Stator pole shoe arc angle machining device and machining method

Abstract

The invention relates to the technical field of motor manufacturing, in particular to a stator pole shoe notch fillet machining device and method. By controlling the rotation of the motor, the precision of the mandrel clamp and the extremely small cutting force of electromachining, the qualified rate of the stator pole shoe fillet is improved by more than 30%. Through rotation of the motor and the array type profiling electrodes, discharge machining can be carried out on a set of stator pole shoe fillets, the machining efficiency is improved by 12-20 times, and the machining period and cost are greatly reduced. By means of the array type profiling electrodes, the consistency of stator pole shoe fillet machining is guaranteed, and the use performance of the motor is improved. Through a rotary discharge machining mode, semi-automatic machining is carried out on multiple stator pole shoe fillets, and a traditional mode of manually grinding the stator pole shoe fillets is replaced. And especially for a micro stator pole shoe fillet, the labor intensity is greatly reduced. The machining efficiency is improved, the machining period is shortened, and the machining cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of motor manufacturing, and in particular to a device and method for processing rounded corners of stator pole shoe slots. Background Art

[0002] In motor manufacturing, the rounded corners of the stator pole shoe slots are crucial for ensuring motor performance and minimizing manufacturing costs. During the winding process, copper wire can easily come into contact with the sharp points on the pole shoe ends, causing scratches or breakage, rendering the stator useless. Therefore, the pole shoe ends are often designed with rounded corners to protect the copper wire from scratches during the winding process.

[0003] Traditional methods for rounding the stator pole shoe slot angles are as follows: One involves the operator using sandpaper or other grinding tools, applying specific techniques to the required angle dimensions. This method is cumbersome and labor-intensive, resulting in poor consistency and a high scrap rate for the polished stators. Each pole shoe slot has four sharp points, each of which must be rounded. For example, a 12-tooth stator has 12 pole shoes, for a total of 48 sharp points that require grinding. Manually grinding these 48 pole shoe points is complex, labor-intensive, and time-consuming. Manually polished corners are subject to variations in operator technique and labor intensity, resulting in irregular and inconsistent corner shapes, impacting motor performance. Manual grinding can also lead to excessively large corners and enlarged pole shoe slots, impacting stator manufacturing yields and increasing motor manufacturing costs.

[0004] Another method is to use CNC machine tools or special machine tools to process the arc angle of the stator pole shoe slot with a rotating tool. This has low processing efficiency and a high stator scrap rate. Since the stator has too many pole shoe tips that need to be processed, the tool needs to process each tip one by one, which affects processing efficiency. Since the stator is formed by pressing together stator punching sheets, excessive cutting force will cause cracks between the punching sheet stacks. Therefore, it is necessary to reduce the tool feed speed to reduce the cutting force and ensure the stator qualification rate. The reduction in tool feed speed seriously affects the stator processing efficiency and increases the manufacturing cost and processing cycle of the motor. For small and micro stators, the pole shoes are extremely thin and cannot withstand the cutting force of the tool, resulting in an extremely high stator scrap rate. For small and micro stators, we usually use manual grinding methods. Summary of the Invention

[0005] The purpose of the present invention is to provide a high-precision and high-efficiency processing device and processing method for the fillet of a stator pole shoe, which has a simple structure, convenient operation and low manufacturing cost.

[0006] The technical solution of the present invention is as follows: A stator pole shoe arc angle processing device includes a rotating mechanism 1, a clamping mechanism 2, a profiling electrode 3, a tailstock 4, a switch mechanism 5, and a mounting plate 6; the rotating mechanism 1, the tailstock 4, and the switch mechanism 5 are fixed on the mounting plate 6 in sequence, the support 12 of the rotating mechanism 1 is an irregular structure, one end is fixed on the mounting plate 6, and the other end is connected to the clamping mechanism 2, and the other end of the clamping mechanism 2 is connected to the tailstock 4. The profiling electrode 3 is installed on the electrode chuck of the machine tool, and the profiling electrode 3 moves so that its side 32 presses the switch mechanism 5 and sends a signal to the motor 11 of the rotating mechanism 1. The motor 11 serves as a power source for rotation and drives the parts on the clamping mechanism 2 to perform indexing rotation.

[0007] The rotating mechanism 1 includes a motor 11, a support 12, a pulley a13, a belt 14, an idler pulley 15, a pulley b16, a fixed block 17, an adjusting screw 18, and a sliding plate 19; the output shaft of the motor 11 is fixedly installed on the support 12 through the mounting hole of the pulley a13; the pulley a13 is connected to the pulley b16 through the belt 14, the fixed block 17 is fastened to the support 12, the shaft of the adjusting screw 18 is inserted into the open slide groove of the fixing block 17, and the two end cylinders of the shaft are clamped in the two end faces of the fixing block 17. The long end of the adjusting screw 18 is a threaded rod, which is screwed into the threaded hole at the left end of the sliding plate 19. The long groove of the support 12 guides the sliding plate 19. The idler pulley 15 is movably connected to the sliding plate 19. The movement of the sliding plate 19 on the support 12 is adjusted by screwing the adjusting screw 18, and then the belt 14 is tightened to complete the pre-tightening of the belt 14.

[0008] The motor 11 includes a bearing seat assembly 110, a positioning shaft 111, and a shield 112; the outer circle of the left end of the bearing seat assembly 110 cooperates with the positioning hole of the support 12, and there are 4 evenly distributed threaded mounting holes on the bearing seat assembly 110, which are fastened to the support 12 by screws; the positioning shaft 111 passes through the bearing of the bearing seat assembly 110 and is inserted into the hole of the pulley B16, and the positioning shaft 111 is driven to rotate by the rotation of the pulley B16.

[0009] The clamping mechanism 2 includes a soft claw 21, a positioning rod 22, a special-shaped washer 23, and a special-shaped tightening sleeve 24; one end of the soft claw 21 is connected to the rotating mechanism 1, and the other end is connected to the positioning rod 22. Multiple special-shaped washers 23 are sleeved on the positioning rod 22 and separate the parts one by one. The special-shaped tightening sleeve 24 is sleeved on the other end of the positioning rod 22 and connected to the tailstock 4.

[0010] The soft claw 21 includes a chassis and a connecting column. The connecting column is provided with a special-shaped hole 213 and a flat 212. The special-shaped hole 213 positions the radial direction of the positioning rod 22. The shape of the hole is consistent with the shape of the positioning rod 22 and the shape of the inner hole of the part, and the circle of the special-shaped hole 213 is coaxial with the outer circle 211 of the chassis. The chassis is inserted into the inner hole of the positioning shaft 111 of the motor of the rotating mechanism 1. The opposite side of the flat 212 contains a top screw hole, and the axial direction of the positioning rod 22 is fixed by the top screw.

[0011] The flat surface 212 is parallel to the groove on the special-shaped hole 213 .

[0012] The special-shaped hole of the special-shaped tightening sleeve 24 completely coincides with the positioning rod 22; its left end face 241 fits with the end face of the part, and the chamfer 242 of the hole in the right end face is a 60° chamfer, which fits with the top face of the tailstock 4. The tightening force transmitted by the top of the tailstock 4 causes the left end face 241 to press the end face of the part, thereby completing the fixation of the part on the positioning rod 22.

[0013] The bottom of the contour electrode 3 is provided with an arc boss 33, which is distributed in a linear array. The shape of the arc boss 33 is completely consistent with the fillet of the part to be machined, and the fillets of multiple groups of parts on the positioning rod 22 can be electrically machined at the same time.

[0014] The switch mechanism 5 includes a switch 51, a switch bracket 52, a column 53, and a base 54. The switch bracket 52 connects the switch 51 to the column 53. The switch bracket 52 has a slotted through-hole that penetrates the column 53 and is freely adjustable in the axial and radial directions of the column 53. The axial direction is limited by a washer at the upper end of the column and the upper end surface of the base 51. Tightening the handle screw 55 deforms the slotted through-hole, tightening the column 53 and securing the switch bracket 52. The column 53 is fixed to the base 54.

[0015] The method for processing the arc angle of the stator pole shoe: using the above-mentioned device for processing, comprises the following steps: S1: After assembling the entire device, multiple stators are inserted into the positioning rod 22 in the order of special-shaped washers 23, stators, and special-shaped washers 23. The rightmost end of the positioning rod 22 is inserted into the special-shaped tightening sleeve 24 and tightened by the top of the tailstock 4; by adjusting the rotating mechanism 1 and the tailstock 4, ensure that the coaxiality of the two ends of the positioning rod 22 of the clamping mechanism 2 is within 0.02~0.05mm.

[0016] S2: Install the entire device on the workbench of the EDM machine, insert the flat key 63 of the mounting plate 6 into the keyway of the workbench, and pre-tighten the mounting plate 6 through the pressure plate on the workbench; install the dial indicator on the spindle of the EDM machine, and use the dial indicator to straighten and fine-tune the fixture mechanism 2 by operating the spindle to ensure that the accuracy of the rotation axis of the fixture mechanism 2 and the X-axis of the machine tool is within 0.02mm; after ensuring the accuracy, tighten the pressure plate screw to press the mounting plate 6 to complete the fixation of the entire device; S3: Use a dial indicator to straighten the flat plate 212 on the soft jaw 21 and adjust it by rotating the rotating mechanism 1 so that the plane runout of the flat plate 212 is within 0.01 mm; S4: Use a vernier caliper to measure the distance from the left end face of the leftmost stator to the right end face of the rightmost stator on the positioning rod 22. This distance = (number of stators x stator thickness + number of special-shaped washers 23 x thickness of special-shaped washers 23) ± 0.05mm; the processing thickness error of the special-shaped washers 23 themselves is within 0.01mm, so that the cumulative thickness error will not exceed ± 0.05mm.

[0017] S5: Edit the machining path of the profiling electrode 3 in the machine tool operating system; the machining path must ensure that after each machining of a stator pole shoe arc angle is completed, the profiling electrode moves to the press switch 51 and presses the contact 511; S6: Start the machine tool, and perform electrical discharge machining on the arc angle of the stator pole shoe using the profiling electrode 3; S7: After the arc angle of the pole shoe is processed, the contour electrode 3 touches the contact 511 of the press switch 51 along the programmed path, causing it to send a signal to the rotating mechanism 1; S8: After receiving the signal, the motor performs indexing rotation, and the machine tool then operates the profiling electrode 3 to process the next pole shoe arc angle; S9: Repeat the above operation until all pole shoe arc angles on the stator are fully EDMed; S10: Loosen the tailstock and remove the stator, special-shaped washer 23 and special-shaped tightening sleeve 24 on the positioning rod 22.

[0018] S11: When a single row of electrodes is worn out and cannot be used, the row spacing of the electrodes 33 is compensated in the CNC program, and the part fillet can be processed continuously until all rows of arc bosses 33 of the profiling electrode 3 are unusable, and then the profiling electrode 3 is replaced as a whole.

[0019] The beneficial effects of the present invention are: 1) Improve processing efficiency, shorten processing cycle and reduce processing costs.

[0020] Through the rotation of the motor and the array-type contoured electrodes, a set of stator pole shoe fillets can be processed by discharge machining, which increases the machining efficiency by 12 to 20 times and significantly reduces the machining cycle and cost.

[0021] 2) Reduce processing scrap rate By controlling the motor rotation, the mandrel fixture accuracy and the extremely small cutting force of the electrical machining, the qualified rate of the stator pole shoe fillet is increased by more than 30%.

[0022] 3) Improve motor performance The array-type contoured electrodes ensure the consistency of the rounded corner processing of the stator pole shoe, thereby improving the performance of the motor.

[0023] 4) Reduce labor intensity The semi-automatic machining of multiple stator pole shoe fillets is achieved through rotary electrical discharge machining, replacing the traditional manual grinding of stator pole shoe fillets. This significantly reduces labor intensity, especially for miniature stator pole shoe fillets. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 Structure diagram of the stator pole shoe arc angle processing device; Figure 2 A three-dimensional diagram of the back side of the rotating mechanism 1; Figure 3 A three-dimensional diagram of the front side of the rotating mechanism 1; Figure 4 3D diagram of fixture mechanism 2; Figure 5 3D image of soft claw; Figure 6 Three-dimensional diagram of the positioning rod; Figure 7 Three-dimensional diagram of special-shaped washers and special-shaped top sleeves; Figure 8 3D image of the contoured electrode; Figure 9 3D diagram of the switch mechanism; Figure 10 3D view of the mounting plate.

[0025] Among them: 1-rotating mechanism, 2-clamping mechanism, 3-contact electrode, 4-tailstock, 5-switch mechanism, 6-mounting plate, 11-motor, 12-support, 13-pulley a, 14-belt, 15-idler wheel, 16-pulley b, 17-fixed block, 18-adjusting screw, 19-sliding plate, 21-soft claw, 22-positioning rod, 23-special-shaped washer, 24-special-shaped top tightening sleeve, 31-mounting surface, 32-side, 33 -Arc boss, 51-switch, 52-switch bracket, 53-column, 55-handled screw, 54-base, 61-handle, 62-base plate, 63-flat key, 110-bearing seat assembly, 111-positioning shaft, 112-shield, 211-outer circle, 212-flat, 213-special-shaped hole, 214-arc, 241-left end face, 242-chamfer, 511-contact, 621-long slot, 622-keyway. DETAILED DESCRIPTION

[0026] The present invention will be further described below with reference to the accompanying drawings and embodiments: This invention proposes a novel method for machining the arc angle of a stator pole piece. This method combines rotary electrical discharge machining (EDM) with a unique machining trajectory, achieving multiple improvements in machining accuracy, efficiency, yield rate, and portability. To complement this method, the invention also incorporates a dedicated stator pole piece arc angle machining device to ensure stable clamping and precise positioning during machining.

[0027] like Figure 1 As shown, the device of the present invention comprises 6 parts, namely: a rotating mechanism 1, a clamping mechanism 2, a contour electrode 3, a tailstock 4, a switch mechanism 5, and a mounting plate 6; like Figure 2 、 Figure 3As shown, the rotating mechanism 1 includes a motor 11, which can be a servo motor or a stepper motor and is designed to provide automatic rotation and high rotation accuracy. Motor 11 is mounted on a support 12 via screws. The output shaft of motor 11 passes through the mounting hole of pulley a13 and is secured with screws. Pulley a13 is connected to pulley b16 via a belt 14, which transmits power and provides precise synchronous motion. The belt can be a flat belt, a synchronous belt, or a wedge belt, customized according to needs. A fixed block 17 is fastened to the support 12 via screws. The shaft of an adjusting screw 18 is inserted into an open slot in the fixed block 17. The cylindrical ends of the shaft are clamped onto the two end surfaces of the fixed block 17, acting as axial limiters for the adjusting screw 18. The long end of the adjusting screw 18 is a threaded rod that screws into a threaded hole on the left end of a sliding plate 19. Using a wrench to rotate the hexagonal block at one end of the adjusting screw 18 rotates the thread, which in turn moves the sliding plate 19. The long slot in the support 12 guides the sliding plate 19. Idle pulley 15 is screwed to sliding plate 19, but it can rotate freely without resistance. Adjusting screw 18 adjusts the movement of sliding plate 19 on support 12, which then presses against belt 14, pre-tightening it. After pre-tightening belt 14, tighten the long hole in sliding plate 19 with a screw to complete the pre-tightening.

[0028] The bearing seat assembly 110 is a universal part, and its function is to support and radially position the positioning shaft 111. The outer circle of the left end of the bearing seat assembly 110 cooperates with the positioning hole of the support 12, and has high positioning accuracy. There are 4 evenly distributed threaded mounting holes on the bearing seat assembly 110, which are fastened to the support 12 by screws. The positioning shaft 111 has high positioning accuracy, and its function ensures the radial direction fixation, accuracy and rotation of the clamping mechanism 2. The positioning shaft 111 passes through the bearing of the bearing seat assembly 110 and is inserted into the hole of the pulley 16, and the rotation of the pulley 16 drives the positioning shaft 111 to rotate. The shield 112 is fastened to the upper side of the support 12 by screws. Its function is to avoid interference between the motor 11 and the contour electrode 3 and corrosion of the motor 11 by cutting oil during processing. The main principle of the rotating mechanism 1 is that the motor 11 rotates the pulley 13, which in turn rotates the pulley 16 via the belt 14. The pulley 16 is fixedly connected to the positioning shaft 111 and passes through the bearing seat assembly 110, thereby enabling the rotation of the positioning shaft 111. The support 12 has an irregular structure and functions to fix the above-mentioned parts, achieve high-precision positioning, and complete the positioning and connection with the clamp mechanism 2 and the fixing mechanism 6.

[0029] like Figure 4-7 As shown, the clamp mechanism 2 is composed of a soft claw 21, a positioning rod 22, a special-shaped washer 23, and a special-shaped tightening sleeve 24, wherein A represents a group of parts.

[0030] The outer circle 211 of the soft claw 21 is inserted into the inner hole of the positioning shaft 111, achieving high coaxial positioning accuracy. A screw passes through the through hole of the soft claw 21 and is fastened to the positioning shaft 111. The arc 214 on the soft claw 2 serves to avoid the screw's nut. The flattened portion 212 on the soft claw 21 is parallel to the groove on the special-shaped hole 213, facilitating alignment of the positioning rod 22. During part machining, the angular deviation of the positioning rod 22 can be measured by straightening the flattened portion 212 with a micrometer. By adjusting the motor rotation, the groove on the special-shaped hole 213 is ultimately made perpendicular or parallel to the part's fillet at 90°. The special-shaped hole 213 on the soft claw 21 serves to radially position the positioning rod 22. The shape of the hole is completely consistent with that of the positioning rod 22 and the inner hole of the part, and the circle of the special-shaped hole 213 is highly coaxial with the outer circle 211.

[0031] The positioning rod 22 serves to position and support multiple parts during machining. The positioning rod 22 is inserted into the shaped hole 213 of the soft jaw 21, ensuring that it rotates radially with the rotating mechanism 1. The opposite side of the flat plate 212 on the soft jaw 21 contains a screw hole. By tightening the screw, the positioning rod 22 is secured axially.

[0032] The function of the special-shaped gasket 23 is to separate the parts and prevent the parts from sticking and being scrapped due to electro-machining. The thickness tolerance of the special-shaped gasket 23 is within 0.01mm, which can reduce the accumulated dimensional errors after assembling multiple parts.

[0033] The shaped clamping sleeve 24 functions to compress and position the part. Its shaped hole completely overlaps with the positioning rod 22. Its left end face 241 mates with the end face of the part, thus compressing the part. The chamfer 242, a 60° chamfer within the opening of the right end face of the shaped clamping sleeve 24, mates with the tailstock center. The tightening force transmitted by the tailstock center causes the left end face 241 to compress the end face of the part, securing the part to the positioning rod 22.

[0034] like Figure 8 As shown, the contouring electrode 3 functions to simultaneously electro-process multiple groups of parts fixed to the positioning rod 22, reducing the need for electrode replacement and alignment after electrode wear. The arcuate bosses 33 of the contouring electrode 3 are arranged in a linear array. The row orientation allows for simultaneous electro-processing of fillets on multiple groups of parts on the positioning rod 22. When a single row of electrodes wears beyond use, the machine tool compensates for the row spacing of another row of intact arcuate bosses 33 and continues processing the fillets until all rows of arcuate bosses 33 on the contouring electrode 3 are unusable, at which point the contouring electrode 3 is replaced.

[0035] The mounting surface 31 is connected and fixed by an electrode chuck. During the machining process, the side surface 32 of the side surface 32 of the moving profiling electrode 3 is controlled by the machine tool program to touch the switch 51, and the switch 51 is used to control the rotating mechanism 1 to perform indexing rotation. The arc boss 33 has the function of electrically processing the fillet of the part. The shape of the arc boss 33 is exactly the same as the fillet of the part to be machined. By moving the profiling electrode 3, the machine tool enables a row of arc bosses 33 to discharge the arc corners of a row of parts on the positioning rod 22. The spacing groove 34 is the gap between two adjacent arc bosses 33. The groove width is slightly smaller than the thickness of the special-shaped washer 23 to ensure that the arc boss 33 can completely process the fillet of the part.

[0036] The tailstock 4 is a universal component, and its function is to tighten and support the special-shaped tightening sleeve 24. By rotating the hand wheel at one end of the tailstock, the top is tightened to the special-shaped tightening sleeve 24.

[0037] like Figure 9 As shown, the switch mechanism 5 controls the movement of the contour electrode 3 through the machine tool, causing its side 32 to press against the contact 511 of the switch 51 and transmit a signal to the motor 11 of the rotating mechanism 1. The motor 11, acting as a rotational power source, drives the components of the fixture mechanism 2 to perform indexed rotation. The switch 51 transmits a signal to the motor 11. The switch 51 includes a through hole that allows screws to be inserted through the threaded holes of the switch bracket 52, securing the switch 51. The contact 511 is contacted by the side 32 of the contour electrode 3, generating a signal. The switch bracket 52 connects the switch 51 to the column 53. The switch bracket 52 includes a slotted through hole that allows insertion into the column 53, allowing for free adjustment in both the axial and radial directions of the column 3. The axial direction is limited by a washer at the upper end of the column and the upper end surface of the base 51. Tightening the handle screw 55 deforms the slotted through-hole, tightening the column 53 and securing the switch bracket 52. The column 53 connects the switch bracket 52 to the base 51 and ensures stable and flexible movement and rotation of the switch bracket 52. The base 54 provides stable support for the column 53. Tightening the base's jackscrew secures the column 53.

[0038] like Figure 10As shown, the mounting plate 6 has the function of ensuring the positioning and installation of the rotating mechanism 1, the tailstock 4, and the switch mechanism 5, and facilitating the positioning of the entire device on the machine tool and the operator's transportation. The handles 61 are distributed at both ends of the upper surface of the base plate and are mounted on the base plate 62 by screws. Their function is to facilitate the operator's handholding. The base plate 62 has the function of providing stable positioning, support and fastening for the entire device. The base plate 62 contains long grooves 621 distributed at both ends of the bottom surface of the base plate. The flat keys 63 are fastened to the base plate 62 by screws. Their function is to quickly and accurately position the entire device on the workbench of the machine tool, thereby reducing the positioning time of the entire mechanism. The base plate 62 contains keyways 622 distributed at both ends of the upper surface of the base plate. After the flat keys 63 are fastened to the positioning grooves of the rotating mechanism 1 and the tailstock 4 by screws, the two are inserted into the keyway 622. Their function is to ensure that the axial directions of the rotating mechanism 1 and the tailstock 4 have high coaxial accuracy. Special note: The functions of the above flat keys and keyways are to ensure the rapid and accurate positioning of the two connected mechanisms and the entire device and the spark machine. Special note: All threaded holes on the base plate 62 function as universal screws to fasten the flat keys 63, handle 61, rotating mechanism 1, tailstock 4, and switch mechanism 5.

[0039] By combining the above device with the rotary EDM method and a special machining trajectory, multiple improvements in machining accuracy, machining efficiency, and machining stability can be achieved. The specific steps are as follows: S1: After assembling the entire assembly, insert the stators into the positioning rods 22 in the order of the shaped washers 23, stators, and shaped washers 23. Insert the rightmost end of the positioning rods 22 into the shaped tightening sleeve 24 and tighten with the tailstock 4. Adjust the rotating mechanism 1 and tailstock 4 to ensure that the coaxiality of the two ends of the positioning rods 22 of the clamping mechanism 2 is within 0.02-0.05 mm. This step is only required for initial installation.

[0040] S2: Install the entire assembly on the EDM machine's workbench. Insert the flat key 63 of mounting plate 6 into the table's keyway. Pre-tighten mounting plate 6 using the table's pressure plate. Install a dial indicator on the EDM machine's spindle. Operate the spindle to straighten and fine-tune fixture 2, ensuring the axis of rotation of fixture 2 and the machine's X-axis are aligned within 0.02 mm. Once accuracy is achieved, tighten the pressure plate screws to compress mounting plate 6, completing the assembly. This step is only necessary when first installing the entire assembly on the EDM machine's workbench.

[0041] S3: Use a dial indicator to straighten flattened plate 212 on soft jaw 21 and adjust it by rotating mechanism 1, ensuring that the plane runout of flattened plate 212 is within 0.01 mm. This step ensures that the arc angle of the stator pole shoe is perpendicular or parallel to the rotation axis of the entire assembly. This step is only required when the entire assembly is first installed on the EDM machine table.

[0042] S4: Use a vernier caliper to measure the distance from the left end face of the leftmost stator on the positioning rod 22 to the right end face of the rightmost stator. This distance is (number of stators x stator thickness + number of shaped washers 23 x thickness of shaped washers 23) ± 0.05 mm. The thickness of shaped washers 23 should be within 0.01 mm, ensuring that the cumulative thickness error does not exceed ± 0.05 mm. If the distance is out of tolerance, fine-tune the tailstock 4 center or replace the stator. This step adjusts for the cumulative error caused by the stacking of multiple stators on the positioning rod 22.

[0043] S5: Edit the machining path of the profiling electrode 3 in the machine tool operating system; the machining path must ensure that after each machining of a stator pole shoe arc angle is completed, the profiling electrode moves to the press switch 51 and presses the contact 511; S6: Start the machine tool, and perform electrical discharge machining on the arc angle of the stator pole shoe using the profiling electrode 3; S7: After the arc angle of the pole shoe is processed, the contour electrode 3 touches the contact 511 of the push switch 51, causing it to send a signal to the rotating mechanism 1; S8: After receiving the signal, the motor performs indexing rotation, and the machine tool then operates the profiling electrode 3 to process the next pole shoe arc angle; S9: Repeat the above operation until all pole shoe arc angles on the stator are fully EDMed; S10: Loosen the tailstock and remove the stator, special-shaped washer 23 and special-shaped tightening sleeve 24 on the positioning rod 22.

[0044] S11: When a single row of electrodes is worn out and unusable, the row spacing of the profiling electrodes 3 is compensated in the NC program, and the part fillet can be processed again until all rows of arc bosses 33 of the profiling electrodes 3 are unusable. The profiling electrodes 3 are then replaced as a whole. This step can reduce the repetitive labor of replacing electrodes.

Claims

1. A stator pole shoe arc angle processing device, characterized in that: The invention comprises a rotating mechanism (1), a fixture mechanism (2), a profiling electrode (3), a tailstock (4), a switch mechanism (5), and a mounting plate (6); the rotating mechanism (1), the tailstock (4), and the switch mechanism (5) are fixed on the mounting plate (6) in sequence; the support (12) of the rotating mechanism (1) is an irregular structure, one end of which is fixed on the mounting plate (6) and the other end is connected to the fixture mechanism (2); the other end of the fixture mechanism (2) is connected to the tailstock (4); the profiling electrode (3) is mounted on the electrode chuck of the machine tool; the profiling electrode (3) moves so that its side surface (32) presses the switch mechanism (5) and sends a signal to the motor (11) of the rotating mechanism (1); the motor (11) serves as a rotational power source and drives the parts on the fixture mechanism (2) to perform indexing rotation.

2. The stator pole shoe arc angle processing device according to claim 1, characterized in that: The rotating mechanism (1) comprises a motor (11), a support (12), a pulley a (13), a belt (14), an idler wheel (15), a pulley b (16), a fixed block (17), an adjusting screw (18), and a sliding plate (19); the output shaft of the motor (11) passes through the mounting hole of the pulley a (13) and is fixedly mounted on the support (12); the pulley a (13) is connected to the pulley b (16) via the belt (14); the fixed block (17) is fastened to the support (12); and the shaft of the adjusting screw (18) is inserted into the fixed block (17). The cylindrical ends of the shaft are clamped in the two end faces of the fixed block (17) in the open slide. The long end of the adjusting screw (18) is a threaded rod, which is screwed into the threaded hole at the left end of the sliding plate (19). The long groove of the support (12) guides the sliding plate (19). The idler wheel (15) is movably connected to the sliding plate (19). The movement of the sliding plate (19) on the support (12) is adjusted by twisting the adjusting screw (18), and then the belt (14) is tightened to complete the pre-tightening of the belt (14).

3. The stator pole shoe arc angle processing device according to claim 1, characterized in that: The motor (11) comprises a bearing seat assembly (110), a positioning shaft (111), and a shield (112); the outer circle of the left end of the bearing seat assembly (110) cooperates with the positioning hole of the support (12); the bearing seat assembly (110) has four evenly distributed threaded mounting holes, which are fastened to the support (12) by screws; the positioning shaft (111) passes through the bearing of the bearing seat assembly (110) and is inserted into the hole of the pulley b (16), and the rotation of the pulley b (16) drives the positioning shaft (111) to rotate.

4. The stator pole shoe arc angle processing device according to claim 1, characterized in that: The clamping mechanism (2) comprises a soft claw (21), a positioning rod (22), a special-shaped washer (23), and a special-shaped top tightening sleeve (24); one end of the soft claw (21) is connected to the rotating mechanism (1), and the other end is connected to the positioning rod (22); a plurality of special-shaped washers (23) are sleeved on the positioning rod (22) and separate the parts one by one; the special-shaped top tightening sleeve (24) is sleeved on the other end of the positioning rod (22) and connected to the tailstock (4).

5. The stator pole shoe arc angle processing device according to claim 4, characterized in that: The soft claw (21) includes a chassis and a connecting column. The connecting column is provided with a special-shaped hole (213) and a flat plate 212. The special-shaped hole (213) positions the radial direction of the positioning rod (22). The shape of the hole is consistent with the shape of the positioning rod (22) and the shape of the inner hole of the part. The circle of the special-shaped hole (213) is coaxial with the outer circle (211) of the chassis. The chassis is inserted into the inner hole of the positioning shaft (111) of the motor of the rotating mechanism (1). The opposite side of the flat plate (212) contains a top screw hole, and the axial direction of the positioning rod (22) is fixed by the top screw.

6. The stator pole shoe arc angle processing device according to claim 5, characterized in that: The flat surface (212) is parallel to the groove on the special-shaped hole (213).

7. The stator pole shoe arc angle processing device according to claim 4, characterized in that: The shaped hole of the shaped tightening sleeve (24) completely overlaps with the positioning rod (22); its left end face (241) fits with the end face of the part, and the chamfer (242) of the hole in the right end face is a 60° chamfer, which fits with the top face of the tailstock (4). The tightening force transmitted by the top of the tailstock (4) causes the left end face (241) to press the end face of the part, thereby completing the fixation of the part on the positioning rod (22).

8. The stator pole shoe arc angle processing device according to claim 1, characterized in that: The bottom of the contoured electrode (3) is provided with an arc boss (33), and the arc bosses (33) are distributed in a linear array, and the shape of the arc bosses (33) is completely consistent with the fillet of the machined part.

9. The stator pole shoe arc angle processing device according to claim 1, characterized in that: The switch mechanism (5) comprises a switch (51), a switch bracket (52), a column (53), and a base (54); the switch bracket (52) connects the switch (51) to the column (53); the switch bracket (52) comprises a slotted through hole, which penetrates the column (53) and is freely adjustable in the axial and radial directions of the column (53); the axial direction is limited by a washer at the upper end of the column and the upper end surface of the base (54); tightening the handle screw (55) causes the slotted through hole to deform, tightens the column (53), fixes the switch bracket (52), and fixes the column (53) on the base (54).

10. A method for machining the arc angle of a stator pole shoe, wherein the method comprises the following steps: S1: After assembling the entire device, multiple stators are inserted into the positioning rod (22) in the order of the special-shaped washer (23), the stator, and the special-shaped washer (23). The rightmost end of the positioning rod (22) is inserted into the special-shaped top tightening sleeve (24) and is tightened by the top of the tailstock (4); by adjusting the rotating mechanism (1) and the tailstock (4), the coaxiality of the two ends of the positioning rod (22) of the clamping mechanism (2) is ensured to be within 0.02~0.05mm; S2: Install the entire device on the workbench of the EDM machine, insert the flat key 63 of the mounting plate (6) into the keyway of the workbench, and pre-tighten the mounting plate (6) through the pressure plate on the workbench; install the micrometer on the spindle of the EDM machine, and use the micrometer to straighten and fine-tune the fixture mechanism (2) by operating the spindle to ensure that the accuracy of the rotation axis of the fixture mechanism (2) and the X-axis of the machine tool is within 0.02 mm; after ensuring the accuracy, tighten the pressure plate screw to press the mounting plate (6) to complete the fixation of the entire device; S3: Use a micrometer to straighten the flat (212) on the soft claw (21), and adjust it by rotating the rotating mechanism (1) so that the plane runout of the flat (212) is within 0.01 mm; S4: Use a vernier caliper to measure the distance from the left end face of the leftmost stator on the positioning rod (22) to the right end face of the rightmost stator. This distance = (number of stators x stator thickness + number of special-shaped washers (23) x thickness of special-shaped washers (23)) ± 0.05 mm. The machining thickness error of the special-shaped washers (23) themselves is within 0.01 mm, so that the cumulative thickness error does not exceed ± 0.05 mm. S5: Editing the processing path of the profiling electrode (3) in the operating system of the machine tool; the processing path must ensure that after each processing of the stator pole shoe arc angle of one angle is completed, the profiling electrode moves to the press switch (51) and presses the contact (511); S6: Start the machine tool and use the profiling electrode (3) to perform electrical discharge machining on the arc angle of the stator pole shoe; S7: After the arc angle of the pole shoe is processed, the contour electrode (3) touches the contact (511) of the press switch (51) along the programmed path, so that the press switch (51) sends a signal to the rotating mechanism (1); S8: After receiving the signal, the motor performs indexing rotation, and the machine tool then operates the profiling electrode (3) to process the next pole shoe arc angle; S9: Repeat the above operation until all pole shoe arc angles on the stator are fully EDMed; S10: Loosen the tailstock and remove the stator, special-shaped washer (23) and special-shaped top sleeve (24) on the positioning rod (22); S11: When a single row of electrodes is worn out and cannot be used, the row spacing of the profiling electrode (3) is compensated in the CNC program, and the part fillet can be processed continuously until all rows of arc bosses (33) of the profiling electrode (3) cannot be used, and then the profiling electrode (3) is replaced as a whole.

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