Manufacturing process of high-rotating-speed rotor for automobile starter

Abstract

The invention discloses a manufacturing process of a high-rotating-speed rotor for an automobile starter, relates to the related technical field of rotor manufacturing, and aims to solve the problems that in the prior art, no insulation operation is carried out on other contact positions of a rotor iron core and a copper wire, the contact position of the copper wire itself and the like, so that current directly flows without passing through a preset circuit path, and the reliability of the rotor is influenced. And short circuit is avoided. Laminating the silicon steel sheets to form a rotor core, and uniformly arranging wire slots on the periphery of the rotor core; inserting the rotor shaft into the hole part of the rotor iron core and fixing the rotor shaft; placing an insulating sheet; inserting a plurality of pieces of insulation paper into each wire slot; the method comprises the following steps of: sleeving a plurality of insulating sleeves at the external bending position of a copper bar, and then obliquely inserting two pins of the copper bar into different wire slots to form an inner-layer pin and an outer-layer pin; bending the pins; insulating paper is stacked and inserted into the outer part of each inner-layer pin; installing a commutator; fixing the winding group; and turning and coating.

Description

Technical Field

[0001] The present invention relates to the technical field related to rotor manufacturing, and specifically to a manufacturing process for a high-speed rotor used in an automotive starter. Background Art

[0002] As a key component in the modern automotive power system, an automotive starter undertakes the important function of converting electrical energy into mechanical energy to drive the engine crankshaft to rotate and achieve engine starting. Since the birth of the electric starter, starter technology has undergone continuous innovation and optimization, greatly improving the driving convenience and safety. A traditional automotive starter generally consists of a motor, a transmission mechanism, an electromagnetic switch, etc. Among them, the motor generates torque through current drive, and the transmission mechanism is responsible for transmitting this torque to the engine crankshaft to start the engine. In an automotive starter, the rotor, as the core component of the motor, its performance directly determines the efficiency and reliability of the starter. With the rapid development of the automotive industry and the continuous improvement of consumers' requirements for automotive performance, higher requirements are put forward for aspects such as the rotational speed, torque output, and durability of the starter rotor. A high-speed rotor can provide a larger starting torque in a short time, ensuring that the engine can start quickly and smoothly under various conditions. In addition, a high-speed rotor can effectively reduce the volume and weight of the starter, reduce energy consumption, and improve the fuel economy of the whole vehicle.

[0003] In recent years, with the rise of new energy vehicles and the continuous expansion of the electric vehicle market, the requirements for starter rotors have been further improved. The motors of electric vehicles need to start and stop frequently, and require quick start and sensitive response, which all put higher requirements on the design and manufacturing process of starter rotors. For example, in the Chinese authorized patent with the publication number CN 107465283 B (a high-speed rotor for an automotive starter and its manufacturing method), the armature assembly and the commutator are sequentially installed in the middle of the armature shaft. The armature assembly is formed by pressing multiple armature sheets together. Heat dissipation holes are evenly arranged in a ring shape in the middle of the armature sheet. The copper wire is wound in a staggered manner for 4 layers in the winding groove. The closed part of the armature sheet encloses the copper wire in the winding groove. The protrusion at the end of the armature sheet forms a closed part after rolling. The closed part restricts the copper wire in the winding groove. There are U-shaped grooves with the same number as the winding grooves on the outer circumference of the commutator. The starting end and the terminating end of the copper wire are stacked in the U-shaped grooves. There is solidified 8411 solventless epoxy resin paint in the gaps between the copper wires and between the copper wire and the winding groove.

[0004] In the above prior art, the insulation treatment for the rotor is insufficient. There are mainly insulating sheets in the U-shaped grooves of the commutator and insulating paper between the winding groove and the copper wire. However, there is no insulation operation at other contact positions between the rotor core and the copper wire, and between the copper wire and itself, which may cause the current to flow directly without passing through the predetermined circuit path, resulting in a short circuit. Summary of the Invention

[0005] The purpose of the present invention is to provide a manufacturing process for a high-speed rotor for an automotive starter, so as to solve the problem that there is no insulation operation at other contact positions between the rotor core and the copper wire, and the contact positions of the copper wire with itself, etc., which will cause the current to flow directly without passing through the predetermined circuit path, thus resulting in a short circuit.

[0006] To achieve the above purpose, the present invention provides the following technical solution: A manufacturing process for a high-speed rotor for an automotive starter, including the following steps:

[0007] S1: Stack silicon steel sheets to form a rotor core, and evenly open wire grooves on the periphery of the rotor core;

[0008] S2: Insert the rotor shaft into the hole of the rotor core and fix it;

[0009] S3: Place two insulating sheets with holes in the middle and on the periphery on both sides of the rotor core;

[0010] S4: Overlap multiple insulating papers end to end to form a ring structure, and insert it into each wire groove;

[0011] S5: First, put multiple insulating sleeves on the external bending positions of the copper bars, and then obliquely insert the two pins of the copper bars into different wire grooves to form inner-layer pins and outer-layer pins;

[0012] S6: Use a pin bending device to bend the two pins of the copper bar in opposite directions;

[0013] S7: Stack the insulating papers into a ring and insert it outside each inner-layer pin;

[0014] S8: Install the commutator. First, insert the inner-layer pins into the commutator grooves, then stack the insulating papers into a ring and insert them between the inner-layer pins and the outer-layer pins. Then, insert the outer-layer pins into the commutator grooves, and finally weld the copper bars and the commutator;

[0015] S9: Put two fixing rings on both outer sides of the winding group formed by the copper bars and fix them under pressure;

[0016] S10: Machine the outer surface and end face of the formed rotor to make the outside flat;

[0017] S11: Coat with an anti-rust coating, and then coat with an insulating coating after drying.

[0018] Preferably, the pin bending device includes an installation bracket. In the middle of the rear end of the upper end of the installation bracket, a fixed vertical frame is welded and fixed. A limit sliding block slides up and down in the fixed vertical frame. The front end of the limit sliding block is integrally connected with a front support plate. On one side of the upper end of the front support plate, an outer fixed limit ring is integrally connected;

[0019] A rear support plate is integrally connected to the rear end of the limit sliding block. A second driving motor is installed at the upper end of the rear support plate. A second gear is installed at the output shaft end of the second driving motor. A first gear is meshed and connected to the front end of the second gear. A second transmission wheel is coaxially connected to the outside of the second gear. A first transmission wheel is arranged at the front end of the second transmission wheel. The second transmission wheel and the first transmission wheel are connected by a transmission belt. A third gear is coaxially connected to the side of the first transmission wheel close to the front support plate.

[0020] The pin bending device further includes an outer bending unit. The outer bending unit includes an outer bending ring. The outer bending ring is located inside the outer fixed limit ring and is rotationally connected to the outer fixed limit ring through a bearing. A first connection ring is fixed to the outside of the outer bending ring. A first toothed ring is fixed to the outside of the first connection ring. The first gear is meshed with the first toothed ring.

[0021] The pin bending device further includes an inner bending unit. The inner bending unit includes an inner bending ring. The inner bending ring is located inside the outer bending ring and is rotationally connected to the outer bending ring through a bearing. A second connection ring is fixed to the outside of the inner bending ring. The second connection ring is located inside the first connection ring and is rotationally connected to the first connection ring through a bearing. A second toothed ring is fixed to the outside of the part of the second connection ring extending out of one side of the first connection ring. The third gear is meshed with the second toothed ring.

[0022] A plurality of pin fixing grooves are arranged in an array on the side of the outer bending ring and the inner bending ring facing the front support plate. The inner pins and outer pins of the copper strip are respectively located in the pin fixing grooves of the inner bending ring and the outer bending ring.

[0023] Preferably, an extrusion fixing part is arranged in the pin fixing groove. The extrusion fixing part is composed of an annular buffer pad and semi-elliptical blocks. A plurality of semi-elliptical blocks are connected in an annular array to the inner surface of the annular buffer pad.

[0024] Preferably, a first driving motor is installed at the upper end of the fixed vertical frame. A vertical threaded rod is connected along the output shaft end of the first driving motor inside the fixed vertical frame. The vertical threaded rod is in threaded connection with the limit sliding block. Sliding vertical rods for limiting the sliding of the limit sliding block are arranged on both sides of the vertical threaded rod inside the fixed vertical frame.

[0025] Preferably, side clamping units are arranged on both sides of the front end of the upper end of the mounting bracket. The side clamping unit includes an outer support vertical frame. A first side clamping component, a second side clamping component and a lower support component are respectively arranged at the front and rear ends and the lower end inside the outer support vertical frame. The structures of the first side clamping component and the second side clamping component are the same.

[0026] Preferably, the lower support assembly includes a lower support plate, lower fixing plates are fixedly arranged at the front and rear ends of the lower end of the lower support plate, a first rack is formed at the upper end of the rear end face of the front lower fixing plate, and an intermediate connecting gear is rotatably connected between the front and rear lower fixing plates along the middle inside the outer support vertical frame, and the intermediate connecting gear meshes with the first rack.

[0027] Preferably, both the first side clamping assembly and the second side clamping assembly include side clamping plates, connecting vertical plates are fixedly arranged at the outer ends of the side clamping plates, connecting cross plates are fixedly arranged on both sides of the lower end of the inner end of the connecting vertical plates, the connecting cross plates on the first side clamping assembly and the second side clamping assembly are respectively located at the lower end and the upper end of the intermediate connecting gear, a second rack is formed at the inner end of one end face of the connecting cross plate facing the intermediate connecting gear, the second rack meshes with the intermediate connecting gear, and an outer limiting rod is fixedly arranged at the upper end of the outer end of the connecting vertical plate.

[0028] Preferably, an intermediate connecting plate is fixedly arranged along the lower end of the intermediate connecting gear between the two lower fixing plates, a lower limiting rod is fixedly arranged at the lower end of the intermediate connecting plate, a compression spring is arranged along the outside of the lower limiting rod between the intermediate connecting plate and the inner end face of the outer support vertical frame, inner sliding grooves are formed in the outer support vertical frame along the movement tracks of the outer limiting rod, the lower fixing plate, the lower limiting rod and the connecting cross plate, an inner sliding cavity is formed in the outer support vertical frame along the movement track of the connecting vertical plate, and outer sliding grooves are formed in the outer support vertical frame along the movement tracks of the lower support plate and the side clamping plate.

[0029] Preferably, arc-shaped buffer pads are fixedly arranged on the inner end faces of the lower support plate and the side clamping plate.

[0030] Preferably, the operation method of the pin bending device includes the following steps:

[0031] S6-1: Place the rotor on the upper end of the front support plate so that the position of the copper bar corresponds to the pin fixing grooves on the outer bending ring and the inner bending ring. Push the rotor to insert the pins of the copper bar into the pin fixing grooves, and the semi-elliptical block presses and fixes the copper bar pins;

[0032] S6-2: The first driving motor drives the vertical threaded rod to rotate, and the limiting sliding block, the rear support plate and the front support plate move downward to drive the rotor to move downward;

[0033] S6-3: When the rotor moves downward, the rotor shaft synchronously moves downward and presses on the upper end of the lower support plate. The intermediate connecting gear is driven to rotate through the meshing connection relationship between the first rack and the intermediate connecting gear. The first side clamping assembly and the second side clamping assembly are driven to move towards the rotor shaft direction through the meshing connection relationship between the intermediate connecting gear and the second rack, and the side clamping plate fixes the rotor shaft;

[0034] S6-4: The output shaft of the second drive motor drives the second gear and the second transmission wheel to rotate. Through the meshing connection relationship of the first toothed ring, the first gear, and the second gear, the outer bending unit is driven to rotate. Through the transmission relationship of the first transmission wheel, the second transmission wheel, and the transmission belt, and the meshing connection relationship of the second toothed ring and the third gear, the inner bending unit is driven to rotate in the opposite direction. The shape of the copper bars located in the pin fixing grooves and the rotor wire grooves remains unchanged, and the copper bars between the commutator and the rotor core are driven to bend;

[0035] S6-5: The first drive motor drives the vertical threaded rod to rotate in the reverse direction, and the rotor shaft loses the clamping forces of the first-side clamping assembly and the second-side clamping assembly.

[0036] Compared with the prior art, the beneficial effects of the present invention are:

[0037] (1) In this invention, an insulating material is added between the pins or between a pin and other conductive components to prevent the direct flow of current. For example, insulating sheets are placed on both sides of the rotor core, insulating paper is inserted into each wire groove, multiple insulating sleeves are sleeved on the externally bent positions of the copper bars, insulating paper is inserted outside each inner-layer pin, and insulating paper is inserted between the inner-layer pins and the outer-layer pins, etc. This makes it so that there is no direct contact between the two end faces of the rotor core, the wire grooves, and the copper bars, and there is no direct contact between the pin ends of adjacent copper bars or between the inner-layer and outer-layer pins of the copper bars. It avoids problems such as no insulation operation at other contact positions between the rotor core and the copper wire or between the copper wire and itself, which would cause the current to flow directly without passing through the predetermined circuit path, thus resulting in a short circuit and not triggering electrical failures.

[0038] (2) In this invention, the two pins of the copper bar are obliquely inserted into different wire grooves to form inner-layer pins and outer-layer pins, and a pin bending device is used to bend the two pins of the copper bar in opposite directions. The pin bending device adopts a gear transmission and bearing rotation structure, achieving synchronous and reverse bending of the copper bar pins, which can reduce the errors of manual bending or separate bending of the inner and outer layers; and the bending angles are consistent, greatly improving the manufacturing precision and efficiency.

[0039] (3) In this invention, the output shaft of the second drive motor drives the second gear and the second transmission wheel to rotate. Through the meshing connection relationship of the first toothed ring, the first gear, and the second gear, the outer bending unit is driven to rotate. Through the transmission relationship of the first transmission wheel, the second transmission wheel, and the transmission belt, and the meshing connection relationship of the second toothed ring and the third gear, the inner bending unit is driven to rotate in the opposite direction. Through the action of the same drive structure and a series of linkage structures, the action synchronization of the outer bending unit and the inner bending unit is high, improving the manufacturing precision. And the shape of the copper bars located in the pin fixing grooves and the rotor wire grooves remains unchanged, and the copper bars between the commutator and the rotor core are driven to bend, avoiding the change in the shape of the copper bars in the wire grooves and the commutator, which is more in line with the manufacturing requirements during the manufacturing process.

[0040] (4)In this invention, when the rotor moves downward, the rotor shaft moves downward synchronously and presses on the upper end of the lower support plate. Through the meshing connection relationship between the first rack and the intermediate connecting gear, the intermediate connecting gear is driven to rotate. Through the meshing connection relationship between the intermediate connecting gear and the second rack, the first side clamping assembly and the second side clamping assembly are driven to move towards the rotor shaft direction, and the side clamping plate fixes the rotor shaft. Through the collaborative action of the side clamping unit and the lower support assembly, the all-round fixation of the rotor during the manufacturing process is realized, effectively preventing the shaking and displacement of the rotor during the processing, and ensuring the manufacturing precision of the rotor. Moreover, there is no need to introduce other driving structures, and self-fixation is achieved by relying on the gravity of the rotor itself. When taking it, only the rotor needs to be moved upward, reducing the fixing steps and disassembly steps. Description of the Drawings

[0041] Figure 1 It is a process flow chart of the manufacturing process of a high-speed rotor for an automotive starter of the present invention;

[0042] Figure 2 It is an overall structural schematic diagram of the pin bending device of the present invention from the side view;

[0043] Figure 3 It is an overall structural schematic diagram of the other side view of the pin bending device of the present invention;

[0044] Figure 4 It is a top view of the pin bending device of the present invention;

[0045] Figure 5 It is a front view of the pin bending device of the present invention;

[0046] Figure 6 It is a cross-sectional view taken along the line A-A of the pin bending device of the present invention;

[0047] Figure 7 It is a connection structural schematic diagram of the first side clamping assembly, the second side clamping assembly and the lower support assembly of the pin bending device of the present invention;

[0048] Figure 8 It is a structural schematic diagram of the outer bending unit of the pin bending device of the present invention;

[0049] Figure 9 It is a structural schematic diagram of the inner bending unit of the pin bending device of the present invention;

[0050] Figure 10 It is a structural schematic diagram of the extrusion fixing part of the pin bending device of the present invention.

[0051] In the figure: 1. Mounting bracket; 2. Side clamping unit; 3. Outer support vertical frame; 4. First side clamping assembly; 5. Second side clamping assembly; 6. Lower support assembly; 7. Lower support plate; 8. Lower fixing plate; 9. First rack; 10. Intermediate connecting gear; 11. Intermediate connecting plate; 12. Lower limit rod; 13. Pressure spring; 14. Side clamping plate; 15. Connecting vertical plate; 16. Outer limit rod; 17. Connecting cross plate; 18. Second rack; 19. Arc-shaped buffer pad; 20. Fixed vertical frame; 21. First driving motor; 22. Vertical threaded rod; 23. Limit sliding block; 24. Rear support plate; 25. Front support plate; 26. Outer fixed limit ring; 27. Outer bending unit; 28. Outer bending ring; 29. First connecting ring; 30. First toothed ring; 31. First gear; 32. Second gear; 33. Inner bending unit; 34. Inner bending ring; 35. Second connecting ring; 36. Second toothed ring; 37. Third gear; 38. First transmission wheel; 39. Second transmission wheel; 40. Transmission belt; 41. Second driving motor; 42. Pin fixing groove; 43. Extrusion fixing piece; 44. Annular buffer pad; 45. Semi-elliptical block. Detailed implementation manners

[0052] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments.

[0053] Please refer to Figures 1 - 5 , Figures 8 - 10 , an embodiment provided by the present invention: A manufacturing process for a high-speed rotor for an automotive starter, including the following steps:

[0054] 1. Stack silicon steel sheets to form a rotor core: Uniformly open wire grooves on the periphery of the rotor core to prepare for the subsequent insertion of copper bars and pin bending.

[0055] 2. Fix the rotor shaft: Insert the rotor shaft into the hole of the rotor core and fix it to ensure the stability of the rotor shaft during subsequent processing.

[0056] 3. Place insulating sheets: Place two insulating sheets with holes in the middle and on the periphery on both sides of the rotor core to isolate the rotor core.

[0057] 4. Insert insulating paper: Overlap multiple insulating papers end to end to form a ring structure and insert it into each wire groove to enhance the insulation performance.

[0058] 5. Insert the copper bar pins into the wire grooves: First, put multiple insulating sleeves on the externally bent positions of the copper bars, and then obliquely insert the two pins of the copper bars into different wire grooves to form inner-layer pins and outer-layer pins to prepare for subsequent bending.

[0059] 6. Pin bending: Use the pin bending device to bend the two pins of the copper strip in opposite directions.

[0060] Bending structure:

[0061] The pin bending device includes a mounting bracket 1, a fixed vertical frame 20 is welded and fixed in the middle of the upper rear end of the mounting bracket 1, a limited sliding block 23 is sliding up and down in the fixed vertical frame 20, a first driving motor 21 is installed on the upper end of the fixed vertical frame 20, a vertical threaded rod 22 is connected along the output shaft end of the first driving motor 21 in the fixed vertical frame 20, the vertical threaded rod 22 is connected to the limited sliding block 23 through threads, and sliding vertical rods are arranged on both sides of the vertical threaded rod 22 in the fixed vertical frame 20 for limiting the sliding of the limited sliding block 23.

[0062] The front end of the limiting sliding block 23 is connected to the front supporting plate 25 , and the rear end is connected to the rear supporting plate 24 ; an outer fixed limiting ring 26 is integrally connected to one side of the upper end of the front supporting plate 25 .

[0063] A second drive motor 41 is installed at the upper end of the rear support plate 24, and a second gear 32 is installed at the output shaft end of the second drive motor 41. The front end of the second gear 32 is meshed and connected with the first gear 31. The outer side of the second gear 32 is coaxially connected with a second transmission wheel 39. The front end of the second transmission wheel 39 is provided with a first transmission wheel 38. The second transmission wheel 39 is connected to the first transmission wheel 38 through a transmission belt 40. The first transmission wheel 38 is coaxially connected with a third gear 37 on the side close to the front support plate 25;

[0064] The pin bending device also includes an outer bending unit 27, which includes an outer bending ring 28. The outer bending ring 28 is located inside the outer fixed limiting ring 26 and is rotatably connected to the outer fixed limiting ring 26 through a bearing. A first connecting ring 29 is fixed to the outer side of the outer bending ring 28. A first gear ring 30 is fixed to the outer side of the first connecting ring 29. A first gear 31 is meshed with the first gear ring 30.

[0065] The pin bending device also includes an inner bending unit 33, which includes an inner bending ring 34, which is located inside the outer bending ring 28 and is rotatably connected to the outer bending ring 28 through a bearing, a second connecting ring 35 is fixed to the outer side of the inner bending ring 34, the second connecting ring 35 is located inside the first connecting ring 29 and is rotatably connected to the first connecting ring 29 through a bearing, a second gear ring 36 is fixed to the outer side of the second connecting ring 35 extending out of one side of the first connecting ring 29, and a third gear 37 is meshed with the second gear ring 36;

[0066] On one side of the front support plate 25, a plurality of pin fixing grooves 42 are arranged in an array on both the outer bending ring 28 and the inner bending ring 34. The inner layer pins and the outer layer pins of the copper strip are respectively located in the pin fixing grooves 42 of the inner bending ring 34 and the outer bending ring 28. An extrusion fixing member 43 is arranged in the pin fixing groove 42, which is composed of an annular buffer pad 44 and a semi-elliptical block 45. A plurality of semi-elliptical blocks 45 are connected to the inner surface of the annular buffer pad 44 in an annular array for fixing the copper strip pins.

[0067] Operation steps:

[0068] Place the rotor on the upper end of the front support plate 25, align the copper strip pins with the pin fixing grooves 42, push the rotor to insert the pins into the grooves, and the semi-elliptical blocks 45 press and fix the pins.

[0069] The first driving motor 21 drives the vertical threaded rod 22 to rotate, driving the limit sliding block 23, the rear support plate 24 and the front support plate 25 to move downward, and then driving the rotor to move downward. After moving in place, fix the rotor shaft.

[0070] The output shaft of the second driving motor 41 drives the second gear 32 and the second transmission wheel 39 to rotate. Through the meshing connection relationship of the first toothed ring 30, the first gear 31 and the second gear 32, the outer bending unit 27 is driven to rotate. Through the transmission relationship of the first transmission wheel 38, the second transmission wheel 39 and the transmission belt 40 and the meshing connection relationship of the second toothed ring 36 and the third gear 37, the inner bending unit 33 is driven to rotate in the opposite direction. The shape of the copper strip located in the pin fixing grooves 42 and the rotor wire grooves remains unchanged, and the copper strip between the commutator and the rotor core is driven to bend.

[0071] The first driving motor 21 rotates the vertical threaded rod 22 in the reverse direction, and the rotor shaft loses the clamping force, completing the pin bending.

[0072] 7. Insert insulating paper: Fold the insulating paper into a ring and insert it outside each inner layer pin to enhance the insulation performance.

[0073] 8. Install the commutator: First, insert the inner layer pins into the commutator grooves, then fold the ring-shaped insulating paper and insert it between the inner layer pins and the outer layer pins. Then insert the outer layer pins into the commutator grooves. Finally, weld the copper strip and the commutator to complete the assembly of the rotor.

[0074] 9. Fix the winding group: Put two fixing rings on both outer sides of the winding group formed by the copper strip and fix them under pressure to ensure the stability of the winding group.

[0075] 10. Turning and coating: Turn the outer surface and end face of the formed rotor to make the outside flat. Coat an anti-rust coating, and after drying, coat an insulating coating to improve the durability and insulation performance of the rotor.

[0076] The rotor fixing structure, such as Figures 1 - 7As shown in the figure:

[0077] Side clamping unit 2: It is arranged on both sides of the front end of the upper end of the mounting bracket 1; it includes an outer support stand 3, a first side clamping assembly 4, a second side clamping assembly 5 and a lower support assembly 6. The structures of the first side clamping assembly 4 and the second side clamping assembly 5 are the same. The first side clamping assembly 4, the second side clamping assembly 5 and the lower support assembly 6 are respectively located at the front, rear and lower ends inside the outer support stand 3.

[0078] Lower support assembly 6: It includes a lower support plate 7. Lower fixing plates 8 are fixed to the front and rear ends of the lower end of the lower support plate 7. A first rack 9 is formed at the upper end of the rear end face of the front lower fixing plate 8. An intermediate connecting gear 10 is rotatably connected between the two lower fixing plates 8 along the front and rear inside the outer support stand 3. The intermediate connecting gear 10 meshes with the first rack 9. Through the meshing relationship between the first rack 9 and the intermediate connecting gear 10, the subsequent linkage process is realized, and thus the support and fixation of the rotor are realized.

[0079] An intermediate connecting plate 11 is fixed along the lower end of the intermediate connecting gear 10 between the two lower fixing plates 8. A lower limiting rod 12 is fixed to the lower end of the intermediate connecting plate 11. A compression spring 13 is arranged along the outside of the lower limiting rod 12 between the intermediate connecting plate 11 and the inner end face of the outer support stand 3, providing a reset acting force for the side clamping assembly to ensure that the clamping of the rotor shaft can be smoothly released after processing is completed.

[0080] Inner sliding grooves are opened along the movement tracks of the outer limiting rod 16, the lower fixing plate 8, the lower limiting rod 12 and the connecting cross plate 17 inside the outer support stand 3. An inner sliding cavity is opened along the movement track of the connecting vertical plate 15 inside the outer support stand 3. Outer sliding grooves are opened along the movement tracks of the lower support plate 7 and the side clamping plate 14 inside the outer support stand 3.

[0081] First side clamping assembly 4 and second side clamping assembly 5: Both include a side clamping plate 14. A connecting vertical plate 15 is fixed to the outer end of the side clamping plate 14. Connecting cross plates 17 are fixed to both sides of the lower end of the inner end of the connecting vertical plate 15. The connecting cross plates 17 on the first side clamping assembly 4 and the second side clamping assembly 5 are respectively located at the lower end and the upper end of the intermediate connecting gear 10. A second rack 18 is formed at the inner end of the end face of the connecting cross plate 17 facing the intermediate connecting gear 10. The second rack 18 meshes with the intermediate connecting gear 10. An outer limiting rod 16 is fixed to the upper end of the outer end of the connecting vertical plate 15. Through the meshing relationship between the second rack 18 and the intermediate connecting gear 10, the fixation of the rotor shaft is realized.

[0082] Arc-shaped buffer pad 19: It is arranged on the inner end faces of the lower support plate 7 and the side clamping plate 14, effectively protecting the surface quality of the rotor during processing.

[0083] When the rotor moves downward, the rotor shaft synchronously moves downward and presses on the upper end of the lower support plate 7. Through the meshing connection relationship between the first rack 9 and the intermediate connecting gear 10, the intermediate connecting gear 10 is driven to rotate. Through the meshing connection relationship between the intermediate connecting gear 10 and the second rack 18, the first side clamping assembly 4 and the second side clamping assembly 5 are driven to move towards the rotor shaft direction, and the side clamping plate 14 fixes the rotor shaft. The first driving motor 21 drives the vertical threaded rod 22 to rotate in the reverse direction, and the rotor shaft loses the clamping force of the first side clamping assembly 4 and the second side clamping assembly 5. Through the gear meshing and sliding structure, the stable clamping of the rotor shaft is realized, and the stability of the rotor during the processing is improved.

[0084] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above-described exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be encompassed within the present invention. Any reference signs in the claims should not be construed as limiting the claims involved.

Claims

1. A manufacturing process for a high-speed rotor for an automobile starter, characterized in that: The steps include: S1: Silicon steel sheets are stacked to form a rotor core, and wire slots are evenly opened on the periphery of the rotor core; S2: insert the rotor shaft into the hole of the rotor core and fix it; S3: placing two insulating sheets with holes in the middle and the periphery on both sides of the rotor core; S4: Overlap multiple insulating papers end to end to form a ring structure and insert it into each wire slot; S5: First, multiple insulating sleeves are put on the outer bending position of the copper bar, and then two pins of the copper bar are obliquely inserted into different wire grooves to form inner pins and outer pins; S6: bend the two pins of the copper strip in opposite directions using a pin bending device; S7: Fold the insulating paper into a ring shape and insert it into the outside of each inner pin; S8: Install the commutator. First, insert the inner pin into the commutator groove. Then fold the insulating paper into a ring shape and insert it between the inner pin and the outer pin. Then insert the outer pin into the commutator groove. Finally, weld the copper bar and the commutator. S9: Put two fixing rings on the outer sides of the winding group formed by the copper bars and fix them with pressure; S10: The outer surface and end face of the rotor formed by turning, and the outer surface is flattened; S11: Apply anti-rust coating, and apply insulation coating after drying.

2. The manufacturing process of a high-speed rotor for an automobile starter according to claim 1, characterized in that: The pin bending device comprises a mounting bracket (1), a fixed vertical frame (20) is welded and fixed in the middle of the upper and rear ends of the mounting bracket (1), a limit sliding block (23) is slidable up and down in the fixed vertical frame (20), a front support plate (25) is integrally connected to the front end of the limit sliding block (23), and an external fixed limit ring (26) is integrally connected to one side of the upper end of the front support plate (25); The rear end of the limiting sliding block (23) is integrally connected with the rear support plate (24); the upper end of the rear support plate (24) is mounted with a second driving motor (41); the output shaft end of the second driving motor (41) is mounted with a second gear (32); the front end of the second gear (32) is meshingly connected with the first gear (31); the outer side of the second gear (32) is coaxially connected with a second transmission wheel (39); the front end of the second transmission wheel (39) is provided with a first transmission wheel (38); the second transmission wheel (39) is transmission-connected with the first transmission wheel (38) via a transmission belt (40); the first transmission wheel (38) is coaxially connected with a third gear (37) on a side close to the front support plate (25); The pin bending device also includes an outer bending unit (27), the outer bending unit (27) includes an outer bending ring (28), the outer bending ring (28) is located inside the outer fixed limiting ring (26) and is rotatably connected to the outer fixed limiting ring (26) via a bearing, a first connecting ring (29) is fixed outside the outer bending ring (28), a first gear ring (30) is fixed outside the first connecting ring (29), and a first gear (31) is meshed with the first gear ring (30); The pin bending device also includes an inner bending unit (33), the inner bending unit (33) includes an inner bending ring (34), the inner bending ring (34) is located inside the outer bending ring (28) and is rotatably connected to the outer bending ring (28) through a bearing, a second connecting ring (35) is fixed to the outside of the inner bending ring (34), the second connecting ring (35) is located inside the first connecting ring (29) and is rotatably connected to the first connecting ring (29) through a bearing, a second gear ring (36) is fixed to the outside of the second connecting ring (35) extending out of one side of the first connecting ring (29), and a third gear (37) is meshed with the second gear ring (36); The outer bending ring (28) and the inner bending ring (34) are both provided with a plurality of pin fixing grooves (42) in an array on one side facing the front support plate (25), and the inner layer pins and the outer layer pins of the copper strip are respectively located in the pin fixing grooves (42) of the inner bending ring (34) and the outer bending ring (28).

3. The manufacturing process of a high-speed rotor for an automobile starter according to claim 2, characterized in that: An extrusion fixing member (43) is arranged in the pin fixing groove (42), and the extrusion fixing member (43) is composed of an annular buffer pad (44) and a semi-elliptical block (45), and a plurality of semi-elliptical blocks (45) are connected to the inner surface of the annular buffer pad (44) in an annular array.

4. The manufacturing process of a high-speed rotor for an automobile starter according to claim 3, characterized in that: A first driving motor (21) is installed at the upper end of the fixed vertical frame (20), a vertical threaded rod (22) is connected to the output shaft end of the first driving motor (21) inside the fixed vertical frame (20), the vertical threaded rod (22) is connected to the limit sliding block (23) through a threaded connection, and sliding vertical rods for limiting the sliding of the limit sliding block (23) are arranged on both sides of the vertical threaded rod (22) inside the fixed vertical frame (20).

5. The manufacturing process of a high-speed rotor for an automobile starter according to claim 4, characterized in that: Side clamping units (2) are provided on both sides of the front end of the upper end of the mounting bracket (1), and the side clamping unit (2) includes an external support frame (3), and the front and rear ends and the lower end inside the external support frame (3) are respectively provided with a first side clamping assembly (4), a second side clamping assembly (5) and a lower supporting assembly (6), and the first side clamping assembly (4) and the second side clamping assembly (5) have the same structure.

6. The manufacturing process of a high-speed rotor for an automobile starter according to claim 5, characterized in that: The lower supporting assembly (6) comprises a lower supporting plate (7), the front and rear ends of the lower end of the lower supporting plate (7) are fixed with lower fixing plates (8), the upper end of the rear end surface of the front lower fixing plate (8) forms a first rack (9), and the inner edge of the outer supporting frame (3) is rotatably connected to the middle between the front and rear lower fixing plates (8), and the middle connecting gear (10) is meshed with the first rack (9).

7. The manufacturing process of a high-speed rotor for an automobile starter according to claim 6, characterized in that: The first side clamping assembly (4) and the second side clamping assembly (5) both comprise a side clamping plate (14), a connecting vertical plate (15) being fixed to the outer end of the side clamping plate (14), connecting horizontal plates (17) being fixed to both sides of the lower inner end of the connecting vertical plate (15), the connecting horizontal plates (17) on the first side clamping assembly (4) and the second side clamping assembly (5) being respectively located at the lower end and the upper end of the intermediate connecting gear (10), the connecting horizontal plate (17) forming a second rack (18) at the inner end of one end surface of the intermediate connecting gear (10), the second rack (18) being meshed with the intermediate connecting gear (10), and an outer limit rod (16) being fixed to the upper end of the outer end of the connecting vertical plate (15).

8. The manufacturing process of a high-speed rotor for an automobile starter according to claim 7, characterized in that: An intermediate connecting plate (11) is fixed between the two lower fixed plates (8) along the lower end of the intermediate connecting gear (10), a lower limit rod (12) is fixed at the lower end of the intermediate connecting plate (11), a pressure spring (13) is arranged between the intermediate connecting plate (11) and the inner end surface of the outer supporting frame (3) along the outside of the lower limit rod (12), an inner sliding groove is provided in the outer supporting frame (3) along the movement trajectory of the outer limit rod (16), the lower fixed plate (8), the lower limit rod (12) and the connecting cross plate (17), an inner sliding cavity is provided in the outer supporting frame (3) along the movement trajectory of the connecting plate (15), and an outer sliding groove is provided in the outer supporting frame (3) along the movement trajectory of the lower support plate (7) and the side clamping plate (14).

9. The manufacturing process of a high-speed rotor for an automobile starter according to claim 7, characterized in that: The inner end surfaces of the lower supporting plate (7) and the side clamping plate (14) are both fixed with arc-shaped buffer pads (19).

10. The manufacturing process of a high-speed rotor for an automobile starter according to claim 8, characterized in that: The operating method of the pin bending device comprises the following steps: S6-1: placing the rotor on the upper end of the front support plate (25) so that the position of the copper bar corresponds to the pin fixing grooves (42) on the outer bending ring (28) and the inner bending ring (34), pushing the rotor so that the pins of the copper bar are inserted into the pin fixing grooves (42), and the semi-elliptical block (45) presses and fixes the copper bar pins; S6-2: The first driving motor (21) drives the vertical threaded rod (22) to rotate, and the limiting sliding block (23), the rear supporting plate (24) and the front supporting plate (25) move downward, driving the rotor to move downward; S6-3: When the rotor moves downward, the rotor shaft moves downward synchronously and is pressed on the upper end of the lower support plate (7), and the meshing connection relationship between the first rack (9) and the intermediate connecting gear (10) drives the intermediate connecting gear (10) to rotate, and the meshing connection relationship between the intermediate connecting gear (10) and the second rack (18) drives the first side clamping assembly (4) and the second side clamping assembly (5) to move toward the rotor shaft, and the side clamping plate (14) fixes the rotor shaft; S6-4: The output shaft of the second driving motor (41) drives the second gear (32) and the second transmission wheel (39) to rotate, and drives the outer bending unit (27) to rotate through the meshing connection relationship among the first gear ring (30), the first gear (31) and the second gear (32), and drives the inner bending unit (33) to rotate in the opposite direction through the transmission relationship among the first transmission wheel (38), the second transmission wheel (39) and the transmission belt (40) and the meshing connection relationship between the second gear ring (36) and the third gear (37). The shape of the copper bars in the pin fixing groove (42) and the rotor wire groove remains unchanged, and the copper bars between the commutator and the rotor core are driven to bend; S6-5: The first drive motor (21) drives the vertical threaded rod (22) to rotate in the opposite direction, and the rotor shaft loses the clamping force of the first side clamping assembly (4) and the second side clamping assembly (5).

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