Method for manufacturing core of pulsed magnet

Abstract

The invention provides a manufacturing method of an iron core of a pulse magnet, and relates to the technical field of magnet manufacturing. The method comprises the steps that according to the set cross section shape of an iron core of the pulse magnet, a first bonding end plate and a second bonding end plate are machined and formed through linear cutting or laser cutting; after processing and forming, integrally laminating and curing the first bonding end plate and the second bonding end plate to form an iron core laminated block; iron core end plates are welded to the two outer sides, oppositely arranged in the same direction, of the iron core stacked block, a welding plate is welded between the two iron core end plates, and an upper iron core assembly and a lower iron core assembly are formed respectively; assembling the upper iron core assembly and the lower iron core assembly into an iron core assembly; a pole head is machined on the iron core assembly through linear cutting; the iron core assembly is divided into an upper iron core assembly and a lower iron core assembly, comb-shaped grooves in the upper iron core assembly and the lower iron core assembly are filled with epoxy plates, the iron core assembly compacted with the epoxy plates is subjected to epoxy bonding, and the iron core structure of the pulse magnet is manufactured.

Description

Technical Field

[0001] This invention relates to the field of magnet manufacturing technology, and in particular to a method for manufacturing the core of a pulse magnet. Background Technology

[0002] Pulsed magnets are key components in large scientific facilities such as synchrotron radiation sources and free-electron laser devices, used to achieve rapid beam injection or extraction of electrons.

[0003] The core component of the pulse magnet is an iron core made of stacked high-permeability silicon steel sheets. This iron core operates under conditions of high beam energy, high integrated magnetic field strength, high operating current, and high-speed pulse excitation, and suffers from extremely high eddy current losses. Existing conventional magnets cannot meet the requirements of these operating conditions. Summary of the Invention

[0004] In view of the above problems, the present invention provides a method for manufacturing the core of a pulse magnet, which has the technical effects of high frequency, high beam energy, high integrated field strength and low iron loss.

[0005] This invention provides a method for manufacturing the core of a pulse magnet, comprising: step S1, forming a first bonding end plate and a second bonding end plate by wire cutting or laser cutting according to a predetermined cross-sectional shape of the pulse magnet core, wherein the first bonding end plate has comb-shaped grooves and the second bonding end plate does not have comb-shaped grooves; step S2, after forming, stacking and solidifying the first and second bonding end plates together to form a core stack; step S3, welding core end plates to two opposite outer sides of the core stack in the same direction, and welding a welding plate between the two core end plates. Step S4: First, the upper and lower iron core components are synthesized separately. Then, the iron core mating surfaces are machined on the upper and lower iron core components, and the upper and lower iron core components are assembled into an iron core assembly along the iron core mating surfaces. Step S5: The pole head is machined on the iron core assembly by wire cutting to ensure the air gap accuracy. Step S6: After the pole head is machined, the iron core assembly is disassembled into an upper iron core assembly and a lower iron core assembly. The comb-shaped grooves in the upper and lower iron core assemblies are filled with epoxy boards, and the iron core assembly with the epoxy boards is epoxy bonded to form the iron core structure of the pulse magnet.

[0006] According to an embodiment of the present invention, in step S1, the first adhesive end plate and the second adhesive end plate are respectively processed by wire cutting or laser cutting, including: stacking and curing multiple non-oriented silicon steel sheets to form the first adhesive end plate and the second adhesive end plate respectively; and processing comb-shaped grooves on the first adhesive end plate to provide a cooling effect.

[0007] According to an embodiment of the present invention, the thickness of each silicon steel sheet is 0.15 mm; the thickness of the first adhesive end plate after lamination and curing is 15 mm; and the thickness of the second adhesive end plate after lamination and curing is 200 mm.

[0008] According to an embodiment of the present invention, before stacking and curing multiple non-oriented silicon steel sheets, the method further includes: coating an insulating layer on the bonding surface of each silicon steel sheet with another silicon steel sheet to block eddy current paths.

[0009] According to an embodiment of the present invention, the grooves in the comb-shaped grooves are equidistant, and the distance between the grooves is 2mm.

[0010] According to an embodiment of the present invention, in step S3, the iron core end plate is made of 316L stainless steel and the welding plate is made of 304 stainless steel.

[0011] According to an embodiment of the present invention, step S2 specifically includes: step S21, after processing and forming, the first bonding end plate and the second bonding end plate are integrally laminated and cured in the same direction to ensure that the lamination coefficient after lamination and curing is ≥95%, and the thickness of the iron core block initially formed after lamination and curing has a processing allowance in the design thickness; step S22, after integral lamination and curing, the iron core block is thinned by peeling so that the iron core block reaches the design thickness.

[0012] According to an embodiment of the present invention, step S21 specifically includes: assembling a stacking mold so that the outer periphery of the stacking mold forms the cross-sectional shape of an iron core; spraying a release agent on each contact surface of the stacking mold; placing a portion of a first adhesive end plate, a second adhesive end plate, and another portion of a first adhesive end plate in sequence on the surface of the release agent in a direction away from the bottom plate of the stacking mold; and then performing overall stacking and curing.

[0013] According to an embodiment of the present invention, the stacking mold includes a base plate, on which a plurality of fixed backing plates are fixedly connected, the outer peripheries of the plurality of fixed backing plates forming the cross-sectional shape of an iron core; the perpendicularity of each fixed backing plate to the base plate does not exceed 0.05 mm; a movable backing plate is installed between each fixed backing plate and the base plate to provide movable space for the fixed backing plates to be pressed from the outer periphery inward.

[0014] According to an embodiment of the present invention, the first adhesive end plate and the second adhesive end plate are respectively formed by stacking and curing multiple non-oriented silicon steel sheets; the overall stacking and curing includes: taking 20 silicon steel sheets as a group, and taking 5 groups of silicon steel sheets in sequence for stacking; wherein, the burr direction of all silicon steel sheets in each group of silicon steel sheets is the same, and the burr direction of the current group of silicon steel sheets is opposite to the burr direction of the previous group of silicon steel sheets; after stacking, the outer side of the silicon steel sheets is tapped to ensure that the outer periphery is aligned and flat.

[0015] Compared with the prior art, the method for manufacturing the core of a pulse magnet provided by the present invention has at least the following beneficial effects:

[0016] (1) Silicon steel sheets are laser-cut, eliminating the need for punching dies and reducing processing costs;

[0017] (2) The core structure is a segmented structure, and the first adhesive end plate and the second adhesive end plate are integrally stacked and cured to prevent the film from cracking during later use;

[0018] (3) The pole face of the iron core stack has a machining allowance, and the whole assembly is wire cut after assembly to ensure the machining accuracy;

[0019] (4) Compared with silicon steel sheets with a thickness of 0.5 mm, thin silicon steel sheets with a thickness of 0.15 mm have lower iron loss and higher magnetic induction intensity;

[0020] (5) To reduce eddy current loss, thin silicon steel sheets with a thickness of 0.15 mm are coated with an insulating layer (such as epoxy resin) between each silicon steel sheet to block the eddy current path. Attached Figure Description

[0021] The above-described features, other objects, and advantages of the present invention will become clearer from the following description of embodiments of the invention with reference to the accompanying drawings, in which:

[0022] Figure 1 A flowchart illustrating a method for manufacturing the core of a pulse magnet according to an embodiment of the present invention is shown schematically.

[0023] Figure 2 A schematic cross-sectional view of a first adhesive end plate according to an embodiment of the present invention is shown;

[0024] Figure 3 A schematic cross-sectional view of a second adhesive end plate according to an embodiment of the present invention is shown;

[0025] Figure 4 A schematic diagram of the structure of the iron core stack according to an embodiment of the present invention is shown;

[0026] Figure 5 A schematic diagram of a core assembly according to an embodiment of the present invention is shown.

[0027] Figure 6 A flowchart illustrating the bonding end plate stacking process according to an embodiment of the present invention is shown schematically.

[0028] Figure 7 A schematic diagram of a stacking die according to an embodiment of the present invention is shown. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0030] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. The terms “comprising,” “including,” etc., as used herein indicate the presence of the stated features, steps, operations, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, or components.

[0031] All terms used herein (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein are to be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.

[0032] Figure 1 A flowchart illustrating a method for manufacturing the core of a pulse magnet according to an embodiment of the present invention is shown.

[0033] like Figure 1 As shown, the method for manufacturing the core of the pulse magnet in this embodiment includes steps S1 to S6.

[0034] Step S1: According to the set cross-sectional shape of the pulse magnet core, the first bonding end plate and the second bonding end plate are respectively processed by wire cutting or laser cutting. The first bonding end plate has comb-shaped grooves, and the second bonding end plate does not have comb-shaped grooves.

[0035] like Figure 2 and Figure 3 As shown, the first and second bonding end plates are respectively formed by stacking and curing multiple non-oriented silicon steel sheets. The first bonding end plate has comb-like grooves for cooling, while the second bonding end plate does not.

[0036] For example, the thickness of each silicon steel sheet is 0.15 mm; the thickness of the first bonding end plate after lamination and curing is 15 mm; and the thickness of the second bonding end plate after lamination and curing is 200 mm. The grooves in the comb-shaped grooves are equidistant, with a distance of 2 mm between each groove.

[0037] Specifically, based on the relevant requirements of the pulse magnet and the cross-sectional shape of the iron core structure, the first bonding end plate with comb-shaped grooves is formed by wire cutting or laser cutting, and a machining allowance is left for the pole face and the iron core mating surface on the first bonding end plate. Similarly, based on the relevant requirements of the pulse magnet and the cross-sectional shape of the iron core structure, the second bonding end plate without comb-shaped grooves is formed by wire cutting or laser cutting, and a machining allowance is left for the pole face and the iron core mating surface on the second bonding end plate.

[0038] In some embodiments, to reduce eddy current losses, before stacking and curing multiple non-oriented silicon steel sheets, an insulating layer is applied to the bonding surface of each silicon steel sheet with another silicon steel sheet to block the eddy current path.

[0039] For example, the insulating layer can be epoxy resin.

[0040] Step S2: After processing and molding, the first bonding end plate and the second bonding end plate are stacked and cured as a whole to form an iron core stack.

[0041] To prevent the silicon steel sheet from cracking during later use, the first and second bonding end plates are integrally laminated and cured in the same direction (i.e., the lamination direction). The lamination and curing process will be described in detail later.

[0042] like Figure 4 As shown, after the iron core stack is formed by lamination and curing, the iron core stack consists of a first bonding end plate (i.e., bonding end plate 1 in the figure), a second bonding end plate (i.e., bonding end plate 1 in the figure), and a first bonding end plate in sequence along the thickness direction of the iron core stack. The second bonding end plate has two outer sides opposite to each other along the thickness direction of the iron core stack, each with a first bonding end plate.

[0043] Step S3: Weld two outer core end plates that are opposite each other in the same direction to the core stack, and weld a welding plate between the two core end plates to assemble the upper core assembly and the lower core assembly respectively.

[0044] like Figure 5 As shown, in the embodiments of the present invention, the upper core assembly and the lower core assembly have the same structure. The upper core assembly and the lower core assembly each include a core stack, a core end plate 1 and a core end plate 2 disposed opposite to each other in the stacking direction of the core stack, and a welding plate welded between the two core end plates.

[0045] In some embodiments, the core end plate is made of 316L stainless steel and the welding plate is made of 304 stainless steel.

[0046] Step S4: Machining the core mating surfaces on the upper core assembly and the lower core assembly respectively, and assembling the upper core assembly and the lower core assembly into a core assembly along the core mating surfaces.

[0047] The core assembly adopts a two-in-one structure, which is composed of an upper core assembly and a lower core assembly.

[0048] Step S5: The pole head is machined on the iron core assembly by wire cutting to ensure the air gap accuracy.

[0049] Step S6: After the pole head is processed, the iron core assembly is split into an upper iron core assembly and a lower iron core assembly. Epoxy plates are used to fill the comb-shaped grooves in the upper and lower iron core assemblies. The iron core assembly with the epoxy plates is then epoxy bonded to form the iron core structure of the pulse magnet.

[0050] After machining the pole head to ensure the air gap accuracy meets the requirements, the upper and lower core assemblies are disassembled. The comb-shaped grooves with a spacing of 2mm are filled with epoxy board, and then the entire core assembly is bonded with epoxy at room temperature. It should be noted that "room temperature" in this epoxy bonding usually refers to standard room temperature conditions of 20℃ to 25℃.

[0051] like Figure 6 As shown, in some embodiments, step S2 specifically includes steps S21 to S22.

[0052] Step S21: After processing and forming, the first bonding end plate and the second bonding end plate are integrally stacked and cured to ensure that the stacking coefficient after stacking and curing is ≥95%, and the thickness of the iron core block initially formed after stacking and curing has a processing margin in the design thickness.

[0053] Further, step S21 specifically includes: assembling a stacking mold so that the outer periphery of the stacking mold forms the cross-sectional shape of the iron core; spraying a release agent on each contact surface of the stacking mold; placing a portion of the first adhesive end plate, a second adhesive end plate, and another portion of the first adhesive end plate in sequence on the surface of the release agent facing away from the bottom plate of the stacking mold; and then performing overall stacking and curing.

[0054] Please continue reading. Figure 4 The first bonding end plate has a comb groove, while the second bonding end plate does not. Then, the whole assembly is stacked and cured. The final iron core block has the first bonding end plate (i.e., bonding end plate 1 in the figure) at both ends along the thickness direction, with a thickness of 15mm. The second bonding end plate (i.e., bonding end plate 1 in the figure) is sandwiched between the first bonding end plates at both ends, with a thickness of 200mm.

[0055] The first and second bonding end plates are stacked flat, and the stacking mold is assembled first. Specifically, as follows... Figure 7As shown, the stacking mold includes a base plate, on which multiple fixed support plates are fixedly connected. The outer peripheries of the multiple fixed support plates enclose the core cross-sectional shape; the perpendicularity of each fixed support plate to the base plate does not exceed 0.05mm. Movable support plates are installed between each fixed support plate and the base plate to provide movable space for the fixed support plates to be pressed inward from the outer periphery.

[0056] For example, each fixed backplate is positioned to the base plate using pins.

[0057] After processing and molding, a release agent is sprayed on each contact surface of the stacking mold. On the surface of the release agent facing away from the bottom plate of the stacking mold, a portion of the first adhesive end plate, a second adhesive end plate, and another portion of the first adhesive end plate are placed in sequence, and then the whole stacking and curing is carried out.

[0058] Since the first and second bonding end plates are respectively formed by stacking and curing multiple non-oriented silicon steel sheets, the overall stacking and curing further includes: taking 20 silicon steel sheets as a group, and taking 5 groups of silicon steel sheets in sequence for stacking; wherein, the burr direction of all silicon steel sheets in each group of silicon steel sheets is the same, and the burr direction of the current group of silicon steel sheets is opposite to the burr direction of the previous group of silicon steel sheets; after stacking, the outer side of the silicon steel sheets is tapped to ensure that the outer periphery is aligned and flat.

[0059] With a machining allowance left on the design thickness after the iron core stack is laminated and cured, the stacking coefficient after lamination and curing is ensured to be ≥95% by pressing with the movable baffle in the stacking mold.

[0060] Step S22: After the overall stacking and curing, the iron core stack is thinned by peeling to achieve the designed thickness.

[0061] As can be seen from the above description, the method for manufacturing the core of a pulse magnet provided by the above embodiments of the present invention achieves at least the following technical effects:

[0062] (1) Silicon steel sheets are laser-cut, eliminating the need for punching dies and reducing processing costs;

[0063] (2) The core structure is a segmented structure, and the first adhesive end plate and the second adhesive end plate are integrally stacked and cured to prevent the film from cracking during later use;

[0064] (3) The pole face of the iron core stack has a machining allowance, and the whole assembly is wire cut after assembly to ensure the machining accuracy;

[0065] (4) Compared with silicon steel sheets with a thickness of 0.5 mm, thin silicon steel sheets with a thickness of 0.15 mm have lower iron loss and higher magnetic induction intensity;

[0066] (5) To reduce eddy current loss, thin silicon steel sheets with a thickness of 0.15 mm are coated with an insulating layer (such as epoxy resin) between each silicon steel sheet to block the eddy current path.

[0067] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified. Furthermore, the word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements.

[0068] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method of manufacturing a core of a pulsed magnet, characterized by, The method comprises the following steps: Step S1, according to the set core cross-section shape of the pulse magnet, the first adhesive end plate and the second adhesive end plate are respectively processed and formed by wire cutting or laser cutting, the first adhesive end plate is provided with a comb-shaped groove, and the second adhesive end plate is not provided with a comb-shaped groove; Step S2, after processing and forming, the first adhesive end plate and the second adhesive end plate are integrally laminated and cured to form a core stack; Step S3, two outer side welding core end plates are arranged in the same direction of the core stack, and a welding plate is welded between the two core end plates to synthesize an upper core assembly and a lower core assembly; Step S4, a core bonding surface is processed on the upper core assembly and the lower core assembly, and the upper core assembly and the lower core assembly are assembled into a core assembly along the core bonding surface; Step S5, a pole head is processed on the core assembly by wire cutting to ensure air gap accuracy; Step S6, after processing the pole head, the core assembly is split into the upper core assembly and the lower core assembly, epoxy plates are inserted into the comb-shaped grooves in the upper core assembly and the lower core assembly, the core assembly with the compacted epoxy plates is subjected to epoxy bonding to manufacture the core structure of the pulse magnet.

2. The method of manufacturing a core of a pulsed magnet according to claim 1, characterized by, In step S1, the first adhesive end plate and the second adhesive end plate are respectively processed and formed by wire cutting or laser cutting, which comprises: A plurality of non-oriented silicon steel sheets are laminated and cured to form the first adhesive end plate and the second adhesive end plate; A comb-shaped groove is processed on the first adhesive end plate to provide a cooling effect.

3. The method of manufacturing a core of a pulsed magnet according to claim 2, wherein The thickness of each silicon steel sheet is 0.15 mm; The thickness of the first adhesive end plate after laminated curing is 15 mm; The thickness of the second adhesive end plate after laminated curing is 200 mm.

4. The method of manufacturing a core of a pulsed magnet according to claim 2, wherein Before laminating and curing the plurality of non-oriented silicon steel sheets, it further comprises: An insulating layer is coated on the bonding surface of each silicon steel sheet and another silicon steel sheet to block the eddy current path.

5. The method of manufacturing a core of a pulsed magnet according to claim 2, wherein The distances between the grooves in the comb-shaped groove are equal, and the distance between the grooves is 2 mm.

6. The method of manufacturing a core of a pulsed magnet according to claim 1, wherein In step S3, the core end plate is made of 316L stainless steel, and the welding plate is made of 304 stainless steel.

7. The method of manufacturing a core of a pulsed magnet according to claim 1, wherein Step S2 specifically comprises: Step S21, after processing and forming, the first adhesive end plate and the second adhesive end plate are integrally laminated and cured in the same direction to ensure that the lamination coefficient after lamination and curing is greater than or equal to 95%, and the thickness of the preliminarily formed core stack after lamination and curing has a processing allowance on the design thickness; Step S22, after the lamination and curing, the core stack is thinned by peeling to reach the design thickness.

8. The method of manufacturing a core of a pulsed magnet according to claim 7, wherein Step S21 specifically comprises: The lamination mold is assembled, and the outer periphery of the lamination mold is surrounded by the core cross-section shape; A portion of the first adhesive end plate, the second adhesive end plate and another portion of the first adhesive end plate are sequentially placed on the surface of the release agent of each contact surface of the lamination mold in a direction away from the bottom plate of the lamination mold, and then the whole is laminated and cured.

9. The method of manufacturing a core of a pulsed magnet according to claim 8, wherein The laminated mold comprises a bottom plate, a plurality of fixed side plates are fixedly connected to the bottom plate, and the outer periphery of the plurality of fixed side plates encloses the cross-sectional shape of the iron core; the perpendicularity of each fixed side plate to the bottom plate is not more than 0.05 mm; A movable side plate is installed between each fixed side plate and the bottom plate, and is used to provide a movable space for the fixed side plate which is pressed from the outer periphery to the inner periphery.

10. The method of manufacturing a core of a pulsed magnet according to claim 8, wherein The first and second adhesive end plates are respectively formed by laminating and curing a plurality of non-oriented silicon steel sheets; The integral laminating and curing comprises: 20 silicon steel sheets are taken as one group, and 5 groups of silicon steel sheets are sequentially laminated; wherein the burr directions of all silicon steel sheets in each group are the same, and the burr direction of the previous group of silicon steel sheets is opposite to the burr direction of the last group of silicon steel sheets; The outer side of the silicon steel sheet is knocked after lamination to ensure that the outer periphery is aligned and flat.

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