A device for bonding rotor magnets of an axial flux motor

Abstract

This utility model discloses an axial flux motor rotor magnet bonding device, belonging to the technical field of motor production equipment. It includes a base, a rotary worktable, a first gluing device, a rotor magnet installation device, and a second gluing device. The use of this utility model can significantly improve rotor productivity. A circular geared disc rotary mechanism arranges 20 magnets into a ring at once, replacing manual placement of each magnet individually, greatly shortening the assembly cycle time. The design with four support plates and eight operating stations enables parallel processing of multiple processes: "feeding—first gluing—magnet installation—second gluing—curing," significantly improving equipment utilization. A direct-drive manipulator, in conjunction with a magnet suction head, accurately picks and places magnets from the precision positioning device to the rotor support, greatly reducing the installation time for a single magnet. This utility model solves two major industry pain points in rotor magnet bonding: low efficiency and poor flatness, and has significant industrial application value.

Description

Technical Field

[0001] This utility model relates to the technical field of motor production equipment, specifically to a device for bonding rotor magnets in an axial flux motor. Background Technology

[0002] Axial flux motors (AFPMs), with their flat, axially arranged stators and rotors, offer significant advantages such as high power density, light weight, short axial dimensions, and fast response. They are widely used in high-end applications including electric vehicle hub-driven propulsion, aerospace electric propulsion, robot joints, wind power generation, and energy storage flywheels. With the rapid expansion of the new energy vehicle, drone, and collaborative robot markets, higher demands are being placed on the mass production and high-quality manufacturing of AFPMs. As the core component for energy conversion in AFPMs, the quality of the magnet bonding in the rotor directly determines the motor's torque fluctuation, air gap uniformity, NVH (noise, vibration, and harshness) performance, and long-term reliability.

[0003] Currently, the industry generally uses a "manual + single machine" method to complete the assembly of rotor magnets. A typical process includes:

[0004] 1. Manual pre-cleaning: Clean the bonding surface of the rotor bracket with a lint-free cloth dampened with alcohol.

[0005] 2. Manual application of adhesive: The operator holds a glue gun and applies epoxy structural adhesive evenly along the annular groove of the bracket. The amount of adhesive is controlled by experience.

[0006] 3. Magnet alignment: Loose magnets are poured into a simple vibratory feeder, and each magnet is manually removed and placed on the auxiliary positioning plate in the N-S polarity order. The alignment process is time-consuming.

[0007] 4. Manual pasting: Use tweezers or a simple presser to press the magnets into the slots one by one, repeatedly checking the height and polarity during the process.

[0008] 5. Curing: Place the rotor along with the simple pressure plate into an oven and cure at 80℃-120℃ for 2-4 hours.

[0009] 6. Manual inspection: After curing, use a feeler gauge or dial indicator to check the flatness of the magnet end face. If any defects are found, manually repair or scrap the magnet.

[0010] However, the commonly used "manual + stand-alone" method has the following drawbacks:

[0011] 1. Low efficiency: Manual piece-by-piece operation results in long assembly cycle time for single rotors, making it difficult to meet the needs of large-scale production; the scattered layout of individual machines requires manual handling between processes, resulting in long logistics distances and serious backlog of WIP (work in process) on site; the training cycle for skilled workers is long, and personnel turnover leads to quality fluctuations.

[0012] 2. Poor quality consistency: The amount and width of glue are greatly affected by human factors, and defects such as insufficient glue, glue overflow, and glue breakage are prone to occur; there is no unified standard for the arrangement and pressing of magnets, and the height difference between adjacent magnets is large, resulting in uneven air gap and increased motor torque pulsation; basic errors such as reversed polarity and missing parts occur frequently, resulting in batch scrap.

[0013] 3. Flatness and dimensional stability are difficult to control: During the curing stage, flat pressure plates and weights are commonly used to press the magnets together, which makes it impossible to apply a uniform and constant axial force to each magnet; epoxy resin shrinks in volume during curing (about 2%-3%), and if the constraint is insufficient, the magnets are prone to warping or displacement; the temperature field of traditional ovens is uneven, with a temperature difference of more than ±5℃, which leads to differences in the curing speed of the adhesive layer and further aggravates the flatness deviation.

[0014] 4. Lack of online inspection and data traceability: The proportion of manual sampling is low, making it difficult to detect defects in the early stages; there are no process data records, making it impossible to establish quality SPC (Statistical Process Control) charts, and making it difficult to analyze the root causes of problems; once a failure occurs at the market end, it is difficult to trace back to the specific batch and process parameters.

[0015] 5. Large equipment footprint and difficult to change models: Each machine has a single function and requires multiple machines to be connected in series; the tooling fixtures have poor versatility, and when changing rotors with different outer diameters or the number of magnets, multiple machines need to be disassembled and debugged, resulting in excessive changeover time; the equipment layout is fixed and cannot adapt to future product upgrades or process iterations. Utility Model Content

[0016] The purpose of this invention is to provide an axial flux motor rotor magnet bonding device to solve the problems of low efficiency, poor quality consistency, difficulty in controlling flatness and dimensional stability, lack of online detection and data traceability, large equipment footprint, and difficulty in changing models that are commonly used in the background art.

[0017] To achieve the above objectives, this utility model provides the following technical solution: an axial flux motor rotor magnet bonding device, comprising a base with a rotary worktable on its top surface, a first gluing device on the left side of the rotary worktable, a rotor magnet mounting device on the rear side, and a second gluing device on the right side; the rotary worktable includes a rotary base with a rotatable disc-shaped worktable disk mounted on its top surface via a thrust bearing, the rotary base housing a rotary motor for driving the worktable disk to rotate; four station support plates are evenly distributed in a ring on the top surface of the rotary base, each station supporting... On the top surface of the plate, at one end away from the center of the worktable disc, there are two side-by-side operating stations; the first glue application device includes a first glue application bracket and a first orthogonal manipulator on its top surface, with a first glue application head on the first orthogonal manipulator; the rotor magnet installation device includes an automatic feeding device, an automatic magnet alignment device, and a magnet precision positioning device arranged in sequence, with an automatic magnet installation device above the magnet precision positioning device; the second glue application device includes a second glue application bracket and a second orthogonal manipulator on its top surface, with a second glue application head on the second orthogonal manipulator.

[0018] Preferably, a rotor bracket positioning fixture is provided at the right operating station on the workstation support plate, and a clamping fixture positioning fixture is provided at the left operating station.

[0019] Preferably, the automatic feeding device includes a magnetic steel feeding base and a magnetic steel feeding vibrating disc is provided on its top surface. A straight magnetic steel feeding slide extending horizontally to the right is provided at the top of the side wall of the magnetic steel feeding vibrating disc. An automatic magnetic steel alignment device is provided at the end of the magnetic steel feeding slide.

[0020] Preferably, the automatic magnet alignment device is a circular toothed disc rotary mechanism that arranges 20 rotor magnets into a circular arrangement.

[0021] Preferably, the magnet precision positioning device is equipped with a radial pushing component, and the magnet precision positioning device is also equipped with a micro-moving component inside, which is located below the rotor magnet and can move slightly upward.

[0022] Preferably, the automatic magnet installation device includes a magnet mounting bracket provided on the top surface of the equipment base, a magnet installation orthogonal manipulator provided at the top of the magnet mounting bracket, and a magnet suction cup head provided on the orthogonal manipulator.

[0023] Preferably, visual inspection components are provided at both the first and second glue application devices to dynamically detect and correct the quality of the glue application.

[0024] Compared with the prior art, the beneficial effects of this utility model are:

[0025] 1. The use of this utility model can significantly improve rotor productivity. The circular toothed disc rotation mechanism arranges 20 magnets into a ring at one time, replacing manual placement of each magnet, and greatly shortening the assembly cycle time. The design of four workstation support plates and eight operating stations enables multiple processes to be carried out in parallel, including "material feeding - first gluing - magnet installation - second gluing - curing", which greatly improves equipment utilization. The magnet installation orthogonal robot, in conjunction with the magnet suction head, completes the precise picking and placing of magnets from the precision positioning device to the rotor support, greatly shortening the installation time of a single magnet.

[0026] 2. Online quality inspection and closed-loop correction: Both the first and second glue application devices are equipped with vision inspection components to monitor glue width, glue height and glue breakage defects in real time, and feed the data back to the direct-drive robot for dynamic correction, which greatly improves the glue quantity qualification rate.

[0027] 3. Compact equipment structure and easy maintenance: The rotary table adopts a thrust bearing + built-in rotary motor structure, which reduces the overall height; the top surface of the equipment base integrates all modules for feeding, aligning, gluing, installation and testing, which greatly reduces the floor space compared with traditional production lines.

[0028] 4. Wide range of applications: By changing the rotor support positioning fixture and clamping fixture positioning fixture, it can quickly adapt to rotors with different outer diameters and different numbers of magnets, realizing flexible production of multiple varieties and small batches.

[0029] 5. In summary, this utility model solves the two major industry pain points of "low efficiency and poor flatness" in rotor magnet pasting by means of innovative rotary multi-station layout, automatic magnet alignment and precise positioning, special drying and positioning fixtures and online visual inspection, and has significant industrial promotion value. Attached Figure Description

[0030] Figure 1 This is a top view of the present invention;

[0031] Figure 2 for Figure 1 Structural diagram;

[0032] Figure 3 for Figure 1 Main view;

[0033] Figure 4 This is a schematic diagram of the rotor magnet installation;

[0034] Figure 5 This is a schematic diagram of a micro-moving component;

[0035] Figure 6 This is a schematic diagram of an axial flux motor;

[0036] Figure 7 This is a rotor diagram of an axial flux motor;

[0037] Figure 8 for Figure 7 Exploded view;

[0038] Figure 9 This is a schematic diagram of rotor clamping and fixing.

[0039] In the diagram: Motor shaft - A1, Motor rotor - A2, Motor stator - A3, Motor housing - A4, Rotor bracket - A5, Bracket connecting bend - A6, Bracket shaft disc - A7, Magnet mounting slot - A8, Rotor magnet - A9, Gap - A10, Upper clamping fixture - A11, Fixing bolt - A12, Lower clamping fixture - A13, Shaft bolt - A14, Equipment base - 1, Rotary worktable - 2, Rotary base - 21, Worktable disc - 22, Station support plate - 23, Rotor bracket positioning fixture - 24, Clamping fixture positioning fixture - 25, First gluing device - 3, First coating... Glue holder-31, first orthogonal robot-32, first glue applicator-33, rotor magnet mounting device-4, automatic feeding device-41, magnet feeding base-411, magnet feeding vibrating tray-412, magnet feeding slide-413, automatic magnet alignment device-42, magnet precision positioning device-43, micro-motion component-431, automatic magnet mounting device-44, magnet mounting bracket-441, magnet mounting orthogonal robot-442, magnet suction head-443, second glue applicator-5, second glue applicator bracket-51, second orthogonal robot-52, second glue applicator-53. Detailed Implementation

[0040] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings and specific embodiments.

[0041] Please refer to Figure 1-9 , Figure 1 This is a top view of the present invention; Figure 2 for Figure 1 Structural diagram; Figure 3 for Figure 1 Main view; Figure 4 This is a schematic diagram of the rotor magnet installation; Figure 5 This is a schematic diagram of a micro-moving component; Figure 6 This is a schematic diagram of an axial flux motor; Figure 7 This is a rotor diagram of an axial flux motor; Figure 8 for Figure 7 Exploded view; Figure 9 This is a schematic diagram of rotor clamping and fixing.

[0042] An axial flux motor includes a motor shaft A1, on which a motor rotor A2 is mounted in the middle and motor stators A3 on both sides. A motor housing A4 is disposed outside the motor shaft A1, the motor rotor A2, and the two motor stators A3. The motor rotor A2 includes a circularly arranged rotor support A5. Multiple support connecting plates A6 extending towards the axis are evenly distributed in a ring around the inner circle of the rotor support A5. The ends of the multiple support connecting plates A6 near the axis are connected to a support shaft disk A7 placed above the rotor support A5. Twenty magnet mounting slots A8 are evenly distributed in a ring on the upper and lower sides of the rotor support A5, and a rotor magnet A9 is glued and fixed in each magnet mounting slot A8.

[0043] During production, firstly, adhesive is applied to the magnet mounting groove A8 on the side of the support shaft disk A7 that is higher than the rotor support A5. One rotor magnet A9 is then bonded to each magnet mounting groove A8. Adhesive is also applied to the gap A10 between adjacent rotor magnets A9. After the rotor magnets A9 are installed, an upper clamping fixture A11 is installed above the rotor magnets A9, and multiple fixing bolts A12 are used to connect the support shaft disk A7 and the upper clamping fixture A11 into one unit. Then, the upper clamping fixture A11, along with the rotor support A5 and the rotor magnets A9, is rotated 180 degrees, turning the other side of the rotor support A5 to the top. The magnet mounting groove A9, now turned upwards... Apply adhesive to the groove A8 and bond a rotor magnet A9 to each magnet mounting slot A8. Then apply adhesive to the gap A10 between two adjacent rotor magnets A9. After the adhesive is applied, install a lower clamping fixture A13 above the rotor magnet A9. Use a axial bolt A14 to pass through the axis of the lower clamping fixture A13 and the axis of the support shaft plate A7 and connect it to the upper clamping fixture A11 to form a whole. This clamps and fixes the rotor support A5 and the rotor magnets A9 bonded and fixed on both sides. Then cure the whole at room temperature or by drying to maintain the size of the rotor magnets A9 on both sides and improve the flatness of the overall rotor magnets A9.

[0044] This utility model provides an axial flux motor rotor magnet bonding device for automatically bonding and fixing rotor magnets A9 on the rotor support A5 and for installing drying fixtures; it includes a device base 1, and a rotary worktable 2 is provided on the top surface of the device base 1, a first adhesive applicator 3 on the left side of the rotary worktable 2, a rotor magnet mounting device 4 on the rear side of the rotary worktable 2, and a second adhesive applicator 5 on the right side of the rotary worktable 2.

[0045] The equipment base 1 is the supporting base for the entire equipment and is rectangular in shape.

[0046] The rotary worktable 2 is a four-station rotary worktable. The front of the rotary worktable 2 is the loading and unloading station, the left side is the first gluing station, the rear side is the magnet installation station, and the right side is the second gluing station. It includes a rotary base 21 set on the top surface of the equipment base 1, and a disc-shaped worktable disc 22 that can rotate is set on the top of the base through a thrust bearing. The rotary base 21 has a built-in rotary motor to drive the worktable disc 22 to rotate. Four worktable support plates 23 are evenly distributed in a ring on the top surface of the rotary base 21. On the top surface of each worktable support plate 23, there are two side-by-side operating stations on the left and right sides. The right operating station is equipped with a rotor bracket positioning fixture 24 for positioning and supporting the rotor bracket A5, and the left operating station is equipped with a clamping fixture positioning fixture 25 for positioning and supporting the upper clamping fixture A11.

[0047] The first adhesive applicator 3 includes a first adhesive applicator bracket 31 disposed on the top surface of the equipment base 1, a first orthogonal manipulator 32 disposed on the top surface of the first adhesive applicator bracket 31, and a first adhesive applicator head 33 disposed on the first orthogonal manipulator 32; the first orthogonal manipulator 32 controls the movement of the first adhesive applicator head 33 to complete the adhesive applicator operation on the magnet mounting slot A8.

[0048] The rotor magnet installation device 4 includes an automatic feeding device 41 for automatic magnet feeding, an automatic magnet alignment device 42 is provided at the end of the automatic feeding device 41, a magnet precision positioning device 43 is provided on the right side of the automatic magnet alignment device 42, and an automatic magnet installation device 44 is provided above the magnet precision positioning device 43.

[0049] The automatic feeding device 41 includes a magnetic steel feeding base 411 provided on the top surface of the equipment base 1. A magnetic steel feeding vibrating plate 412 is provided on the top surface of the magnetic steel feeding base 411. A straight magnetic steel feeding slide 413 extending horizontally to the right is provided at the top of the side wall of the magnetic steel feeding vibrating plate 412 for aligning the rotor magnets A9 into a straight line. An automatic magnetic steel alignment device 42 is provided at the end of the magnetic steel feeding slide 413.

[0050] The automatic magnet alignment device 42 is a circular toothed disc rotation mechanism used to arrange the rotor magnets A9 into a circular arrangement, with a quantity of 20.

[0051] The magnet precision positioning device 43 is equipped with a radial pushing component, and the magnet precision positioning device 43 is also equipped with a micro-movement component 431 inside. The micro-movement component 431 is below the rotor magnet A9 and can move slightly upward. The micro-movement component 431 assists the magnet chuck head in picking up the rotor magnet A9.

[0052] The automatic magnet installation device 44 includes a magnet installation bracket 441 provided on the top surface of the equipment base 1. A magnet installation orthogonal manipulator 442 is provided at the top of the magnet installation bracket 441, and a magnet suction head 443 is provided on the orthogonal manipulator 442.

[0053] In use, the rotor magnets A9 are vibrated one by one into the automatic magnet alignment device 42 and arranged in a circular pattern by the vibration of the magnet feeding vibrating plate 412 and the linear vibration of the magnet feeding slide 413. Then, the 20 rotor magnets A9 are transferred into the precision positioning mechanism 25 by the magnet chuck head 443. The radial pushing component moves the 20 rotor magnets A9 radially inward, and their position dimensions are consistent with the position of the magnet mounting slot A8 on the rotor support A5. At this time, the magnet chuck head 443 can pick up the entire group of rotor magnets A9 from the magnet precision positioning device 43. At the same time, the micro-movement component 431 assists in micro-movement upward. The magnet chuck head 443 moves the rotor magnets A9 to the top of the rotary table 2 and installs the entire group of rotor magnets A9 into the rotor support A5. Then it returns to the top of the automatic magnet alignment device 42 and repeats the above action cycle to continuously complete the installation of rotor magnets A9.

[0054] The structure of the second glue applicator 5 is the same as that of the first glue applicator 3, including a second glue applicator bracket 51 provided on the top surface of the equipment base 1, a second orthogonal manipulator 52 provided on the top surface of the second glue applicator bracket 51, and a second glue applicator head 53 provided on the second orthogonal manipulator 52; by controlling the movement of the second glue applicator head 53 through the second orthogonal manipulator 52, the glue applicator operation on the gap A10 is completed.

[0055] In addition, visual inspection components can be configured at both the first glue application device 3 and the second glue application device 5 to dynamically detect and correct the quality of the glue application.

[0056] The installation of rotor magnet A9 using the above-mentioned axial flux motor rotor magnet bonding equipment includes the following steps:

[0057] First, at the loading / unloading station, the bracket shaft plate A7, with the side higher than the rotor bracket A5 facing upwards, is placed on the rotor bracket positioning fixture 24. The worktable disc 22 rotates 90° clockwise to reach the first gluing station. The first orthogonal robot 32 of the first gluing device 3 drives the first gluing head 33 to apply glue to the magnet mounting slot A8. After gluing, the worktable disc 22 rotates 90° clockwise to reach the magnet mounting station. At this time, the magnet suction head 443 has obtained the rotor magnet A9 magnet assembly from the magnet precision positioning device 43 using the suction principle. The magnet mounting orthogonal robot 442 then installs the rotor magnet A9 into the magnet mounting slot A8. After the rotor magnet A9 is installed, the worktable disc 22 rotates 90° clockwise to reach the second gluing device 5. The second gluing head 53 applies glue to the gap A10 between the rotor magnets A9.

[0058] The second step involves rotating the worktable disc 22 90° clockwise back to the loading / unloading station. At this station, the clamping fixture A11 is installed and secured with fixing bolts A12. Then, the entire assembly is rotated 180° and placed on the clamping fixture positioning fixture 25. A new rotor bracket A5 can be placed at the rotor bracket positioning fixture 24. The loading / unloading and drying fixture installation operations at the loading / unloading station can be completed manually or automatically.

[0059] The third step involves the worktable disc 22 continuing to rotate clockwise. Following the steps outlined in the first step, the other side of the rotor bracket A5 can be glued, and the rotor magnet A9 can be installed.

[0060] Fourth step: After the rotor magnet A9 on the other side of the rotor bracket A5 is pasted, rotate it back to the loading and unloading station. At this time, the lower clamping fixture A13 can be installed in place and fixed with the shaft bolt A14.

[0061] The fifth step is to unload the rotor after installing the upper clamping fixture A11 and the lower clamping fixture A13. Generally speaking, one rotor product is unloaded for every two rotations.

[0062] Although embodiments of the present invention have been shown and described, it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, it will be understood by those skilled in the art that all other embodiments obtained by making various changes, modifications, substitutions and alterations to these embodiments without departing from the principles and spirit of the present invention and without creative effort are within the scope of protection of the present invention.

Claims

1. An axial flux motor rotor magnet sticking apparatus, characterized in that: The equipment includes a base (1) with a rotary worktable (2) on its top surface, a first gluing device (3) on the left side of the rotary worktable (2), a rotor magnet mounting device (4) on the rear side, and a second gluing device (5) on the right side; the rotary worktable (2) includes a rotary base (21) with a rotatable disc-shaped worktable disc (22) mounted on its top surface via a thrust bearing, the rotary base (21) housing a rotary motor for driving the worktable disc (22) to rotate; four workstation support plates (23) are evenly distributed in a ring on the top surface of the rotary base (21), and two workstation support plates (23) are provided on the top surface of each workstation support plate (23) at one end away from the center of the worktable disc (22). The first adhesive applicator (3) includes a first adhesive applicator bracket (31) and a first orthogonal manipulator (32) on its top surface. The first orthogonal manipulator (32) is equipped with a first adhesive applicator head (33). The rotor magnet installation device (4) includes an automatic feeding device (41), an automatic magnet alignment device (42), and a magnet precision positioning device (43) arranged in sequence. The magnet precision positioning device (43) is equipped with an automatic magnet installation device (44) above it. The second adhesive applicator (5) includes a second adhesive applicator bracket (51) and a second orthogonal manipulator (52) on its top surface. The second orthogonal manipulator (52) is equipped with a second adhesive applicator head (53).

2. The axial flux motor rotor magnet sticking apparatus according to claim 1, wherein: The operating station on the right side of the workstation support plate (23) is provided with a rotor bracket positioning fixture (24), and the operating station on the left side is provided with a clamping fixture positioning fixture (25).

3. The axial flux motor rotor magnet sticking apparatus of claim 1, wherein: The automatic feeding device (41) includes a magnetic steel feeding base (411) and a magnetic steel feeding vibrating plate (412) is provided on its top surface. The top of the side wall of the magnetic steel feeding vibrating plate (412) is provided with a straight magnetic steel feeding slide (413) extending horizontally to the right. The end of the magnetic steel feeding slide (413) is provided with a magnetic steel automatic alignment device (42).

4. The axial flux motor rotor magnet sticking apparatus of claim 1, wherein: The automatic magnet alignment device (42) is a circular toothed disc rotation mechanism that arranges 20 rotor magnets into a circular arrangement.

5. The axial flux motor rotor magnet sticking apparatus of claim 1, wherein: The magnet precision positioning device (43) is equipped with a radial pushing component, and the magnet precision positioning device (43) is equipped with a micro-movement component (431) inside. The micro-movement component (431) is below the rotor magnet and can move slightly upward.

6. The axial flux motor rotor magnet sticking apparatus of claim 1, wherein: The automatic magnet installation device (44) includes a magnet installation bracket (441) provided on the top surface of the equipment base (1), and a magnet installation orthogonal manipulator (442) is provided at the top of the magnet installation bracket (441), and a magnet suction head (443) is provided on the orthogonal manipulator (442).

7. The axial flux motor rotor magnet sticking apparatus of claim 1, wherein: Visual inspection components are provided at both the first glue application device (3) and the second glue application device (5) to dynamically detect and correct the quality of the glue application.

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