Rotor punching sheet manufacturing process

Abstract

The invention discloses a rotor punching sheet manufacturing process, and relates to the field of rotor punching sheet manufacturing, and the rotor punching sheet manufacturing process comprises the following steps: firstly, determining the power of a motor, determining the reference boundary dimension of the motor, selecting the dimension parameters of a motor base in the design process of the motor, and determining the related dimension parameters; the size of the original motor is fully utilized, the output torque of the motor is improved as much as possible, the rotating speed of the motor is reduced, and the number of motor poles is determined; determining the inner diameter of the stator punching sheet of the motor according to the technical performance of the high-voltage three-phase asynchronous motor, the data of the iron core and the winding, the inner diameter of the iron core of the base and the corresponding number of poles of the motor; after a production manufacturer and an insulation scheme are determined in the later period, correction can be carried out according to actual conditions, so that the size of the motor can be correspondingly and finely adjusted, and the overall adjustment effect is facilitated.

Description

Technical Field

[0001] This invention relates to the field of rotor lamination manufacturing, specifically a rotor lamination manufacturing process. Background Technology

[0002] A rotor is a rotating body supported by bearings. Objects without their own axis of rotation, such as optical discs, can be considered rotors when rigidly connected or equipped with an additional shaft. When the main rotor rotates at high speeds, the shaft undergoes deflection deformation as its speed approaches its critical speed. Resonance can even cause mechanical damage. The natural frequencies of the rotor's lateral vibration are multi-order, and therefore its corresponding critical speeds are also multi-order. When the rotor's operating speed is below the first critical speed, it is called a rigid rotor, while when the rotor's operating speed is above the first critical speed, it is called a flexible rotor.

[0003] There is no unified standard for the insulation of traditional coils. Different manufacturers have different production processes and different insulation standards that cannot be used. It is difficult to refer to the insulation standards of relevant manufacturers for design. The insulation spacing between turns is not designed properly, and the main insulation effect is poor by 1.3mm. After the manufacturer and insulation scheme are determined, it is impossible to make corrections according to the actual situation. The overall adjustment effect is poor and it is impossible to make corresponding fine adjustments according to the motor size.

[0004] Therefore, those skilled in the art have provided a rotor lamination manufacturing process to solve the problems mentioned in the background art. Summary of the Invention

[0005] The purpose of this invention is to provide a rotor lamination manufacturing process to solve the problems mentioned in the background art, such as the lack of a unified standard for the insulation of traditional coils, the different production processes of various manufacturers, the different insulation standards that cannot be adopted, the difficulty in designing by referring to the insulation standards of relevant manufacturers, the unreasonable design of the inter-turn insulation spacing, the poor main insulation effect of 1.3mm, the inability to make corrections according to the actual situation after the production manufacturer and insulation scheme are determined, the overall adjustment effect is poor, and the inability to make corresponding fine adjustments according to the motor size.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A rotor lamination manufacturing process, comprising the following steps:

[0008] First, determine the motor power, determine the reference external dimensions of the motor, select the frame size parameters during the motor design process, and determine the relevant size parameters;

[0009] Make full use of the original motor's size, maximize the motor's output torque, reduce the motor speed, and determine the number of motor poles.

[0010] Based on the technical performance, core and winding data of the high-voltage three-phase asynchronous motor, the inner diameter of the core of the frame and the corresponding number of motor poles are used to determine the inner diameter of the stator laminations of the motor.

[0011] Based on the motor size data, the motor is designed, and the inner diameter of the motor is finally determined, thus confirming the motor design result.

[0012] The motor is modeled and simulated to verify its performance. Simultaneously, motor temperature simulation is performed, including temperature simulation during rated operation, ultimately achieving finite element simulation verification of the motor.

[0013] As a preferred embodiment of the present invention: the first step of determining the motor power, determining the reference external dimensions of the motor, selecting the frame size parameters during the motor design process, and determining the relevant size parameters includes the following steps:

[0014] The motor power must be determined to be 315kW and the voltage to be 1140V, while referring to the technical specifications of relevant explosion-proof motors in China.

[0015] When the motor is mounted in B3 mode, the center height of the frame can be selected as 400mm. Similarly, if the motor is mounted in B5 mode, the motor specification can be selected as 400mm.

[0016] The design of the motor mainly refers to the size parameters of the 400 frame, from which the YB400 and Y400 series can be selected;

[0017] The outer diameter of the iron core of the YB400 frame motor is 650mm, while the outer diameter of the Y400 motor is 670mm. Since this motor is an explosion-proof motor, it is designed with reference to the YB series motors, and the outer diameter of the iron core can be selected as 650mm.

[0018] As a preferred embodiment of the present invention: the determination of the number of motor poles by making full use of the original motor's volume, maximizing the motor's output torque, and reducing the motor's speed includes the following steps:

[0019] The original motor had 4 poles and a synchronous speed of 1500 r / min. In order to make full use of the original motor's size, maximize the motor's output torque, and reduce the motor speed, the number of motor poles was set to 20.

[0020] As a preferred embodiment of the present invention: the determination of the inner diameter of the stator laminations of the motor based on the technical performance of the high-voltage three-phase asynchronous motor, the core and winding data, the inner diameter of the frame core, and the corresponding number of motor poles includes the following steps:

[0021] Referring to the technical performance, core and winding data of the Y-series high-voltage three-phase asynchronous motor, the inner diameter of the core of the Y400 frame is 480, 465, and 420. Since the inner diameter can be increased with more poles, the inner diameter of the core of this motor can be calculated using 480 and 465.

[0022] As a preferred embodiment of the present invention: the step of designing the motor based on the motor size data and finally determining the inner diameter of the motor to achieve the determination of the motor design result includes the following steps:

[0023] By using the motor's dimensions, the motor can be designed, and the final inner diameter of the motor is determined to be 465mm.

[0024] As a preferred embodiment of the present invention: the process of modeling and simulating the motor to verify its performance, and simultaneously performing motor temperature simulation, including temperature simulation during rated operation of the motor, ultimately achieving finite element simulation verification of the motor, includes the following steps:

[0025] Temperature simulation was performed on the motor during rated operation. The motor is water-cooled, the motor cooling water temperature does not exceed 25℃, and the cooling water flow rate is 1.8m3 / s. According to the calculation, the maximum temperature of the motor winding is about 86℃.

[0026] As a preferred embodiment of the present invention: the process of modeling and simulating the motor to verify its performance, and simultaneously performing motor temperature simulation, including temperature simulation during rated operation of the motor, ultimately achieving finite element simulation verification of the motor, includes the following steps:

[0027] If the manufacturer has a ready-made water-cooled motor housing, and the cooling structure is different from this solution, the final motor temperature rise will differ, so further confirmation is required.

[0028] Compared with the prior art, the beneficial effects of the present invention are:

[0029] This invention discloses a rotor lamination manufacturing process, overcoming the shortcomings of traditional coil insulation, which lacks a unified standard and varies between manufacturers due to different production processes. This design references the insulation standards of relevant manufacturers, with inter-turn insulation of 0.25mm and main insulation of 1.3mm. Permanent magnet motors differ from ordinary induction motors in manufacturing and processes, such as magnetic shielding. Additionally, due to the higher number of poles, the yoke is thinner. These differences necessitate collaboration with the manufacturer to determine the rationality of the process. The motor frame uses a standard YBSS or YB frame. Ideally, the OEM manufacturer should have experience with similar motors to leverage existing structural components. Due to the magnetic shielding measures, the rotor strength of a permanent magnet motor is slightly lower than that of an induction motor; therefore, care must be taken during manufacturing and handling. After determining the OEM manufacturer and insulation scheme, adjustments can be made based on actual conditions, leading to minor adjustments in motor dimensions for better overall performance. Attached Figure Description

[0030] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0031] Figure 1 This is a schematic diagram of a rotor lamination manufacturing process.

[0032] Figure 2 This is a schematic diagram of the installation data for an explosion-proof three-phase asynchronous motor used in a YBS series conveyor during a rotor lamination manufacturing process.

[0033] Figure 3 This is a schematic diagram of the core and winding data of a YB series high-voltage explosion-proof three-phase asynchronous motor in a rotor lamination manufacturing process.

[0034] Figure 4 This is a schematic diagram of technical data for a Y-series high-voltage three-phase asynchronous motor in a rotor lamination manufacturing process.

[0035] Figure 5 This is a schematic diagram of the magnetic field lines distribution of a motor in a rotor lamination manufacturing process.

[0036] Figure 6 This is a schematic diagram of the magnetic flux density distribution of a motor in a rotor lamination manufacturing process.

[0037] Figure 7 This is a schematic diagram of the no-load back electromotive force of a motor in a rotor lamination manufacturing process.

[0038] Figure 8 This is a schematic diagram of the rated load torque of a motor when the average torque reaches 12788 Nm during constant operation in a rotor lamination manufacturing process.

[0039] Figure 9 This is a schematic diagram of the rated current of a motor when the effective value of the stable operating current is 177.5A in a rotor lamination manufacturing process.

[0040] Figure 10 This is a schematic diagram of the motor inductance in a rotor lamination manufacturing process.

[0041] Figure 11 This is a schematic diagram of the radial temperature distribution of a motor during a rotor lamination manufacturing process.

[0042] Figure 12 This is a schematic diagram of the axial temperature distribution of a motor during a rotor lamination manufacturing process. Detailed Implementation

[0043] In this embodiment of the invention, a rotor lamination manufacturing process includes the following steps:

[0044] First, determine the motor power, determine the reference external dimensions of the motor, select the frame size parameters during the motor design process, and determine the relevant size parameters;

[0045] When determining motor power, the main process involves motor selection and system calculation. The corresponding application scenario and load type should be clearly defined, such as constant load, variable load, impact load, and frequent start-stop. When determining the reference dimensions of the motor, it is necessary to initially estimate the relationship between the motor power and the dimensions. Based on the motor's power rating and speed range, combined with empirical data and similar motors, specific parameter design is required.

[0046] Make full use of the original motor's size, maximize the motor's output torque, reduce the motor speed, and determine the number of motor poles.

[0047] Refer to similar motors and analyze their structure, such as whether they are open, closed, explosion-proof, or compact. After analysis, when determining the number of poles, the main considerations are the required speed, torque, and speed range direction. The application scenario, performance requirements, and cost should be taken into account, and a comprehensive selection should be made based on budget and energy efficiency requirements.

[0048] Based on the technical performance, core and winding data of the high-voltage three-phase asynchronous motor, the inner diameter of the core of the frame and the corresponding number of motor poles are used to determine the inner diameter of the stator laminations of the motor.

[0049] The technical performance of high-voltage three-phase asynchronous motors mainly includes the determination of specific core performance parameters, power density, and volume. When determining the core and winding data, it is necessary to determine the specific materials and processes, and then determine the specific structural parameters. By determining the stator core, rotor core, and air gap length, specific performance indicators are determined, including the performance indicators of iron loss and no-load current. Finally, when designing the windings, it is necessary to perform coordinated optimization of the core and windings.

[0050] Based on the motor size data, the motor is designed, and the inner diameter of the motor is finally determined, thus confirming the motor design result.

[0051] When determining the inner diameter of a motor, it is necessary to comprehensively consider factors such as power, speed, electromagnetic load, mechanical strength, and manufacturing process. Based on the design of the relationship between power and speed, the relationship between power and speed and the influence of the number of poles are determined. Then, the constraints of mechanical strength and manufacturing process need to be determined.

[0052] The motor is modeled and simulated to verify its performance. Simultaneously, motor temperature simulation is performed, including temperature simulation during rated operation, ultimately achieving finite element simulation verification of the motor.

[0053] A motor model is established, and parameters such as inner diameter, air gap length, and slot shape are optimized to ensure that the motor efficiency, power factor, temperature rise, and other performance indicators meet the design requirements. The simulation steps include geometric modeling, mesh generation, boundary condition setting, and solution and post-processing.

[0054] First, determine the motor power, then determine the reference external dimensions of the motor, select the frame dimensions during the motor design process, and finalize the relevant dimensional parameters, including the following steps:

[0055] The motor power must be determined to be 315kW and the voltage to be 1140V, while referring to the technical specifications of relevant explosion-proof motors in China.

[0056] When the motor is mounted in B3 mode, the center height of the frame can be selected as 400mm. Similarly, if the motor is mounted in B5 mode, the motor specification can be selected as 400mm.

[0057] The design of the motor mainly refers to the size parameters of the 400 frame, from which the YB400 and Y400 series can be selected;

[0058] The outer diameter of the iron core of the YB400 frame motor is 650mm, while the outer diameter of the Y400 motor is 670mm. Since this motor is an explosion-proof motor, it is designed with reference to the YB series motors, and the outer diameter of the iron core can be selected as 650mm.

[0059] It is necessary to comprehensively consider factors such as mechanical strength, heat dissipation performance, installation compatibility, and manufacturing cost. Specifically, it is necessary to calculate the initial estimate of motor power and speed, then determine the impact of speed on the height of the base, and then check the mechanical strength and stiffness. Stress analysis and finite element analysis are required to verify the stress distribution of the base under the following working conditions. Then, stress analysis is performed through three parts: electromagnetic force, centrifugal force, and centrifugal force. The deformation of the base must be controlled within the allowable range. Stiffness can be improved by increasing the wall thickness, optimizing the layout of reinforcing ribs, or using cast steel and welded structures.

[0060] To fully utilize the original motor's size, maximize its output torque, and minimize its speed, the number of poles in the motor is determined by the following steps:

[0061] The original motor had 4 poles and a synchronous speed of 1500 r / min. In order to make full use of the original motor's size, maximize the motor's output torque, and reduce the motor speed, the number of motor poles was set to 20.

[0062] Based on the technical performance, core and winding data of the high-voltage three-phase asynchronous motor, the inner diameter of the core of the frame and the corresponding number of motor poles are used to determine the inner diameter of the stator laminations, including the following steps:

[0063] Referring to the technical performance, core and winding data of the Y-series high-voltage three-phase asynchronous motor, the inner diameter of the core of the Y400 frame is 480, 465, and 420. Since the inner diameter can be increased with more poles, the inner diameter of the core of this motor can be calculated using 480 and 465.

[0064] When determining the inner diameter of the motor stator laminations, it is necessary to match the power and speed, and then constrain the air gap length. This is because an air gap that is too small can easily cause stator rubbing failure, while an air gap that is too large will increase magnetic resistance and reduce efficiency. It is necessary to avoid failures. Then, design considerations should be determined to avoid the possibility that an inner diameter that is too large may lead to insufficient lamination stiffness, causing deformation or vibration. Electromagnetic verification can also be performed. The selection of the inner diameter of the motor core is a core part of motor design. It should not affect the electromagnetic performance, mechanical strength, heat dissipation efficiency and manufacturing cost of the motor. The design principles can be selected from the following aspects: priority of electromagnetic performance, guarantee of mechanical strength and process adaptability. Of course, it is necessary to determine the specific influencing factors, mainly power and speed, air gap length and cooling method.

[0065] Based on the motor size data, the motor is designed, and the final inner diameter of the motor is determined, thus confirming the motor design result. This includes the following steps:

[0066] By using the motor's dimensions, the motor can be designed, and the final inner diameter of the motor is determined to be 465mm.

[0067] The motor is modeled and simulated to verify its performance. Temperature simulation is also performed, including temperature simulation during rated operation. The final step is to achieve finite element simulation verification of the motor, comprising the following steps:

[0068] Temperature simulation was performed on the motor during rated operation. The motor is water-cooled, the motor cooling water temperature does not exceed 25℃, and the cooling water flow rate is 1.8m3 / s. According to the calculation, the maximum temperature of the motor winding is about 86℃.

[0069] The process of modeling and simulating the motor to verify its performance, including temperature simulation during rated operation, ultimately achieves finite element simulation verification of the motor. This includes the following steps:

[0070] If the manufacturer has a ready-made water-cooled motor housing, and the cooling structure is different from this solution, the final motor temperature rise will differ, so further confirmation is required.

[0071] The specific motor performance after the design is summarized in Table 1 below:

[0072] Table 1

[0073]

[0074]

[0075]

[0076] By combining theoretical analysis, simulation, and experimental testing, a comprehensive evaluation of the electromagnetic, mechanical, thermal, and environmental performance of the motor is conducted. Before verification, specific core performance parameters, such as electromagnetic, mechanical, thermal, and environmental performance, are determined. Electromagnetic performance verification is then performed through no-load, load, and stall tests. Mechanical and thermal performance verifications are then conducted. Through rigorous verification, the motor failure rate can be significantly reduced, its service life extended, and its market competitiveness enhanced.

[0077] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A rotor lamination manufacturing process, characterized in that, The rotor lamination manufacturing process includes the following steps: First, determine the motor power, determine the reference external dimensions of the motor, select the frame size parameters during the motor design process, and determine the relevant size parameters; Make full use of the original motor's size, maximize the motor's output torque, reduce the motor speed, and determine the number of motor poles. Based on the technical performance, core and winding data of the high-voltage three-phase asynchronous motor, the inner diameter of the core of the frame and the corresponding number of motor poles are used to determine the inner diameter of the stator laminations of the motor. Based on the motor size data, the motor is designed, and the inner diameter of the motor is finally determined, thus confirming the motor design result. The motor is modeled and simulated to verify its performance. Simultaneously, motor temperature simulation is performed, including temperature simulation during rated operation, ultimately achieving finite element simulation verification of the motor.

2. The rotor lamination manufacturing process according to claim 1, characterized in that, The process begins by determining the motor power, identifying the reference dimensions of the motor, selecting the frame dimensions during the motor design process, and determining the relevant dimensional parameters. This includes the following steps: The motor power must be determined to be 315kW and the voltage to be 1140V, while referring to the technical specifications of relevant explosion-proof motors in China. When the motor is mounted in B3 mode, the center height of the frame can be selected as 400mm. Similarly, if the motor is mounted in B5 mode, the motor specification can be selected as 400mm. The design of the motor mainly refers to the size parameters of the 400 frame, from which the YB400 and Y400 series can be selected. The outer diameter of the iron core of the YB400 frame motor is 650mm, while the outer diameter of the Y400 motor is 670mm. Since this motor is an explosion-proof motor, it is designed with reference to the YB series motors, and the outer diameter of the iron core can be selected as 650mm.

3. The rotor lamination manufacturing process according to claim 1, characterized in that, The process of fully utilizing the original motor's volume, maximizing the motor's output torque, reducing the motor's speed, and determining the number of motor poles includes the following steps: The original motor had 4 poles and a synchronous speed of 1500 r / min. In order to make full use of the original motor's size, maximize the motor's output torque, and reduce the motor speed, the number of motor poles was set to 20.

4. The rotor lamination manufacturing process according to claim 1, characterized in that, The determination of the inner diameter of the stator laminations of the high-voltage three-phase asynchronous motor, based on the technical performance, core and winding data, frame core inner diameter, and corresponding number of motor poles, includes the following steps: Referring to the technical performance, core and winding data of the Y-series high-voltage three-phase asynchronous motor, the inner diameter of the core of the Y400 frame is 480, 465, and 420. Since the inner diameter can be increased with more poles, the inner diameter of the core of this motor can be calculated using 480 and 465.

5. The rotor lamination manufacturing process according to claim 1, characterized in that, The process of designing the motor based on its dimensions and determining its inner diameter, thus finalizing the motor design, includes the following steps: By using the motor's dimensions, the motor can be designed, and the final inner diameter of the motor is determined to be 465mm.

6. The rotor lamination manufacturing process according to claim 1, characterized in that, The process of modeling and simulating the motor to verify its performance, including temperature simulation during rated operation, ultimately achieves finite element simulation verification of the motor. This includes the following steps: Temperature simulation was performed on the motor during rated operation. The motor is water-cooled, the motor cooling water temperature does not exceed 25℃, and the cooling water flow rate is 1.8m3 / s. According to the calculation, the maximum temperature of the motor winding is about 86℃.

7. The rotor lamination manufacturing process according to claim 1, characterized in that, The process of modeling and simulating the motor to verify its performance, including temperature simulation during rated operation, ultimately achieves finite element simulation verification of the motor. This includes the following steps: If the manufacturer has a ready-made water-cooled motor housing, and the cooling structure is different from this solution, the final motor temperature rise will differ, so further confirmation is required.

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