A large-power wheel rim propeller stator core assembling tool and assembling method

Abstract

The application discloses a kind of high-power flange propeller stator core's round assembling tool and round assembling method, including base support assembly, mandrel, segmented clamping mechanism, radial compression mechanism and end face leveling mechanism;Base support assembly includes horizontal base, and horizontal base is provided with outer hoop, and the inner wall of outer hoop is provided with annular support guide rail;Mandrel is coaxially arranged with outer hoop;Segmented clamping mechanism includes a plurality of segmented clamping units, for the stator core segmented with outer hoop clamping;Radial compression mechanism includes a plurality of radial compression units, for applying radial compression force to stator core segment;End face leveling mechanism includes leveling pressing plate, and leveling pressing plate can be lifted and set on mandrel, for applying axial compression force to stator core segment.The present application can realize the high-precision coaxial positioning of stator core segment, uniform compression round assembling, improve the overall structural precision and electromagnetic performance of core, improve assembly efficiency and manufacturing safety.

Description

Technical Field

[0001] This invention relates to the field of ship propulsion equipment manufacturing technology, and in particular to a tooling and method for assembling the stator core of a high-power rim propeller. Background Technology

[0002] As a new generation of shaftless propulsion devices for ships, the rim propulsion system eliminates the traditional drive shaft structure, arranges the motor stator on the inner wall of the guide tube and integrates the rotor on the outer edge of the propeller. It has the advantages of compact structure, low noise and high propulsion efficiency, and has been widely used in the power systems of scientific research vessels, special operation vessels and marine platforms.

[0003] High-power rim-driven propellers have stringent requirements for motor power density, electromagnetic performance, and structural stability. Their stator cores are mostly made by stacking and rounding high-grade silicon steel sheets. Due to limitations in large diameter, transportation, processing equipment, and processing costs, the stator core cannot be manufactured as a single piece and must be produced using a segmented rounding method.

[0004] The existing stator core splicing has the following main defects: 1. Poor positioning accuracy of the spliced ​​core makes it easy for misalignment and uneven gaps to occur on the spliced ​​surface of the segmented iron core, resulting in distortion of the iron core magnetic circuit, increased local eddy current loss, reduced motor efficiency, and easy generation of electromagnetic vibration and noise during operation; 2. Due to the lack of specialized tooling, manual correction is required during the core assembly process, resulting in insufficient clamping stability. Heavy core sections are prone to slippage and tilting, making it difficult to guarantee coaxiality and roundness during assembly, which significantly increases the difficulty of subsequent winding installation. 3. The unreasonable fastening process of the splicing circle is that the traditional bolts are directly tightened, which can easily cause the end face of the iron core to be squeezed and deformed, the silicon steel sheets to be loose between layers, the iron core stacking coefficient to decrease, and affect the insulation and structural reliability of the motor. 4. The stator core of the high-power rim propeller has a large diameter and heavy weight. The existing splicing method lacks an anti-tipping support structure, resulting in high safety risks during assembly and low splicing efficiency, which cannot meet the needs of mass production.

[0005] Therefore, there is an urgent need to develop a special tooling that is compatible with high-power rim thrusters, has high positioning accuracy, stable clamping, and can achieve high-precision circular assembly, in order to solve the technical problems of low circular assembly accuracy, poor assembly efficiency, and insufficient structural stability in the existing technology. Summary of the Invention

[0006] This invention addresses the problems of low accuracy in assembling the stator core of existing high-power rim-driven propellers, poor assembly stability, reliance on manual correction, and poor clamping stability. It provides a tooling and method for assembling the stator core of a high-power rim-driven propeller. Through a dedicated positioning and clamping tooling, it achieves high-precision coaxial positioning and uniform pressing of the stator core segments for assembly, improving the overall structural accuracy and electromagnetic performance of the core, and enhancing assembly efficiency and manufacturing safety.

[0007] The first aspect of the present invention provides a tooling for rounding the stator core of a high-power rim propeller, including a base support assembly, a mandrel, a segmented clamping mechanism, a radial pressing mechanism and an end face leveling mechanism; The base support assembly includes a horizontal base, an outer sleeve is provided on the horizontal base, and an annular support guide rail is provided on the inner wall of the outer sleeve; The mandrel is fixed to the horizontal base, and the mandrel is coaxially arranged with the outer sleeve; The segmented clamping mechanism includes several segmented clamping units, which are used to clamp the stator core in segments to the outer sleeve. The radial clamping mechanism includes several radial clamping units, which are arranged in a ring around the mandrel. The radial clamping units apply radial clamping force to the stator core segments in the direction of the ring support guide rail. The end face leveling mechanism includes a leveling pressure plate, which is liftably sleeved on the mandrel. The leveling pressure plate is used to apply axial clamping force toward the horizontal base direction to the stator core segments.

[0008] In a first aspect of the present invention, as a preferred embodiment, a plurality of lifting support seats are provided on the horizontal base, and the plurality of lifting support seats are arranged in a ring array inside the outer sleeve. An anti-tipping block is provided on the lifting support seat, and a positioning gap is formed between the anti-tipping block and the ring support guide rail of the outer sleeve, which allows the stator core to enter in sections.

[0009] In a first aspect of the present invention, as a preferred embodiment, the horizontal base is provided with a plurality of guide grooves, which are arranged radially along the mandrel; The bottom of the lifting support is provided with a slider, which slides within the guide groove, thereby enabling the lifting support to move back and forth along the direction of the guide groove.

[0010] In a first aspect of the present invention, as a preferred embodiment, the top of the lifting support is provided with a lifting column; the anti-tipping block is detachably connected to the lifting column by fasteners, and the lifting column drives the anti-tipping block to move back and forth in the height direction. The anti-overturning block has a first contoured surface on its outer side, which is adapted to the inner wall of the stator core segment.

[0011] In a first aspect of the invention, as a preferred embodiment, the segmented clamping unit includes a C-shaped clamp, a five-star handle, and a top rod; The C-shaped clamp is mounted on the top of the outer sleeve and stator core segment; the two ends of the C-shaped clamp are respectively provided with an inner clamping arm and an outer clamping arm, the inner clamping arm extending into the interior of the stator core segment and the outer clamping arm extending into the exterior of the outer sleeve; the push rod is screwed to the outer clamping arm, and the end of the push rod is provided with a pressing block, which is used to contact the outer wall of the outer sleeve; the five-star handle is screwed to the inner clamping arm, one end of the five-star handle is provided with a driving end, and the other end is used to apply pressure to the stator core segment.

[0012] In a first aspect of the present invention, as a preferred embodiment, the segmented clamping unit further includes a clamping claw, which is disposed between the inner clamping arm and the stator core segment, for transmitting the pressure applied by the five-star handle to the stator core segment; The clamping claw is detachably connected to the lifting column by fasteners; a second contoured surface is provided on the outer side of the clamping claw, which is adapted to the inner wall of the stator core segment, and a flexible insulating pad is provided on the second contoured surface.

[0013] In a first aspect of the invention, as a preferred embodiment, the radial clamping mechanism includes a core plate, the core plate being fixed to the mandrel; The radial clamping unit includes a guide rod, a pressure head, a guide bracket, and a servo drive. The guide bracket is fixed to the core plate, and a guide hole is provided inside the guide bracket. The guide rod passes through the guide hole and is connected to the servo drive. The pressure head is located at the end of the guide rod. Power is provided by the servo drive to drive the guide rod to extend along the direction of the guide hole, thereby driving the pressure head to apply radial clamping force to the stator core in segments.

[0014] In a first aspect of the invention, as a preferred embodiment, the pressure head includes an inner pressure plate, a buffer member, and an outer pressure plate, the inner pressure plate being connected to a guide rod; a buffer gap is formed between the inner pressure plate and the outer pressure plate, the buffer member being disposed within the buffer gap, the buffer member providing an elastic force that drives the inner pressure plate and the outer pressure plate closer to or further apart; the outer pressure plate has a mating surface on its outer side, the mating surface being adapted to the inner side of the anti-overturning block; the pressure applied by the pressure head is transmitted to the stator core segment through the anti-overturning block; a pressure sensor is integrated within the pressure head, the pressure sensor being used to monitor the radial clamping force output by the outer pressure plate in real time; It also includes a control system, which is electrically connected to the servo drive and the pressure sensor respectively. The control system can control the output power of the servo drive based on the output data of the pressure sensor.

[0015] In a first aspect of the present invention, as a preferred embodiment, a locking stud is provided at the top end of the mandrel; The end face leveling mechanism includes a leveling plate and a locking nut; a bushing is provided on the leveling plate, the leveling plate extends circumferentially to the top of the stator core segment, and the bushing is sleeved on the top of the mandrel; the locking nut is screwed to the locking stud, and the bottom surface of the locking nut contacts the top surface of the bushing; through the cooperation of the locking nut and the locking stud, the leveling plate is driven to move axially, applying axial pressure towards the horizontal base to the stator core segment.

[0016] A second aspect of the present invention provides a method for rounding the stator core of a high-power rim-driven propeller, comprising the following steps: Provides a tooling for assembling the stator core of a high-power rim-driven propeller as described in any of the first aspects of the present invention; provides stator core segments to be assembled; Tooling debugging and benchmark calibration; Stator core segmentation pretreatment includes cleaning burrs from the rounded end faces, testing insulation performance, and applying insulating grease. The stator core is hoisted and positioned in sections. The stator core sections are hoisted into the outer sleeve and initially positioned by the annular support guide rail. The stator core sections are then clamped in the outer sleeve by the section clamping mechanism to achieve coaxial initial positioning of the stator core sections. Radial pressure is applied to each stator core segment in the direction of the outer sleeve through a radial clamping mechanism; An axial pressure towards the horizontal base is applied to each stator core segment by an end-face leveling mechanism. Hold the pressure for at least 30 minutes; welding; Tooling unloading and finished product inspection: Remove the finished product and inspect its dimensions, stacking factor and insulation performance.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The high-power rim-driven propeller stator core assembly fixture and method of this invention, using a mandrel as the core reference, combined with a segmented clamping mechanism and a radial pressing mechanism, achieves high-precision coaxial positioning of multiple stator core segments for assembly. The mandrel positioning reference surface has a cylindricity of 0.015mm, a coaxiality tolerance of ≤0.02mm, and a circular support guide rail roundness tolerance of ≤0.02mm, structurally ensuring that all core segments are strictly coaxially arranged. The radial pressing mechanism adopts a multi-set circular array of guide brackets, with coaxiality and guide hole roundness tolerances both ≤0.02mm. Combined with servo drive and pressure sensor closed-loop control, the gap between the assembly surfaces can be controlled within 0.01mm. The overall roundness and coaxiality of the core are significantly improved, effectively reducing motor eddy current losses and electromagnetic noise, and significantly improving the operating efficiency of the high-power rim-driven propeller.

[0018] 2. The high-power rim-driven propeller stator core assembly fixture and method of this invention integrates anti-tipping supports, flexible clamping, and a pressure feedback system, resulting in strong clamping stability and adaptability to the assembly of large-diameter, heavy-weight stators. The anti-tipping block, through its lifting support seat and guide groove, possesses radial and axial movement freedom. Its contoured surface precisely matches the inner wall of the stator core, providing continuous lateral constraint during the assembly process, effectively preventing core slippage or tipping and significantly reducing assembly safety risks. The segmented clamping mechanism adopts a C-shaped clamp with a coaxial design of a five-star handle and a push rod, providing symmetrical clamping forces of inward pushing and outward pushing. A high-precision pressure sensor is integrated within the pressure head, forming a closed-loop circuit with the control system to monitor and adjust the radial clamping force in real time. This solves the problem of core deformation caused by uneven pressure in traditional processes and can stably adapt to the mass production needs of high-power stator cores.

[0019] 3. The high-power rim-driven propeller stator core assembly tooling and method of this invention allows for the adaptation of stator cores with different inner diameters by simply changing the clamping jaws and anti-tipping blocks. The horizontal base is equipped with guide grooves, and the lifting support slides within these grooves via a bottom slider, allowing for free radial adjustment of its position. The lifting column, through the engagement of studs and adjusting nuts, achieves axial height adjustment, further expanding the adaptability range. This significantly reduces the tooling manufacturing cost for multi-specification products, decreases production line changeover time, and improves assembly efficiency by more than 40% compared to traditional processes. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the assembly tooling for the stator core of the high-power rim propeller of the present invention. Figure 2 This is a schematic diagram of the internal structure of the circular assembly tooling for the stator core of the high-power rim propeller of the present invention. Figure 3 This is another internal structural schematic diagram of the tooling for rounding the stator core of the high-power rim propeller of the present invention; Figure 4 This is a top view of the assembly tooling for the stator core of the high-power rim propeller of the present invention; Figure 5 This is a front view of the assembly tooling for the stator core of the high-power rim propeller of the present invention. Figure 6 This is a cross-sectional view of section AA of the assembly tooling for the stator core of the high-power rim propeller of the present invention; Figure 7 This is a schematic diagram of the horizontal base of the circular assembly tooling for the high-power rim propeller stator core of the present invention. Figure 8 This is a schematic diagram of the radial clamping mechanism of the circular assembly tooling for the high-power rim propeller stator core of the present invention. Figure 9 This is a schematic diagram of the radial clamping mechanism of the high-power rim propeller stator core assembly tooling of the present invention from another angle. Figure 10 This is a schematic diagram of the connection of the C-clamp of the assembly tooling for the stator core of the high-power rim propeller of the present invention.

[0021] In the diagram: 10. Base support assembly; 11. Horizontal base; 111. Annular support guide rail; 112. Guide groove; 12. Lifting support seat; 121. Slider; 122. Lifting column; 123. Adjusting nut; 124. Support seat pressure plate; 13. Anti-tipping block; 131. First contour surface; 14. Base; 15. Base; 20. Mandrel; 21. Locking stud; 30. Segmented clamping mechanism; 31. Segmented clamping unit; 311. C-clamp; 31 2. Handle; 313. Top rod; 314. Clamping claw; 3141. Second contour surface; 40. Radial clamping mechanism; 41. Radial clamping unit; 411. Guide rod; 412. Pressure head; 4121. Inner pressure plate; 4122. Buffer; 4123. Outer pressure plate; 413. Guide bracket; 42. Core plate; 50. End face leveling mechanism; 51. Leveling pressure plate; 511. Bushing; 52. Locking nut; 80. Outer clamp; 90. Stator core segmentation. Detailed Implementation

[0022] The invention will now be further described with reference to the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments. Unless otherwise specified, the materials and equipment used in this embodiment are commercially available. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0023] In the description of this application, it should be understood that the terms "upper," "lower," "front," "rear," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In the description of this application, "a plurality of" means two or more, unless otherwise precisely specified.

[0024] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "connected," "linked," and "connected" should be interpreted broadly. For example, they can refer to a fixed connection, a connection through an intermediary, or a connection within two elements or an interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0025] The terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such process, method, product, or apparatus.

[0026] Example 1: like Figures 1-10 As shown, this embodiment provides a jig for rounding the stator core of a high-power rim-driven propeller. This embodiment uses a jig adaptable to a 2MW rim-driven propeller stator core. The stator core in this embodiment is formed by rounding twelve arc-shaped silicon steel sheets. The stator core has an outer diameter of φ2360mm, an inner diameter of φ2230mm, and a single stator core segment (90mm) weighs approximately 100kg.

[0027] The high-power rim propeller stator core assembly tooling of this embodiment includes a base support assembly 10, a mandrel 20, a segmented clamping mechanism 30, a radial pressing mechanism 40, and an end face leveling mechanism 50.

[0028] The base support assembly 10 includes a horizontal base 11, which is mainly used to ensure the overall horizontal stability of the tooling. An outer sleeve 80 is provided on the horizontal base 11, and an annular support guide rail 111 is provided on the inner wall of the outer sleeve 80; the annular support guide rail 111 provides a reference circumference for the stator core to be assembled.

[0029] The mandrel 20 is disposed on the horizontal base 11, and the mandrel 20 is coaxially disposed with the outer sleeve 80. In this embodiment, the mandrel 20 serves as the positioning reference for the inner circle of the stator core. In this embodiment, the radial direction refers to the radial direction of the mandrel 20, the axial direction refers to the axial direction of the mandrel 20, the inner side refers to the side close to the axis of the mandrel 20, and the outer side refers to the side away from the axis of the mandrel 20.

[0030] The segmented clamping mechanism 30 includes several segmented clamping units 31, which are evenly arranged around the mandrel 20. The number of segmented clamping units 31 is the same as the number of stator core segments 90, which is 12 sets. They are used to provide clamping force to clamp each stator core segment 90 with the outer sleeve 80 and to clamp each stator core segment 90 on the annular support guide rail 111 on the inner wall of the outer sleeve 80.

[0031] The radial clamping mechanism 40 includes several radial clamping units 41, each radial clamping unit 41 corresponding to each segment clamping unit 31. Twelve sets of radial clamping units 41 are arranged in a ring around the mandrel 20. The radial clamping units 41 apply a radial clamping force to the stator core segments 90 in the direction of the annular support guide rail 111 to achieve uniform radial clamping of each core segment.

[0032] The end face leveling mechanism 50 includes a leveling pressure plate 51, which is movably sleeved on the mandrel 20. The leveling pressure plate 51 is used to apply an axial pressing force to the stator core segment 90 in the direction of the horizontal base 11 to correct the warping of the core laminations and ensure the overall flatness of the end face of the core after assembly.

[0033] Based on the above structure, the high-power rim-driven propeller stator core assembly fixture of this embodiment specifically addresses the problems of low assembly accuracy, poor assembly stability, reliance on manual correction, and poor clamping stability in existing high-power rim-driven propeller stator cores. This assembly fixture uses the mandrel 20 as the positioning reference for the inner circle of the stator core, while the annular support guide rail 111 provides a reference circumference for the stator core assembly. The two remain coaxial, ensuring consistent radial distance between each core segment during the assembly process, thus solving the coaxiality deviation problem caused by the lack of a precise reference in traditional processes. The segmented clamping mechanisms 30 are evenly arranged circumferentially along the mandrel 20, with their number corresponding to the core segments. They can independently and synchronously clamp each core segment to the outer sleeve 80, avoiding uneven force and poor clamping stability issues during manual correction. The radial clamping mechanism 40 corresponds to the segmented clamping mechanism 30, applying uniform radial pressure towards the outer sleeve 80 to each segment of the iron core, ensuring that each segment of the iron core is tightly fitted to the annular support guide rail 111, significantly improving the overall roundness and structural stability of the iron core. The end face leveling mechanism applies axial pressure to the iron core through a liftable leveling pressure plate 51, effectively correcting the warping deformation generated during the rounding process of the iron core laminations, ensuring the flatness of the iron core end face after rounding, thereby improving the uniformity of the axial magnetic circuit. This embodiment provides a dedicated rounding fixture to achieve high-precision coaxial positioning and uniform clamping of the stator iron core segments 90, improving the overall structural accuracy and electromagnetic performance of the iron core, and increasing assembly efficiency and manufacturing safety. The overall structure is compact and easy to operate. The number of segmented clamping mechanisms 30 and radial clamping mechanisms 40 can be flexibly adjusted according to the number of iron core segments, adapting to the assembly requirements of rim-driven propeller stators of different power levels, significantly improving manufacturing safety and product consistency.

[0034] In this embodiment, the tooling base support assembly 10 is made of Q345 high-strength steel, welded together and then precision machined. Specifically, it includes a base 14, a base 15, and a horizontal base 11. The base 14 is a flat ground or a steel plate platform. The bottom of the base 15 is firmly connected to the base 14 by fixing bolts. The bottom surface of the horizontal base 11 is equipped with shock-absorbing pads and fixing bolts. The shock-absorbing pads can effectively absorb operational vibrations, ensuring the overall horizontal stability and vibration resistance of the tooling, and meeting the requirements of heavy-duty and high-precision working conditions.

[0035] The horizontal base 11 measures φ2500mm × 600mm, the outer sleeve 80 has an inner diameter of φ2310mm, and the roundness tolerance of the annular support guide rail 111 is ≤0.02mm, providing a reference circumference for the core assembly. The annular support guide rail 111 can be the complete inner wall surface of the outer sleeve 80, in which case the bottom surface of the stator core segment 90 is directly supported by the horizontal base 11, with the horizontal base providing bottom support. Alternatively, the annular support guide rail 111 can be a portion of the inner wall surface of the outer sleeve 80, such as... Figure 6-7As shown, the inner wall of the outer sleeve 80 has an annular groove, and the annular surface of the annular groove is the annular support guide rail 111. At this time, a stepped surface is formed at the bottom of the inner wall of the outer sleeve 80. The stepped surface can serve as a bottom support component for the stator core segment 90. The level of the stepped surface is consistent with that of the horizontal base 11, which limits the end face of the stator core segment 90.

[0036] In this embodiment, a plurality of lifting support seats 12 are provided on the horizontal base 11. The number of lifting support seats 12 corresponds to the number of stator core segments 90, and there are 12 sets of each. The 12 sets of lifting support seats 12 are arranged in a ring array inside the outer sleeve 80. Anti-tipping blocks 13 are provided on the lifting support seats 12. The anti-tipping blocks 13 can form a positioning gap between themselves and the inner wall of the annular support guide rail 111 of the outer sleeve 80, which allows the stator core segments 90 to enter. This ensures that the stator core segments 90 can enter the predetermined position smoothly and accurately during the hoisting process, effectively preventing the core from tilting or falling off during the rounding process, and providing an anti-tipping function for the stator core segments 90 during the initial positioning process.

[0037] Furthermore, the horizontal base 11 is provided with multiple guide grooves 112, which are arranged radially around the spindle 20. The bottom of the lifting support 12 is provided with a slider 121, which slides within the guide grooves 112, allowing the lifting support 12 to move back and forth along the guide grooves 112. This provides the lifting support 12 and the anti-tipping block 13 connected to it with radial freedom of movement. A support plate 124 can be provided above the guide grooves 112, forming a channel between the guide grooves 112 and the support plate 124 for the lifting support 12 to slide. This guides and limits the radial displacement of the lifting support 12, making the radial displacement of the anti-tipping block 13 more stable and reliable, and limiting its extreme position. The support plate 124 prevents the lifting support 12 from derailing from the guide grooves 112.

[0038] A lifting column 122 is provided on the top of the lifting support base 12, and the anti-tipping block 13 is detachably connected to the middle section of the lifting column 122 by fasteners. The lifting column 122 drives the anti-tipping block 13 to move back and forth in the height direction, giving it the freedom of axial movement, which can be adapted to stator cores of different lengths.

[0039] The anti-tipping block 13 has a first contoured surface 131 on its outer side. The first contoured surface 131 is adapted to the inner wall of the stator core segment 90, specifically an arc-shaped surface. An elastic buffer pad can be provided on the surface of the first contoured surface 131.

[0040] The aforementioned lifting column 122 can automatically drive the anti-tipping block 13 to rise and fall via a hydraulic rod.

[0041] In this embodiment, the cooperation between the guide groove 112 and the slider 121 enables the lifting support 12 and the anti-tipping block 13 to have radial freedom of movement, flexibly adapting to the requirements of stator core assembly with different inner diameters. Simultaneously, the lifting column 122 provides the anti-tipping block 13 with axial freedom of movement, accommodating stator core segments 90 of different lengths, further enhancing the applicability of the tooling and improving its versatility and flexibility. The first contoured surface 131 on the outer side of the anti-tipping block 13 adapts to the inner wall of the stator core segment 90, providing precise fit support and anti-tipping protection during the assembly process, significantly improving the safety and stability of the assembly process. In use, by replacing the anti-tipping block 13 that is adapted to the inner side of the stator core segment 90, and adjusting the radial and / or axial position of the anti-tipping block 13, stator cores of different lengths and / or inner diameters can be assembled. This allows one set of tooling to be used for the assembly of multiple types of stator cores, effectively solving the problem of poor versatility and difficulty in adapting to multiple specifications of traditional assembly tooling.

[0042] The mandrel 20 is vertically fixed to the center of the base support assembly 10 and has a hollow stepped structure. The maximum diameter of the mandrel 20 is φ360mm. The outer wall of the mandrel 20 is provided with a positioning reference surface that matches the inner circle of the stator core. The cylindricity of the positioning reference surface is 0.015mm; the coaxiality tolerance between the positioning reference surface and the annular support guide rail is ≤0.02mm. The mandrel 20 indirectly achieves the positioning of the inner circle of the core through the radial clamping mechanism 40 as an intermediate force transmission component. In this embodiment, the mandrel 20 is used as the central reference, and the uniform pressure transmitted by the radial clamping mechanism 40 ensures that all core segments are radially positioned with the axis of the mandrel 20 as the common center.

[0043] The segmented clamping unit 31 in this embodiment includes a C-shaped clamp 311, a five-star handle 312, and a push rod 313. The C-shaped clamp 311 is mounted on the top of the outer sleeve and stator core segment 90. The C-shaped clamp 311 has an inner clamping arm and an outer clamping arm at both ends, with the inner clamping arm extending to the inside of the stator core segment 90 and the outer clamping arm extending to the outside of the outer sleeve 80. The push rod 313 is screwed to the outer clamping arm, and a pressing block is provided at the end of the push rod 313. The pressing block is used to contact the outer wall of the outer sleeve 80. The five-star handle 312 is screwed onto the inner clamping arm. One end of the five-star handle 312 is provided with a drive end, and the other end is used to apply pressure to the stator core segment 90. The drive end of the five-star handle serves as a torque input end. Tightening the five-star handle 312 causes the other end of the five-star handle 312 to rotate towards the stator core segment 90 due to the threaded engagement between the five-star handle 312 and the inner clamping arm, thereby applying pressure to the stator core segment 90. The five-star handle 312 is coaxially arranged with the push rod 313. Please refer to... Figure 6As shown, by mounting the C-type clamp 311 on the top of the outer sleeve 80 and the stator core segment 90, a stable bridge-type opposing clamping structure is formed. The inner clamping arm extends to the inside of the core and the outer clamping arm extends to the outside of the outer sleeve 80, thus realizing bidirectional locking from the core to the outer sleeve 80.

[0044] Furthermore, the segmented clamping unit 31 also includes a clamping claw 314, which is disposed between the inner clamping arm and the stator core segment 90, and is used to transmit the pressure applied by the five-star handle 312 to the stator core segment 90.

[0045] The clamping claw 314 is detachably connected to the top of the lifting column 122 by fasteners; by replacing the clamping claw 314 and adjusting its radial or axial position by the lifting support 12, it can be adapted to different sizes of iron core specifications.

[0046] The clamping claw 314 has a second contoured surface 3141 on its outer side. The second contoured surface 3141 is adapted to the inner wall of the stator core segment 90, specifically an arc-shaped surface. A flexible insulating pad is provided on the second contoured surface 3141. The thickness of the flexible insulating pad is preferably 2-3mm. A polyurethane flexible pad can be used to avoid scratching the core insulation coating during clamping.

[0047] By positioning the clamping claw 314 between the inner clamping arm and the stator core segment 90, the clamping force applied by the five-star handle 312 is evenly transmitted to the surface of the stator core segment 90, avoiding stress concentration caused by direct contact. The clamping claw 314 is detachably connected to the top of the lifting column 122, facilitating quick replacement of core segments of different specifications and improving the versatility of the tooling. The second contoured surface 3141 is precisely fitted to the inner wall of the stator core segment 90, ensuring uniform distribution of clamping force by increasing the contact area. A flexible insulating pad is laid on the second contoured surface 3141, providing elastic cushioning while effectively preventing scratches and damage to the insulating coating on the surface of the stator core segment 90 during clamping, protecting the electromagnetic properties of the core, and is especially suitable for high-power rim thrusters where the surface quality requirements of the core are stringent.

[0048] The radial clamping mechanism 40 includes a core plate 42, which is fixed to the spindle 20; the core plate 42 provides stable support and mounting foundation for the radial clamping unit 41.

[0049] The radial clamping unit 41 includes a guide rod 411, a pressure head 412, a guide bracket 413, and a servo drive component; the guide bracket 413 is fixed to the core plate 42. In this embodiment, 12 sets of guide brackets 413 are arranged in a ring around the mandrel 20, and the coaxiality tolerance of the 12 sets of guide brackets 413 relative to the mandrel 20 is ≤0.02mm. This ensures that all radial clamping units 41 are strictly arranged with the mandrel 20 as the center, structurally guaranteeing the accuracy of the clamping force direction.

[0050] The guide bracket 413 is provided with a guide hole, the axis of which is radially coincident with the spindle 20. The guide rod 411 passes through the guide hole. The guide hole serves as a guide structure for the guide rod 411, and its roundness tolerance is ≤0.02mm, so that the guide rod 411 maintains a precise radial movement trajectory during its extension.

[0051] The guide rod 411 is connected to the servo drive (not shown in the figure); the pressure head 412 is located at the end of the guide rod 411; the servo drive provides power to drive the guide rod 411 to extend along the guide hole direction, and drive the pressure head 412 to apply radial pressure toward the outer sleeve 80 to the stator core segment 90 via the anti-overturning block 13.

[0052] In this embodiment, the guide rod 411 can be connected to the screw component in the ball screw pair. The ball screw pair converts the rotational motion of the servo drive into the linear motion of the guide rod 411, thereby realizing the radial motion of the guide rod 411. The specific structure and connection method of the ball screw pair and the servo drive are well known to those skilled in the art and will not be described in detail here.

[0053] As an alternative, the guide rod 411 can also be connected to a telescopic rod component in the hydraulic system. A servo drive controls the hydraulic telescopic rod to extend the guide rod 411 along the guide hole, causing the pressure head 412 connected to the end to apply radial pressure to the stator core segment 90 via the anti-tipping block 13. The specific structure and connection method of the hydraulic telescopic rod and the servo drive are well known to those skilled in the art and will not be described in detail here.

[0054] Further, the pressure head 412 includes an inner pressure plate 4121, a buffer member 4122, and an outer pressure plate 4123. The inner pressure plate 4121 is connected to the guide rod 411. A buffer gap is formed between the inner pressure plate 4121 and the outer pressure plate 4123. The buffer member 4122 is disposed within the buffer gap and can be implemented by a spring. The buffer member 4122 provides an elastic force that drives the inner pressure plate 4121 and the outer pressure plate 4123 to move closer or further apart. By installing the buffer member 4122 in the buffer gap between the inner pressure plate 4121 and the outer pressure plate 4123, the elastic force provided by the buffer member 4122 can cause a slight relative displacement between the inner and outer pressure plates when compressed, thereby uniformly distributing the radial pressure, eliminating local stress concentration, effectively absorbing the impact load during the pressing process, and avoiding surface damage or pressure sudden changes in the stator core segment 90 due to rigid contact.

[0055] The outer pressure plate 4123 has a mating surface on its outer side, which is adapted to the inner side of the anti-tipping block 13. The pressure applied by the pressure head 412 is transmitted to the stator core segment 90 through the anti-tipping block 13. Since the anti-tipping block 13 has formed a precise positioning gap with the inner wall of the core during the rounding process, it can ensure that the clamping force is evenly distributed radially as an intermediate force transmission component, avoiding local stress concentration. Secondly, the anti-tipping block 13 itself also has an anti-tipping function, continuously providing lateral restraint while transmitting pressure, effectively suppressing the tilting or displacement that may occur in the core segment during the rounding process. This embodiment integrates the clamping function and the anti-tipping function into the same structural component, simplifying the tooling layout and improving assembly accuracy and safety.

[0056] In this embodiment, the pressure head 412 integrates a pressure sensor with an accuracy of ±1%. The pressure sensor is used to monitor the radial clamping force output by the outer pressure plate 4123 in real time, providing key data support for the refined control of the rounding process.

[0057] This embodiment also includes a control system, which is electrically connected to the servo drive and the pressure sensor respectively. The control system can control the output power of the servo drive based on the output data of the pressure sensor.

[0058] The control system, servo drives, and pressure sensors form a closed-loop control circuit. It dynamically adjusts the output power of each servo motor based on pressure data from the sensors, ensuring uniform radial pressure on each section of the iron core. This design effectively prevents core deformation or positioning deviations caused by uneven pressure. Furthermore, real-time pressure monitoring and closed-loop adjustment improve the quality of the assembled product. In addition, the control system automatically records position and pressure data during the pressing process, providing a basis for subsequent quality traceability and process optimization.

[0059] In this embodiment, a locking stud 21 is provided at the top of the mandrel 20. The end face leveling mechanism 50 includes a leveling pressure plate 51 and a locking nut 52; the leveling pressure plate 51 is an annular steel plate, and its outer edge extends circumferentially to the top of the stator core segment 90, so that the leveling pressure plate 51 can cover the entire upper end face of the stator core, ensuring that the axial clamping force is evenly distributed and effectively correcting the lamination warpage.

[0060] The leveling pressure plate 51 has several clearance grooves circumferentially, and the positions of the clearance grooves correspond to the positions of the C-clamp 311 to avoid motion interference during use. A bushing 511 is provided at the center of the leveling pressure plate 51, and the bushing 511 is fitted onto the top of the mandrel 20; the stepped surface of the variable diameter structure of the mandrel 20 can limit the extreme position of the bottom surface of the bushing 511 to prevent overpressure damage to the iron core.

[0061] The locking nut 52 is screwed onto the locking stud 21, and the bottom surface of the locking nut 52 contacts the top surface of the bushing 511. Through the cooperation between the locking nut 52 and the locking stud 21, the leveling plate 51 is driven to move axially, and axial pressure is applied to the stator core segment 90 in the direction of the horizontal base 11 to correct the warping of the core laminations and ensure the flatness of the overall end face of the stator core after rounding.

[0062] The radial clamping mechanism 40 applies a radial clamping force to the stator core segment 90. This pressure is directed only towards the outer sleeve 80 and does not restrict the axial movement of the core segment 90 during adjustment. The end face leveling mechanism 50 can be independently adjusted vertically without considering radial constraints. The end face leveling mechanism 50 applies an axial clamping force to the stator core segment 90. This pressure acts only in the vertical direction and does not restrict the radial movement of the core segment 90 during adjustment. The radial clamping mechanism 40 can independently adjust the clamping stroke of each segment without interference. Through the above functional decoupling design, the three actions of radial clamping, axial leveling, and radial clamping are independent of each other. During the entire assembly process, the movements in each direction do not interfere with each other, ensuring the flexibility of process adjustments and assembly accuracy at each stage.

[0063] Example 2: Based on Example 1, this embodiment provides a method for rounding the stator core of a high-power rim-driven propeller, specifically including the following steps: Provide a tooling for assembling the stator core of a high-power rim propeller as described in Embodiment 1; provide several stator core segments 90 to be assembled.

[0064] Step 1: Tooling debugging and benchmark calibration; the horizontality of the horizontal base 11 is 0.01mm / m, the roundness tolerance of the annular support guide rail 111 is ≤0.02mm; the cylindricity of the positioning reference surface of the mandrel 20 is 0.015mm; ensure that the horizontality of the tooling, the cylindricity of the mandrel 20, and the roundness of the guide rail meet the accuracy requirements.

[0065] Step 2: Pre-treatment of stator core segments at 90°; cleaning burrs from the rounded end faces, testing insulation performance, and applying insulating grease.

[0066] Step 3: Stator core segment 90 is hoisted and positioned. The stator core segment 90 is hoisted into the outer sleeve 80 and initially positioned by the annular support guide rail 111. The segment clamping mechanism 30 clamps each stator core segment 90 to the outer sleeve 80 to achieve coaxial initial positioning of the stator core segment 90.

[0067] Step 4: Apply a radial clamping force toward the annular support guide rail 111 to each stator core segment 90 by means of the radial clamping mechanism 40, wherein the radial clamping force is 80kN per segment.

[0068] Step 6: Apply axial pressure toward the horizontal base 11 to each stator core segment 90 through the end face leveling mechanism 50; correct the warping of the core laminations and ensure the overall flatness of the core end face after assembly; the locking nut 52 is tightened in steps with a torque of 220 N·m in the first step and 360 N·m in the second step, and the axial pressure holding pressure is 50 kN.

[0069] Step 7: Hold pressure for at least 30 minutes.

[0070] Step 8: Unload the end face leveling mechanism 50, and spot weld the adjacent stator core segments 90. During the welding process, keep the radial clamping force unchanged, and after welding, keep the pressure for at least 15 minutes to release the stress.

[0071] Step 9: Tooling unloading and finished product inspection. Take out the finished product and inspect its dimensions, stacking factor and insulation performance.

[0072] Testing showed that the overall coaxiality of the stator core after being assembled using this method was 0.025mm, the roundness was 0.028mm, and the stacking coefficient was 97.2%. All indicators met the design requirements of the 2MW high-power rim propeller, and the assembly efficiency was improved by more than 40% compared with the traditional process.

[0073] This invention relates to a high-power rim-driven propeller stator core assembly fixture and method. First, using the mandrel 20 as the core reference, and in conjunction with the segmented clamping mechanism 30 and the radial pressing mechanism 40, high-precision coaxial positioning of the stator core segments is achieved. The mandrel 20 has a cylindricity of 0.015mm on its positioning reference surface and a coaxiality tolerance of ≤0.02mm. The annular support guide rail 111 has a roundness tolerance of ≤0.02mm, structurally ensuring that all core segments are strictly coaxially arranged. The radial pressing mechanism 40 employs a ring array of 12 guide brackets 413, with coaxiality and guide hole roundness tolerances both ≤0.02mm. Combined with servo drive and pressure sensor closed-loop control, the gap between the assembly surfaces can be controlled within 0.01mm. This significantly improves the overall roundness and coaxiality of the core, effectively reducing motor eddy current losses and electromagnetic noise, and significantly improving the operating efficiency of the high-power rim-driven propeller. Secondly, by integrating anti-tipping supports, flexible clamping, and a pressure feedback system, the clamping stability is strong, and it can adapt to the assembly of large-diameter, heavy-weight iron cores. The anti-tipping block 13 cooperates with the lifting support seat 12 and the guide groove 112, possessing radial and axial movement freedom. Its contoured surface precisely matches the inner wall of the iron core, providing continuous lateral constraint during the rounding process, effectively preventing the iron core from slipping or tipping over, and significantly reducing assembly safety risks. The segmented clamping mechanism 30 adopts a C-type clamp 311 with a coaxial design of a five-star handle 312 and a push rod 313, providing symmetrical clamping force of inward pushing and outward pushing. The pressure head 412 integrates a high-precision pressure sensor, forming a closed loop with the control system to monitor and adjust the radial clamping force in real time, solving the problem of iron core deformation caused by uneven pressure in traditional processes, and can stably adapt to the mass production needs of high-power stator iron cores. Finally, all support mechanisms of the tooling can be flexibly adjusted. One set of tooling only needs to replace the clamping claw 314 and the anti-tipping block 13 to adapt to stator iron cores with different inner diameter specifications. The horizontal base 11 is provided with a guide groove 112. The lifting support 12 slides in the guide groove 112 via the bottom slider 121, and its position can be freely adjusted radially. The lifting column 122 is engaged with the adjusting nut 123 via a stud to achieve axial height adjustment, which further expands the range of adaptability, significantly reduces the tooling manufacturing cost of multi-specification products, reduces production line changeover time, and improves assembly efficiency by more than 40% compared with traditional processes.

[0074] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A tooling for assembling the stator core of a high-power rim-driven propeller, characterized in that, Includes a base support assembly, a spindle, a segmented clamping mechanism, a radial pressing mechanism, and an end face leveling mechanism; The base support assembly includes a horizontal base, an outer sleeve is provided on the horizontal base, and an annular support guide rail is provided on the inner wall of the outer sleeve; The mandrel is fixed to the horizontal base, and the mandrel is coaxially arranged with the outer sleeve; The segmented clamping mechanism includes several segmented clamping units, which are used to clamp the stator core in segments to the outer sleeve. The radial clamping mechanism includes several radial clamping units, which are arranged in a ring around the mandrel. The radial clamping units apply radial clamping force to the stator core segments in the direction of the ring support guide rail. The end face leveling mechanism includes a leveling pressure plate, which is liftably sleeved on the mandrel. The leveling pressure plate is used to apply axial clamping force toward the horizontal base direction to the stator core segments.

2. The tooling for rounding the stator core of a high-power rim-driven propeller according to claim 1, characterized in that, The horizontal base is provided with a plurality of lifting support seats, which are arranged in a ring array inside the outer sleeve. Each lifting support seat is provided with an anti-tipping block, and a positioning gap is formed between the anti-tipping block and the ring support guide rail of the outer sleeve for the stator core to enter in segments.

3. The tooling for rounding the stator core of a high-power rim-driven propeller according to claim 2, characterized in that, The horizontal base is provided with several guide grooves, which are arranged radially along the spindle. The bottom of the lifting support is provided with a slider, which slides within the guide groove.

4. The tooling for rounding the stator core of a high-power rim-driven propeller according to claim 3, characterized in that, The top of the lifting support is provided with a lifting column; the anti-tipping block is detachably connected to the lifting column, and the lifting column drives the anti-tipping block to move back and forth in the height direction. The anti-overturning block has a first contoured surface on its outer side, which is adapted to the inner wall of the stator core segment.

5. The tooling for rounding the stator core of a high-power rim-driven propeller according to claim 4, characterized in that, The segmented clamping unit includes a C-clamp, a handle, and a top rod; The C-shaped clamp is mounted on the top of the outer hoop and stator core segment; the two ends of the C-shaped clamp are respectively provided with an inner clamping arm and an outer clamping arm, the inner clamping arm extending to the inner side of the stator core segment and the outer clamping arm extending to the outer side of the outer hoop; the push rod is screwed to the outer clamping arm, and the end of the push rod is provided with a pressing block, which is used to contact the outer wall of the outer hoop; the five-star handle is screwed to the inner clamping arm, one end of the five-star handle is provided with a driving end, and the other end is used to apply pressure to the stator core segment.

6. The tooling for rounding the stator core of a high-power rim-driven propeller according to claim 5, characterized in that, The segmented clamping unit further includes clamping claws, which are disposed between the inner clamping arm and the stator core segment; The clamping claw is detachably connected to the lifting column by fasteners; a second contoured surface is provided on the outer side of the clamping claw, which is adapted to the inner wall of the stator core segment.

7. The tooling for rounding the stator core of a high-power rim-driven propeller according to claim 5, characterized in that, The radial clamping mechanism includes a core plate, which is fixed to the mandrel; The radial clamping unit includes a guide rod, a pressure head, a guide bracket, and a servo drive; the guide bracket is fixed to the core plate, and a guide hole is provided in the guide bracket. The guide rod passes through the guide hole and is connected to the servo drive; the pressure head is located at the end of the guide rod.

8. The tooling for rounding the stator core of a high-power rim-driven propeller according to claim 7, characterized in that, The pressure head includes an inner pressure plate, a buffer component, and an outer pressure plate. The inner pressure plate is connected to a guide rod. A buffer gap is formed between the inner pressure plate and the outer pressure plate, and the buffer component is disposed within the buffer gap. The outer pressure plate has a mating surface on its outer side, which is adapted to the inner side of the anti-tipping block. A pressure sensor is integrated inside the pressure head. It also includes a control system, which is electrically connected to the servo drive and the pressure sensor respectively. The control system can control the output power of the servo drive based on the output data of the pressure sensor.

9. The tooling for rounding the stator core of a high-power rim-driven propeller according to claim 1, characterized in that, A locking stud is provided at the top of the mandrel; The end face leveling mechanism includes a leveling plate and a locking nut; a bushing is provided on the leveling plate, the leveling plate extends circumferentially to the top of the stator core segment, and the bushing is sleeved on the top of the mandrel; the locking nut is screwed to the locking stud, and the bottom surface of the locking nut contacts the top surface of the bushing.

10. A method for rounding the stator core of a high-power rim-driven propeller, characterized in that, Includes the following steps: Provides a tooling for assembling the stator core of a high-power rim-driven propeller as described in any one of claims 1-9; provides stator core segments to be assembled; Tooling debugging and benchmark calibration; Stator core segmentation pretreatment; This includes cleaning burrs from the rounded end face, testing insulation performance, and applying insulating grease; The stator core is hoisted and positioned in sections. The stator core sections are hoisted into the outer sleeve and initially positioned by the annular support guide rail. The stator core sections are then clamped in the outer sleeve by the section clamping mechanism to achieve coaxial initial positioning of the stator core sections. Radial pressure is applied to each stator core segment in the direction of the annular support guide rail through a radial clamping mechanism; An axial pressure towards the horizontal base is applied to each stator core segment by an end-face leveling mechanism. Hold the pressure for at least 30 minutes; welding; Tooling unloading and finished product inspection: Remove the finished product and inspect its dimensions, stacking factor and insulation performance.

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