CN113145845B

CN113145845B - Full-automatic pressureless magnetic powder forming machine and manufacturing method of magnetic powder forming blank

Info

Publication number: CN113145845B
Application number: CN202110240538.XA
Authority: CN
Inventors: 吕振
Original assignee: Shanghai Hirano Magnetic Gas Co ltd
Current assignee: Shanghai Hirano Magnetic Gas Co ltd
Priority date: 2021-03-04
Filing date: 2021-03-04
Publication date: 2023-11-07
Anticipated expiration: 2041-03-04
Also published as: CN113145845A

Abstract

A full-automatic pressureless magnetic powder forming machine and a manufacturing method of magnetic powder forming blanks, wherein the full-automatic pressureless magnetic powder forming machine comprises a manufacturing system device for forming blanks of magnetic powder with one die of anisotropic magnetic powder sintered magnet and a magnet sintered body which is sintered without bringing the die into a furnace; the manufacturing system device comprises a side wall die, a powder distribution device for supplying powder distribution process of powder to the powder distribution box, an AT air-shot device for filling the powder in the powder distribution box into the side wall die, a powder falling forming device for forming a magnetic powder blank forming body by taking the side wall die with the closed powder as a free fall, a magnetic field orientation mechanism for taking the side wall die with the closed powder blank forming body as a magnetic field orientation mechanism and a rotary disassembly mechanism for taking out the magnetic powder forming blank by rotary disassembly of the side wall die, wherein the side wall die comprises a side plate, an end plate, a bottom plate, a partition plate, a magnetic pole and a cover plate, and is divided into more than 2 parts of spaces. The application solves the problem of how to avoid sintering the magnetic powder in the mold communicated with the mold in the prior art.

Description

Full-automatic pressureless magnetic powder forming machine and manufacturing method of magnetic powder forming blank

Technical Field

The application relates to the technical field of magnetic anisotropic rare earth sintered magnets, in particular to a full-automatic pressureless magnetic powder forming machine and a manufacturing method of a magnetic powder forming blank.

Background

In the conventional method for producing a thin-plate-shaped rare earth sintered magnet, the sintered magnet requires sintering and molding the magnetic powder in the mold connected to the mold, and has the following disadvantages: (1) A large number of molds are required, and since the molds must be precisely manufactured, the manufacturing cost of the molds is high. (2) In order to use the mould to repeatedly enter the sintering furnace for sintering, the wall thickness of each part such as the mould, the partition plate and the like must be increased, and the material cost is increased; (3) At the same time, the occupied volume of the mold increases, and productivity of each device such as the powder filling device, the powder magnetic field orientation device, and the sintering device decreases. (4) The die can react with magnetic powder in no matter what material the die is made of under the high-temperature sintering of the sintering furnace, so that the service life of the die is reduced. (5) The mold is repeatedly used for sintering, so that the deformation of the metal mold cannot be completely eliminated, and the precision of the sintered magnet body is affected. The production method has the problem of consuming a great deal of manpower, financial resources and material resources.

Therefore, in the production process of rare earth sintered magnets, how to avoid sintering together the magnetic powder in the mold-connected mold is a problem to be solved.

Disclosure of Invention

The application aims to provide a full-automatic pressureless magnetic powder forming machine and a manufacturing method of magnetic powder forming blanks, which mainly solve the problem of how to avoid sintering magnetic powder bodies in a mold communicated with the mold in the prior art.

In order to achieve the above purpose, the technical scheme adopted by the application is as follows: a device and a method for a full-automatic pressureless magnetic powder embryo making machine are characterized in that: the full-automatic pressureless magnetic powder forming machine comprises a magnetic powder forming blank (M025) which is used for forming one mould of the anisotropic magnetic powder sintered magnet and a manufacturing system device of a magnet sintered body which does not need to bring a mould into a furnace for sintering; the manufacturing system device comprises a side wall die (M000), an AT powder distribution device (3400), an AT air shooting device (3600), an MT powder falling forming device (3800), an orientation mechanism and a rotary disassembly mechanism (7300), wherein the side wall die (M000) comprises a side plate (M001), an end plate (M002), a bottom plate (M003), a baffle plate (M004), a magnetic pole (M005) and a cover plate (M006); the manufacturing system device is used for disassembling, assembling and cleaning the side wall mould (M000); 1 or more partition boards (M004) are arranged in a die cavity formed by a side plate (M001), an end plate (M002) and a bottom plate (M003) in the side wall die (M000), and the inside of the die cavity is divided into a plurality of equal spaces by the partition boards (M004); the AT powder distribution device (3400) comprises a powder distribution box (M301), wherein the AT powder distribution device (3400) is used for supplying magnetic powder to the powder distribution box (M301), the AT air-shot device (3600) is used for filling the magnetic powder in the powder distribution box (M301) into an air-shot process in a side wall die (M000) with more than 2 parts of divided spaces, the MT powder falling forming device (3800) is used for taking the side wall die (M000) sealed with the magnetic powder as a free falling body to form a powder blank forming body, and the orientation mechanism is used for applying a pulse magnetic field to the magnetic powder blank forming body in the side wall die (M000); the rotary disassembling mechanism (7300) is used for rotary disassembling the side wall die (M000) and taking out the magnetic powder molding blank (M025).

Further, the end plates (M002) at the two ends of the side wall mold (M000) are respectively connected with the magnetic poles (M005).

The manufacturing method of the magnetic powder forming blank (M025) adopts the full-automatic pressureless magnetic powder forming machine, and is characterized in that: before the powder supply side wall die (M000) process, an AT powder distribution device (3400) is arranged to uniformly distribute magnetic powder into a powder distribution box (M301) by the powder distribution box (M301).

Further, the magnetic powder in the powder distribution box (M301) is filled into the side wall mold (M000) divided into a plurality of equal spaces through the air beating process of the AT air beating device (3600) so that the side wall mold (M000) is filled with a prescribed amount of magnetic powder.

Further, the MT powder falling forming device (3800) further comprises a grooved pressing die (3823); after the side wall die (M000) completes the air-shot process and is filled with magnetic powder, the side wall die (M000) is transferred to an MT powder-falling forming device (3800) in the powder-falling forming process, a grooved pressing die (3823) is pressed into the upper opening of the side wall die (M000), the grooved pressing die (3823) is integrated with the side wall die (M000), and free falling vibration pressing is repeated from a certain height, so that the density of the magnetic powder in the side wall die (M000) is increased.

Further, the orientation step of magnetizing and orienting the magnetic powder molding blank (M025) in the side wall mold (M000) by applying a pulsed magnetic field is performed at the same place; the filling process and the orientation process may be performed at different locations.

Further, the side wall mold (M000) with the magnetization orientation is subjected to a rotary disassembly mechanism (7300) to replace a bottom plate (M003) of the side wall mold (M000) by a graphite backing plate, and the side plates (M001), the end plates (M002), the magnetic poles (M005) and the cover plates (M006) are separated in a rotary manner; taking out a magnetic powder molding blank (M025) with a plurality of clapboards (M004) stored on a graphite backing plate; the extraction process can also be carried out in different independent closed places.

Further, the side plates (M001), the 2 end plates (M002), the 1 bottom plate (M003), the 2 magnetic poles (M005) and the 1 cover plate (M006) of the side wall mold (M000) are recycled after being disassembled and cleaned; the magnetic powder forming blanks (M025) separated by a plurality of clapboards (M004) enter a sintering channel together for preparing sintering; and recycling after the automatic cleaning.

Further, the powder distribution process, the air shot process, the powder falling forming process, the orientation process, the taking-out process and the preparation process are performed in a single chamber or a plurality of chambers connected by ventilation, and the single chamber or the plurality of chambers are filled with inert gas.

Further, the side wall mold (M000) is composed of 2 side plates (M001), 2 end plates (M002), 1 bottom plate (M003), 1 or more separators (M004), 2 magnetic poles (M005), and 1 cover plate (M006).

Further, the side wall mold (M000) is provided with magnetic poles (M005) at both ends.

Further, the magnetic powder molding preform (M025) is sintered together with the separator (M004) in magnet sintering.

Further, the magnetic powder molding preform (M025) is provided with a manipulator device and a conveying device for conveying the side wall mold (M000) between the next steps after the completion of the previous step in each step.

Further, the full-automatic pressureless magnetic powder forming machine also comprises a cleaning side cleaning box (1000) and an upper cover plate supplying mechanism (4600); the upper cover plate (M006) provided with the side wall mold (M000) after the magnetic powder molding blank (M025) is taken out is classified and conveyed to a cleaning side cleaning box (1000) and an upper cover plate supplying mechanism (4600) manipulator device and a conveying device.

Further, the full-automatic pressureless magnetic powder forming machine also comprises a sintering preparation box (8000), wherein the sintering preparation box (8000) is connected with a rotary disassembly mechanism (7300) through a sintering furnace conveying mechanism (7600); the sintering preparation box (8000) is provided with a conveying passage device connected with a sintering furnace.

Further, the sidewall mold (M000) further includes a grooved stamper (3823); the side wall mold (M000) is composed of 2 side plates (M001), 2 end plates (M002), 1 bottom plate (M003), 1 or more partition plates (M004), 2 magnetic poles (M005), 1 cover plate (M006), and 1 grooved punch (M009), and the side wall mold (M000) is assembled by changing the shape of each of the above components, and is used for manufacturing magnetic powder molding blanks (M025) of rare earth sintered magnets in the form of flat plates (2C) and sector flat plates (2C) of various specifications.

In view of the technical characteristics, the application has the following beneficial effects:

1. the application discloses a full-automatic pressureless magnetic powder forming machine, which comprises a magnetic powder forming blank for forming one mould of an anisotropic magnetic powder sintered magnet and a manufacturing system device of a magnetic powder sintered body which is not required to be brought into a furnace for sintering, wherein the side wall mould is detachably designed to realize that the side wall mould is not required to be sintered together with the magnetic powder forming blank, and the production of rare earth sintered magnets can be completed. Therefore, the production cost of the rare earth sintered magnet can be greatly reduced, the production efficiency is improved, the service life of the side wall die is prolonged, the side wall die can be recycled, the precision of the sintered magnet body is not affected, and a large amount of manpower, financial resources and material resources can be saved.

2. Through the air beating process of the AT air beating device and the powder falling forming process of the MT powder falling forming device, the filling density of the powder in the side wall die can be effectively improved, namely, after the powder in the powder distribution box is beaten by the high frequency, uniform force and plane plate of the AT air beating device, the powder falls into the powder forming die uniformly through the screen mesh of the box, and then the powder in the powder forming die falls from high gravity acceleration in a plurality of times by the MT powder falling forming device, the powder forms a powder body, the upper part and the lower part of the powder body are uniform in density, and the overall filling density of the powder body is uniform to a high degree.

Drawings

FIG. 1 is a plan layout view of a fully automatic pressureless magnetic powder forming machine;

FIG. 2-1 is a front view of a sidewall mold-M000 (sidewall mold before the powder dispensing process).

Fig. 2-2 is a side view of the sidewall mold-M000 (sidewall mold before the powder dispensing process).

Fig. 2-3 are top views of sidewall molds-M000 (sidewall molds before the powder distribution process).

Fig. 2 to 4 are front views of the sidewall mold-M000 (sidewall mold in the powder distribution process, i.e., sidewall mold in the process of filling magnetic powder with air-shots).

Fig. 2 to 5 are side views of the sidewall mold-M000 (sidewall mold in the powder distribution process, i.e., sidewall mold in the process of filling magnetic powder with air-shots).

Fig. 2 to 6 are top views of the sidewall mold-M000 (sidewall mold in the powder distribution process, i.e., sidewall mold in the process of filling magnetic powder with air-shots).

Fig. 2 to 7 are front views of the side wall mold-M000 (side wall mold in the fall powder molding process).

Fig. 2-8 are side views of a sidewall mold-M000 (sidewall mold in the powder fall molding process).

Fig. 2 to 9 are plan views of the side wall mold-M000 (side wall mold in the fall powder molding process).

Fig. 3-1 is a plan view of a side wall mold-M000 (i.e., a flat-shaped magnetic powder molding preform M025, i.e., type 2B).

Fig. 3-2 is a plan view of the side wall mold-M000 (i.e., a flat-plate-shaped magnetic powder molding preform M025 showing the removal direction of the side plates and end plates).

Fig. 3-3 are product diagrams of sidewall mold-M000 (i.e., flat-plate-shaped magnetic powder forming blanks M025).

Fig. 3-4 are plan views of a sidewall mold-M000 (i.e., a sector-shaped flat-plate-shaped magnetic powder molding preform M025, i.e., type 2C).

Fig. 4-1 is a side view of an ATMT chassis 3000 (including an AT powder distribution device, an AT air-beat device, and an MT powder fall forming device).

Fig. 4-2 is a top view of an ATMT chassis 3000 (including an AT powder distribution device, an AT air-shot device, and an MT powder fall forming device).

Fig. 5 is a device plan view (partial) of an ATMT chassis-3000.

Fig. 6 is a powder distribution device of ATMT casing-3000.

Fig. 7-1 is a plan view of an AT air-beat apparatus of an ATMT cabinet-3000.

Fig. 7-2 is a plan view of the MT powder fall forming device.

FIG. 8 is a plan view of an orientation side purge bin-4000, a pulsed magnetic field orientation-5000, an orientation side transition bin-6000.

Fig. 9-1 is a plan view of a spin-on chassis-7000.

FIG. 9-2 is a schematic diagram of the graphite plate replenishment mechanism and the sintering furnace conveyance mechanism in the spin-on machine case.

FIG. 10-1 is a schematic structural view of a powder distribution stirring rod.

Fig. 10-2 is a schematic structural view of the powder stirring assembly.

Fig. 10-3 is a front view of the toner hopper plenum.

Fig. 10-4 are top views of the powder flapper air chamber.

Fig. 10-5 are perspective views of the cloth powder box.

Fig. 10-6 are cross-sectional views of cloth powder cartridges.

In the figure: cleaning side cleaning box-1000, cleaning side transition box-2000, ATMT machine box-3000, orientation side cleaning box-4000, 5. Pulse magnetic field orientation-5000, orientation side transition box-6000, rotary disassembling machine box-7000, sintering preparation box-8000, total air box-A10, total electric control box-B20 and total pulse power supply box-C30.

Side wall mould-M000, side plate-M001, end plate-M002, bottom plate-M003, partition plate-M004, magnetic pole-M005, upper cover plate-M006, magnetic powder forming blank-M025.

The device comprises an ATMT main body frame-3001, an ATMT frame flat plate-3002, an ATMT main body box-3003, a charging box body charging bucket-3004, a wiring air channel pipe-3005 and a first crushing weighing and quantifying mechanism-3100; side mold handling mechanism-3200, side mold gripper assembly-3230; side mold conveying mechanism-3300, side mold conveying sliding table component-3330;

AT powder distributing device-3400, powder distributing box-M301, box screen-M301 b, box turning plate-M301 c, powder distributing barrel drag chain-3401, powder distributing drag chain bracket-3402, powder distributing translational rack-3403, powder distributing translational fixed bottom plate-3404, powder distributing elevating motor-3410, elevating motor telescopic rod 3410a, powder barrel side fixed plate-3411, powder distributing barrel-3412, powder barrel charging port-3412 a, barrel connecting plate-3413, gate floating plate-3414, floating joint-3415, gate connecting plate-3416, hinge connecting piece-3417, gate guide rod-3418, gate movable block-3419, powder barrel gate-3420, gate sliding seat-3421, material barrel fixed hoop block-3422, powder distributing guide rail connecting slide block-3423, screw electric cylinder mounting folded plate-3424, guide shaft-3425, servo motor-3426, screw electric cylinder-3427, powder distributing stirring assembly-3430, stirring motor-3431, stirring rod-3432, stirring blade-3433, vibration doctor blade-3460, vibration and vibration weighing mechanism for two times;

AT feed box conveying mechanism-3500, screw electric lever-3511, feed box gripper-3513;

AT air beating device-3600, box 2-station 2, electromagnetic valve-3610, electromagnetic valve mounting plate-3611, powder pumping plate-3612, servo motor-3613, powder beating mechanism guide shaft-3614, spring top block-3615, powder beating mechanism frame-3616, powder beating device die cavity-3620, air inlet nozzle-3621, exhaust pipe-3622, sealing strip-3623, air beating plate-3624 and air beating film-3625;

ATMT handling mechanism-3700, box 1-station 1, load linear guide rail-3710;

MT falls powder forming device-3800, box 3-station 3, fixed upper plate-3810, movable frame-3811, movable clamp plate-3812, guide pillar-3813, tightening cylinder-3814, die clamp plate-3815, tightening buffer support plate-3816, fixed bottom plate-3817, standard cylinder-3818, steady cylinder-3819, adjusting bolt-3820, upper plate lock assembly-3821, lower plate lock assembly-3822, grooved die-3823, pushing tray-3824, locking cylinder-3825, cylinder fixed frame-3826.

The device comprises an orientation side cleaning box body-4001, an orientation side cleaning machine frame-4002, an MA side conveying mechanism-4100, a channel conveying mechanism-4200, an MT head cleaning mechanism-4300, a disassembly position before orientation-4400, a multifunctional cradle head before orientation-4500, an upper cover plate supplying mechanism-4600 and a channel-4700.

An orientation mechanism (5000) and an orientation coil-5500.

The device comprises an orientation side transition box body-6001, an orientation side transition rack-6002, a spin-disassembly-front waiting position-6100 spin-disassembly side conveying mechanism-6200.

The device comprises a rotary disassembly box body-7001, a rotary disassembly rack-7002, a rotary disassembly box transition position-7100, a rotary disassembly multifunctional cradle head-7200, a rotary disassembly mechanism-7300, a graphite plate supplementing mechanism-7400, a mould opening mechanism-7500, a sintering furnace conveying mechanism-7600 and a recovery conveying mechanism-7700.

Detailed Description

The application is further described below in conjunction with the detailed description. It is to be understood that these examples are illustrative of the present application and are not intended to limit the scope of the present application. Furthermore, it should be understood that various changes and modifications can be made by one skilled in the art after reading the teachings of the present application, and such equivalents are intended to fall within the scope of the application as defined in the appended claims.

See the figure1To the picture10-6Embodiment 1, embodiment 1 provides a full-automatic pressureless magnetic powder forming machine, which is characterized in that: the full-automatic pressureless magnetic powder forming machine comprises a magnetic powder forming blank M025 which is used for forming one mould of the anisotropic magnetic powder sintered magnet and a manufacturing system device of a magnet sintered body which is sintered without bringing a mould into a furnace; the manufacturing system device comprises a side wall die M000, an AT powder distribution device 3400, an AT air beat device 3600, an MT powder falling forming device 3800, an orientation mechanism and a rotary disassembling mechanism 7300, wherein the side wall die M000 comprises a side plate M001, an end plate M002, a bottom plate M003, a baffle plate M004, a magnetic pole M005 and a cover plate M006; the manufacturing system device is used for disassembling, assembling and cleaning the side wall die M000; the side wall die M000 is characterized in that a die cavity formed by a side plate M001, an end plate M002 and a bottom plate M003 is filled with 1 or more partition plates M004, and the inside of the die cavity is divided into 2 or more equal spaces by the partition plates M004; the AT powder distribution device 3400 comprises a powder distribution box M301, wherein the AT powder distribution device 3400 is used for supplying powder to the powder distribution box M301, the AT air-beating device 3600 is used for filling the powder in the powder distribution box M301 into an air-beating process of a side wall die M000 divided into more than 2 parts, the MT powder-beating forming device 3800 is used for taking the side wall die M000 sealed with the powder as a free falling body to form a powder forming blank M025, and the orientation mechanism is used for taking the powder forming blank M025 in the side wall die M000 as an orientation process of applying a pulse magnetic field; the rotary disassembling mechanism 7300 is used for rotary disassembling the side wall die M000 to take out the magnetic powder molding blank M025.

The end plates M002 at two ends of the side wall die M000 are respectively connected with the magnetic poles M005.

The powder in the powder distribution box M301 is filled into the side wall mold M000 divided into 2 or more equal spaces by the air-beating process of the AT air-beating device 3600 so that the side wall mold M000 is filled with a predetermined amount of powder.

The MT powder falling forming device 3800 further comprises a grooved pressing die 3823; after the side wall die M000 completes the air-shot process and is filled with magnetic powder, the side wall die M000 is transferred to the MT powder-falling forming device 3800 in the powder-falling forming process, a grooved press die 3823 is pressed into the upper opening of the side wall die M000, the grooved press die 3823 is integrated with the side wall die M000, and the free falling and jolt pressing are repeated from a certain height, so that the density of the magnetic powder in the side wall die M000 is increased.

The side wall die (M000) with the magnetizing orientation is subjected to rotary disassembly by a rotary disassembly mechanism (7300) to replace a bottom plate (M003) of the side wall die (M000) by a graphite backing plate, and the side wall die is separated from 2 side plates (M001), 2 end plates (M002), 2 magnetic poles (M005) and 1 cover plate (M006) in a rotary manner; taking out a magnetic powder molding blank (M025) with a plurality of clapboards (M004) stored on a graphite backing plate; the extraction process can also be carried out in different independent closed places.

The side plates M001, 2 end plates M002, 1 bottom plate M003, 2 magnetic poles M005 and 1 cover plate M006 of the side wall die M000 are separated by rotary disassembly, and then are automatically recycled after all the side plates are cleaned.

The powder distribution process, the air beating process, the powder falling forming process, the orientation process, the taking-out process and the preparation process are performed in a single cavity or a plurality of cavities connected by ventilation, and the single cavity or the plurality of cavities are filled with inert gas.

The side wall mold M000 is composed of components of 2 side plates M001, 2 end plates M002, 1 bottom plate M003, 1 or more partition plates M004, 2 magnetic poles M005, and 1 cover plate M006.

The side wall mold M000 has magnetic poles M005 at both ends.

The magnetic powder molding preform M025 is sintered together with the separator M004.

In the manufacturing of each process, the magnetic powder molding preform M025 is provided with a manipulator device and a conveying device for conveying the sidewall mold M000 between the next processes after the completion of the previous process.

The full-automatic pressureless magnetic powder forming machine also comprises a cleaning side cleaning box 1000 and an upper cover plate supplying mechanism 4600; the upper cover plate M006 having the sidewall mold M000 after the magnetic powder molding preform M025 is sorted and transferred to the cleaning-side cleaning tank 1000, the upper cover plate replenishment mechanism 4600, and the transfer device.

The full-automatic pressureless magnetic powder forming machine also comprises a sintering preparation box 8000, wherein the sintering preparation box 8000 is connected with a rotary disassembly mechanism 7300 through a sintering furnace conveying mechanism 7600; the sinter preparation box 8000 is provided with a flange seal door connected to the sinter oven tunnel.

The sidewall mold M000 further includes a grooved die-3823; the side wall mold M000 is composed of 2 side plates M001, 2 end plates M002, 1 bottom plate M003, 1 or more separators M004, 2 magnetic poles M005, 1 cover plate M006, and 1 slot die-3823, and the side wall mold M000 is assembled by the shape change of the above-mentioned components, and is used for manufacturing the magnetic powder molding blanks M025 of rare earth sintered magnets such as the 2B-type magnetic powder molding blanks in fig. 3-1 to 3-3, the 2C-type magnetic powder molding blanks in fig. 3-4, etc. in the form of flat plates of various specifications.

In the sintering step of the magnetic powder molding preform M025, the magnetic powder molding preform M025 and the separator M004 are removed from the side wall mold M000, and sintered in a 1-1 parallel state.

In the present application, the side plate M001, the end plate M002, and the bottom plate M003 of the side wall mold M000 divided into at least 2 spaces may be assembled in the same inert gas as other steps, that is, the powder distribution step, the air shot step, the powder fall forming step, the orientation step, the take-out step, and the preparation step.

The apparatus and method of the fully automatic pressureless magnetic powder molding machine according to the present application can be carried out in the same chamber in the above-described order, regardless of the mold and the separator, if other assembling means for assembling the mold and/or the separator are provided inside.

In the method for producing the magnetic powder molding preform M025 of the present application, the powder distribution step, the powder beating step, the orientation step, and the removal step are performed in an inert gas because the magnetic powder has high reactivity and is easily oxidized, and may be ignited in the air. The inert gas atmosphere is, for example, a nitrogen atmosphere or an argon atmosphere, and is an atmosphere in which oxygen and water are reduced as much as possible. The sintering step is usually performed in vacuum or under reduced pressure. Further, the powder distribution step, the powder fall molding step, the orientation step, and the removal step may be repeated to produce 1000 to 2000 oriented filled molded bodies (i.e., oriented magnetic powder molding blanks M025) and then the sintering step may be performed.

In the side wall mold M000 used in the method for producing the magnetic powder molding preform M025 of the present application, in order to prevent the bottom plate M003 from falling off from the side plate M001 in the powder falling molding step to be performed later, the bottom plate M003, the partition plate M004, and the side plate M001 are fixed by a locking structure, and the entire structure is generally configured to be opened and closed by being mounted in contact with the lower surface of the bottom plate M003 in a manner so that the powder on the upper surface of the bottom plate M003 is densified. In the present application, the upper cover M006 is installed on the sidewall mold M000, that is, the upper cover M006 is covered on the upper surface of the sidewall mold M000 after the powder falling molding process is completed.

The prescribed amount (weight) of the magnetic powder can be calculated from the volume in the space of the side wall die M000 and the packing density of the magnetic powder after packing, and the density of the magnetic powder after packing of the side wall die M000 cannot be adjusted to be too high, and the sintered body density after sintering of the magnetic powder molding preform M025 cannot be increased to be too low. The optimum packing density (typically around 45-55% of theoretical density) for each powder is determined experimentally.

The magnetic powder is put into the space divided by the spacer (i.e., the partition plate M004) in the side wall mold M000, and the grooved press die 3823 is pressed into the side wall mold M000, so that the side wall mold M000 in this state repeatedly falls and impacts from a certain height, the density of the magnetic powder in the side wall mold M000 is gradually increased, and the volume of the magnetic powder molding preform M025 is reduced. In order to uniformly increase the density of the magnetic powder, the sidewall mold M000 repeatedly drops the sidewall mold M000 and the magnetic powder therein in a state in which the grooved press 3823 is weighted, and a difference in the density of the magnetic powder in the upper and lower portions in the cavity of the sidewall mold M000 is less likely to occur, so that uniform filling of the magnetic powder can be achieved. At this time, the packing density of the magnetic powder is the initial set value.

By filling powder in a plurality of small spaces divided in one side wall die M000 large space (i.e., dividing the large space into a plurality of small spaces by a partition M004), alloy powder (e.g., magnetic powder) can be filled uniformly in all the small spaces. In the case of a large space, because the weighing is only needed to weigh a large space for 1 time relative to 1 die, the powder adding uniformity of the powder in the small space is easy to realize. The main surface (surface having a large area) of the packed alloy powder packed compact is parallel to the separator M004, and the distance of movement from the start of packing to the top of the powder at the end of packing is large, so that the variation in density is alleviated during the packing, and the effect of such homogenization is large. Even if the separator M004 is thin, the separator M004 is not bent by the pressure difference due to the small difference in filling density of the adjacent spaces.

Alternatively, a side wall mold M000 holding a magnetic powder-filled molded body (i.e., a magnetic powder molded preform M025) is placed on a flat plate in an orientation mechanism, and an upper cover plate M006 is covered. The bottom plate M003 of the mold used in the filling step is not required to be carried into the orientation mechanism, and even if the bottom plate M003 is not present after the filling step of the side wall mold M000, the filled molded body does not come off from the side wall of the mold, and therefore, only the side plate M001 of the side wall mold M000 and the magnetic powder filled molded body therein may be carried into the orientation mechanism and placed on another bottom plate to perform the orientation step. In the orientation step, a pulsed magnetic field is applied to the filled compact to orient the alloy powder, thereby producing an oriented filled compact. The oriented filled molded article has shape retention and does not deform or collapse under a small mechanical vibration stimulus.

The sintered magnet is generally thin plate-shaped, and a magnetic field is applied in a direction perpendicular to the thin plate of the sintered magnet. In the alloy powder (for example, magnetic powder) compact, the compact in which the alloy powder is separated by each separator M004 is in the form of a thin plate, and a pulsed magnetic field is applied in a direction perpendicular to the main surface (surface having a large area) of the thin plate-like compact to orient the powder. In the structure of the present application, even in the case of a sheet-like molded body (i.e., the magnetic powder molded blank M025), since the magnetic field orientation is performed while a plurality of molded bodies are aligned in a row, the length of the magnetization direction with respect to the cross-sectional area perpendicular to the magnetization direction can be increased, and as a result, bending of the orientation can be reduced, and therefore deformation due to the orientation of the sintered body (i.e., the sintered magnetic powder molded blank M025) can be reduced,

alternatively, in the removing step, the side plate M001 constituting the side wall mold M000 may be pulled away from the oriented charge molded body (i.e., the oriented magnetic powder molding preform M025), and the oriented charge molded body may be removed from the side wall mold M000. If there is a separator M004, the orientation-filled molded body is taken out together with the separator M004. When the magnetic pole M005 is used, the magnetic pole M005 may be taken out at the same time. The side plate M001 of the side wall mold M000 is removed, and the oriented charge molded body on the bottom plate M003 is moved to a sintering platen made of a material resistant to the sintering temperature. The bottom plate M003 of the side wall die M000 can be made of a sintering temperature resistant material, and the bottom plate M003 and the oriented magnetic powder forming blank M025 can be directly sintered in a furnace.

In order to maintain the shape of the oriented packed compact of the magnetic powder, the packing density varies greatly depending on the average particle diameter of the powder, the shape of the particles, the presence or absence of the lubricant to be added to the powder, the amount of lubricant to be added, and the like, the packing density of the magnetic powder required to maintain the shape of the oriented packed compact for a standard rare earth sintered magnet must be about 35% or more of the theoretical density of the magnetic powder. In the powder added with the lubricant, the value is about 40% or more. Thus, when the filling density of the magnetic powder filled in the sintering mold (i.e., the side wall mold M000) reaches a certain value or more, the magnetic powder particles are interlaced with each other, and the shape thereof (i.e., the magnetic powder molding preform M025) is maintained. The alloy powder shape is maintained to increase the filling density of the powder, and the interaction between the magnetized magnetic powder particles is increased by magnetizing the magnetic powder by the magnetic field.

In the application, from the powder beating process to the orientation process, in the taking-out process, the magnetic powder molding blank M025 is taken out from the side wall die M000, the side wall die M000 is used once, and then the side wall die M000 is reused.

In the side plate (M001) bottom plate M003 of the side wall mold M000 of the present application, other plates may be used in the powder distribution step, the filling step, the orientation step, and the removal step.

The full-automatic pressureless magnetic powder forming machine further comprises a cleaning side cleaning box 1000, a cleaning side transition box 2000, an ATMT machine box 3000, an orientation side cleaning box 4000, a pulse magnetic field orientation 5000, an orientation side transition box 6000, a rotary disassembling machine box 7000, a sintering preparation box 8000, a total air box A10, a total electric control box B20 and a total pulse power supply box C30, and is used for manufacturing magnetic powder forming blanks M025 of rare earth sintered magnets such as flat plates, curved arc plates and fan-shaped flat plates.

All manufacturing processes are carried out in a sealed cabinet filled with inert gas.

Firstly, placing a magnetic powder charging basket into a charging box charging basket 3004 and connecting the charging basket with a connecting pipe; the magnetic powder enters the first crushing weighing and quantifying mechanism 3100, and the magnetic powder is weighed for the first time according to the setting.

AT this time, the side mold conveying mechanism 3200 is started, the side mold gripper moves the side mold M000 from the standby position to the slide table of the side mold conveying mechanism 3300, the side mold conveying mechanism 3300 is started, and the conveying slide table conveys the side mold M000 to the station 2BOX2 of the AT air-shot device 3600 for standby.

The first crushing weighing and quantifying mechanism 3100 adds magnetic powder into the powder distribution barrel 3412, the powder distribution stirring assembly 3430 in the powder distribution barrel 3412 starts stirring the magnetic powder, and the powder falling oscillator 3450 starts oscillating; the lower opening of the powder distribution cylinder 3412 is opened, and simultaneously, the AT powder distribution device 3400 drives the powder distribution cylinder 3412 to reciprocate left and right above the powder distribution BOX M301 of the station 1BOX1, the magnetic powder is uniformly scattered in the powder distribution BOX M301, the second weighing mechanism 3460 is started, and the powder distribution is stopped immediately after the magnetic powder is scattered to a set weight (namely, the powder distribution process). The AT material BOX conveying mechanism 3450 conveys the powder distribution BOX M301 to the upper surface of a side wall die M000 of a station 2BOX2 of the AT air beating device 3600, the AT servo motor 3613 is started, the AT powder beating device die cavity 3620 is pressed into the powder distribution BOX M301, the AT air beating device 3600 operates, and magnetic powder in the powder distribution BOX M301 is evenly beaten into the side wall die M000 layer by layer (namely, an air beating process); after the air shooting is completed, the ATMT handling mechanism 3700 carries the side wall die M000 onto the station 3BOX3 of the movable frame 3811 of the MT powder falling forming 3800, the smooth cylinder 3819 is started to drive the grooved pressing die 3823 to move downwards to press the side wall die M000, the locking cylinder 3825 is locked and limited downwards, the standard cylinder 3818 drives the movable frame 3811 to move upwards, the standard cylinder 3818 releases ascending power to enable the movable frame 3811 to bear the side wall die M000 to fall together, and the magnetic powder in the side wall die M000 is fallen and formed in a repeated reciprocating free falling mode (namely, the powder falling forming process).

The MT-side conveying mechanism 4100 conveys the sidewall mold M000 in the MT powder fall molding device 3800 out to the conveying mechanism 4200, the conveying mechanism 4200 conveys the sidewall mold M000 to the pre-orientation disassembly position 4400, the MT punch cleaning mechanism 4300 cleans the residual powder of the MT grooved punch M009, the orientation multifunctional cradle 4500 disassembles the transition frame mounted on the sidewall mold M000, the orientation multifunctional cradle 4500 cleans the excessive magnetic powder above the sidewall mold M000, the orientation multifunctional cradle 4500 grabs the upper cover plate M006 from the upper cover plate replenishment position 4620 and mounts it on the sidewall mold M000, the sidewall mold M000 is conveyed into the orientation coil 5000 by the conveying mechanism 4200 for orientation magnetization, and the sidewall mold M000 is conveyed to the pre-rotation waiting position 6100 by the channel conveying mechanism 4200.

The rotary disassembly side carrying mechanism 6200 carries the mold into the rotary disassembly transition position 7100, the rotary disassembly multifunctional cradle head 7200 carries the side wall mold M000 into the rotary disassembly mechanism 7300 from the rotary disassembly transition position 7100, the rotary disassembly mechanism 7300 rotates the side wall mold M000 by 180 degrees with the bottom surface facing upwards, and the rotary disassembly mechanism 7300 and the rotary disassembly multifunctional cradle head 7200 cooperate to disassemble the bottom plate M003 under the side wall mold M000; the rotary disassembly multifunctional holder 7200 conveys the die bottom plate M003 to the recovery conveying mechanism 7700, the rotary disassembly multifunctional holder 7200 grabs the graphite backing plate from the graphite plate supplying mechanism 7400 and places the graphite backing plate on the bottom surface of the side wall die M000; the spin-disassembly mechanism 7300 rotates the mold 180 degrees right side up; the rotary disassembly mechanism 7300 and the rotary disassembly multifunctional holder 7200 cooperate to disassemble the upper cover plate M006 of the side wall die M000; the spin-disassembly multifunctional cradle head 7200 conveys the side wall mold M000 upper cover plate M006 to the recovery conveying mechanism 7700, the spin-disassembly mechanism 7300 conveys the side wall mold M000 to the mold opening mechanism 7500, and the mold opening mechanism 7500 opens the side wall mold M000; the rotary disassembly multifunctional holder 7200 conveys the disassembled side plates M001, the end plates M002 and the magnetic poles M005 to the recycling conveying mechanism 7700, and the sintering furnace conveying mechanism-7600 conveys the graphite backing plate supporting the magnetic powder forming blanks M025 to a sintering channel for conveying the sintering furnace (namely, the magnetic powder forming blanks M025 are temporarily placed in the sintering preparation box 8000 before being sintered in the sintering furnace); the recovery transport mechanism 7700 transports the recovered articles to each preceding process for recycling.

Claims

1. A full-automatic pressureless magnetic powder forming machine is characterized in that: the full-automatic pressureless magnetic powder forming machine comprises a magnetic powder forming blank (M025) which is used for forming one mould of the anisotropic magnetic powder sintered magnet and a manufacturing system device of a magnet sintered body which does not need to bring a mould into a furnace for sintering; the manufacturing system device comprises a side wall die (M000), an AT powder distribution device (3400), an AT air shooting device (3600), an MT powder falling forming device (3800), an orientation mechanism (5000) and a rotary disassembly mechanism (7300), wherein the side wall die (M000) comprises a side plate (M001), an end plate (M002), a bottom plate (M003), a partition plate (M004), magnetic poles (M005) and a cover plate (M006); the manufacturing system device is used for disassembling, assembling and cleaning the side wall mould (M000); 1 or more partition boards (M004) are arranged in a die cavity formed by a side plate (M001), an end plate (M002) and a bottom plate (M003) in the side wall die (M000), and the inside of the die cavity is divided into a plurality of equal spaces by the partition boards (M004); the AT powder distribution device (3400) comprises a powder distribution box (M301), wherein the AT powder distribution device (3400) is used for supplying powder to the powder distribution box (M301), the AT air-shot device (3600) is used for filling the powder in the powder distribution box (M301) into an air-shot process in a side wall mould (M000) with more than 2 parts of divided spaces, the MT powder-drop forming device (3800) is used for taking the side wall mould (M000) sealed with the powder as a free falling body to form a powder forming blank (M025), and the orientation mechanism is used for taking the powder forming blank (M025) in the side wall mould (M000) as an orientation process for applying a pulse magnetic field; the rotary disassembling mechanism (7300) is used for rotary disassembling the side wall die (M000) and taking out the magnetic powder molding blank (M025).

2. A fully automatic pressureless magnetic powder forming machine according to claim 1, characterized in that: and the end plates (M002) at the two ends of the side wall mould (M000) are respectively connected with the magnetic poles (M005).

3. A method for manufacturing a magnetic powder molding blank, using a fully automatic pressureless magnetic powder molding machine as set forth in claim 1 or 2, characterized in that: the manufacturing method comprises the following steps of powder distribution, wherein the powder distribution is performed by supplying magnetic powder to a powder distribution box (M301) through an AT powder distribution device (3400);

an air-beating step of filling magnetic powder in a powder distribution box (M301) into a side wall mold (M000) having a space divided into more than 2 parts by an AT air-beating device (3600);

a powder-falling forming step of forming a magnetic powder forming blank (M025) by freely falling a side wall mold (M000) sealed with magnetic powder through an MT powder-falling forming device (3800);

an orientation step of applying a pulsed magnetic field to the magnetic powder molding preform (M025) in the sidewall mold (M000) by an orientation mechanism;

and a removal step of removing the magnetic powder molding preform (M025) by rotating and disassembling the sidewall mold (M000) by a rotating and disassembling mechanism (7300).

4. A method of manufacturing a magnetic powder molding preform according to claim 3, wherein: an AT powder distribution device (3400) is arranged to uniformly distribute magnetic powder into the powder distribution box (M301) towards the powder distribution box (M301).

5. A method of manufacturing a magnetic powder molding preform according to claim 4, characterized in that: the powder distribution box (M301) distributes uniformly magnetic powder, and the powder is transferred and filled into a side wall mold (M000) divided into a plurality of equal spaces through the air beating process of the AT air beating device (3600), so that the side wall mold (M000) is filled with uniformly-distributed magnetic powder of a specified quantity.

6. A method of manufacturing a magnetic powder molding preform according to claim 5, characterized in that: after the side wall die (M000) completes the air shooting process and transfers the filling magnetic powder, the side wall die (M000) is automatically conveyed to an MT powder falling forming device (3800) in a powder falling forming process through an ATMT conveying mechanism (3700); the MT powder falling forming device (3800) further comprises a grooved pressing die (3823), the grooved pressing die (3823) is pressed into the upper opening of the side wall die (M000), the grooved pressing die (3823) is integrated with the side wall die (M000), and the upper part and the lower part of the magnetic powder in the side wall die (M000) are repeatedly and freely dropped from a certain height to perform vibration pressing, so that the density uniformity precision of the upper part and the lower part of the magnetic powder in the side wall die (M000) is improved.

7. A method of producing a magnetic powder molding preform according to claim 4, 5 or 6, characterized in that: magnetizing and orienting the magnetic powder molding blank (M025) in the side wall mold (M000) by applying a pulse magnetic field, wherein the magnetizing and orienting steps are performed in the same place; the magnetizing orientation process is transferred in different independent closed places.

8. A method of manufacturing a magnetic powder molding preform according to claim 7, characterized in that: replacing the bottom plate (M003) of the side wall die (M000) with a graphite backing plate by a rotary disassembly mechanism (7300) to separate 2 side plates (M001), 2 end plates (M002), 2 magnetic poles (M005) and 1 cover plate (M006) in a rotary manner; taking out a magnetic powder molding blank (M025) with a plurality of clapboards (M004) stored on a graphite backing plate; the removal process is carried out in different independent closed places.

9. A method of manufacturing a magnetic powder molding preform according to claim 8, characterized in that: the side plates (M001), the 2 end plates (M002), the 1 bottom plate (M003), the 2 magnetic poles (M005) and the 1 cover plate (M006) of the side wall die (M000) are automatically recycled after being disassembled and cleaned; the graphite backing plate, the partition plate (M004) and the magnetic powder forming blank (M025) enter a sintering channel together to be ready for sintering; and the graphite backing plate and the partition plate (M004) are recycled after being sintered.

10. A method of producing a magnetic powder molded preform according to any one of claims 4 or 5 or 7 or 8 or 9, characterized in that: the powder distribution process, the air shooting process, the powder falling forming process, the orientation process and the taking-out process are performed in a single cavity or a plurality of cavities connected by ventilation, and the single cavity or the plurality of cavities are filled with inert gas.

11. A method of producing a magnetic powder molded preform according to any one of claims 4, 5, 6, 8, or 9, characterized in that: the side wall mold (M000) is composed of components of 2 side plates (M001), 2 end plates (M002), 1 bottom plate (M003), 1 or more partition plates (M004), 2 magnetic poles (M005) and 1 cover plate (M006).

12. A method of producing a magnetic powder molded preform according to any one of claims 4, 5, 6, 8, or 9, characterized in that: the side wall mold (M000) has magnetic poles (M005) at both ends.

13. A method of manufacturing a magnetic powder molding preform according to claim 8, characterized in that: the magnetic powder molding preform (M025) is sintered together with the separator (M004) in magnet sintering.

14. A method of manufacturing a magnetic powder shaped blank (M025) according to any one of claims 4 or 5 or 6 or 8 or 9, characterized in that: the magnetic powder molding blank (M025) is provided with a manipulator device and a conveying device for conveying a side wall die (M000) between the next working procedures after the previous working procedures are completed in the manufacturing process of each working procedure.

15. A method of manufacturing a magnetic powder molding preform according to claim 8, characterized in that: the full-automatic pressureless magnetic powder forming machine also comprises a cleaning side cleaning box (1000) and an upper cover plate supplying mechanism (4600); the side wall mold (M000) cover plate (M006) after the magnetic powder molding blank (M025) is taken out is classified and conveyed to a cleaning side cleaning box (1000) and an upper cover plate supplying mechanism (4600) manipulator device and a conveying device.

16. A method of manufacturing a magnetic powder molding preform according to claim 9, characterized in that: the full-automatic pressureless magnetic powder forming machine also comprises a sintering preparation box (8000), wherein the sintering preparation box (8000) is connected with a rotary disassembly mechanism (7300) through a sintering furnace conveying mechanism (7600); the sinter preparation box (8000) is provided with a sealing flange door connected with a sintering furnace channel.

17. A method of manufacturing a magnetic powder molding preform according to claim 11, characterized in that: the sidewall mold (M000) further comprises a fluted stamper (3823); the side wall mold (M000) is composed of 2 side plates (M001), 2 end plates (M002), 1 bottom plate (M003), 1 or more separators (M004), 2 magnetic poles (M005), 1 cover plate (M006), and 1 grooved press mold (3823) by shape change, and the side wall mold (M000) is combined to manufacture a magnetic powder molding preform (M025) of a rare earth sintered magnet of a flat plate shape (2B).

18. A method of manufacturing a magnetic powder molding preform according to claim 11, characterized in that: the sidewall mold (M000) further comprises a fluted stamper (3823); the side wall mold (M000) is composed of 2 side plates (M001), 2 end plates (M002), 1 bottom plate (M003), 1 or more separators (M004), 2 magnetic poles (M005), 1 cover plate (M006), and 1 grooved press mold (3823) by shape change, and the side wall mold (M000) is combined to manufacture a magnetic powder molding preform (M025) of a rare earth sintered magnet in the shape of a fan-shaped flat plate (2C).