Laminated iron core bonding manufacturing method

Abstract

The invention discloses a laminated iron core bonding manufacturing method, which belongs to the field of motors, and comprises the following steps: performing laser texturing on the surface of a plate made of amorphous alloy, and etching a microstructure on the surface of the plate; dispensing and laminating the plurality of plates to form a plurality of layers of plates; blanking the multi-layer plate to form a plurality of multi-layer laminated sheets; a plurality of multi-layer laminations are stacked in the height direction, glue dispensing is conducted on the surface of each multi-layer lamination in the stacking process, the multiple stacked multi-layer laminations are laminated and cured, laser ultrasonic scanning is conducted on the manufactured iron core, the iron core generates reflected waves and transmitted waves, the reflected waves and the transmitted waves are collected, and the iron core is obtained. According to the method, damage reflected waves are extracted from aliasing signals, abnormal waves are captured, energy space-time distribution characteristics of a damage sensitive frequency band are extracted, imaging is carried out, plane positioning, size inversion and morphology reconstruction of debonding defects are achieved, a laminated iron core is made of an amorphous alloy material, and the amorphous alloy material is not damaged due to the fact that a bonding method is adopted for manufacturing.

Description

Technical Field

[0001] This invention relates to electric motors, and more particularly to a method for manufacturing laminated iron cores by bonding. Background Technology

[0002] Existing motor cores are formed by stacking silicon steel sheets, but cores made of silicon steel sheets have high losses and temperature rise during use. Therefore, amorphous alloy materials are used to make the laminations. The high permeability, low coercivity, high saturation magnetic flux density and low loss of amorphous alloy materials can effectively reduce the losses and temperature rise of the core during use.

[0003] However, the thinness, brittleness, and hardness of amorphous alloys at room temperature make their stamping process difficult, cause rapid die wear, and result in high stamping costs. Therefore, when amorphous alloy strips are stamped and stacked, the resulting stacks are easily damaged. Furthermore, the fixing process of multiple stacked stacks typically employs welding, riveting, and adhesive bonding. The thermal process of welding can destroy the amorphous structure, leading to crystallization, which directly degrades material properties. Riveting easily damages the stacks made of amorphous alloys. When using adhesive bonding, the low surface energy of amorphous alloys makes it difficult for the adhesive to spread sufficiently, resulting in poor bonding and delamination within the core. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, one of the objectives of the present invention is to provide a method for bonding and manufacturing a laminated iron core made of amorphous alloy material.

[0005] One of the objectives of this invention is achieved through the following technical solution:

[0006] A method for bonding and manufacturing a laminated iron core includes the following steps:

[0007] Plate processing: Laser texturing is applied to the surface of amorphous alloy plates to etch microstructures onto the surface of the amorphous alloy plates to enhance hydrophobicity;

[0008] Board bonding: Apply adhesive to multiple boards. When applying adhesive to each board, first measure the size of the adhesive dots spread on the board after laser texturing. Arrange the adhesive dots tangentially according to the size of the spread. Apply adhesive according to the arrangement of adhesive dots, allowing the adhesive to penetrate into the microstructure of the board surface. Stack multiple boards to form a multi-layer board.

[0009] Stacking and punching: punching multiple layers of sheet material to form multiple stacked sheets;

[0010] Laminate bonding: Multiple multilayer laminates are stacked along the height direction. During the stacking process, adhesive is applied to the upper and / or lower surfaces of each multilayer laminate. The stacked multilayer laminates are then pressed and cured. The initial pressure during pressing and curing is P1, which allows gas to escape between the multiple multilayer laminates. The main pressure is P2, which ensures the adhesive flows fully. The holding pressure is P3, which inhibits the adhesive from cooling and cracking. P1 < P3 < P2.

[0011] Quality inspection: Laser ultrasonic scanning is performed on the completed iron core to generate reflected and transmitted waves. The reflected and transmitted waves are collected, and damage reflected waves are extracted from the aliasing signals. Abnormal waves are captured, and the spatiotemporal distribution characteristics of energy in the damage-sensitive frequency band are extracted and imaged to realize the planar positioning, size inversion and morphology reconstruction of debonding defects.

[0012] Furthermore, in the plate processing step, the laser texture is a femtosecond laser or a water-guided laser.

[0013] Furthermore, in the plate processing step, the shape of the laser texture is a concave microstructure or a linear microgroove.

[0014] Furthermore, in the board bonding step, the tangential arrangement of the adhesive dots specifically refers to the rectangular array arrangement or the staggered arrangement of the adhesive dots.

[0015] Furthermore, when the adhesive dots are arranged in an alternating pattern, the line connecting the centers of three adjacent adhesive dots forms a 60° angle.

[0016] Furthermore, in the quality inspection step, the incident wave and the reflected wave field are first separated by windowing in the frequency-wavenumber domain using a three-dimensional Fourier transform on the collected reflected wave and transmitted wave to eliminate the interference of the substrate signal; then the damaged reflected wave is extracted from the aliased signal.

[0017] Furthermore, after extracting the spatiotemporal distribution characteristics of the energy in the damage-sensitive frequency band and imaging them, the planar location, size inversion, and morphology reconstruction of the debonding defect are achieved by combining multiple physical quantities such as the arrival time shift of the reflected wave, phase distortion, amplitude attenuation, wavenumber field anomaly, and time-frequency domain energy mutation.

[0018] Furthermore, in the board bonding step, the multiple boards are stacked to form a multilayer board, specifically: the initial pressure during stacking and curing is P1, which allows the gas between the multiple boards to be discharged; the main pressure is P2, which allows the adhesive to flow fully; the holding pressure is P3, which inhibits the adhesive from cooling and cracking, and P1 < P3 < P2.

[0019] Compared to existing technologies, the present invention's method for bonding and manufacturing multilayer iron cores involves laser texturing the surface of an amorphous alloy sheet to etch a microstructure, thereby enhancing hydrophobicity. Multiple sheets are then glued together. Before glue application to each sheet, the size of the glue dots spread on the laser-textured sheet is measured, and the dots are arranged tangentially according to this size. Glue is then applied according to this dot arrangement, allowing the glue to penetrate deep into the microstructure of the sheet surface. The multiple sheets are then stacked to form a multilayer sheet. The multilayer sheet is then punched to form multiple multilayer laminates. These multilayer laminates are then stacked along their height, with glue applied to the upper and / or lower surfaces of each laminate during the stacking process. Multiple multilayer laminates are stacked and cured. The initial pressure during stacking and curing is P1, which allows gas to escape between the multiple multilayer laminates. The main pressure is P2, which allows the adhesive to flow fully. The holding pressure is P3, which inhibits the adhesive from cooling and cracking. P1 < P3 < P2. The completed iron core is subjected to laser ultrasonic scanning to generate reflected and transmitted waves. The reflected and transmitted waves are collected, and damage reflected waves are extracted from the mixed signals. Abnormal waves are captured, and the energy spatiotemporal distribution characteristics of the damage-sensitive frequency band are extracted and imaged. This enables planar localization, size inversion, and morphological reconstruction of debonding defects. The multilayer iron core is made of amorphous alloy material and manufactured using an adhesive method. Attached Figure Description

[0020] Figure 1 This is a flowchart of the method for bonding and manufacturing the laminated iron core according to the present invention;

[0021] Figure 2 This is a diagram showing the adhesive arrangement in the laminated iron core bonding manufacturing method of the present invention. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or it can be fixed through another intermediate component. When a component is said to be "connected to" another component, it can be directly connected to the other component or it may be fixed through another intermediate component. When a component is said to be "set on" another component, it can be set directly on the other component or it may be set through another intermediate component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0025] like Figure 1 As shown, the method for manufacturing a laminated iron core according to the present invention includes the following steps:

[0026] A method for bonding and manufacturing a laminated iron core includes the following steps:

[0027] Plate processing: Laser texturing is applied to the surface of amorphous alloy plates to etch microstructures onto the surface of the amorphous alloy plates to enhance hydrophobicity;

[0028] Board bonding: Apply adhesive to multiple boards. When applying adhesive to each board, first measure the size of the adhesive dots spread on the board after laser texturing. Arrange the adhesive dots tangentially according to the size of the spread. Apply adhesive according to the arrangement of adhesive dots, allowing the adhesive to penetrate into the microstructure of the board surface. Stack multiple boards to form a multi-layer board.

[0029] Stacking and punching: punching multiple layers of sheet material to form multiple stacked sheets;

[0030] Laminate bonding: Multiple multilayer laminates are stacked along the height direction. During the stacking process, adhesive is applied to the upper and / or lower surfaces of each multilayer laminate. The stacked multilayer laminates are then pressed and cured. The initial pressure during pressing and curing is P1, which allows gas to escape between the multiple multilayer laminates. The main pressure is P2, which ensures the adhesive flows fully. The holding pressure is P3, which inhibits the adhesive from cooling and cracking. P1 < P3 < P2.

[0031] Quality inspection: Laser ultrasonic scanning is performed on the completed iron core to generate reflected and transmitted waves. The reflected and transmitted waves are collected, and damage reflected waves are extracted from the aliasing signals. Abnormal waves are captured, and the spatiotemporal distribution characteristics of energy in the damage-sensitive frequency band are extracted and imaged to realize the planar positioning, size inversion and morphology reconstruction of debonding defects.

[0032] Specifically, in the sheet processing step, the sheet is made of non-alloy material, specifically iron-based non-alloy material. Iron-based non-alloy material can significantly reduce core loss and temperature rise. However, the thinness, brittleness, and hardness of non-alloy materials at room temperature make their punching difficult. Furthermore, when welding or riveting is used to fix the laminations together, the welding thermal process can destroy the amorphous structure, leading to crystallization, which directly degrades the material properties. The riveting pressure can easily damage the laminations made of amorphous alloy materials. In this application, adhesive bonding is used. To address the problem of low surface energy of amorphous alloy materials, making it difficult for adhesive to spread sufficiently and resulting in poor bonding and delamination in the core, laser texturing is applied to the surface of the amorphous alloy sheet to enhance hydrophobicity. Due to the lack of grain boundaries and other characteristics of amorphous materials, they have a low thermal conductivity and unique long-range disorder and short-range order atomic-scale inhomogeneity, making it easy to construct micro- and nano-structures on the surface of amorphous alloys.

[0033] Specifically, laser texturing utilizes femtosecond lasers or water-guided lasers to create concave microstructures or linear microgrooves on the surface of the substrate. During laser texturing, the height of the texture is related to the number of laser scans. As the number of scans increases, the height of the texture increases. When the number of scans is low, the texture depth is insufficient to trap enough air to support the droplets, resulting in some droplets making full contact with the rough surface and thus having a small contact angle. When the number of scans is too high, cracks are more likely to form. In this embodiment, the number of laser scans is 6-8.

[0034] The specific steps of board bonding are as follows: When adhesive dots are sprayed onto the surface of the object to be bonded, they begin to spread outwards at a specific speed. The speed of this spreading depends on the affinity between the adhesive dots and the surface of the object to be bonded. The spreading phenomenon is essentially the continuous movement of the solid-liquid-gas three-phase contact line until it reaches a stable state and stops moving. Bonding between iron core laminations is a superimposed constraint spreading process. First, adhesive dots are sprayed onto the surface of one iron core lamination, and then it is bonded to another iron core lamination. During this process, the adhesive dots spread and diffuse outwards after being superimposed. Therefore, it is necessary to measure the size of the adhesive dots spread on the board after laser texturing, and then design the arrangement of the adhesive dots based on the size of the spread.

[0035] Please continue reading. Figure 2The adhesive dots are arranged tangentially, specifically in a rectangular array or a staggered arrangement. When the adhesive dots are staggered, the lines connecting the centers of three adjacent dots form a 60° angle. The entire lamination process involves spraying adhesive dots onto the bottom of the upper layer, followed by a rapid downward movement of the upper layer to contact the lower layer, causing a change in the shape of the adhesive dots. As the adhesive dots move to contact the lower layer, the downward speed of the upper layer slows down, and the shape of the adhesive dots remains unchanged or changes only slightly. Subsequently, the adhesive dots continue to spread under the pressure of the two parallel layers until the upper layer falls to a fixed position and the spreading stops.

[0036] The process of stacking multiple boards to form a multi-layer board is as follows: the initial pressure during the stacking and curing is P1, which allows the gas between the multiple boards to be expelled; the main pressure is P2, which allows the adhesive to flow fully; and the holding pressure is P3, which inhibits the adhesive from cooling and cracking. P1 < P3 < P2.

[0037] The specific quality inspection steps are as follows: Utilizing the characteristics of interface delamination and debonding defects, which cause a series of changes in the waveform, phase information, amplitude, flight time, and propagation speed of reflected and transmitted waves, the quality of adhesive bonding is inspected. First, the collected reflected and transmitted waves are windowed in the frequency-wavenumber domain using a three-dimensional Fourier transform to separate the incident and reflected wave fields, eliminating substrate signal interference. Then, the damaged reflected wave is extracted from the aliased signal. Combining spatial window Fourier transform technology to capture local wavenumber anomalies, STFT is simultaneously used to extract the spatiotemporal energy distribution characteristics of the damage-sensitive frequency band and perform imaging. By comprehensively considering multiple physical quantities such as reflected wave arrival time shift, phase distortion, amplitude attenuation, wavenumber field anomalies, and time-frequency domain energy mutations, the planar location, size inversion, and morphological reconstruction of debonding defects are successfully achieved. The signal tomography and feature fusion strategy significantly improves the detection effect, with a signal-to-noise ratio improvement of over 11 dB, imaging quality reaching millimeter level, depth detection error less than 1.7%, and size detection error less than 1.2%.

[0038] Compared to existing technologies, the present invention's method for bonding and manufacturing multilayer iron cores involves laser texturing the surface of an amorphous alloy sheet to etch a microstructure, thereby enhancing hydrophobicity. Multiple sheets are then glued together. Before glue application to each sheet, the size of the glue dots spread on the laser-textured sheet is measured, and the dots are arranged tangentially according to this size. Glue is then applied according to this dot arrangement, allowing the glue to penetrate deep into the microstructure of the sheet surface. The multiple sheets are then stacked to form a multilayer sheet. The multilayer sheet is then punched to form multiple multilayer laminates. These multilayer laminates are then stacked along their height, with glue applied to the upper and / or lower surfaces of each laminate during the stacking process. Multiple multilayer laminates are stacked and cured. The initial pressure during stacking and curing is P1, which allows gas to escape between the multiple multilayer laminates. The main pressure is P2, which allows the adhesive to flow fully. The holding pressure is P3, which inhibits the adhesive from cooling and cracking. P1 < P3 < P2. The completed iron core is subjected to laser ultrasonic scanning to generate reflected and transmitted waves. The reflected and transmitted waves are collected, and damage reflected waves are extracted from the mixed signals. Abnormal waves are captured, and the energy spatiotemporal distribution characteristics of the damage-sensitive frequency band are extracted and imaged. This enables planar localization, size inversion, and morphological reconstruction of debonding defects. The multilayer iron core is made of amorphous alloy material and manufactured using an adhesive method.

[0039] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the invention patent. It should be noted that, for those skilled in the art, several modifications and improvements can be made without departing from the concept of the present invention. These are all equivalent modifications and improvements made to the above embodiments based on the essential technology of the present invention, and all of these fall within the protection scope of the present invention.

Claims

1. A method for manufacturing a laminated iron core by bonding, characterized in that, Includes the following steps: Plate processing: Laser texturing is applied to the surface of amorphous alloy plates to etch microstructures onto the surface of the amorphous alloy plates to enhance hydrophobicity; Board bonding: Apply adhesive to multiple boards. When applying adhesive to each board, first measure the size of the adhesive dots spread on the board after laser texturing. Arrange the adhesive dots tangentially according to the size of the spread. Apply adhesive according to the arrangement of adhesive dots, allowing the adhesive to penetrate into the microstructure of the board surface. Stack multiple boards to form a multi-layer board. Stacking and punching: punching multiple layers of sheet material to form multiple stacked sheets; Laminate bonding: Multiple multilayer laminates are stacked along the height direction. During the stacking process, adhesive is applied to the upper and / or lower surfaces of each multilayer laminate. The stacked multilayer laminates are then pressed and cured. The initial pressure during pressing and curing is P1, which allows gas to escape between the multiple multilayer laminates. The main pressure is P2, which ensures the adhesive flows fully. The holding pressure is P3, which inhibits the adhesive from cooling and cracking. P1 < P3 < P2. Quality inspection: Laser ultrasonic scanning is performed on the completed iron core to generate reflected and transmitted waves. The reflected and transmitted waves are collected, and damage reflected waves are extracted from the aliasing signals. Abnormal waves are captured, and the spatiotemporal distribution characteristics of energy in the damage-sensitive frequency band are extracted and imaged to realize the planar positioning, size inversion and morphology reconstruction of debonding defects.

2. The method for manufacturing laminated iron cores by bonding according to claim 1, characterized in that: In the plate processing step, the laser texture is a femtosecond laser or a water-guided laser.

3. The method for manufacturing laminated iron cores by bonding according to claim 1, characterized in that: In the plate processing step, the shape of the laser texture is a concave microstructure or a linear microgroove.

4. The method for manufacturing laminated iron cores by bonding according to claim 1, characterized in that: In the board bonding step, the tangential arrangement of the adhesive dots specifically refers to the rectangular array arrangement or the staggered arrangement of the adhesive dots.

5. The method for manufacturing laminated iron cores by bonding according to claim 4, characterized in that: When the adhesive dots are arranged in an alternating pattern, the line connecting the centers of three adjacent adhesive dots forms a 60° angle.

6. The method for manufacturing laminated iron cores by bonding according to claim 1, characterized in that: In the quality inspection step, the incident wave and the reflected wave field are first separated by windowing in the frequency-wavenumber domain using a three-dimensional Fourier transform on the collected reflected wave and transmitted wave to eliminate the interference of the substrate signal; then the damaged reflected wave is extracted from the aliased signal.

7. The method for manufacturing laminated iron cores by bonding according to claim 6, characterized in that: After extracting the spatiotemporal distribution characteristics of the energy in the damage-sensitive frequency band and imaging them, the planar location, size inversion, and morphology reconstruction of the debonding defect are achieved by combining multiple physical quantities such as the arrival time shift of the reflected wave, phase distortion, amplitude attenuation, wavenumber field anomaly, and time-frequency domain energy mutation.

8. The method for manufacturing laminated iron cores by bonding according to claim 1, characterized in that: In the board bonding step, multiple boards are stacked to form a multilayer board. Specifically, the initial pressure during the stacking and curing process is P1, which allows the gas between the multiple boards to be discharged; the main pressure is P2, which allows the adhesive to flow fully; and the holding pressure is P3, which inhibits the adhesive from cooling and cracking. P1 < P3 < P2.

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