TWI846473B - Self-adhesive combined ion core and manufacturing method and fixture thereof - Google Patents

Abstract

A self-adhesive combined ion core and manufacturing method, fixture, and use thereof are provided. The fixture comprises a barrel body, an upper cover, a lower cover, an axis screw, a positioning pin, and a positioning tube. The upper cover is located on a top of the barrel body. The upper cover has a first through hole, a second through hole, and a third through hole. The first through hole is located in the center of the upper cover. The second through hole and the third through hole are arranged at intervals around a circumference of the upper cover. The lower cover is located at a bottom of the barrel. The axis screw passes through the first through hole. The positioning pin passes through the second through hole. The positioning tube passes through third through hole. By arranging the unit iron cores annularly inside the barrel body of the fixture, and pressurizing and heating the inside of the fixture, a self-adhesive combined iron core is obtained. Each electromagnetic steel sheet in the unit iron core has an adhesion of 6 MPa. The self-adhesive combined ion core can be used in radial flux motor and axial flux motor.

Description

Self-adhesive composite iron core and its preparation method and fixture

The present invention relates to a modular iron core, in particular a self-adhesive modular iron core. The present invention also relates to a fixture for the self-adhesive modular iron core.

In the prior art, the stator core of the waterwheel motor can be divided into one-piece core, unfolded core and combined core. The one-piece core adopts the concentrated winding method to wind the enameled wire. However, the size of the winding needle is limited by the size of the opening of the winding slot, which makes it impossible to wind the enameled wire with a larger diameter than the opening of the winding slot, resulting in a small winding space and a low slot occupancy rate. Therefore, if the waterwheel motor needs to use a thicker enameled wire, it must use multiple wires in parallel to reduce the impedance of the motor winding. In addition, the winding speed of the winding machine cannot be too fast during operation, otherwise there will be a risk of needle collision.

The unit cores of the expanded core are arranged in a straight line. Compared with the integrated core, the teeth of the unit cores of the expanded core are open. Therefore, in the winding process, the coil can be easily installed on the ruler without the risk of hitting the pin. Therefore, it can improve production efficiency and increase the winding saturation and efficiency of the waterwheel motor. However, in the full circle process of the expanded core, convex points will be generated at the bends between the unit cores. Therefore, when placed inside the motor shell, it is easy to interfere with the motor shell, thereby generating additional iron filings and causing pollution inside the motor. In addition, if the motor housing is a metal housing, it is easy to scratch the inner wall of the motor housing and cause conduction, causing the motor stator to have a leakage magnetic path, thereby increasing iron loss and reducing magnetic flux density.

The modular iron core is composed of several unit iron cores connected in series. Its advantages are that each unit iron core can be wound separately, which improves the winding process and increases the slot occupancy rate. In the rounding process, it is not easy to produce bumps at the bends between the unit iron cores, so it is not easy to interfere with the motor housing and generate additional iron filings. In addition, compared with the unfolded iron core, the size of the modular iron core machine is smaller, and for thicker wire diameter enameled wire or rectangular wire (hari-pin), the winding process can also be changed to rotating the iron core and fixing the winding needle to complete the winding. However, when the combined iron core is used in a waterwheel motor, since the waterwheel motor has a large torque requirement, an iron core with a larger outer diameter and a higher thickness is required. Therefore, during the winding process, the iron core is easily broken due to the winding tension. To solve this problem, multiple riveting points or welding stacking methods are generally used to prepare the modular iron core. However, riveting points will damage the magnetic flux diameter of the iron core stator, thereby reducing the efficiency of the waterwheel motor and increasing the iron loss of the waterwheel motor; while welding stacking will damage the interlayer impedance of the iron core stator, thereby increasing eddy current copper loss, and also cause the magnetic properties of the iron core to deteriorate due to the high temperature during welding.

Based on the above shortcomings of the existing technology, developing a combined iron core that can improve the winding quality and neatness of the enameled wire and increase the winding slot occupancy rate is an urgent problem to be solved in this field.

In order to solve the above-mentioned problems of the prior art, the purpose of the present invention is to provide a jig for preparing a self-adhesive assembled iron core, which can maintain the verticality between each unit iron core through the positioning pin and the positioning tube, and can keep the true roundness of each unit iron core during the rounding process, so as to avoid the unit iron core from being skewed.

Another purpose of the present invention is to provide a method for preparing a self-adhesive composite iron core, which can pressurize, heat and round multiple unit iron cores at the same time through a jig, so as to achieve the purpose of quickly preparing a self-adhesive composite iron core.

Another object of the present invention is to provide a self-adhesive composite iron core, through which each electromagnetic steel sheet in a plurality of electromagnetic steel sheets, each nickel steel sheet in a plurality of nickel steel sheets, or each iron-based amorphous metal in a plurality of iron-based amorphous metals has a bonding force of 6MPa for bonding, so as to achieve the purpose of obtaining a composite iron core without riveting or welding stacking.

Another purpose of the present invention is to provide a self-adhesive composite iron core for use in radial flux motors or axial flux motors.

In order to achieve the above-mentioned purpose, the present invention provides a self-adhesive assembled iron core fixture, comprising: a barrel; an upper cover, adapted to the barrel and located at the top of the barrel, the upper cover having a first through hole, a plurality of second through holes and a plurality of third through holes, the first through hole being located at the center of the upper cover, each of the plurality of second through holes and each of the plurality of third through holes being arranged at intervals around the circumference of the upper cover; a lower cover, adapted to the barrel and located at the bottom of the barrel; an axial screw, penetrating the first through hole; a plurality of positioning pins, respectively penetrating each of the plurality of second through holes; and a plurality of positioning tubes, respectively penetrating each of the plurality of third through holes.

In a specific embodiment, the barrel is circular.

The present invention also provides a method for preparing a self-adhesive assembled iron core, comprising the steps of: providing the above-mentioned jig; providing a unit iron core, arranging a plurality of the unit iron cores in a ring shape inside the barrel body, and covering the upper cover on the top of the barrel body, wherein the unit iron core is made by stacking a plurality of electromagnetic steel sheets, a plurality of nickel steel sheets or a plurality of iron-based amorphous metals; passing the axial screw through the first through hole and through the interior of the barrel body to the lower cover, so as to press the upper cover, the barrel body and the lower cover. ; each of the plurality of positioning pins is passed through the second through hole and through the interior of the barrel to the lower cover; each of the plurality of positioning tubes is passed through the third through hole and through the interior of the barrel to the lower cover, so that each positioning pin and each positioning tube are respectively located between each of the plurality of unit iron cores; and the interior of the fixture is pressurized to 1MPa to 3MPa and heated to 120℃ to 150℃ for 30 minutes to 3 hours to obtain the self-adhesive assembled iron core.

In a specific embodiment, after the step of pressurizing and heating the interior of the fixture, the step further includes: combining the unit iron core with a winding frame.

In one specific embodiment, the interior of the fixture is heated to 120°C for 3 hours.

In one embodiment, the interior of the fixture is heated to 150°C for 30 minutes.

In a specific embodiment, each of the plurality of electromagnetic steel sheets, the plurality of nickel steel sheets or the plurality of iron-based amorphous metals further includes a round rivet point.

In a specific embodiment, the unit core has a T-shape or a square shape.

The present invention also provides a self-adhesive composite iron core prepared by a method for preparing a self-adhesive composite iron core, wherein each electromagnetic steel sheet, each nickel steel sheet or each iron-based amorphous metal in the unit iron core has a bonding force of 6MPa.

The present invention also provides a use of a self-adhesive composite iron core, which can be used in a radial flux motor or an axial flux motor.

The self-adhesive composite iron core produced by the method of preparing the self-adhesive composite iron core of the aluminum plate of the present invention can improve the winding tension of the enameled wire, thereby improving the winding quality and neatness, and improving the winding slot occupancy rate of the enameled wire in the waterwheel motor, and increasing the efficiency of the waterwheel motor. In addition, the self-adhesive composite iron core of the present invention can also be applied to radial flux motors and axial flux motors. Furthermore, the jig for preparing the self-adhesive modular iron core of the present invention can quickly produce the self-adhesive modular iron core, and can keep the verticality between the unit iron cores in the self-adhesive modular iron core, and can keep the true roundness of each unit iron core during the rounding process, thereby avoiding the unit iron core from being skewed.

1: Fixture

10: Barrel body

20: Upper cover

21: First through hole

22: Second through hole

23: The third through hole

30: Lower cover

40: Axial screw

50: Positioning pin

60: Positioning tube

70: Electromagnetic steel sheet

71: Unit iron core

80: Winding frame

90: Shell

Figure 1A is a top view of the self-adhesive modular iron core fixture of the present invention.

Figure 1B is a cross-sectional view of the self-adhesive modular iron core fixture of the present invention.

Figure 1C is a three-dimensional diagram of the appearance of the self-adhesive modular iron core fixture of the present invention.

Figure 2 is a three-dimensional diagram of the unit iron core of the self-adhesive modular iron core of the present invention.

Figure 3A is a three-dimensional diagram of the self-adhesive modular iron core of the present invention after the unit iron core and the winding frame are assembled.

Figure 3B is a three-dimensional diagram of the self-adhesive modular iron core and winding frame of the present invention after assembly.

Figure 4 is a three-dimensional diagram of the self-adhesive modular iron core of the present invention being applied to a waterwheel motor.

Figure 5 is a graph showing the iron damage results of the self-adhesive composite iron core and the riveted composite iron core of the present invention under 50Hz conditions.

Figure 6 is a graph showing the iron damage results of the self-adhesive composite iron core and the riveted composite iron core of the present invention under 60Hz conditions.

Figure 7 is a graph showing the iron damage results of the self-adhesive composite iron core and the riveted composite iron core of the present invention under 200Hz conditions.

Figure 8 is a graph showing the iron damage results of the self-adhesive composite iron core and the riveted composite iron core of the present invention under 400Hz conditions.

The following is a description of the implementation of the present invention through specific concrete embodiments. People familiar with this technology can understand other advantages and effects of the present invention through the contents disclosed in this manual. However, the exemplary embodiments disclosed in the present invention are only for the purpose of description and should not be regarded as limiting the scope of the present invention. In other words, the present invention can also be implemented or applied through other different specific embodiments, and the details in this manual can also be modified and changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention.

Unless otherwise specified herein, the singular forms "a", "an" and "the" used in the specification and the attached patent application include plural individuals. Unless otherwise specified herein, the term "or" used in the specification and the attached patent application includes the meaning of "and/or".

Preparation Example 1 Preparation of self-adhesive composite iron core

The preparation method of the self-adhesive assembled iron core includes the following steps: Referring to Figures 1A, 1B and 1C, a fixture 1 is provided, the fixture 1 includes a circular barrel 10, an upper cover 20, a lower cover 30, an axial screw 40, 5 positioning pins 50 and 10 positioning tubes 60, the upper cover 20 is adapted to the circular barrel 10 and is located at the top of the circular barrel 10, the upper cover 20 has a first through hole 21, 5 second through holes 22 and 10 third through holes 23, the first through hole 21 is located at the center of the upper cover 20, and there is a gap between every two third through holes 23 and one second through hole 22. The lower cover 30 is arranged around the circumference of the upper cover 20 at intervals; the lower cover 30 is adapted to the circular barrel 10 and is located at the bottom of the circular barrel 10; the axial screw 40 passes through the first through hole 21 and passes through the interior of the circular barrel 10 to the lower cover 30, each positioning pin 50 passes through the second through hole 22 and passes through the interior of the circular barrel 10 to the lower cover 30, and each positioning tube 60 passes through the third through hole 23 and passes through the interior of the circular barrel 10 to the lower cover 30; referring to Figures 1A and 2, a plurality of T-shaped electromagnetic steel sheets 70 are stacked to obtain a unit iron core 71, and then 15 unit iron cores 71 are stacked. 1 are arranged in a ring shape inside the circular barrel body 10, and the upper cover 20 is covered on the top of the circular barrel body 10; the axial screw 40 is passed through the first through hole 21, and passes through the interior of the circular barrel body 10 to the lower cover 30, so as to press and lock the upper cover 20, the circular barrel body 10 and the lower cover 30, wherein the locking torque of the screw on the fixture 1 is 5Nm; each positioning pin 50 is passed through the second through hole 22, and passes through the interior of the circular barrel body 10 to the lower cover 30, and each positioning tube 60 is passed through the third through hole 23, and passes through the interior of the circular barrel body 10 to the lower cover 30, so that each positioning pin 50 is passed through the second through hole 22, and passes through the interior of the circular barrel body 10 to the lower cover 30, and each positioning pin 60 is passed through the third through hole 23, and passes through the interior of the circular barrel body 10 to the lower cover 30, so that each positioning pin 50 is passed through the second through hole 2 ... The pin 50 and the positioning tubes 60 are respectively located between the unit iron cores 71 so that the upper cover 20 and the lower cover 30 can maintain verticality after being pressed together, and each unit iron core 71 can maintain true roundness during the rounding process; the inside of the fixture 1 is pressurized to 2MPa and heated to 150℃ for 1.5 hours so that each T-shaped electromagnetic steel sheet 70 in each unit iron core 71 has a bonding force of 6MPa; and referring to Figures 2, 3A and 3B, each unit iron core 71 is combined with the winding frame 80 to obtain a self-adhesive assembled iron core as shown in Figure 3B.

Preparation Example 2 Preparation of riveted assembled iron core

The riveted composite iron core with square riveting points is manufactured using a known method.

Preparation Example 3 Preparation of the first waterwheel motor

The preparation method of the first waterwheel motor includes the following steps: Referring to FIG. 4, each unit iron core 71 in the self-adhesive assembled iron core obtained in Preparation Example 1 is wound with enameled wire and then placed inside the outer shell 90 of the waterwheel to obtain the first waterwheel motor.

Preparation Example 4 Preparation of the second waterwheel motor

The preparation method of the second waterwheel motor includes the steps of: winding the enameled wire around each unit iron core in the riveted assembled iron core obtained in Preparation Example 2, and placing it inside the outer shell of the waterwheel to obtain the second waterwheel motor.

Example 1 Detection of iron damage in self-adhesive assembled iron core and riveted assembled iron core

The iron loss of the self-adhesive composite iron core and the riveted composite iron core was tested using an iron loss measuring instrument (model: BROCKHAUS MPG-200D). Figures 5 to 8 show the iron loss results of the self-adhesive composite iron core and the riveted composite iron core under the conditions of 50Hz, 60Hz, 200Hz and 400Hz, respectively. The results show that under the conditions of 50Hz, 60Hz, 200Hz and 400Hz, the iron loss of the self-adhesive composite iron core is less than that of the riveted composite iron core by approximately 28.74%, 29.68%, 30.86% and 27.68%, respectively. Therefore, the self-adhesive composite iron core of the present invention can effectively reduce iron loss.

Example 2 Testing the performance of the first waterwheel motor and the second waterwheel motor

The performance of the first and second waterwheel motors was tested using the power system measurement platform established by T71. The results showed that the reaction potential value of the riveted composite iron core was 20.4V‧s/rad, while the reaction potential value of the self-adhesive composite iron core was 21.09V‧s/rad, and the reaction potential value of the self-adhesive composite iron core increased by 3.4% compared to the reaction potential value of the riveted composite iron core. In addition, the single unit efficiency of the second waterwheel motor was 85.76%, and the single unit efficiency of the first waterwheel motor was 86.3%, which showed that the efficiency of the first waterwheel motor increased by about 0.54% compared to the second waterwheel motor.

As can be seen from the above, the self-adhesive composite iron core prepared by the method of preparing the self-adhesive composite iron core of the present invention can improve the winding tension of the enameled wire, thereby improving the winding quality and neatness, and improving the winding slot occupancy rate of the enameled wire in the waterwheel motor, and increasing the efficiency of the waterwheel motor. In addition, the self-adhesive composite iron core of the present invention can also be applied to radial flux motors and axial flux motors. Furthermore, the jig for preparing the self-adhesive modular iron core of the present invention can quickly produce the self-adhesive modular iron core, and can keep the verticality between the unit iron cores in the self-adhesive modular iron core, and can keep the true roundness of each unit iron core during the rounding process, thereby avoiding the phenomenon of the unit iron core being skewed.

The above embodiments are merely illustrative of the self-adhesive composite iron core and its preparation method, fixture and use of the present invention, and are not intended to limit the present invention. Anyone familiar with this technology may modify and change the above embodiments without violating the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be as set forth in the scope of the patent application described below.

10: Barrel body

20: Upper cover

30: Lower cover

40: Axial screw

50: Positioning pin

60: Positioning tube

Claims (10)

A self-adhesive assembled iron core fixture comprises: a barrel; an upper cover, adapted to the barrel and located at the top of the barrel, the upper cover having a first through hole, a plurality of second through holes and a plurality of third through holes, the first through hole being located at the center of the upper cover, each of the plurality of second through holes and each of the plurality of third through holes being arranged at intervals around the circumference of the upper cover; a lower cover, adapted to the barrel and located at the bottom of the barrel; an axial screw, penetrating the first through hole; a plurality of positioning pins, respectively penetrating each of the plurality of second through holes; and a plurality of positioning tubes, respectively penetrating each of the plurality of third through holes. A fixture as described in claim 1, wherein the barrel is round. A method for preparing a self-adhesive assembled iron core, comprising the steps of: providing a jig as described in claim 1 or 2; providing a unit iron core, arranging a plurality of the unit iron cores in a ring shape inside the barrel body, and fitting the upper cover to the top of the barrel body, wherein the unit iron core is made by stacking a plurality of electromagnetic steel sheets, a plurality of nickel steel sheets, or a plurality of iron-based amorphous metals; passing the axial screw through the first through hole and through the interior of the barrel body to the lower cover, so as to press the upper cover, the barrel body, and the lower cover together. and lock; each of the plurality of positioning pins is passed through the second through hole and through the interior of the barrel to the lower cover, and each of the plurality of positioning tubes is passed through the third through hole and through the interior of the barrel to the lower cover, so that each positioning pin and each positioning tube are respectively located between each of the plurality of unit iron cores; and the interior of the fixture is pressurized to 1MPa to 3MPa, and heated to 120℃ to 150℃ for 30 minutes to 3 hours to obtain the self-adhesive assembled iron core. The preparation method as described in claim 3, wherein after the step of pressurizing and heating the interior of the jig, further comprises the step of combining the unit iron core with a winding frame. The preparation method as described in claim 3, wherein the interior of the fixture is heated to 120°C for 3 hours. The preparation method as described in claim 3, wherein the interior of the fixture is heated to 150°C for 30 minutes. The preparation method as described in claim 3, wherein each of the plurality of electromagnetic steel sheets, the plurality of nickel steel sheets or the plurality of iron-based amorphous metals further comprises a round rivet point. The preparation method as described in claim 3, wherein the unit core has a T-shaped or square shape. A self-adhesive composite iron core produced by the method for preparing a self-adhesive composite iron core as described in any one of claims 3 to 8, wherein each electromagnetic steel sheet, each nickel steel sheet or each iron-based amorphous metal in the unit iron core has a bonding force of 6MPa. A self-bonded composite iron core as described in claim 9, wherein the self-bonded composite iron core is used for a radial flux motor or an axial flux motor.

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