CN102510141B - Amorphous, microcrystalline or nano-crystalline alloy stator iron core for axial magnetic flux motor and manufacture method for stator iron core - Google Patents
Amorphous, microcrystalline or nano-crystalline alloy stator iron core for axial magnetic flux motor and manufacture method for stator iron core Download PDFInfo
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Abstract
The invention discloses an amorphous, microcrystalline or nano-crystalline alloy stator iron core for an axial magnetic flux motor and a manufacture method for the stator iron core. The manufacture method includes the steps: firstly, rolling and cutting a coiled amorphous, microcrystalline or nano-crystalline alloy wide band into an alloy strip coil (6) which is twice as high as that of the finished iron core, then uniformly punching a plurality of strip slots (17) in the middle of the alloy strip coil at intervals with the same equipment, performing insulation coating treatment and further coiling the alloy strip coil on an inner core (24) of the iron core, wherein the strip slots (17) are as same as open slots (26) in width, and the length of each strip slot (17) is twice of the depth of each open slot (26); next, adding an iron core outer-circumference protecting layer on the outer circumference face of the coiled alloy strip coil, then transversely halving the alloy strip coil into two identical alloy iron cores along the axial perpendicular plane of the alloy strip coil; and finally, carrying out high-temperature annealing treatment on the iron cores formed by processing. The stator iron cores prepared by the method are more excellent in performance, and particularly applicable to a high-speed motor, a high-power density motor and a high-torque density motor.
Description
Technical field
The invention belongs to the magnetic circuit part field of motor, be specifically related to a kind of amorphous, crystallite or nanocrystalline alloy stator iron core and manufacture method thereof for axial-flux electric machine, this kind of stator core is especially applicable to being applied in and requires energy-efficient high rotating speed, high power density and high torque density electrical machine.
Background technology
Motor is the highest electric equipment of power consumption in the world, improve electric efficiency to energy-saving and emission-reduction, alleviate energy shortage and environmental pollution is all significant.At present, the raising of electric efficiency is subject to the great attention of countries in the world.A lot of applications not only require motor to have high efficiency, also will have the characteristics such as high power density, high torque density or high rotating speed, such as electric automobile, Aero-Space, high speed compressor etc.The silicon steel core that conventional motors is used has been difficult to meet more and more harsher performance requirement.Because non-crystaline amorphous metal soft magnetic material has low-loss, high magnetic permeability, high strength and the characteristic such as corrosion-resistant, with the research that its alternative silicon steel is applied to electric machine iron core, be subject in recent years the great attentions of a lot of countries.
First have a look radial flux (or claim radial air gap) amorphous electric machine iron core and progress.The disclosed amorphous metal stator core of in June, 1998 U.S. Honeywell WO99/66624 of house journal is that the band with different length is superimposed as and carries out hot curing after arc or C shape and process and form with the toothed stator iron core to internal diameter direction.2004 HIT (Hitachi) the disclosed method of patent of invention US6737951B1 be will amorphous band to carry out hot curing processing after stack, cut into again one side and even there is the polyhedron amorphous block of arch surface in two sides, then these amorphous blocks are rearranged to the stator core of complete.All there is air gap in the amorphous alloy iron core that these two kinds of methods are made, has affected to a certain extent the performance of iron core in stitching portion.Within 2004, the patent WO2004/070740 of U.S. Metglas Inc discloses the method for photoetching etching legal system for amorphous stator core, and the method complex process, efficiency are low, is not suitable for batch production.The patent of invention CN101286676A of Antai Science and Technology Co., Ltd in 2008 discloses a kind of first hot curing and has processed the amorphous block method of the making stator core of integral cutting moulding again of making, for the radial flux amorphous iron core that processability is outstanding has been established technical foundation, but make the restriction that the size of iron core has been received amorphous alloy strips width.Shenzhen Huarenxing Technology Co., Ltd. has proposed to use the method for the means making large scale radial flux amorphous alloy iron core splicing in patent CN101882816A.
Because amorphous alloy strips is the continuous thin-band material with constant width, while making axial-flux electric machine stator core, the watt level of motor is not subject to the restriction of amorphous alloy strips width substantially, and the utilance of material exceeds several times than making radial magnetic field motor iron core, add that axial-flux electric machine has power density and torque density is high, the short advantages such as motor radiating that are beneficial to of axial distance, have more advantage so non-crystaline amorphous metal is made motor in axial magnetic field stator core.The patent US005731649A of U.S. LE company in 1998 discloses and has used the amorphous block of reeling to constitute electric machine iron core, and the amorphous cylinder of use direct winfing causes vortex current looping circuit as the tooth of iron core stator core, and iron loss is very large.Until 2006 NianLE companies disclose a kind of method of first producing annular non-crystaline amorphous metal block, milling out the processing amorphous alloy stator iron core of axial tooth slot structure again in patent US7018498B2.The method can be produced high performance axial magnetic flux amorphous alloy stator iron core.But, because non-crystaline amorphous metal becomes very crisp after heat treatment, while especially carrying out the Milling Process of the amorphous alloy iron core that teeth groove is intensive, easily there is tooth portion and come off or damage, cause rate of finished products to reduce.And Milling Process will, at the inner gravitation of introducing of amorphous alloy stator iron core, cause iron core hydraulic performance decline.The manufacture method of amorphous alloy iron core for a kind of axial-flux electric machine is also disclosed in the patent CN101741153A of Hitachi Ind Equipment Sys of Amada Co., Ltd., first in the mode of resin casting mold, produce annular non-crystal block, then cut out the bar-shaped non-crystal block that a plurality of shapes are identical with size, re-use discoid iron core holding member these bar-shaped non-crystal blocks are combined into amorphous alloy stator iron core.The amorphous alloy iron core that the method is made is comprised of a plurality of little amorphous blocks, and core interior exists air gap, but also need to use iron core holding member that separated amorphous iron core block combination is arrived together, complex procedures.
The problem such as in sum, the technology of existing making Amorphous Metal Motor iron core still exists complex process, cost is high, rate of finished products is low and performance is undesirable.
In view of the feature that amorphous alloy strips be applicable to be made axial-flux electric machine stator core, this patent provides a kind of processing method of making high-performance axial magnetic flux amorphous motor stator core.
Summary of the invention
The object of the present invention is to provide a kind of amorphous, crystallite or nanocrystalline alloy stator iron core and manufacture method thereof for axial-flux electric machine, the method cost is low, production efficiency is high and rate of finished products is high, and the performance of amorphous, crystallite or nanocrystalline alloy stator iron core by the method manufacturing is more excellent, has excellent soft magnet performance and outward appearance neatly smooth.
In order to achieve the above object, the invention provides following technical scheme:
A manufacture method for amorphous, crystallite or nanocrystalline alloy stator iron core for axial-flux electric machine, this stator core is torus, has a plurality of radial opening grooves 26 on an annular end face, wherein, method comprises following steps:
(1) use centre slitting installation, by the amorphous of rolling, crystallite or nanometer crystal alloy broadband, along the alloy strip steel rolled stock volume that becomes to have fixed width with length direction roller shear, described fixed width is the twice of finished product iron core height;
(2) alloy strip steel rolled stock of above-mentioned fixed width is provided in a passive rotating roller 5, be handled as follows successively: 1. jet-bedding is processed, at described alloy strip steel rolled stock middle part, continuous punching extrudes the trough of belt 17 on vertical resulatant gold ribbon material length direction, and its width and open slot 26 width equate, length is the twice of open slot 26 degree of depth; 2. being coated with insulating barrier processes; 3. reel and process, alloy strip steel rolled stock is wound on the iron core inner core 24 with inner core groove 4, and described trough of belt 17 is corresponding with inner core groove 4 positions, thereby form, be equivalent to the alloy strip steel rolled stock volume 25 with bathtub construction 15 that two axial magnetic flux iron core teeth portion make-ups connect; Described rotating roller 5 and iron core inner core 24 are controlled and are carried out synchronous intermittent rotation by a high precision numerical control dividing head 23;
(3) in step (2), when thering is the alloy strip steel rolled stock volume 25 of bathtub construction 15, reel while reaching required external diameter, on strip coil periphery, add the cylindrical protective layer that one deck and described periphery have identical bathtub construction, then along alloy strip steel rolled stock spool to vertical plane, its decile crosscut is become two shapes and size identical and there is amorphous, crystallite or the nanocrystalline alloy stator iron core 28 of axial tooth slot structure;
(4) amorphous step (3) being obtained, crystallite or nanocrystalline alloy stator iron core 28 carry out annealing in process.
Described amorphous, crystallite or nanometer crystal alloy broadband material chosen from Fe base, iron are Ni-based, cobalt base amorphous, crystallite and nanometer crystal alloy strip.
The material of described iron core inner core 24 and cylindrical protective layer is selected from silicon steel, magnetism-free stainless steel, iron, aluminium, copper, titanium and alloy thereof, pottery, organic siliconresin, nylon, carbon fiber.
In the coiling of described step (2) is processed, by high precision numerical control dividing head 23, control the intermittent rotation of iron core inner core realization as follows: high precision numerical control dividing head 23 drives iron core inner core 24 interval t rotation at regular intervals once, the anglec of rotation is θ=360 °/n, wherein n is amorphous, the axial tooth 27 of crystallite or nanocrystalline alloy stator iron core or the quantity of open slot 26, the distance that iron core inner core 24 drives alloy strip steel rolled stock to advance forward is simultaneously s=π * r* θ/180, and in the dead time t after iron core heart 24 rotation θ angles, just completing a jet-bedding processes.
During described jet-bedding is processed, the drift of use and the gap between jet-bedding are 1/10～1/2 of amorphous alloy strips gross thickness.
In described jet-bedding is processed, the trough of belt 17 on described alloy strip steel rolled stock can be rectangle, ellipse or other arbitrary shapes, and the shape of described trough of belt 17 is identical with the shape of inner core groove 4 on described iron core inner core 24.
The band number of plies≤10 layer of described alloy strip steel rolled stock volume.
Described trough of belt 17 is positioned at alloy strip steel rolled stock inside, is closed figures, and quantity >=1 of described trough of belt 17 on vertical band length direction.
The center line of described trough of belt 17 all points to the central axis of amorphous, crystallite or nanocrystalline alloy stator iron core 28, and the shape of trough of belt 17 and size do not increase and change with described amorphous, crystallite or nanocrystalline alloy stator iron core radius; Yet described tooth 16 can broaden gradually along with the increase of described amorphous, crystallite or nanocrystalline alloy stator iron core radius.
In described step (2), 1. jet-bedding is processed with the order that is 2. coated with insulating barrier processing and can be exchanged.
Described step (4) is to carry out under the protective atmosphere of nitrogen or argon gas.
Described step (4) is to complete adding under the condition in magnetic field, and magnetic field intensity is 2-40mT, and magnetic direction is along circumferencial direction unshakable in one's determination.
Insulating coating liquid is selected from a kind of in solution, colloidal sol or the suspension-turbid liquid of tetraethoxysilane, waterglass, MgO fine powder, SiO2 fine powder or insulating ceramics fine powder.
Amorphous, crystallite or nanocrystalline alloy stator iron core 28 after described step (4) is processed are carried out to resin hot curing processing.
In described resin hot curing processing, dipping lacquer process is carried out under vacuum.
A kind of amorphous, crystallite or nanocrystalline alloy stator iron core for axial-flux electric machine, this stator core is torus, on an annular end face, there are a plurality of radial opening grooves, the horizontal decile of stator core base substrate that wherein this stator core is obtained through roller shear, jet-bedding, coating, coiling and annealing in process by alloy strip steel rolled stock is cut into two identical stator cores and forms, this stator core base substrate comprises iron core inner core 24, is wound on the alloy strip steel rolled stock with bathtub construction and cylindrical protective layer on iron core inner core 24;
Wherein: iron core inner core 24 is comprised of a pair of annular collet 1 and cylinder 2, n the inner core groove 4 that distributing uniformly at the stack shell middle part of cylinder 2; The trough of belt 17 that has a plurality of vertical alloy strip steel rolled stock length directions on the alloy strip steel rolled stock of reeling, the twice that the width of inner core groove 4 and trough of belt 17 all equates with open slot, length is the open slot degree of depth;
In winding process, described in the trough of belt 17 that has on the alloy strip steel rolled stock of bathtub construction corresponding with inner core groove 4 positions on iron core inner core 24, thereby form, be equivalent to the alloy strip steel rolled stock volume 25 with bathtub construction 15 that two axial magnetic flux iron core teeth portion make-ups connect;
The periphery of cylindrical protective layer has the groove identical with trough of belt 17.
Trough of belt 17 on described alloy strip steel rolled stock can be rectangle, ellipse or other arbitrary shapes, and the shape of described trough of belt 17 is identical with the shape of inner core groove 4 on described iron core inner core 24.
The present invention compares and has the following advantages with the technology of preparing of existing axial magnetic flux amorphous, crystallite or nanocrystalline alloy stator iron core:
(1) what the present invention prepared amorphous, crystallite or the employing of nanocrystalline alloy stator iron core is the method for reeling after jet-bedding, avoided alloy material due to the problem that is difficult to process complicated bathtub construction that thin, crisp and hard characteristic causes, reduced to a great extent axial amorphous, crystallite or nanocrystalline alloy stator iron core production cost, improved production efficiency and iron core rate of finished products;
(2) preparation method of amorphous of the present invention, crystallite or nanocrystalline alloy stator iron core can save resin hot curing forming processes, and then can shorten production procedure, saving production cost, can also make production process environmental protection and energy saving more;
(3) preparation method of amorphous of the present invention, crystallite or nanocrystalline alloy stator iron core has used iron core inner core and periphery protective layer to carry out the fixing and protection of machinery to axial magnetic flux alloy-iron core, replace resin hot curing bonding forming in the past, improved the stability of amorphous, crystallite or nanocrystalline iron core, avoided because alloy thin band is between layers because the bonding not firm iron core that causes ftractures, falls the problems such as tooth;
(4) preparation method of amorphous of the present invention, crystallite or nanocrystalline alloy stator iron core can not use binding agent to carry out layers cementing, and then can avoid causing due to the introducing of adhesive stress the problem of the decline of alloy-iron core soft magnet performance;
(5) hot curing that the preparation method of amorphous of the present invention, crystallite or nanocrystalline alloy stator iron core carries out is processed after jet-bedding and coiling and molding, so the stress that jet-bedding and coiling operation are introduced can be eliminated by annealing, and then the soft magnet performance of amorphous, crystallite or nanometer crystal alloy material excellence can farthest be retained in iron core;
(6) loss of amorphous of the present invention, crystallite or nanocrystalline alloy stator iron core is far below silicon steel stator core, magnetic permeability is far above silicon steel core, so use the motor of described amorphous, crystallite or nanocrystalline alloy stator iron core to there is low-temperature-rise, high efficiency advantage, be especially applied to pot motor, high power density and high torque density electrical machine effect more obvious.
Accompanying drawing explanation
Fig. 1 is the schematic diagram of amorphous alloy stator iron core inner core of the present invention;
Fig. 2 is the schematic diagram of jet-bedding, coating and coiling and molding process in amorphous alloy stator iron core manufacture process of the present invention;
Fig. 3 is for adopting the schematic appearance of the amorphous alloy stator iron core of manufacture method manufacturing of the present invention;
Fig. 4 is the schematic diagram that the amorphous alloy stator iron core of annealing in process is carried out in tooling fixture preparation that packs into of the present invention;
Fig. 5 is that dissimilar axial magnetic flux stator core is when magnetic flux density is 0.6T, core loss is with the curve chart of frequency change, wherein, the axial magnetic flux stator core that the silicon steel sheet that in figure, the 1 expression trade mark is DR255 is made, 2 represent the axial magnetic flux amorphous alloy stator iron core that does not use resin hot curing to process prepared by the present invention, and 3 represent the axial magnetic flux amorphous alloy stator iron core of use resin hot curing processing prepared by the present invention;
Fig. 6 is that dissimilar axial magnetic flux stator core is when magnetic flux density is 1.0T, core loss is with the curve chart of frequency change, wherein, the axial magnetic flux stator core that the silicon steel sheet that in figure, the 1 expression trade mark is DR255 is made, 2 represent the axial magnetic flux amorphous alloy stator iron core that does not use resin hot curing to process prepared by the present invention, and 3 represent the axial magnetic flux amorphous alloy stator iron core of use resin hot curing processing prepared by the present invention.
Reference numeral
1 annular collet 2 cylinders
3 inner core tooth 4 inner core grooves
5 rotating roller 6 amorphous alloy strips volumes
7 first backing roll 8 first registration rollers
Platform in 9 second registration rollers 10
11 mesopores 12 are presented a theatrical performance as the last item on a programme
14 trash receptacle in 13
15 bathtub construction 16 teeth
17 trough of belt 18 second backing rolls
19 coating pond 20 the 3rd backing rolls
21 coating solution 22 scraping fluid plates
23 high precision numerical control dividing head 24 iron core inner cores
25 have the alloy strip steel rolled stock volume of bathtub construction
26 open slot 27 axial tooths
28 amorphous, crystallite or nanocrystalline alloy stator iron core
29 square plate 30 long screws
The 31 circular inner tubes of a tyre
Embodiment
Because the method that adopts preparation method of the present invention to prepare amorphous for axial-flux electric machine, crystallite or nanocrystalline alloy stator iron core is identical, only need to replace corresponding material, and select different technological parameters according to the performance of different materials, can prepare the alloy stator core of amorphous, crystallite or the different materials such as nanocrystalline, therefore, only take below and prepare amorphous alloy stator iron core as example, in conjunction with the accompanying drawings and embodiments, the specific embodiment of the present invention is described in further detail.
Preparation in accordance with the present invention, the first step is to use the cutter sweep of the routines such as amorphous alloy strips roller shear equipment longitudinally to cut along band length direction the non-crystaline amorphous metal broadband of rolling, to form the amorphous alloy strips volume of preset width, wherein preset width is pre-twice of making amorphous alloy stator iron core height.Amorphous alloy strips volume can be individual layer strip coil, can be also multiple strip coil, and the general band number of plies is generally not more than 10 layers.Amorphous alloy strips and the method for producing this kind of alloy strip steel rolled stock are not done to special restriction.
Second step is that iron core inner core 24 is as shown in Figure 1 arranged on the device of making axial magnetic flux amorphous alloy iron core as shown in Figure 2, by high precision numerical control dividing head 23, controls rotation.The amorphous alloy strips that roller shear in the first step is obtained having to preset width carries out jet-bedding, is coated with insulating barrier and reels and process.Wherein, the lamination coefficient of the amorphous alloy strips in amorphous alloy iron core can be realized control by adjusting the size of the tension stress on amorphous alloy strips in winding process, more lamination coefficient is higher for pulling force, and this kind of amorphous alloy iron core lamination stack coefficient general control is between 0.75～0.90.The silicon steel plate that iron core inner core 24 is 0.5mm by thickness is made, and drives can realize at any angle rotate by high precision numerical control dividing head 23.High precision numerical control dividing head 23 at regular intervals interval t drives iron core inner core 24 to realize once rotation, anglec of rotation θ=360 °/n, wherein n represents the quantity of tooth or the trough of belt of amorphous alloy stator iron core, and the distance that meanwhile iron core inner core 24 drives amorphous alloy strips to advance is forward s=π * r* θ/180; In dead time t after each rotation θ angle, notching device completes a jet-bedding processing.Jet-bedding finish dealing with after amorphous alloy iron core under the drive of high precision numerical control dividing head 23, carry out on the once rotation of θ angle, carry out again subsequently jet-bedding and process, so repeatable operation by the amorphous alloy strips with bathtub construction be wound on iron core inner core 24, form be equivalent to that two axial magnetic flux iron core teeth portion make-ups link together there is bathtub construction alloy strip steel rolled stock volume 25.
The shape of trough of belt can be rectangle, ellipse etc., and the groove on inner core should be consistent with trough of belt, and groove when trough of belt is rectangle on inner core is also rectangle, and groove when trough of belt is oval on inner core is also for oval.
The 3rd step is to reel while reaching certain size when having the external diameter of bathtub construction alloy strip steel rolled stock volume 25, takes off, and use the methods such as welding or rivet on its periphery, to add the cylindrical protective layer that one deck and periphery have identical bathtub construction from winding apparatus.Then, along the axial vertical plane of strip coil, its decile crosscut is become to two identical amorphous alloy stator iron cores of shape and size with axial tooth slot structure, as shown in Figure 3.
The 4th step is that the amorphous alloy stator iron core to making in previous step carries out annealing in process.The object of annealing is remove the volatilizable composition in coating solution and eliminate the stress that jet-bedding operates and winding process is introduced at amorphous alloy core inner, further improves the soft magnet performance of amorphous alloy iron core.Annealing schedule is as follows, first from room temperature, is warming up to 100-150 ℃, insulation 1-3 hour; Continue to be again warming up between 300-560 ℃ insulation 0-5 hour; Then after being cooled to room temperature, take out iron core.Described annealing in process need complete in the protective atmospheres such as nitrogen or argon gas, also can be simultaneously completes adding under the condition in magnetic field.
So far, axial-flux electric machine amorphous alloy stator iron core completion of processing.Can also be according to practical application request, the amorphous alloy stator iron core through annealing in process prepared by said method carries out resin hot curing processing, and this step is inessential operation optionally.If the amorphous alloy iron core that the method is made is used in the magnetic flux density of stator core is required is not but very high, but require very Gao Shixu to carry out this step processing to the restriction of noise.Amorphous alloy iron core is immersed in epoxy resin, and in order to make epoxy resin can fully be immersed in amorphous alloy stator iron core inside, dipping lacquer process can be carried out under vacuum environment.After epoxy resin is fully immersed in amorphous alloy iron core, taking-up iron core is put into baking oven and is carried out hot curing processing.
embodiment 1
The band name composition of making axial magnetic flux amorphous alloy stator iron core is Fe
80si
9b
11(at.%), thickness is 30 ± 1 μ m, and width is 140mm, surfacing.The external diameter of amorphous alloy stator iron core to be produced is 180mm, internal diameter 100mm, and high 40mm, groove depth 30mm, teeth groove quantity is 30.First use roller shear equipment that amorphous alloy strips roller shear is become to the amorphous alloy strips volume that width is 80mm, then the amorphous alloy strips that is 80mm by width carries out secondary coiling formation 2, and heavily the amorphous alloy thin roll coil of strips are stand-by.Used thickness is that the silicon steel sheet of 0.5mm is made into iron core inner core as shown in Figure 1, iron core inner core is that annular collet 1 and the internal diameter that 180mm, internal diameter are 100mm is that the cylinder 2 that 100mm, height are 80mm forms by external diameter, at the stack shell middle part of cylinder 2, distributing uniformly 30 inner core teeth 3 and 30 inner core grooves 4, wherein the width of inner core groove 4 is 0.50mm, length is 60mm.In addition; the cylindrical protective layer being added on amorphous alloy strips volume periphery is also made by the silicon steel sheet of 0.50mm; for external diameter is that 180mm, height are the cylinder of 80mm, cylinder 2 stack shells middle parts are also uniform-distribution with the identical rectangular channel of cylinder size and dimension of 30 and iron core inner core 24.
The jet-bedding of axial magnetic flux amorphous alloy stator iron core, coating and operating winding process are as shown in Figure 2, first the 2 heavy amorphous alloy strips that are 80mm by width are wrapped in rotating roller 5, through the first backing roll 7, to first, second registration roller 8,9, enter and rush platform 10, on rushing platform 10, go out grooved and enter dip-coating insulation coating solution in coating solution 21 by the second backing roll 18 and the 3rd backing roll 20, through scraping fluid plate 22, remove unnecessary coating solution, be finally wound on and on the iron core inner core 24 by high precision numerical control dividing head 23 driven rotary, form the alloy strip steel rolled stock volume 25 with bathtub construction.
Wherein, the material in coating pond 19 is PVC, and coating solution 21 is wherein that the positive silicic acid second vinegar of 9.999% (wt.%) is, the mixed liquor of the nitric acid of the deionized water and 0.001% (wt.) of the alcohol, 2% (Wt.%) of 88% (wt.%).
High precision numerical control dividing head 23 drives iron core inner core 24 every rotation in 1 second once, the anglec of rotation is θ=360 °/30=12 °, wherein 30 is teeth groove numbers of iron core, and the distance that meanwhile iron core inner core 24 drives amorphous alloy strips to advance is forward s=π * r*12/180 (mm).In 1 second dead time after 12 ° of each rotations, presenting a theatrical performance as the last item on a programme 12 is pressed in amorphous alloy strips to rush on platform 10, and drift 13 sweeps away rapidly, and non-crystaline amorphous metal waste material falls into trash receptacle 14 from punching 11; Then drift 13 and present a theatrical performance as the last item on a programme and 12 lift successively, now having completed a jet-bedding processes, the bathtub construction 15 of going out comprises tooth 16 and the trough of belt 17 of the amorphous alloy stator iron core of manufacturing, then high precision numerical control dividing head 23 drives iron core inner core 24 to rotate 12 ° again, start jet-bedding, operating winding next time, along with the increase of radius unshakable in one's determination, rotate distance that amorphous alloy strips advances also along with becoming large at every turn.So repeatable operation by the amorphous alloy strips with bathtub construction be wound on iron core inner core 24, form be equivalent to that two axial magnetic flux iron core teeth portion make-ups link together there is bathtub construction alloy strip steel rolled stock volume 25.
When reaching 179mm, takes off from equipment together with iron core inner core 24 the amorphous alloy strips volume external diameter with bathtub construction; cylindrical protective layer is welded on the periphery of amorphous alloy strips volume, then along amorphous alloy strips spool to vertical plane, its decile crosscut is become to two identical amorphous alloy stator iron cores of shape and size with axial tooth slot structure.So far, complete the machine-shaping operation of axial magnetic flux amorphous alloy stator iron core, produced as shown in Figure 3 the amorphous alloy stator iron core with open slot 26 and axial tooth 27.
Finally amorphous alloy stator iron core is carried out to the high temperature anneal.For fear of amorphous alloy stator iron core, in high-temperature annealing process, there is thermal deformation, need to use magnetism-free stainless steel tooling fixture as shown in Figure 4 to carry out deformation protection to amorphous alloy stator iron core.The main body of tooling fixture is the square plate 29 that two thickness are 30mm, and it is made by magnetism-free stainless steel, and dull and stereotyped four jiaos are equipped with respectively long screw 30, can to the deformation of the upper and lower both ends of the surface of amorphous alloy stator iron core, protect by fastening the realization in annealing process of screw.At upper and lower two square plate 27 centers, all have the circular hole with amorphous alloy stator iron core inner circle measure-alike (diameter 100mm).Circular hole by square plate is inserted into the circular inner tube of a tyre 31 in amorphous alloy stator iron core, prevents that the inside diameter of amorphous alloy stator iron core is to deformation occurs.Described the high temperature anneal is under nitrogen protection, adds along carrying out under the condition in iron core circumferencial direction magnetic field, and concrete technology is as follows:
1) at the axial centre place of described amorphous alloy stator iron core, adding one can alive copper rod, and between copper rod and amorphous alloy stator iron core, with earthenware insulation, then the whole electric furnace of putting under nitrogen protection carries out heating anneal processing;
2) take and add the D.C. magnetic field that intensity is 20mT when the rate of heat addition of 60 ℃/min is warming up to 300 ℃, then be warmed up to 390 ℃ with identical heating rate;
3) keep magnetic field constant, at 380 ℃ of insulation 90min; 4) while being then cooled to 300 ℃ with the speed of 40 ℃/min, remove magnetic field, then take out amorphous alloy stator iron core after being cooled to room temperature with identical cooling rate.
The roller shear of amorphous alloy strips, jet-bedding, coating, coiling and annealing in process are all identical with the technique of embodiment 1.Exactly the amorphous alloy stator iron core of making in embodiment 1 being carried out to a resin hot curing again processes.Concrete technology is as follows: amorphous alloy stator iron core is soaked in the epoxy resin in the stainless steel tank of people, and together with dip tank, put into vacuum tank and be evacuated to below 1Pa, this vacuum keep 30 minutes.Then lay down vacuum environment, take out amorphous alloy iron core and put into baking oven and carry out hot curing processing at 170 ℃, turn off baking oven power supply after being incubated 4 hours to naturally cool to room temperature by amorphous alloy stator iron core.So far, the axial magnetic flux amorphous alloy stator iron core of processing through resin hot curing completes.
The silicon steel sheet (thickness 0.35mm) that the use trade mark is DR255 has been made the silicon steel core with amorphous alloy stator iron core same size, and with the axial magnetic flux amorphous alloy stator iron core that does not use resin hot curing to process, and the axial magnetic flux amorphous alloy stator iron core that uses resin hot curing to process has carried out performance parameter contrast, DC magnetic performance is in Table 1, and core loss is shown in Fig. 5 and Fig. 6 with the change curve of frequency.
Data in contrast table 1, Fig. 5 and Fig. 6 are found, the axial magnetic flux amorphous alloy stator iron core magnetic permeability that does not use resin hot curing processing prepared by said method is far above silicon steel core, when excitation intensity is 100A/m, magnetic flux density just can reach 1.12T, is the more than 2 times of silicon steel core under identical excitation intensity; And the loss of amorphous alloy iron core is very low, frequency range when 50-1000Hz loss value all less than 1/7 of silicon steel core.The amorphous alloy stator iron core excellent in soft magnetic properties that visible the method is made, while being especially applied to electric machine iron core under high frequency, advantage will be more obvious.From the data of table 1, Fig. 5 and Fig. 6, it can also be seen that the amorphous alloy stator iron core soft magnet performance of processing through resin hot curing slightly declines than the amorphous alloy stator iron core of processing without resin hot curing, but its advantage is to make the noise of amorphous alloy stator iron core significantly reduce, but also can improve the mechanical stability of amorphous alloy iron core.
The DC magnetic contrast of the amorphous alloy stator iron core that table 1 trade mark is the silicon steel stator core of DR255, the amorphous alloy stator iron core of processing without hot curing, process through hot curing.
Claims (17)
1. a manufacture method for amorphous, crystallite or nanocrystalline alloy stator iron core for axial-flux electric machine, this stator core is torus, has a plurality of radial opening grooves (26) on an annular end face, it is characterized in that: the method comprises following steps:
(1) use centre slitting installation, by the amorphous of rolling, crystallite or nanometer crystal alloy broadband, along the alloy strip steel rolled stock volume that becomes to have fixed width with length direction roller shear, described fixed width is the twice of finished product iron core height;
(2) alloy strip steel rolled stock of above-mentioned fixed width is provided in a passive rotating roller (5), be handled as follows successively: 1. jet-bedding is processed, at alloy strip steel rolled stock middle part continuous punching, extrude the trough of belt (17) on vertical resulatant gold ribbon material length direction, its width and open slot (26) width equates, length is the twice of open slot (26) degree of depth; 2. being coated with insulating barrier processes; 3. reel and process, alloy strip steel rolled stock is wound on the iron core inner core (24) with inner core groove (4), and described trough of belt (17) is corresponding with inner core groove (4) position, thereby form, be equivalent to the alloy strip steel rolled stock volume (25) with bathtub construction (15) that two axial magnetic flux iron core teeth portion make-ups connect; Described rotating roller (5) and iron core inner core (24) are controlled and are carried out synchronous intermittent rotation by a high precision numerical control dividing head (23);
(3) in step (2), when thering is the alloy strip steel rolled stock volume (25) of bathtub construction (15), reel while reaching required external diameter, on strip coil periphery, add the cylindrical protective layer that one deck and described periphery have identical bathtub construction, then along alloy strip steel rolled stock spool to vertical plane, its decile crosscut is become two shapes and size identical and there is amorphous, crystallite or the nanocrystalline alloy stator iron core (28) of axial tooth slot structure;
(4) amorphous step (3) being obtained, crystallite or nanocrystalline alloy stator iron core (28) carry out annealing in process.
2. method as described in claim 1, is characterized in that: described amorphous, crystallite or nanometer crystal alloy broadband material chosen from Fe base, iron are Ni-based, cobalt base amorphous, crystallite and nanometer crystal alloy strip.
3. method as described in claim 1, is characterized in that: the material of described iron core inner core (24) and cylindrical protective layer is selected from silicon steel, magnetism-free stainless steel, iron and alloy thereof, aluminium and alloy thereof, copper and alloy thereof, titanium and alloy thereof, pottery, organic siliconresin, nylon, carbon fiber.
4. method as described in claim 1, it is characterized in that: in the coiling of described step (2) is processed, by high precision numerical control dividing head (23), control the intermittent rotation of iron core inner core (24) realization as follows: high precision numerical control dividing head (23) drives iron core inner core (24) interval t rotation at regular intervals once, the anglec of rotation is θ=360 °/n, wherein n is amorphous, the quantity of the axial tooth of crystallite or nanocrystalline alloy stator iron core (27) or open slot (26), the distance that iron core inner core (24) drives alloy strip steel rolled stock to advance forward is simultaneously s=π * r* θ/180, and in the dead time t after iron core inner core (24) rotation θ angle, just completing a jet-bedding processes.
5. method as described in claim 1, is characterized in that: during described jet-bedding is processed, the drift of use and the gap between jet-bedding are 1/10～1/2 of amorphous alloy strips gross thickness.
6. method as described in claim 1, it is characterized in that: in described jet-bedding is processed, trough of belt on described alloy strip steel rolled stock (17) can be rectangle, ellipse or other arbitrary shapes, and the shape of described trough of belt (17) is identical with the shape of the upper inner core groove (4) of described iron core inner core (24).
7. method as described in claim 1, is characterized in that: the band number of plies≤10 layer of described alloy strip steel rolled stock volume.
8. method as described in claim 1, is characterized in that: described trough of belt (17) is positioned at alloy strip steel rolled stock inside, is closed figures, and quantity >=1 of described trough of belt (17) on vertical band length direction.
9. method as described in claim 1, it is characterized in that: described bathtub construction (15) comprises tooth (16) and the trough of belt (17) of the stator core of manufacturing, the center line of described trough of belt (17) all points to the central axis of amorphous, crystallite or nanocrystalline alloy stator iron core (28), and the shape of trough of belt (17) and size do not increase and change with described amorphous, crystallite or nanocrystalline alloy stator iron core radius; Yet tooth (16) can broaden gradually along with the increase of described amorphous, crystallite or nanocrystalline alloy stator iron core radius.
10. method as described in claim 1, is characterized in that: in described step (2), 1. jet-bedding is processed and is 2. coated with the order that insulating barrier processes and can exchanges.
11. methods as described in claim 1, is characterized in that: described step (4) is to carry out under the protective atmosphere of nitrogen or argon gas.
12. methods as described in claim 1, is characterized in that: described step (4) is to complete adding under the condition in magnetic field, and magnetic field intensity is 2-40mT, and magnetic direction is along circumferencial direction unshakable in one's determination.
13. methods as described in claim 1, is characterized in that: insulating coating liquid is selected from a kind of in solution, colloidal sol or the suspension-turbid liquid of tetraethoxysilane, waterglass, MgO fine powder, SiO2 fine powder or insulating ceramics fine powder.
14. methods as described in claim 1, is characterized in that: amorphous, crystallite or nanocrystalline alloy stator iron core (28) after described step (4) is processed are carried out to resin hot curing processing.
15. methods as described in claim 14, is characterized in that: described resin hot curing process in dipping lacquer process under vacuum, carry out.
16. 1 kinds of amorphous, crystallite or nanocrystalline alloy stator iron cores for axial-flux electric machine prepared by the method for claim 1, this stator core is torus, on an annular end face, there are a plurality of radial opening grooves, it is characterized in that: the horizontal decile of stator core base substrate that this stator core is obtained through roller shear, jet-bedding, coating, coiling and annealing in process by alloy strip steel rolled stock is cut into two identical stator cores and forms, this stator core base substrate comprises iron core inner core (24), is wound on the alloy strip steel rolled stock with bathtub construction and cylindrical protective layer on iron core inner core (24);
Wherein: iron core inner core (24) is comprised of a pair of annular collet (1) and cylinder (2), n the inner core groove (4) that distributing uniformly at the stack shell middle part of cylinder (2); The trough of belt (17) that has a plurality of vertical alloy strip steel rolled stock length directions on the alloy strip steel rolled stock of reeling, the twice that width all equates with open slot, length is the open slot degree of depth of inner core groove (4) and trough of belt (17);
In winding process, trough of belt (17) on the described alloy strip steel rolled stock with bathtub construction is corresponding with inner core groove (4) position on iron core inner core (24), thereby form, is equivalent to the alloy strip steel rolled stock volume (25) with bathtub construction (15) that two axial magnetic flux iron core teeth portion make-ups connect;
The periphery of cylindrical protective layer has the groove identical with trough of belt (17).
17. stator cores as claimed in claim 16, it is characterized in that: the trough of belt on described alloy strip steel rolled stock (17) can be rectangle, ellipse or other arbitrary shapes, and the shape of described trough of belt (17) is identical with the shape of the upper inner core groove (4) of described iron core inner core (24).
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| CN102761175B (en) * | 2012-07-20 | 2015-04-29 | 安泰科技股份有限公司 | Stator iron core for axial magnetic field, and manufacturing method thereof |
| CN102975424A (en) * | 2012-12-08 | 2013-03-20 | 山西太钢不锈钢股份有限公司 | Composite electrical steel material |
| JP2014223641A (en) * | 2013-05-16 | 2014-12-04 | 住友重機械工業株式会社 | Manufacturing method of press working product and press working steel plate |
| DE112016000531T5 (en) | 2015-01-30 | 2017-11-02 | Prippell Technologies, Llc | Stator of an electric machine with liquid-cooled tines |
| CN105490400B (en) * | 2015-12-21 | 2018-08-24 | 安泰科技股份有限公司 | Axial magnetic field amorphous, nanocrystalline motor stator core and its manufacturing method |
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| CN106026555A (en) * | 2016-07-27 | 2016-10-12 | 白国华 | Axial magnetic flux motor iron core and preparation method thereof |
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| CN109474089B (en) * | 2018-12-18 | 2024-05-21 | 刘胜恒 | Iron core of amorphous motor and production method thereof |
| CN109687657A (en) * | 2018-12-21 | 2019-04-26 | 重庆长基科技有限公司 | A kind of stator module and preparation method thereof |
| CN110142321B (en) * | 2019-05-21 | 2020-09-18 | 东北大学 | Device and method for continuous punch forming of amorphous thin-wall structural part |
| CN110266154A (en) * | 2019-07-26 | 2019-09-20 | 北极鸥盘式特种电机深圳有限公司 | The rapid processing technique of disc type electric machine amorphous iron core |
| CN111478530A (en) * | 2020-06-01 | 2020-07-31 | 苏州英磁新能源科技有限公司 | Manufacturing process of radial flux cylinder type motor iron core |
| US20230299624A1 (en) * | 2020-07-20 | 2023-09-21 | Danfoss (Tianjin) Ltd. | Stator for disk motor, stator supporting ring and compressor |
| CN112058607A (en) * | 2020-09-03 | 2020-12-11 | 河南鑫昊晟达实业有限公司 | Method for coating both sides of ultrathin metal strip of amorphous nanocrystalline and the like and continuous annealing device |
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