Amorphous-nanocrystalline composite stator core for high-speed permanent magnet motor and preparation method of amorphous-nanocrystalline composite stator core

Abstract

The invention discloses an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor and a preparation method of the amorphous-nanocrystalline composite stator core, and belongs to the technical field of high-speed motor stator core design and manufacturing. The problem that an existing silicon steel-iron-based amorphous composite iron core is too large in loss under high frequency is solved, the magnetic flux conduction efficiency at the interface of the composite iron core is improved, noise is reduced, and the problem that the magnetic performance degradation degree is inconsistent due to uneven stress distribution in the existing machining or operation process is solved. The amorphous-nanocrystalline composite stator iron core for the high-speed permanent magnet motor is of a multi-layer structure formed by alternately arranging amorphous alloy iron core layers and nanocrystalline alloy iron core layers in the axial direction, and the top layer and the bottom layer of the multi-layer structure are the amorphous alloy iron core layers; the preparation method comprises the following steps: 1, fixture design; 2, gum dipping treatment; 3, integrally curing; 4, processing; 5, heat treatment; and 6, surface treatment. The amorphous-nanocrystalline composite stator iron core for the high-speed permanent magnet motor and the preparation method of the amorphous-nanocrystalline composite stator iron core are provided.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of high-speed motor stator core design and manufacturing. BACKGROUND

[0002] High-speed permanent magnet motors are core power units for strategic emerging industries such as new energy vehicles, aerospace, and industrial automation. Their performance directly affects the efficiency, reliability, and energy density of the entire system. With technological advancements, higher demands are being placed on motors for higher speeds, higher power densities, and higher efficiency. However, traditional motor designs face severe challenges under high-frequency, high-speed operating conditions, particularly the high-frequency loss problem of silicon steel stator cores, which has become a technological bottleneck. Traditional silicon steel stators experience a dramatic increase in eddy current losses at high frequencies, leading to decreased efficiency and excessive temperature rise. Although some researchers have used iron-based amorphous alloys or iron-based nanocrystalline alloys as stator core materials to overcome these problems, the following issues remain: while iron-based amorphous alloys have low high-frequency losses, their saturation magnetic flux density is low and they are brittle; while iron-based nanocrystalline alloys have higher magnetic flux density, their hysteresis losses account for a large proportion. Therefore, neither a single iron-based amorphous material nor a single iron-based nanocrystalline material can meet the dual requirements of low loss and high magnetic flux density for high-speed motors. In the field of motor stator core technology, existing patents such as CN 105119396 B and CN 106602754 B have explored iron-based amorphous-silicon steel composite solutions to balance material properties. Patent CN 105119396 B utilizes the axially spaced stacking of silicon steel laminations from waste motors with amorphous iron cores to improve the efficiency of remanufacturing motors. However, patent CN 106602754 B argues that the non-uniform axial distribution of silicon steel cores and amorphous iron cores in patent CN 105119396 B can easily cause wear and tear on rotating parts such as bearings due to uneven radial electromagnetic force distribution during high-speed motor rotation. Furthermore, using the original silicon steel core structure design can lead to a mismatch between the soft magnetic properties of the iron core and the electromagnetic scheme of the motor, failing to leverage the energy-saving advantages of iron-based amorphous materials. Therefore, patent CN 106602754 B improves upon these issues, balancing low loss and high saturation magnetic induction, and solving the problem of low saturation magnetic induction in iron-based amorphous alloys and a sharp increase in eddy current losses in silicon steel at high frequencies. However, while these silicon steel-amorphous composite structures partially improve high-frequency performance, they introduce inherent defects. First, there is a fundamental contradiction between high-frequency performance and saturation magnetostriction. The crystalline structure of silicon steel results in a high magnetostriction coefficient, leading to significant losses at high frequencies. Even after composite formation, this limits the potential of the core in high-frequency applications such as electric drives for new energy vehicles or power supplies for high-end servers. Second, the "interface mismatch" problem in magnetic properties is prominent. The permeability, coercivity, and other parameters of silicon steel and iron-based amorphous stator materials differ significantly, resulting in poor magnetic flux transmission at the composite interface and easily generating additional eddy current losses and electromagnetic noise. Furthermore, mechanical stress sensitivity becomes a bottleneck. Iron-based amorphous materials are brittle, while silicon steel responds differently to stress. Uneven stress distribution during processing or operation leads to inconsistent degrees of magnetic property degradation, affecting the long-term stability of the core. These limitations stem from the differences in the microstructure of the material combination—silicon steel is crystalline, while iron-based amorphous stator materials are amorphous, resulting in insufficient compatibility between the two. Summary of the Invention

[0003] This invention aims to solve the problem of excessive loss in existing silicon steel-iron-based amorphous composite iron cores at high frequencies, improve the magnetic flux conduction efficiency at the interface of the composite iron core, reduce noise, and solve the problem that uneven stress distribution during processing or operation leads to inconsistent magnetic performance degradation. In this way, it provides an amorphous-nanocrystalline composite stator iron core for high-speed permanent magnet motors and its preparation method.

[0004] A high-speed permanent magnet motor amorphous-nanocrystalline composite stator core is a multi-layer structure formed by alternating amorphous alloy core layers and nanocrystalline alloy core layers along the axial direction, wherein the top and bottom layers of the multi-layer structure are both amorphous alloy core layers.

[0005] The amorphous alloy core layer is formed by stacking multiple iron-based amorphous alloy sheets, and the thickness of a single iron-based amorphous alloy sheet is 0.025mm~0.03mm; the nanocrystalline alloy core layer is formed by stacking multiple iron-based nanocrystalline alloy sheets, and the thickness of a single iron-based nanocrystalline alloy sheet is 0.02mm~0.025mm.

[0006] The ratio of the total volume of the amorphous alloy core layer to the total volume of the nanocrystalline alloy core layer in the amorphous-nanocrystalline composite stator core for the high-speed permanent magnet motor is 1:(0.5~2).

[0007] A method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor, comprising the following steps:

[0008] I. Fixture Design:

[0009] The fixture consists of a frame-shaped fixing plate, fastening screws, and a frame; the frame consists of a bottom frame and four L-shaped columns, with the four L-shaped columns vertically positioned at the four corners of the bottom frame; the frame-shaped fixing plate is fitted onto the four L-shaped columns, and the side of the frame-shaped fixing plate that contacts the L-shaped columns has threaded holes, with fastening screws installed in the threaded holes.

[0010] II. Impregnation treatment:

[0011] Iron-based amorphous alloy sheets and iron-based nanocrystalline alloy sheets are stacked sequentially along the axial direction to obtain a laminate. The laminate is placed on the bottom frame of the frame, and then the frame fixing plate is inserted into the four L-shaped columns of the frame. When the distance between the frame fixing plate and the upper surface of the laminate is 3mm~5mm, the frame fixing plate is fixed to the L-shaped columns with fastening screws to obtain a fixture containing the laminate. The fixture containing the laminate is immersed in the adhesive, and then the fixture is shaken up and down. Finally, after standing and soaking, it is taken out and the fixture is removed to obtain the amorphous-nanocrystalline composite block after adhesive impregnation.

[0012] III. Overall curing:

[0013] Two unimpregnated iron-based amorphous alloy sheets are placed on the top and bottom surfaces of the resin-impregnated amorphous-nanocrystalline composite block, and then cured in a hydraulic press to obtain the composite block.

[0014] IV. Processing:

[0015] The composite block is sequentially wire-cut, cleaned, and dried to obtain the cut iron core.

[0016] V. Heat Treatment:

[0017] The cut iron core is annealed to obtain the annealed iron core.

[0018] VI. Surface Treatment:

[0019] The annealed iron core is pickled, then immersed in a glue solution, and finally taken out and air-dried to obtain an amorphous-nanocrystalline composite stator core for high-speed permanent magnet motors.

[0020] The beneficial effects of this invention are:

[0021] 1. Through innovative composite structure design, the extremely low iron loss characteristics of iron-based amorphous alloys are cleverly combined with the excellent high-frequency performance of iron-based nanocrystalline alloys, thereby fundamentally solving the problem of excessive loss at high frequencies in existing silicon steel-iron-based amorphous composite cores.

[0022] 2. By alternating the axial arrangement of iron-based amorphous alloys and iron-based nanocrystalline alloys in a structural design, the "interface mismatch" problem of the magnetic properties of existing silicon steel-amorphous composite iron cores is solved, improving the magnetic flux conduction efficiency at the interface of the composite iron core and reducing noise, as described in this invention. Figure 8 The torque of the middle cogging gear is reduced.

[0023] 3. Iron-based amorphous alloys are of the same origin as iron-based amorphous alloys, which can solve the problem that uneven stress distribution during processing or operation of silicon steel-iron-based amorphous composite cores can lead to inconsistent magnetic performance degradation, thus extending the long-term stability of the core.

[0024] 4. The preparation method provided by this invention is simple in process and has controllable cost, making it suitable for large-scale industrial production and providing key material support for the high performance of high-speed motors. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of the amorphous-nanocrystalline composite stator core for the high-speed permanent magnet motor of the present invention. 1 is the amorphous-nanocrystalline composite stator core for the high-speed permanent magnet motor. 1-1, 1-3 and 1-5 are amorphous alloy core layers, and 1-2 and 1-4 are nanocrystalline alloy core layers.

[0026] Figure 2This is a schematic diagram of the axial shape of the amorphous-nanocrystalline composite stator core for the high-speed permanent magnet motor of the present invention;

[0027] Figure 3 This is a schematic diagram of the structure of the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet of the present invention;

[0028] Figure 4 This is a schematic diagram of the structure of the composite block material prepared in step three of the present invention;

[0029] Figure 5 This is a schematic diagram of the fixture design in step one of the present invention;

[0030] Figure 6 A comparison diagram of motor core losses between the amorphous-nanocrystalline composite stator core prepared in Example 1 and the amorphous-silicon steel composite stator core prepared in the comparative experiment;

[0031] Figure 7 Comparison of motor eddy current losses between the amorphous-nanocrystalline composite stator core prepared in Example 1 and the amorphous-silicon steel composite stator core prepared in the comparative experiment;

[0032] Figure 8 A comparison diagram of the cogging torque of the motors using the amorphous-nanocrystalline composite stator core prepared in Example 1 and the amorphous-silicon steel composite stator core prepared in the comparative experiment. Detailed Implementation

[0033] Specific implementation method one, combined with Figures 1 to 2 Detailed description: This embodiment is an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor. It is a multi-layer structure formed by alternating amorphous alloy core layers and nanocrystalline alloy core layers along the axial direction, and the top and bottom layers of the multi-layer structure are both amorphous alloy core layers.

[0034] The amorphous alloy core layer is formed by stacking multiple iron-based amorphous alloy sheets, and the thickness of a single iron-based amorphous alloy sheet is 0.025mm~0.03mm; the nanocrystalline alloy core layer is formed by stacking multiple iron-based nanocrystalline alloy sheets, and the thickness of a single iron-based nanocrystalline alloy sheet is 0.02mm~0.025mm.

[0035] The ratio of the total volume of the amorphous alloy core layer to the total volume of the nanocrystalline alloy core layer in the amorphous-nanocrystalline composite stator core for the high-speed permanent magnet motor is 1:(0.5~2).

[0036] This specific embodiment of the iron-based nanocrystalline alloy is obtained by controlling annealing to precipitate nanocrystals in an iron-based amorphous matrix. This alloy possesses high saturation magnetic induction, extremely high permeability, and extremely low high-frequency loss. Furthermore, it shares the same origin as the iron-based amorphous alloy material (such as FeSiB-based), resulting in lower interfacial magnetic reluctance and enabling smooth magnetic flux transfer. Therefore, this specific embodiment uses a composite of iron-based amorphous alloy and iron-based nanocrystalline alloy to prepare the stator core of a high-speed motor. This not only solves the problem of excessive losses at high frequencies in existing silicon steel-amorphous composite cores but also improves the magnetic flux conduction efficiency at the composite core interface, reducing noise. Moreover, the shared origin of the iron-based amorphous stator material and the nanocrystalline stator material can solve the problem of uneven stress distribution during processing or operation of silicon steel-amorphous composite cores, leading to inconsistent magnetic performance degradation and extending the long-term stability of the core.

[0037] The beneficial effects of this embodiment are:

[0038] 1. Through innovative composite structure design, the extremely low iron loss characteristics of iron-based amorphous alloys are cleverly combined with the excellent high-frequency performance of iron-based nanocrystalline alloys, thereby fundamentally solving the problem of excessive loss at high frequencies in existing silicon steel-iron-based amorphous composite cores.

[0039] 2. By alternating the axial arrangement of iron-based amorphous alloys and iron-based nanocrystalline alloys in a structural design, the "interface mismatch" problem of the magnetic properties of existing silicon steel-amorphous composite iron cores is solved, improving the magnetic flux conduction efficiency at the interface of the composite iron core and reducing noise, as described in this invention. Figure 8 The torque of the middle cogging gear is reduced.

[0040] 3. Iron-based amorphous alloys are of the same origin as iron-based amorphous alloys, which can solve the problem that uneven stress distribution during processing or operation of silicon steel-iron-based amorphous composite cores can lead to inconsistent magnetic performance degradation, thus extending the long-term stability of the core.

[0041] 4. The preparation method provided in this embodiment is simple in process and has controllable cost, making it suitable for large-scale industrial production and providing key material support for the high performance of high-speed motors.

[0042] Specific Implementation Method Two: This implementation method differs from Specific Implementation Method One in that: the amorphous alloy core layer is made of Fe-Si-B amorphous alloy with a saturation magnetic induction intensity of not less than 1.56T and a resistivity of not less than 130μΩ·cm; the nanocrystalline alloy core layer is made of Fe-Cu-Nb-Si-B nanocrystalline alloy with a saturation magnetic induction intensity of not less than 1.35T and a resistivity of not less than 115μΩ·cm. Everything else is the same as in Specific Implementation Method One.

[0043] Specific Implementation Method Three: This implementation method differs from Specific Implementation Method One or Two in that the single-layer thickness of the amorphous alloy core layer in the amorphous-nanocrystalline composite stator core for the high-speed permanent magnet motor is 3.3mm~10mm, and the single-layer thickness of the nanocrystalline alloy core layer is 5mm~20mm. Everything else is the same as in Specific Implementation Method One or Two.

[0044] Specific Implementation Method Four: This implementation method differs from Specific Implementation Methods One to Three in that the outer contours of both the iron-based amorphous alloy core layer and the iron-based nanocrystalline alloy core layer are circular; an epoxy resin insulating layer is provided on the outer surface of the amorphous-nanocrystalline composite stator core for the high-speed permanent magnet motor and between each layer. Everything else is the same as in Specific Implementation Methods One to Three.

[0045] Specific implementation method five, combined with Figures 3 to 5 Detailed description: This embodiment describes a method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor, which is carried out according to the following steps:

[0046] I. Fixture Design:

[0047] The fixture consists of a frame-type fixing plate 3-1, fastening screws 3-2, and a frame 3-3. The frame 3-3 consists of a bottom frame and four L-shaped columns, with the four L-shaped columns vertically positioned at the four corners of the bottom frame. The frame-type fixing plate 3-1 is fitted onto the four L-shaped columns, and the side of the frame-type fixing plate 3-1 that contacts the L-shaped columns has threaded holes, with fastening screws 3-2 installed in the threaded holes.

[0048] II. Impregnation treatment:

[0049] Iron-based amorphous alloy sheets and iron-based nanocrystalline alloy sheets are stacked sequentially along the axial direction to obtain a laminate. The laminate is placed on the bottom frame of frame 3-3. Then, the frame fixing plate 3-1 is fitted onto the four L-shaped columns of frame 3-3. When the distance between the frame fixing plate 3-1 and the upper surface of the laminate is 3mm~5mm, the frame fixing plate 3-1 is fixed to the L-shaped columns using fastening screws 3-2 to obtain a fixture containing the laminate. The fixture containing the laminate is immersed in the adhesive solution, and then the fixture is shaken up and down. Finally, after standing and soaking, the fixture is removed and the adhesive-impregnated amorphous-nanocrystalline composite block is obtained.

[0050] III. Overall curing:

[0051] Two unimpregnated iron-based amorphous alloy sheets are placed on the top and bottom surfaces of the resin-impregnated amorphous-nanocrystalline composite block, and then cured in a hydraulic press to obtain the composite block.

[0052] IV. Processing:

[0053] The composite block is sequentially wire-cut, cleaned, and dried to obtain the cut iron core.

[0054] V. Heat Treatment:

[0055] The cut iron core is annealed to obtain the annealed iron core.

[0056] VI. Surface Treatment:

[0057] The annealed iron core is pickled, then immersed in a glue solution, and finally taken out and air-dried to obtain an amorphous-nanocrystalline composite stator core for high-speed permanent magnet motors.

[0058] In step one of this specific embodiment, the dimensions of the four sides of the inner space of frame 3-3 are 4mm to 6mm longer than the sides of the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet. This ensures that each iron-based amorphous alloy sheet and iron-based nanocrystalline alloy sheet is placed flat and with minimal misalignment in the thickness direction, while also ensuring uniform impregnation of the layers between the parts of the amorphous / nanocrystalline wafers encased by frame 3-3 during impregnation. To ensure that the amorphous / nanocrystalline wafers are constrained on all sides without affecting the impregnation process, the cross-section of each side of frame 3-3 is designed to be L-shaped. The frame-type fixing plate 3-1 has L-shaped holes that mate with the four pillars of frame 3-3, and the size of these holes is slightly larger than the size of the four pillars to facilitate sliding on the pillars. Additionally, threaded holes are provided on the side of frame 3-3 that contacts frame 3-3, and fastening screws 3-2 are installed on these holes for fixing the frame-type fixing plate 3-1.

[0059] In step two of this specific embodiment, before placing the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet, the frame-type fixing clamp 3-1 must be removed. After the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet are placed, they are then fitted onto the uprights of the frame 3-3. When the distance between the frame-type fixing clamp 3-1 and the upper surface of the laminate is 3mm to 5mm, it is fixed to the uprights with fastening screws 3-2. This ensures that each amorphous / nanocrystalline wafer has longitudinal space to move during adhesive impregnation, facilitating the smooth entry of adhesive between the layers. Then, the entire clamp is immersed in the adhesive solution and shaken up and down to allow the adhesive to fully penetrate into the gaps between the laminates. After immersion, it is removed.

[0060] In step three of this specific embodiment, unimpregnated iron-based amorphous alloy sheets are placed on the top and bottom surfaces of the amorphous-nanocrystalline composite block after resin impregnation to prevent it from sticking to the press platform during curing.

[0061] In step four of this specific implementation method, the cured composite block is processed using wire cutting, and then ultrasonic cleaning is used to remove the wire cutting fluid residue.

[0062] In this specific implementation method, step five is to eliminate the mechanical stress generated during wire cutting, restore the magnetic properties of the material, and also to perform annealing treatment on the processed iron core.

[0063] In step six of this specific implementation method, the oxide layer on the surface of the iron core after heat treatment is first removed by pickling, and then it is insulated and rust-proofed by immersing the entire core in epoxy resin solution, and then taking it out and letting it air dry naturally.

[0064] Specific Implementation Method Six: This implementation method differs from Specific Implementation Method Five in that: the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet mentioned in step two are both square sheets, and the side length of the square space formed by the inner sides of the four L-shaped pillars in step two along the horizontal direction is 4mm~6mm longer than the side length of the square sheet; the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet mentioned in step two are obtained after acid pickling. Specifically, the acid pickling involves first immersing in a 5%~10% (v / v) pickling agent for 3min~5min, then rinsing with clean water, then immersing in a 5%~10% (v / v) calcium carbonate solution or a 5%~10% (v / v) calcium bicarbonate solution for 1min~2min, and finally rinsing with clean water until the surface pH is neutral; the pickling agent is hydrochloric acid solution. Everything else is the same as in Specific Implementation Method Five.

[0065] The purpose of pickling described in this specific embodiment is to remove surface oxides and impurities to ensure a smooth surface.

[0066] In this specific embodiment, the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet are cut into several square sheets, with the side length being 4mm to 6mm larger than the designed stator diameter to allow for precision machining. Then, the surface oxides and impurities are removed by pickling to ensure a smooth surface.

[0067] Specific Implementation Method Seven: This implementation method differs from Specific Implementation Method Five or Six in that: the adhesive solution mentioned in steps two and six is ​​a mixture of epoxy resin and curing agent; in step two, the solution is left to stand and soak for 25 to 35 minutes before being removed; in step six, the solution is immersed in the adhesive solution for 10 to 12 minutes. Everything else is the same as in Specific Implementation Method Five or Six.

[0068] Specific Implementation Method Eight: This implementation method differs from Specific Implementation Methods Five to Seven in that the curing treatment described in step three is carried out as follows: First, the hydraulic press is pressurized to 29.5 MPa~30.5 MPa, then the temperature is increased to 198℃~202℃ at a heating rate of 19℃ / min~21℃ / min, and maintained at a temperature of 198℃~202℃ and a pressure of 29.5 MPa~30.5 MPa for 9.8h~10.2h. Then, the furnace is cooled, and finally the pressure is released. The rest is the same as in Specific Implementation Methods Five to Seven.

[0069] Specific Implementation Method Nine: This implementation method differs from Specific Implementation Methods Five to Eight in that the annealing treatment described in step five is specifically performed at a temperature of 385℃~395℃ for 14min~16min, followed by furnace cooling. Everything else is the same as in Specific Implementation Methods Five to Eight.

[0070] The purpose of the annealing treatment described in step five of this specific embodiment is to eliminate the mechanical stress generated during wire cutting and restore the magnetic properties of the material.

[0071] Specific Implementation Method Ten: This implementation method differs from Specific Implementation Methods Five to Nine in that the cleaning described in step four is carried out according to the following steps: using a sodium carbonate solution with a volume percentage of 2%~3% as the cleaning agent, at a power density of 0.3W / cm³... 2 ~0.5W / cm 2 Under the specified conditions, ultrasonic cleaning is performed for 2-5 minutes. The pickling process in step six is ​​specifically carried out as follows: first, immersion in a 5%-10% (v / v) pickling agent for 3-5 minutes, then rinsing with water, followed by immersion in a 5%-10% (v / v) calcium carbonate solution or a 5%-10% (v / v) calcium bicarbonate solution for 1-2 minutes, and finally rinsing with water until the surface pH is neutral. The pickling agent is hydrochloric acid solution. Other aspects are the same as in specific embodiments five to nine.

[0072] The beneficial effects of the present invention are verified using the following embodiments:

[0073] Example 1: Taking the preparation of an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor with an outer diameter of 58 mm, an inner diameter of 28 mm, and an axial length of 30 mm as an example:

[0074] A high-speed permanent magnet motor amorphous-nanocrystalline composite stator core is a five-layer structure consisting of three amorphous alloy core layers and two nanocrystalline alloy core layers arranged alternately along the axial direction, with the top and bottom layers of the multi-layer structure being amorphous alloy core layers.

[0075] The amorphous alloy core layer is composed of 179 iron-based amorphous alloy sheets stacked together, and the thickness of each iron-based amorphous alloy sheet is 0.028 mm; the nanocrystalline alloy core layer is composed of 341 iron-based nanocrystalline alloy sheets stacked together, and the thickness of each iron-based nanocrystalline alloy sheet is 0.022 mm; the single-layer thickness of the amorphous alloy core layer in the amorphous-nanocrystalline composite stator core for high-speed permanent magnet motor is 5 mm, and the single-layer thickness of the nanocrystalline alloy core layer is 7.5 mm;

[0076] In the aforementioned high-speed permanent magnet motor amorphous-nanocrystalline composite stator core, the ratio of the total volume of the amorphous alloy core layer to the total volume of the nanocrystalline core segment is 1:1.

[0077] The amorphous alloy core layer is made of 1K101 material, with a saturation magnetic induction intensity of 1.56T and a resistivity of 130μΩ·cm; the nanocrystalline alloy core layer is made of 1K107 material, with a saturation magnetic induction intensity of 1.35T and a resistivity of 115μΩ·cm.

[0078] The outer contours of the iron-based amorphous alloy core layer and the iron-based nanocrystalline alloy core layer are both circular; the outer surface of the amorphous-nanocrystalline composite stator core for high-speed permanent magnet motor and the layers between each layer are provided with epoxy resin insulation layers.

[0079] The above-mentioned method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor is carried out according to the following steps:

[0080] I. Fixture Design:

[0081] The fixture consists of a frame-type fixing plate 3-1, fastening screws 3-2, and a frame 3-3. The frame 3-3 consists of a bottom frame and four L-shaped columns, with the four L-shaped columns vertically positioned at the four corners of the bottom frame. The frame-type fixing plate 3-1 is fitted onto the four L-shaped columns, and the side of the frame-type fixing plate 3-1 that contacts the L-shaped columns has threaded holes, with fastening screws 3-2 installed in the threaded holes.

[0082] II. Impregnation treatment:

[0083] The first group of 178 iron-based amorphous alloy sheets, the second group of 341 iron-based nanocrystalline alloy sheets, the second group of 179 iron-based amorphous alloy sheets, the second group of 341 iron-based nanocrystalline alloy sheets, and the third group of 178 iron-based amorphous alloy sheets are stacked axially to obtain a laminated component. The laminated component is placed on the bottom frame of frame 3-3. Then, the frame-shaped fixing plate 3-1 is fitted onto the four L-shaped columns of frame 3-3. When the distance between the frame-shaped fixing plate 3-1 and the upper surface of the laminated component is 3mm~5mm, the frame-shaped fixing plate 3-1 is fixed to the L-shaped columns using fastening screws 3-2 to obtain a fixture containing the laminated component. The fixture containing the laminated component is immersed in the adhesive solution, and then the fixture is shaken up and down. Finally, it is left to stand and soak for 30 minutes before being removed and the fixture is taken out to obtain the amorphous-nanocrystalline composite block after being impregnated with adhesive.

[0084] Both the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet are square sheets with a size of 73mm × 73mm. There are 537 iron-based amorphous alloy sheets divided into 3 equal parts, and 682 iron-based nanocrystalline alloy sheets divided into 2 equal parts. Both the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet are obtained after pickling. The pickling process specifically involves immersing the sheet in a 5% (v / v) pickling agent for 3 minutes, rinsing with water, then immersing it in a 5% (v / v) calcium carbonate solution for 2 minutes, and finally rinsing with water until the surface pH is neutral. The pickling agent is a hydrochloric acid solution.

[0085] III. Overall curing:

[0086] Two unimpregnated iron-based amorphous alloy sheets were placed on the top and bottom sides of the amorphous-nanocrystalline composite block after resin impregnation. The block was then placed in a hydraulic press. The hydraulic press was first pressurized to 30 MPa, and then heated to 200°C at a heating rate of 20°C / min. The block was then maintained at 200°C and 30 MPa for 10 hours. The block was then cooled in the furnace and finally depressurized to obtain the composite block.

[0087] IV. Processing:

[0088] The composite block is sequentially wire-cut, cleaned, and dried to obtain the cut iron core.

[0089] V. Heat Treatment:

[0090] The cut iron core was annealed for 15 minutes at a temperature of 390℃ and then cooled in the furnace to obtain the annealed iron core.

[0091] VI. Surface Treatment:

[0092] The annealed iron core was pickled, then immersed in the adhesive solution for 10 minutes, and finally removed and air-dried to obtain an amorphous-nanocrystalline composite stator core.

[0093] The adhesive solution mentioned in steps two and six is ​​a mixture of epoxy resin and curing agent, with the brand name MX-6272;

[0094] The cleaning described in step four is carried out according to the following steps: using a 3% sodium carbonate solution (by volume) as the cleaning agent, at a power density of 0.3 W / cm²... 2 Under the conditions, ultrasonic cleaning for 2 minutes;

[0095] The pickling process described in step six is ​​carried out as follows: first, immerse the surface in a 5% pickling agent for 3 minutes, then rinse with water, then immerse it in a 5% calcium carbonate solution for 2 minutes, and finally rinse with water until the surface pH is neutral; the pickling agent is a hydrochloric acid solution.

[0096] Comparative Experiment: This comparative experiment differs from Example 1 in that the 0.022mm thick iron-based nanocrystalline alloy sheet is replaced with a 0.2mm thick silicon steel sheet (DW315 grade); the composite stator core is a 5-layer structure consisting of 3 amorphous alloy core layers and 2 silicon steel layers alternating axially; due to the increased thickness of the silicon steel sheet, the number of silicon steel sheets used is reduced, but the thickness of each silicon steel layer remains unchanged at 7.5mm; step six yields the amorphous-silicon steel composite stator core. Everything else is the same as in Example 1.

[0097] Figures 6 to 8 The test was conducted under the conditions of a motor frequency of 400 Hz and a speed of 12000 rad / min. Figure 6 A comparison diagram of motor core losses between the amorphous-nanocrystalline composite stator core prepared in Example 1 and the amorphous-silicon steel composite stator core prepared in the comparative experiment; Figure 7 Comparison of motor eddy current losses between the amorphous-nanocrystalline composite stator core prepared in Example 1 and the amorphous-silicon steel composite stator core prepared in the comparative experiment; Figure 8 The figure shows a comparison of the cogging torque of the motor teeth of the amorphous-nanocrystalline composite stator core prepared in Example 1 and the amorphous-silicon steel composite stator core prepared in the comparative experiment. As can be seen from the figure, the example utilizes the high saturation magnetic induction characteristics of the amorphous alloy while also leveraging the high-frequency, low-loss advantages of the nanocrystalline material. Due to the low-loss characteristics of the stator material, the average loss of the amorphous-nanocrystalline composite stator core is significantly lower than that of the amorphous-silicon steel composite stator core, at only 1.2 × 10⁻⁶. -4 W is close to 0, such as Figure 6 As shown, the average eddy current loss of the amorphous-nanocrystalline composite stator is also much smaller than that of the amorphous-silicon steel composite core, at only 3.53 × 10⁻⁶. -17 W is close to 0, such as Figure 7As shown, the peak-to-peak value (pk2pk value) of the cogging torque of the amorphous-silicon steel composite core is 27.5053 mN·m, while the peak-to-peak value (pk2pk value) of the cogging torque of the amorphous-nanocrystalline composite stator is 21.6612 mN·m. Compared to the amorphous-silicon steel composite core, the cogging torque is reduced by 21.2%. Figure 8 As shown.

Claims

1. An amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor, characterized in that... It is a multi-layer structure consisting of alternating amorphous alloy core layers and nanocrystalline alloy core layers along the axial direction, with the top and bottom layers of the multi-layer structure being amorphous alloy core layers. The amorphous alloy core layer is formed by stacking multiple iron-based amorphous alloy sheets, and the thickness of a single iron-based amorphous alloy sheet is 0.025mm~0.03mm; the nanocrystalline alloy core layer is formed by stacking multiple iron-based nanocrystalline alloy sheets, and the thickness of a single iron-based nanocrystalline alloy sheet is 0.02mm~0.025mm. The ratio of the total volume of the amorphous alloy core layer to the total volume of the nanocrystalline alloy core layer in the amorphous-nanocrystalline composite stator core for the high-speed permanent magnet motor is 1:(0.5~2).

2. The amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor according to claim 1, characterized in that... The amorphous alloy core layer is made of Fe-Si-B amorphous alloy with a saturation magnetic induction intensity of not less than 1.56T and a resistivity of not less than 130μΩ·cm; the nanocrystalline alloy core layer is made of Fe-Cu-Nb-Si-B nanocrystalline alloy with a saturation magnetic induction intensity of not less than 1.35T and a resistivity of not less than 115μΩ·cm.

3. The amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor according to claim 1, characterized in that... The single-layer thickness of the amorphous alloy core layer in the high-speed permanent magnet motor amorphous-nanocrystalline composite stator core is 3.3mm~10mm, and the single-layer thickness of the nanocrystalline alloy core layer is 5mm~20mm.

4. The amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor according to claim 1, characterized in that... The outer contours of the iron-based amorphous alloy core layer and the iron-based nanocrystalline alloy core layer are both circular; the outer surface of the amorphous-nanocrystalline composite stator core for high-speed permanent magnet motor and the layers between each layer are provided with epoxy resin insulation layers.

5. The method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor as described in claim 1, characterized in that... It is done in the following steps: I. Fixture Design: The clamp consists of a frame-type fixing plate (3-1), fastening screws (3-2), and a frame (3-3); the frame (3-3) consists of a bottom frame and four L-shaped columns, with the four L-shaped columns vertically positioned at the four corners of the bottom frame; the frame-type fixing plate (3-1) is fitted onto the four L-shaped columns, and the side of the frame-type fixing plate (3-1) that contacts the L-shaped columns has threaded holes, with fastening screws (3-2) installed in the threaded holes. II. Impregnation treatment: Iron-based amorphous alloy sheets and iron-based nanocrystalline alloy sheets are stacked sequentially along the axial direction to obtain a laminate. The laminate is placed on the bottom frame of the frame (3-3). Then, the frame fixing plate (3-1) is fitted onto the four L-shaped columns of the frame (3-3). When the distance between the frame fixing plate (3-1) and the upper surface of the laminate is 3mm~5mm, the frame fixing plate (3-1) is fixed to the L-shaped column using fastening screws (3-2) to obtain a fixture containing the laminate. The fixture containing the laminate is immersed in the adhesive solution. Then, the fixture is shaken up and down. Finally, it is left to stand and soak before being removed and the fixture is taken out to obtain the amorphous-nanocrystalline composite block after being impregnated with adhesive. III. Overall curing: Two unimpregnated iron-based amorphous alloy sheets are placed on the top and bottom surfaces of the resin-impregnated amorphous-nanocrystalline composite block, and then cured in a hydraulic press to obtain the composite block. IV. Processing: The composite block is sequentially wire-cut, cleaned, and dried to obtain the cut iron core. V. Heat Treatment: The cut iron core is annealed to obtain the annealed iron core. VI. Surface Treatment: The annealed iron core is pickled, then immersed in a glue solution, and finally taken out and air-dried to obtain an amorphous-nanocrystalline composite stator core for high-speed permanent magnet motors.

6. The method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor according to claim 5, characterized in that... The iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet mentioned in step two are both square sheets, and the side length of the square space formed by the inner sides of the four L-shaped pillars in step two along the horizontal direction is 4mm~6mm longer than the side length of the square sheet; the iron-based amorphous alloy sheet and the iron-based nanocrystalline alloy sheet mentioned in step two are obtained after pickling. The pickling process specifically involves first immersing the sheet in a pickling agent with a volume percentage of 5%~10% for 3min~5min, then rinsing it with clean water, then immersing it in a calcium carbonate solution or a calcium bicarbonate solution with a volume percentage of 5%~10% for 1min~2min, and finally rinsing it with clean water until the surface pH is neutral; the pickling agent is a hydrochloric acid solution.

7. The method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor according to claim 5, characterized in that... The adhesive solution mentioned in steps two and six is ​​a mixture of epoxy resin and curing agent; after standing and soaking for 25 min to 35 min in step two, it is taken out; and after immersion in the adhesive solution for 10 min to 12 min in step six.

8. The method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor according to claim 5, characterized in that... The curing process described in step three is carried out in the following steps: First, pressurize the hydraulic press to 29.5MPa~30.5MPa, then heat it to 198℃~202℃ at a heating rate of 19℃ / min~21℃ / min, and maintain it at a temperature of 198℃~202℃ and a pressure of 29.5MPa~30.5MPa for 9.8h~10.2h, then cool it with the furnace, and finally depressurize it.

9. The method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor according to claim 5, characterized in that... The annealing process described in step five is specifically performed at a temperature of 385℃~395℃ for 14min~16min, followed by furnace cooling.

10. The method for preparing an amorphous-nanocrystalline composite stator core for a high-speed permanent magnet motor according to claim 5, characterized in that... The cleaning described in step four is carried out according to the following steps: using a sodium carbonate solution with a volume percentage of 2%~3% as the cleaning agent, at a power density of 0.3W / cm³... 2 ~0.5W / cm 2 Under the conditions described, ultrasonic cleaning is performed for 2 to 5 minutes; the pickling described in step six is ​​specifically carried out according to the following steps: first, immerse in a pickling agent with a volume percentage of 5% to 10% for 3 to 5 minutes, then rinse with clean water, then immerse in a calcium carbonate solution or a calcium bicarbonate solution with a volume percentage of 5% to 10% for 1 to 2 minutes, and finally rinse with clean water until the surface pH is neutral; the pickling agent is a hydrochloric acid solution.

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