Manufacturing method for axial lead of slip ring device

Abstract

Disclosed in the present invention is a manufacturing method for an axial lead of a slip ring device. The manufacturing method for an axial lead of a slip ring device comprises: selecting a raw material and performing hot forging to obtain an initial forged piece, specifically, performing upsetting, drawing out, and corner rounding on the raw material; performing cold forging on the initial forged piece, specifically, reheating the initial forged piece to 300°C-350°C, maintaining the temperature for 5-6 hours, and performing corner rounding on the heat-preserved initial forged piece by means of a rounding die manufactured by a preset process; performing solution and aging heat treatment on the cold-forged initial forged piece; and machining the initial forged piece having undergone solution and aging heat treatment to obtain a final forged piece, comprising: dividing the initial forged piece into two parts in an axial direction, and machining dividing surfaces; and assembling two axial leads and machining same to obtain the final forged piece. The present invention can effectively reduce consumables, shorten the machining time, and significantly improve the strength of the forged piece.

Description

A method for manufacturing axial leads of a slip ring device Technical Field

[0001] This invention relates to the field of electromechanical engineering, and more particularly to a method for manufacturing an axial lead of a slip ring device. Background Technology

[0002] Slip rings, also known as collector rings, are commonly used in high-performance, high-precision equipment. They greatly assist in the rotational movements of high-end industrial electrical equipment and precision electrical equipment, and are frequently used in aerospace equipment, automated processing equipment, mining equipment, medical equipment, radar equipment, etc. Slip rings provide these devices with a reliable energy signal transmission solution, enabling more complex movements. The axial leads in the slip ring rotor serve to transfer electrical energy from the stationary part (stator) to the rotating part (rotor), ensuring that the rotating body receives the necessary power supply while rotating continuously.

[0003] The current manufacturing process for such products involves forging them into strip-shaped copper forgings and then machining them. Due to the change in product shape, the forgings often result in large containment blocks. Larger forgings are more difficult to fully integrate the material during deformation, necessitating the use of heavy-duty forging equipment and extended heating times. Furthermore, to meet performance requirements, larger deformation amounts are often achieved through cold forging technology, further complicating the process. The larger containment blocks also increase heat treatment and machining time, leading to significant energy and material consumption, which cannot meet the needs of modern enterprises. Summary of the Invention

[0004] In view of the above-mentioned shortcomings, the present invention provides a method for manufacturing axial leads of a slip ring device, which can effectively reduce material consumption, shorten processing time, and significantly improve the strength of forgings.

[0005] To achieve the above objectives, the embodiments of the present invention adopt the following technical solutions:

[0006] A method for manufacturing an axial lead of a slip ring device, the method comprising:

[0007] Raw materials are selected and hot forging is carried out to obtain preliminary forgings. Specifically, the raw materials are upset, drawn, and rounded.

[0008] The initial forging is subjected to cold forging treatment, specifically by reheating the initial forging to 300~350℃ and holding it for 5~6 hours, and then using a die manufactured by a preset process to perform rounding treatment on the initial forging after holding it.

[0009] The initial forgings after cold forging are subjected to solution aging heat treatment;

[0010] The process of processing a primary forging after solution aging heat treatment to obtain a final forging includes: dividing the primary forging into two parts along the axial direction and machining the dividing surface; assembling the two parts along the axial direction and machining them to obtain the final forging.

[0011] According to one aspect of the present invention, the raw material is a chromium-zirconium-copper material, wherein Zr: 0.05-0.25%, Cr: 0.50-1.50%, and Cu+Cr+Zr≥99.7%.

[0012] According to one aspect of the present invention, a die manufactured by a preset process is used to round the initial forging after heat preservation. Specifically, the forging is rounded by using a die to make the deformation of the forging 15-20mm.

[0013] According to one aspect of the present invention, the step of selecting raw materials and hot forging to obtain a preliminary forging specifically involves heating the raw materials to 650~850°C, upsetting and drawing the raw materials, and after the final drawing, pressing the shoulders, removing excess material, and rounding the raw materials to obtain the preliminary forging.

[0014] According to one aspect of the present invention, the preset process includes: selecting a blank that meets the forging requirements; casting the blank to obtain a casting; and machining the casting to obtain a die.

[0015] According to one aspect of the present invention, the mold includes a mold base, an upper mold clip, and a lower mold clip.

[0016] According to one aspect of the present invention, the process of machining the casting to obtain the mold specifically involves machining the upper and lower cavities of the mold, wherein the upper and lower cavities of the mold are machined to leave a mold closing gap.

[0017] According to one aspect of the invention, the mold closing gap is 10-15 mm.

[0018] According to one aspect of the present invention, the process of processing the initial forging after solution aging heat treatment to obtain the final forging specifically involves assembling two axial lead wires on a machining template and machining the outer diameter of the initial forging to a predetermined size to obtain the final forging.

[0019] According to one aspect of the present invention, the planar symmetry of the vehicle template is not greater than 0.05 mm, and the flatness is not greater than 0.05 mm.

[0020] Advantages of implementing the present invention: (1) The amount of material removed from the surface of the forging is small, which shortens the processing time and can also maximize the integrity of the internal metal flow lines of the original forging and the amount of material remaining on the heat-treated surface, so that the product has high strength performance and can easily extend the service life of the product.

[0021] (2) Assembling two products together is suitable for batch processing of products. It can also ensure the uniformity and interchangeability of the dimensions between products, avoid the need for repairs during equipment assembly, and facilitate equipment installation. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 is a schematic diagram of the structure of the present invention;

[0024] Figure 2 is a flowchart of the present invention;

[0025] Figure 3 is a schematic diagram of the forming process of obtaining a preliminary forging by hot forging the raw material according to the present invention;

[0026] Figure 4 is a schematic diagram of the first forming process of the initial forging of the forging part according to the present invention.

[0027] Figure 5 is a schematic diagram of the second forming process of the initial forging of the present invention;

[0028] Figure 6 is a heat treatment process curve diagram of the present invention;

[0029] Figure 7 is a structural schematic diagram of the vehicle template of the present invention;

[0030] Figure 8 is a structural schematic diagram of the mold-dropping tooling described in this invention;

[0031] Figure 9 is a schematic diagram of Comparative Example 1 of the present invention;

[0032] Figure 10 is a schematic diagram of the product of the present invention.

[0033] 1. Slip ring; 2. Diverter ring; 3. Mold holder; 4. Upper mold clip; 5. Lower mold clip; 6. Mold template. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Comparative Example 1:

[0036] Existing methods for manufacturing axial leads:

[0037] As shown in Figure 9, a method for manufacturing an axial lead of a slip ring device includes:

[0038] S1: Select raw materials and perform hot forging to obtain preliminary forgings;

[0039] Select raw materials and forge them to obtain a preliminary forging in the shape of a rectangular strip (as shown by the solid line in Figure 9).

[0040] The raw material is chromium zirconium copper.

[0041] S2: Machining the initial forging to obtain the product;

[0042] The initial forging is machined to obtain a semi-circular product with steps (as shown by the dotted line in Figure 9).

[0043] Products manufactured using the above method will form larger forging containment blocks due to changes in product shape. The larger the forging, the more difficult it is to fully knead the material during deformation, which necessitates the use of large-tonnage forging equipment and extended heating time. Furthermore, to improve performance requirements, the forgings undergo greater deformation and cold forging technology, making the process more complex. Larger containment blocks also increase heat treatment and machining time.

[0044] Example 1:

[0045] As shown in Figures 1 and 2, a method for manufacturing an axial lead of a slip ring device is provided, comprising:

[0046] S1: Select raw materials and perform hot forging to obtain the initial forging.

[0047] The axial leads are used in conjunction with the slip ring rotor at a high speed of 3000 r / min. Therefore, chromium-zirconium-copper alloy is selected as the raw material, and its chemical composition should meet the following requirements: Zr: 0.05~0.25%, Cr: 0.50~1.50%, Cu+Cr+Zr≥99.7%. The performance requirements should meet the following table:

[0048]

[0049] The raw material is heated to 650-850℃ to fully utilize its excellent plasticity. After the first heating cycle (upsetting height ≤ 300 mm, drawing length ≥ 600 mm) and the second heating cycle (upsetting height ≤ 300 mm, drawing length ≥ 900 mm), the end is shouldered, excess material is removed, and the remaining material is rounded (as shown in Figure 3), resulting in the preliminary forging. The preliminary forging undergoes multiple upsetting and drawing cycles with the forging hammer, ensuring its internal metal flow lines are complete and its structure is dense.

[0050] S2: Cold forging is performed on the initial forging.

[0051] To ensure that copper forgings have reliable mechanical properties, cold forging at low temperatures is a necessary process choice.

[0052] S201: Heating the initial forging after cooling.

[0053] After the initial forging has completely cooled, reheat it to 300-350℃ and hold it at that temperature for 5-6 hours to ensure thorough heating.

[0054] S202: The die-casting mold, manufactured through a pre-set process, is used to round the initial forging after heat preservation.

[0055] Drop mold: In accordance with the requirements that tooling molds should be economical and have a high reusability, the process R&D personnel designed the drop mold tooling separately as a drop mold base and drop mold upper clip and drop mold lower clip to improve the versatility of the drop mold.

[0056] In this embodiment, the hole size of the die holder is φ350mm, and the buckle circle range of the upper and lower die is set to φ20 mm~φ300 mm. In actual production, various specifications of upper and lower die buckles can be designed and manufactured according to product needs, and replaced in the die holder to complete the forging of products of different specifications.

[0057] Using a slamming die (as shown in Figure 4), the initial forging after heat preservation is rounded, so that the forging retains a deformation of 15-20mm, which enables the forging to have high strength in its original state, preparing it for subsequent solution aging heat treatment.

[0058] Cold deformation forging of forgings is carried out within a temperature range of 300-350℃ to ensure the best mechanical properties. This is a new attempt in process development and a summary of process personnel’s skillful control over the properties of copper materials and process experience in this manufacturing field.

[0059] Preset process:

[0060] Before forging, the forging process scheme is determined through dimensional design and 3D simulation.

[0061] S211: Select a blank that meets the requirements for tooling forging.

[0062] All the mold-making tools are made of 40Cr.

[0063] S212: Casting the blank to obtain the mold base, upper mold clip, and lower mold clip.

[0064] The die holder, upper die holder, and lower die holder are obtained by casting. Since the die holder needs to be used for a long time under the impact of the forging hammer, impact resistance, high strength, and heavy structure are its important characteristics.

[0065] S213: Process the cavities of the upper and lower mold clamps.

[0066] The cavities of the upper and lower clips of the die are machined, leaving a 10mm-15mm mold closing gap. The upper and lower clips of the rear die are also used for a long time under the impact of the forging hammer, and need sufficient strength, but the surface hardness should be controlled at 300-330HBW to prevent breakage.

[0067] S3: Perform solution aging heat treatment on the initial forging after cold forging.

[0068] After cold-forming, the initial forgings possess high strength, but this still does not meet the design requirements for normal equipment operation, necessitating performance heat treatment. The heat treatment process should employ solution aging. Prolonged holding at 350℃ in the furnace will result in a more uniform internal structure and more representative performance data.

[0069] The initial forgings after cold forging are subjected to solution aging heat treatment. Specifically, the temperature is heated to no higher than 600℃, homogenized to 350±10℃ for 1 to 3 hours, held for 3 hours, and air-cooled to no higher than 70℃. The heat treatment process curve is shown in Figure 6.

[0070] S4: The initial forging after heat treatment is processed to obtain the final forging.

[0071] Example 2:

[0072] As shown in Figures 1 and 2, a method for manufacturing an axial lead of a slip ring device is provided, comprising:

[0073] S1: Select raw materials and perform hot forging to obtain the initial forging.

[0074] The axial leads are used in conjunction with the slip ring rotor at a high speed of 3000 r / min. Therefore, chromium-zirconium-copper alloy is selected as the raw material, and its chemical composition should meet the following requirements: Zr: 0.05~0.25%, Cr: 0.50~1.50%, Cu+Cr+Zr≥99.7%. The performance requirements should meet the following table:

[0075]

[0076] The raw material is heated to 650-850℃ to fully utilize its excellent plasticity. After the first heating cycle (upsetting height ≤ 300 mm, drawing length ≥ 600 mm) and the second heating cycle (upsetting height ≤ 300 mm, drawing length ≥ 900 mm), the end is shouldered, excess material is removed, and the remaining material is rounded (as shown in Figure 3), resulting in the preliminary forging. The preliminary forging undergoes multiple upsetting and drawing cycles with the forging hammer, ensuring its internal metal flow lines are complete and its structure is dense.

[0077] S2: Cold forging is performed on the initial forging.

[0078] To ensure that copper forgings have reliable mechanical properties, cold forging at low temperatures is a necessary process choice.

[0079] S201: Heating the initial forging after cooling.

[0080] After the initial forging has completely cooled, reheat it to 300-350℃ and hold it at that temperature for 5-6 hours to ensure thorough heating.

[0081] S202: The die-casting mold, manufactured through a pre-set process, is used to round the initial forging after heat preservation.

[0082] Drop mold: In accordance with the requirements that tooling molds should be economical and have a high reusability, the process R&D personnel designed the drop mold tooling separately as a drop mold base and drop mold upper clip and drop mold lower clip to improve the versatility of the drop mold.

[0083] In this embodiment, the hole size of the die holder is φ350mm, and the buckle circle range of the upper and lower die buckles is set to φ20 mm~φ300 mm. In actual production, various specifications of upper and lower die buckles can be designed and manufactured according to product needs, and replaced in the die holder to complete the forging of products of different specifications.

[0084] Using a slamming die (as shown in Figure 4), the initial forging after heat preservation is rounded, so that the forging retains a deformation of 15-20mm, which enables the forging to have high strength in its original state, preparing it for subsequent solution aging heat treatment.

[0085] Cold deformation forging of forgings is carried out within a temperature range of 300-350℃ to ensure the best mechanical properties. This is a new attempt in process development and a summary of process personnel’s skillful control over the properties of copper materials and process experience in this manufacturing field.

[0086] Preset process:

[0087] Before forging, the forging process scheme is determined through dimensional design and 3D simulation.

[0088] S211: Select a blank that meets the requirements for tooling forging.

[0089] All the mold-making tools are made of 40Cr.

[0090] S212: Casting the blank to obtain the mold base, upper mold clip, and lower mold clip.

[0091] The die holder, upper die holder, and lower die holder are obtained by casting. Since the die holder needs to be used for a long time under the impact of the forging hammer, impact resistance, high strength, and heavy structure are its important characteristics.

[0092] S213: Process the cavities of the upper and lower mold clamps.

[0093] The cavities of the upper and lower clips of the die are machined, leaving a 10mm-15mm mold closing gap. The upper and lower clips of the rear die are also used for a long time under the impact of the forging hammer, and need sufficient strength, but the surface hardness should be controlled at 300-330HBW to prevent breakage.

[0094] S3: Perform solution aging heat treatment on the initial forging after cold forging.

[0095] After cold-forming, the initial forgings possess high strength, but this still does not meet the design requirements for normal equipment operation, necessitating performance heat treatment. The heat treatment process should employ solution aging. Prolonged holding at 350℃ in the furnace will result in a more uniform internal structure and more representative performance data.

[0096] The initial forgings after cold forging are subjected to solution aging heat treatment. Specifically, the temperature is heated to no higher than 600℃, homogenized to 350±10℃ for 1 to 3 hours, held for 3 hours, and air-cooled to no higher than 70℃. The heat treatment process curve is shown in Figure 6.

[0097] S4: Before processing, conduct physical and chemical tests on the heat-treated initial forgings.

[0098] The physical and chemical tests are used to determine whether the initial forgings after heat treatment meet the predetermined standards.

[0099] S5: The initial forging after heat treatment is processed to obtain the final forging.

[0100] S501: Divide the initial forging into two parts along the axial direction and machine the dividing surface;

[0101] The forging is split in two along the axial direction, and the split surface is milled.

[0102] In this embodiment, the forging is first divided into two along the axial direction, and the dividing surface is milled; 35mm process steps and φ17mm process holes are machined at both ends of the forging.

[0103] S502: Assemble the two axial lead wires on the template and perform outer diameter machining on the initial forging.

[0104] As shown in Figure 4, the two axial lead wires are assembled, a machining template is added in the middle, and the outer circle of the product is machined to the predetermined size.

[0105] The template primarily serves as a shim between the two axial leader lines, enabling simultaneous machining of both lines during turning and ensuring they are of the same dimensional specifications. The template thickness is 12mm (+0.05, -0.10), with a plane symmetry ≤0.05mm and a flatness ≤0.05mm. These design precision requirements are prerequisites for ensuring the dimensional accuracy of the axial leader lines after machining.

[0106] In this embodiment, after assembling the two axial lead wires, a 12mm thick car template is added in the middle, and each end of the car template is fastened with two sets of M16 bolts.

[0107] S503: Machining the initial forging after the outer diameter is machined to the predetermined size to obtain the final forging.

[0108] As shown in Figure 5, after completing the outer diameter machining, the template is disassembled, and the product's designed length is milled. Machining of two axial lead wires is completed in one go, saving nearly half the time.

[0109] Figure 4 shows a comparison of the mechanical data before and after optimization:

[0110]

[0111] The final product is shown in Figure 10.

[0112] The technological advantages of this invention:

[0113] 1. Save raw materials:

[0114] The forging before optimization (Comparative Example 1) was forged according to the original specifications (forging size 1570mm×230mm×125mm), consuming 390kg of raw materials per piece. The equipment used two pieces of the product, consuming a total of 780kg of raw materials. The forging after optimization (Example 1) was forged to obtain the same product specifications as Comparative Example 1, consuming a total of 367kg of raw materials, which is 2.13 times less raw material compared to the previous method.

[0115] 2. Improved mechanical properties:

[0116] The low-temperature cold forging of forgings involves slamming and rounding the forgings, resulting in smaller machining allowances, smooth surfaces, uniform and dense internal structures, and significantly improved forging strength, leaving sufficient allowance for subsequent solution aging heat treatment of the forgings.

[0117] 3. Time-saving processing:

[0118] The original product processing method required a combination of a planar milling machine and a machining center, which placed high demands on the selection of processing equipment.

[0119] First, a surface milling machine is used for roughing to remove surface machining allowances. Then, a machining center is used to mill the product's outline dimensions. Due to the high surface roughness requirements, the machining center needs to perform layered machining, resulting in each piece requiring 35-40 hours of processing time. Furthermore, the large amount of material removed from the forging surface leads to incomplete metal flow within the product, and the excessive removal of material from the heat-treated surface also affects the product's lifespan.

[0120] In this embodiment, the optimized forging surface has only an 8-10mm machining allowance. The machining method is as follows: first, the forging is split in two along the axial direction, and the split surface is milled; 35mm process steps and φ17mm process holes are machined at both ends of the forging; then, the two axial lead wires are assembled (Figure 5), with a 12mm machining template installed in the middle (Figure 8), and each end is fastened with two sets of M16 bolts; the outer diameter of the product is machined to the design size; after the outer diameter is machined, the machining template is removed, and the product is milled to the design length. The machining of two axial lead wires is completed in one go, saving nearly half the time.

[0121] Benefits of optimized manufacturing processes:

[0122] 1. No material removal is required on the surface of the forging, which shortens the processing time and maximizes the preservation of the integrity of the original internal metal flow lines and the amount of heat-treated surface residue, giving the product high strength performance and making it easier to extend the product's service life.

[0123] 2. The cold bending (cold forging) forming process is easy to master, the manufacturing process is convenient and quick, and the product shape is stable and uniform, making it suitable for mass production.

[0124] The above description is merely an embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for manufacturing an axial lead of a slip ring device, characterized in that, The method for manufacturing the axial lead of the slip ring device includes: Raw materials are selected and hot forging is carried out to obtain preliminary forgings. Specifically, the raw materials are upset, drawn, and rounded. The initial forging is subjected to cold forging treatment, specifically by reheating the initial forging to 300~350℃ and holding it for 5~6 hours, and then using a die manufactured by a preset process to perform rounding treatment on the initial forging after holding it. The initial forgings after cold forging are subjected to solution aging heat treatment; The process of processing the initial forging after solution aging heat treatment to obtain the final forging includes: dividing the initial forging into two parts along the axial direction and machining the dividing surface; and assembling the two parts along the axial direction.

2. The method for manufacturing an axial lead of a slip ring device according to claim 1, characterized in that, The raw material is chromium-zirconium-copper material, wherein Zr: 0.05~0.25%, Cr: 0.50~1.50%, and Cu+Cr+Zr≥99.7%.

3. The method for manufacturing an axial lead of a slip ring device according to claim 1, characterized in that, The die, manufactured using a pre-set process, is used to round the initial forging after heat preservation. Specifically, the die is used to round the forging, resulting in a deformation of 15-20mm.

4. The method for manufacturing an axial lead of a slip ring device according to claim 1, characterized in that, The process of selecting raw materials and hot forging them to obtain preliminary forgings involves heating the raw materials to 650~850℃, upsetting and drawing the raw materials, and after the final drawing, pressing the shoulders, removing excess material, and rounding the raw materials to obtain preliminary forgings.

5. The method for manufacturing an axial lead of a slip ring device according to claim 1, characterized in that, The preset process includes: selecting a blank that meets the forging requirements; casting the blank to obtain a casting; and machining the casting to obtain a die.

6. A method for manufacturing an axial lead of a slip ring device according to claim 5, characterized in that, The mold includes a mold base, an upper mold buckle, and a lower mold buckle.

7. A method for manufacturing an axial lead of a slip ring device according to claim 6, characterized in that, The process of processing the casting to obtain the mold specifically involves processing the upper and lower cavities of the mold, leaving a mold closing gap after the upper and lower cavities of the mold are processed.

8. A method for manufacturing an axial lead of a slip ring device according to claim 7, characterized in that, The mold closing gap is 10~15mm.

9. A method for manufacturing an axial lead of a slip ring device according to any one of claims 1 to 8, characterized in that, The process of processing the initial forging after solution aging heat treatment to obtain the final forging involves assembling two axial lead wires on a template and machining the outer diameter of the initial forging to a predetermined size to obtain the final forging.

10. A method for manufacturing an axial lead of a slip ring device according to claim 9, characterized in that, The planar symmetry of the vehicle template is no greater than 0.05mm, and the flatness is no greater than 0.05mm.

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