unwinding device (4); the tension control device (3) is provided on the left side of the drive rewinding device (2); the motor rotor winding platform (5) is provided on the left side of the tension control device (3); the loading and unloading manipulator (6) is provided on the outside of the motor rotor winding platform (5); the prepreg tape unwinding device (1), the drive rewinding device (2), the tension control device (3), the film unwinding device (4), the motor rotor winding platform (5), the loading and unloading manipulator (6) and the curing oven (7) are all provided inside the aluminum alloy door and window (9); The prepreg unwinding device (1) comprises an unwinding spindle (101), a spindle tightening rubber ring (102), a friction disc (103), a spindle fixed shaft (104), a friction belt (105), a tension spring (106) and an adjusting screw (107); the unwinding spindle (101), the spindle tightening rubber ring (102) and the friction disc (103) are all mounted on the spindle fixed shaft (104); the friction belt (105) is mounted on the friction disc (103); and the tension spring (106) and the adjusting screw (107) are both connected to the friction belt (105); The drive rewinding device (2) comprises a drive roller (201), a drive roller mounting seat (202), a synchronous gear (203), a drive motor (204), a passive roller (205), a spherical flange seat (206) and a filament bundle (207); the drive roller (201) is mounted on the drive roller mounting seat (202); the synchronous gear (203) is mounted on the drive roller mounting seat (202); the passive roller (205) is arranged on the right side of the drive roller (201); the filament bundle (207) is wound around the drive roller (201) and the passive roller (205); the spherical flange seat (206) is mounted on the upper side of the passive roller (205); and the synchronous gear (203) is mounted on the output end of the drive motor (204); The tension control device (3) comprises a motor rotor (301), a pneumatic tailstock (302), a pneumatic clamping claw (303), a rotor driving motor (304), a front-end winding reciprocating motor (305) and a front-end winding connecting plate (306); the motor rotor (301), the pneumatic tailstock (302), the pneumatic clamping claw (303), the rotor driving motor (304), the front-end winding reciprocating motor (305) and the front-end winding connecting plate (306) are all arranged in the aluminum alloy door and window (9); the motor rotor (301) is arranged between the pneumatic tailstock (302) and the pneumatic clamping claw (303); the front-end winding reciprocating motor (305) is connected to the front-end winding connecting plate (306); and the rotor driving motor (304) is connected to a belt; A front-end winding assembly fixing frame (10) is provided on the outside of the prepreg tape unwinding device (1), and the prepreg tape unwinding device (1), the drive rewinding device (2), the tension control device (3) and the film unwinding device (4) are all mounted on the front-end winding assembly fixing frame (10).

2. A novel motor rotor sheath winding system according to claim 1, characterized in that: A suspension control screen (8) is installed on the aluminum alloy door and window (9).

3. A novel motor rotor sheath winding system according to claim 2, characterized in that: The prepreg unwinding device (1) adopts a folding unwinding structure.

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