Installation tool and installation process for magnetic steel of direct-drive permanent magnet synchronous motor

Abstract

The invention relates to the technical field of motor magnetic steel installation, in particular to an installation tool and an installation process for magnetic steel of a direct-drive permanent magnet synchronous motor. Comprising a detachable assembly, a fixing assembly and a rotor assembly, the detachable assembly comprises a tool pressing plate and a magnetic steel pressing block, the fixing assembly comprises a punching sheet pressing plate and a double-thread screw, and the rotor assembly comprises a rotor connecting piece, a rotor punching sheet and magnetic steel. The rotor punching sheet and the magnetic steel are fixedly installed through the punching sheet pressing plate which is fixedly connected to the end portion of the rotor connecting piece, the rotor punching sheet is provided with a plurality of reserved installation holes in a penetrating mode to be installed with the double-thread screw in a matched mode, the rotor punching sheet is provided with a magnetic steel groove, and the magnetic steel is placed in the magnetic steel groove. The magnetic steel is fixed through the magnetic steel pressing block installed on the tool pressing plate. The magnetic steel of the direct-drive permanent magnet synchronous motor is installed through a special installation tool and an installation technology, the possibility that gaps are generated between the magnetic steel is reduced, and the performance of the motor is improved.

Description

Technical Field

[0001] This invention relates to the field of motor magnet installation technology, and in particular to an installation fixture and process for magnets in a direct-drive permanent magnet synchronous motor. Background Technology

[0002] A direct-drive permanent magnet synchronous motor is a synchronous motor that uses permanent magnets to generate a magnetic field. Its characteristics include providing extremely high output torque and direct connection to the load. Direct-drive permanent magnet synchronous motors can directly drive heavy loads without a reduction gear, eliminating mechanical transmission components such as gearboxes. Compared to traditional motors, they offer higher efficiency, better dynamic performance, fewer losses, and lower noise, making them widely used in various fields.

[0003] The working principle of a direct-drive permanent magnet synchronous motor is based on the interaction between the rotating magnetic field generated by the stator windings and the constant magnetic field of the rotor permanent magnets. High-strength permanent magnets, or magnets, are mounted on the rotor, often using adhesive bonding. However, due to the repulsive force between the axial magnets, the rotor laminations are easily displaced axially before the adhesive cures, resulting in gaps between the laminations. After the adhesive cures, gaps remain between the magnets. During motor operation, it is impossible to prevent the magnets from shifting or falling out, leading to a significant reduction in motor performance.

[0004] Therefore, there is an urgent need for a tooling and installation process for the magnets of a direct-drive permanent magnet synchronous motor to solve the above-mentioned technical problems. Summary of the Invention

[0005] The purpose of this invention is to solve the problems in the background art and provide an installation fixture and installation process for the magnets of a direct-drive permanent magnet synchronous motor.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A fixture for mounting magnets in a direct-drive permanent magnet synchronous motor includes a detachable component, a fixed component, and a rotor assembly. The detachable component includes a fixture pressure plate and a magnet clamping block. The fixed component includes a lamination pressure plate and a double-ended screw. The rotor assembly includes a rotor connector, rotor laminations, and magnets. The rotor assembly is fixedly mounted by the lamination pressure plate fixedly connected to the end of the rotor connector. The rotor laminations have several pre-drilled mounting holes that cooperate with the double-ended screw for mounting. The rotor laminations have magnet slots, and the magnets are placed in the magnet slots. In the detachable component, the rotor laminations are fixedly mounted by the fixture pressure plate fixedly connected to the end of the rotor connector, and the magnets are fixedly mounted by the magnet clamping block fixedly connected to the fixture pressure plate.

[0007] Preferably, the tooling pressure plate and the lamination pressure plate are plates with fan-shaped rings at the ends, and their outer circles fit the outer contour of the rotor assembly. During installation, they completely cover the rotor assembly, achieving stable surface contact with the largest area. The clamping force applied by the bolt structure is transformed into a uniformly distributed surface pressure through the shape of the fan-shaped ring, and is vertically and evenly transmitted to the rotor assembly, ensuring that the force applied to the rotor assembly is evenly distributed, thereby achieving effective fixation of the rotor assembly and making the ends of the rotor laminations and magnets flush with the rotor connector.

[0008] Preferably, the outer diameter of the tooling plate is not greater than the distance from the magnet slot to the axis of the rotor connector, and the outer diameter of the lamination plate is not less than the distance from the outermost point of the magnet to the axis of the rotor connector. This precisely defines the force application boundary of the tooling plate, ensuring that the force application range of the lamination plate completely covers the entire circumferential projection area of ​​the rotor assembly. This achieves effective fixation of the rotor lamination by the tooling plate and the rotor assembly by the lamination plate, ensuring that the ends of the rotor lamination and the magnet are flush with the rotor connector, while avoiding interference between the edge of the tooling plate and the magnet slot, thus preventing damage. The difference in the outer diameter of the tooling plate and the lamination plate provides working space for the magnet clamping block used to fix the magnet later.

[0009] Preferably, the magnet pressing block is provided with a positioning boss, the height of which is equal to the thickness of the tooling plate, so that the magnet pressing block can be quickly positioned to a predetermined position. The lower surface of the magnet pressing block body is in contact with the tooling plate, and the lower surface of the positioning boss is in contact with the end of the magnet at the same height as the rotor connector. When the bolt structure applies a clamping force to the magnet pressing block, the force is decomposed into two synchronous force flows. One part is transmitted to the tooling plate through the body of the magnet pressing block, and the other part is transmitted directly and vertically to the end of the magnet through the positioning boss of the magnet pressing block. By splitting the force, the tooling plate and the magnet are synchronously clamped and fixed, and the magnet is ensured to be clamped until its end is flush with the end of the rotor connector.

[0010] Preferably, the rotor laminations are mounted on the double-ended screw through the pre-drilled mounting holes. Several rotor laminations are stacked in a staggered manner. By misaligning the rotor laminations axially, a small phase difference in the circumferential direction is generated between the magnets mounted on adjacent layers of rotor laminations. This interrupts the continuous air gap, making the air gap magnetic flux density distribution along the axial direction closer to a sine wave. This optimizes the continuity of the magnetic circuit in the axial direction, forming a more uniform and stable magnetic field distribution. This significantly weakens the harmonic components in the magnetic field generated by the rotor, thereby effectively reducing iron loss and torque pulsation. At the same time, it reduces magnetic noise at the source, generates greater output torque, and further improves motor performance.

[0011] An installation process for magnets in a direct-drive permanent magnet synchronous motor includes the following steps: S1. Install the lamination plate and fix the double-ended screw. Clean the surface of the required parts. Fix the lamination plate with screws at the end of the rotor connector. Pass the double-ended screw through the reserved mounting hole of the lamination plate and fix the double-ended screw with a nut. S2. Rotor lamination installation and tooling plate fixing: Clean the surface of the required parts, align the reserved mounting holes of the rotor laminations with the double-ended screws and stack them crosswise until they are the same height as the rotor connector. Then, fix the rotor laminations at the end of the rotor connector with the tooling plate, fix the tooling plate with screws, and lock the double-ended screws with nuts. S3. Magnet bonding and magnet clamping block fixation: Clean the surface of the required parts, add glue to the inner diameter of the magnet, and bond it to the magnet slot of the rotor lamination. After bonding, remove the double-headed screw nut at the end of the tooling plate, put in the magnet clamping block, and fix the magnet clamping block and tooling plate with the nut. S4. Remove the detachable components and fix the lamination plate. Clean the surface of the required parts. After the glue has cured, remove the magnet block and tooling plate. Fix the lamination plate with screws at the end of the rotor connector and tighten the double-ended screw with nuts.

[0012] Preferably, in step S3, the magnets are pasted and fixed to the magnet clamps in a group sequence; the magnets are grouped, and each group contains at least one magnet. The magnets are pasted into the magnet grooves in a group sequence. After the magnets in the current group are pasted, the magnet clamps corresponding to the current group are fixed. This way, during the installation process, only the repulsive force between a group of magnets needs to be dealt with, reducing the total repulsive force acting simultaneously on the magnets and giving the magnets sufficient initial fixing strength.

[0013] Preferably, in step S4, the detachable components are removed and fixed to the lamination plate in a group sequence. After the glue on the magnets of the current group has cured, the detachable components corresponding to the current group are removed and the lamination plate corresponding to the current group is fixed. The overall installation task is decomposed into multiple units to prevent gaps from forming between the magnets and the rotor laminations before the glue cures. This reduces the difficulty and complexity of operation while ensuring installation accuracy, and improves the flexibility and efficiency of production.

[0014] Preferably, the projection of the tooling plate on the circumferential direction of the rotor assembly covers the magnet slots. For each group of magnets, the number of magnets is no more than the number of magnet slots covered by the corresponding tooling plate. This ensures that the clamping force transmitted by the tooling plate and the corresponding magnet clamping block of the current group, applied by the bolt structure, only needs to cover a limited predetermined area. This ensures that the magnet clamping block of the current group is sufficient to simultaneously clamp and fix all the magnets in the group, thereby allowing the magnets covered by the current group and the rotor laminations to be independently and reliably fixed. This avoids the force dispersion caused by an excessively large area, which would prevent the clamping force from acting effectively and evenly on each magnet and rotor lamination, thus achieving effective initial fixing.

[0015] In summary, the present invention has the following beneficial effects: 1. The present invention provides a mounting fixture and installation process for magnets of a direct-drive permanent magnet synchronous motor. It provides a dedicated mounting fixture and a dedicated installation process to ensure that the magnets can be stably fixed, significantly reducing the possibility of gaps between magnets, solving the problem that magnets cannot be fixed by glue alone during motor operation, optimizing magnetic circuit performance and mechanical stability, reducing the difficulty and complexity of operation, improving production flexibility and efficiency, and further improving motor performance. 2. The installation fixture and installation process for the magnets of a direct-drive permanent magnet synchronous motor described in this invention decomposes the magnet fixing device into a detachable component and a fixing component, providing temporary and strong axial mechanical constraints during the adhesive curing period, effectively resisting the axial repulsive force between magnets, preventing the magnets from displacing before the adhesive cures, thereby preventing the magnets from driving the rotor laminations to generate axial displacement and inter-laminar gaps. 3. The installation fixture and process for the magnets of a direct-drive permanent magnet synchronous motor described in this invention implements step-by-step installation of the magnets, reduces the total repulsive force acting simultaneously on the magnets, and ensures that the magnets always maintain the predetermined relative position after the adhesive cures. This solves the problem of gaps between magnets after adhesive curing due to repulsive forces, and guarantees the final bonding strength. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the installation fixture structure of the present invention; Figure 2This is a schematic diagram of the assembly structure of the detachable component, the fixed component, and the rotor component of the present invention; Figure 3 This is a schematic diagram of the assembly structure of the fixed component and the rotor component of the present invention; Figure 4 This is a schematic diagram of the rotor assembly structure of the present invention; Figure 5 This is a schematic diagram of the rotor assembly structure of the present invention; Figure 6 This is a schematic diagram of the installation tooling assembly structure of the present invention.

[0017] In the figure, 1-removable component, 11-tooling plate, 12-magnetic steel block, 121-positioning boss, 2-fixed component, 21-punch plate, 22-double-ended screw, 3-rotor assembly, 31-rotor connector, 32-rotor lamination, 321-reserved mounting hole, 322-magnetic slot, 33-magnet. Detailed Implementation

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

[0019] Example 1

[0020] according to Figure 1 , Figure 2 As shown, an installation fixture for magnets in a direct-drive permanent magnet synchronous motor includes a detachable component 1, a fixing component 2, and a rotor assembly 3. The detachable component 1 includes a fixture pressure plate 11 and a magnet pressing block 12. The fixing component 2 includes a lamination pressure plate 21 and a double-ended screw 22. The rotor assembly 3 includes a rotor connector 31, rotor laminations 32, and magnets 33. The rotor assembly 3 is fixedly installed by the lamination pressure plate 21, which is fixedly connected to the end of the rotor connector 31. The rotor laminations 32 are provided with several reserved mounting holes 321 to cooperate with the double-ended screw 22 for installation. The rotor laminations 32 are provided with magnet slots 322, and the magnets 33 are placed in the magnet slots 322. In the detachable component 1, the rotor laminations 32 are fixedly installed by the fixture pressure plate 11, which is fixedly connected to the end of the rotor connector 31, and the magnets 33 are fixedly installed by the magnet pressing block 12, which is fixedly connected to the fixture pressure plate 11.

[0021] according to Figure 2 , Figure 3As shown, the tooling pressure plate 11 and the lamination pressure plate 21 are plates with fan-shaped rings at the ends. The outer circle fits the outer contour of the rotor assembly 3. During installation, they completely cover the rotor assembly 3 to achieve the largest area of ​​stable surface contact. The clamping force applied by the bolt structure is transformed into a uniformly distributed surface pressure through the shape of the fan-shaped ring, which is transmitted vertically and evenly to the rotor assembly 3. This ensures that the force applied to the rotor assembly 3 is evenly distributed, thereby achieving effective fixation of the rotor assembly 3 and making the rotor laminations 32 and magnets 33 flush with the ends of the rotor connector 31.

[0022] according to Figure 2 As shown, the outer diameter of the tooling plate 11 is not greater than the distance from the magnet slot 322 to the axis of the rotor connector 31, and the outer diameter of the lamination plate 21 is not less than the distance from the outermost point of the magnet 33 to the axis of the rotor connector 31. This precisely defines the force application boundary of the tooling plate 11, ensuring that the force application range of the lamination plate 21 completely covers the entire circumferential projection area of ​​the rotor assembly. This achieves effective fixation of the rotor lamination 32 by the tooling plate 11 and the rotor assembly 3 by the lamination plate 21, ensuring that the rotor lamination 32 and the magnet 33 are flush with the ends of the rotor connector 31, while avoiding interference between the edge of the tooling plate 11 and the magnet slot 322, which could cause damage. The difference in the outer diameter of the tooling plate 11 and the lamination plate 21 also provides working space for the magnet clamping block 12 used to fix the magnet 33.

[0023] according to Figure 2 As shown, the magnet pressure block 12 is provided with a positioning boss 121. The height of the positioning boss 121 is equal to the thickness of the tooling pressure plate 11, so that the magnet pressure block 12 can be quickly positioned to the predetermined position. The lower surface of the magnet pressure block 12 body is in contact with the tooling pressure plate 11, and the lower surface of the positioning boss 121 is in contact with the end of the magnet 33, which is at the same height as the rotor connector 31. When the bolt structure applies a clamping force to the magnet pressure block 12, it decomposes the force into two synchronous force flows. One part is transmitted to the tooling pressure plate 11 through the body of the magnet pressure block 12, and the other part is transmitted directly and vertically to the end of the magnet 33 through the positioning boss 121 of the magnet pressure block 12. By splitting the force, the tooling pressure plate 11 and the magnet 33 are synchronously clamped and fixed, and the magnet 33 is ensured to be clamped until its end is flush with the end of the rotor connector 31.

[0024] according to Figure 4 , Figure 5As shown, the rotor laminations 32 are mounted on the double-ended screw 22 through the reserved mounting holes 321. Several rotor laminations 32 are stacked crosswise. By staggering the rotor laminations 32 in the axial direction, a small phase difference in the circumferential direction is generated between the magnets 33 mounted on the adjacent layers of rotor laminations 32. This interrupts the continuous air gap, making the air gap magnetic flux density distribution along the axial direction closer to a sine wave. This optimizes the continuity of the magnetic circuit in the axial direction, forms a more uniform and stable magnetic field distribution, and significantly weakens the harmonic components in the magnetic field generated by the rotor. This effectively reduces iron loss and torque pulsation, while reducing magnetic noise at the source, generating greater output torque, and further improving motor performance.

[0025] Example 2

[0026] according to Figures 1-6 As shown, an installation process for the magnets of a direct-drive permanent magnet synchronous motor includes the following steps: S1. Install the lamination plate 21 and fix it to the double-ended screw 22. Clean the surface of the required parts. Fix the lamination plate 21 with screws at the end of the rotor connector 31. Pass the double-ended screw 22 through the reserved mounting hole of the lamination plate 21 and fix the double-ended screw 22 with nuts. S2. The rotor lamination 32 is installed and fixed with the tooling plate 11. The surface of the required parts is cleaned. The reserved mounting holes 321 of the rotor lamination 32 are aligned with the double-ended screw 22 and stacked crosswise. After stacking to the same height as the rotor connector 31, the rotor lamination 32 is fixed at the end of the rotor connector 31 with the tooling plate 11, the tooling plate 11 is fixed with screws, and the double-ended screw 22 is locked with nuts. S3. The magnet 33 is pasted and fixed to the magnet pressure block 12. The surface of the required parts is cleaned, glue is added to the inner diameter of the magnet 33, and it is pasted into the magnet groove 322 of the rotor lamination 32. After pasting, the double-headed screw 22 nut at the end of the tooling pressure plate 11 is removed, the magnet pressure block 12 is placed in, and the magnet pressure block 12 is fixed to the tooling pressure plate 11 with the nut. S4. Remove the detachable component 1 from the lamination plate 21, clean the surface of the required parts, and after the glue has cured, remove the magnet block 12 and the tooling plate 11. Fix the lamination plate 21 with screws at the end of the rotor connector 31 and tighten the double-ended screw 22 with nuts.

[0027] according to Figure 6 As shown, in step S3, the magnets 33 are pasted and fixed to the magnet clamping block 12 in a group sequence; the magnets 33 are grouped, and each group contains at least one magnet 33. The magnets 33 are pasted into the magnet groove 322 in a group sequence. After the current group of magnets 33 is pasted, the magnet clamping block 12 is fixed, so that during the installation process, only the repulsive force between a group of magnets 33 needs to be dealt with, reducing the total repulsive force of the magnets 33 acting simultaneously, so that the magnets 33 obtain sufficient initial fixing strength.

[0028] according to Figure 6 As shown, in step S4, the detachable component 1 is removed and fixed to the lamination plate 21 in the order of groups. After the glue cures, the detachable component 1 corresponding to the current group is removed and the lamination plate 21 corresponding to the current group is fixed. The overall installation task is decomposed into multiple units to prevent gaps from forming between the magnet 33 and the rotor lamination 32 before the glue cures. This reduces the difficulty and complexity of operation while ensuring installation accuracy, and improves the flexibility and efficiency of production.

[0029] according to Figure 6 As shown, the projection of the tooling pressure plate 11 on the circumference of the rotor assembly 3 covers the magnet slots 322. For each group of magnets 33, the number of magnets 33 is no more than the number of magnet slots 322 covered by the corresponding tooling pressure plate 11. This ensures that the clamping force transmitted by the tooling pressure plate 11 and the corresponding magnet clamping block 12 of the current group, which is applied by the bolt structure, only needs to cover a limited predetermined area. This ensures that the magnet clamping block 12 of the current group is sufficient to simultaneously clamp and fix all the magnets 33 in the group. As a result, the magnets 33 covered by the current group and the rotor laminations 32 can be fixed independently and reliably. This avoids the force dispersion caused by the large range, which prevents the clamping force from being applied effectively and evenly to each magnet 33 and rotor lamination 32, thus achieving effective initial fixation.

[0030] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. An installation fixture for magnets of a direct-drive permanent magnet synchronous motor, comprising a detachable assembly (1), a fixed assembly (2), and a rotor assembly (3), wherein the detachable assembly (1) comprises a fixture pressure plate (11) and a magnet pressure block (12), the fixed assembly (2) comprises a lamination pressure plate (21) and a double-ended screw (22), and the rotor assembly (3) comprises a rotor connector (31), rotor laminations (32), and magnets (33), wherein the rotor assembly (3) is fixedly installed by the lamination pressure plate (21) fixedly connected to the end of the rotor connector (31); The rotor lamination (32) is provided with several reserved mounting holes (321) to cooperate with the double-headed screw (22) for installation. The rotor lamination (32) is provided with a magnet slot (322) and the magnet (33) is placed in the magnet slot (322). In the detachable assembly (1), the rotor lamination (32) is fixedly installed with the tooling plate (11) fixedly connected to the end of the rotor connector (31), and the magnet (33) is fixedly installed with the magnet pressing block (12) fixedly connected to the tooling plate (11).

2. The mounting fixture for the magnets of a direct-drive permanent magnet synchronous motor according to claim 1, characterized in that, The tooling pressure plate (11) and the stamping pressure plate (21) are plates with fan-shaped rings at the ends.

3. The mounting fixture for the magnets of a direct-drive permanent magnet synchronous motor according to claim 1, characterized in that, The outer diameter of the tooling pressure plate (11) is not greater than the distance from the magnet slot (322) to the axis of the rotor connector (31), and the outer diameter of the lamination pressure plate (21) is not less than the distance from the outermost point of the magnet (33) to the axis of the rotor connector (31).

4. The mounting fixture for the magnets of a direct-drive permanent magnet synchronous motor according to claim 1, characterized in that, The magnetic steel pressure block (12) is provided with a positioning boss (121), the height of which is equal to the thickness of the tooling pressure plate (11).

5. The mounting fixture for the magnets of a direct-drive permanent magnet synchronous motor according to claim 1, characterized in that, The rotor laminations (32) are mounted on the double-headed screw (22) through the reserved mounting holes (321), and a plurality of the rotor laminations (32) are stacked in a cross manner.

6. An installation process for the magnets of the direct-drive permanent magnet synchronous motor according to any one of claims 1 to 5, characterized in that, Includes the following steps: S1. Install the lamination plate (21) and fix the double-ended screw (22). Clean the surface of the required parts. Fix the lamination plate (21) with screws at the end of the rotor connector (31). Pass the double-ended screw (22) through the reserved mounting hole of the lamination plate (21) and fix the double-ended screw (22) with nuts. S2. The rotor lamination (32) is installed and fixed with the tooling plate (11). The surface of the required parts is cleaned. The reserved mounting holes (321) of the rotor lamination (32) are aligned with the double-ended screw (22) and stacked crosswise. After stacking to the same height as the rotor connector (31), the rotor lamination (32) is fixed at the end of the rotor connector (31) with the tooling plate (11), the tooling plate (11) is fixed with screws, and the double-ended screw (22) is locked with nuts. S3. The magnet (33) is pasted and fixed to the magnet pressure block (12). The surface of the required parts is cleaned. Glue is added to the inner diameter of the magnet (33) and pasted into the magnet groove (322) of the rotor lamination (32). After pasting, the double-headed screw (22) nut at the end of the tooling pressure plate (11) is removed, and the magnet pressure block (12) is placed in. The magnet pressure block (12) and the tooling pressure plate (11) are fixed with the nut. S4. Remove the detachable component (1) and fix it to the lamination plate (21). Clean the surface of the required parts. After the glue has cured, remove the magnet block (12) and the tooling plate (11). Fix the lamination plate (21) with screws at the end of the rotor connector (31) and lock the double-ended screw (22) with nuts.

7. The installation process of the magnets in a direct-drive permanent magnet synchronous motor according to claim 6, characterized in that, In step S3, the magnets (33) are pasted and fixed to the magnet pressing block (12) in the order of groups; the magnets (33) are grouped, and each group contains at least one magnet (33). The magnets (33) are pasted into the magnet groove (322) in the order of groups. After the magnets (33) of the current group are pasted, the magnet pressing block (12) corresponding to the current group is fixed.

8. The installation process of the magnets in a direct-drive permanent magnet synchronous motor according to claim 6, characterized in that, In step S4, the detachable component (1) is removed and fixed to the stamping plate (21) in the order of groups. After the glue has cured, the detachable component (1) corresponding to the current group is removed and the stamping plate (21) corresponding to the current group is fixed.

9. The installation process of the magnets in a direct-drive permanent magnet synchronous motor according to claim 7, characterized in that, The tooling plate (11) projects onto the circumferential direction of the rotor assembly (3) and covers the magnet slots (322). For each group of magnets (33), the number of magnets (322) is no more than the number of magnet slots (322) covered by the tooling plate (11).

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