阅读说明：本技术 一种大回转扭斜圆扣自铆转子制造方法 (Manufacturing method of large-rotation skew round buckle self-riveting rotor ) 是由 王成勇 于 2020-06-12 设计创作，主要内容包括：本发明提供了一种大回转扭斜圆扣自铆转子制造方法,属于电机转子制造技术领域,包括步骤：板材原料步进输送至扣点工位,扣点工位包括多组适配的扣点凸模、扣点凹模,且对应扣点凸模、扣点凹模的中心轴线水平偏移预设距离,扣点凸模、扣点凹模分别呈圆柱形设置,且扣点凸模的中心轴线相对于对应扣点凹模的中心轴线水平偏移预设距离,且扣点凸模冲入转子冲片的深度不超过转子冲片的厚度,扣点工位冲制多个圆柱形扣点,扣点包括定位凹槽和定位凸起,定位凹槽、定位凸起均呈竖向的圆柱形设置并分别位于转子冲片上下两侧,每个扣点定位凹槽的中心轴线相对于对应定位凸起的中心轴线水平偏移预设距离。(The invention provides a method for manufacturing a large-rotation skew round buckle self-riveting rotor, which belongs to the technical field of motor rotor manufacturing and comprises the following steps: the plate raw materials are conveyed to a buckling point station in a stepping mode, the buckling point station comprises buckling point male dies and buckling point female dies which are matched with one another in multiple groups, the buckling point male dies correspond to the buckling point male dies, the horizontal offset preset distance of the central axis of each buckling point female die is smaller than the horizontal offset preset distance of the central axis of each corresponding buckling point female die, the depth of the buckling point male dies, which are punched into a rotor punching sheet, does not exceed the thickness of the rotor punching sheet, the buckling point station punches a plurality of cylindrical buckling points, each buckling point comprises a positioning groove and a positioning bulge, the positioning grooves and the positioning bulges are vertically arranged in a cylindrical mode and are respectively located on the upper side and the lower side of the rotor punching sheet, and the horizontal offset preset distance of the central axis of each buckling point positioning groove is larger than the horizontal offset preset distance of.)

1. A manufacturing method of a large-rotation skew round buckle self-riveting rotor is characterized by comprising the following steps:

s1: conveying the plate raw materials to a first shaft hole station in a stepping mode, and punching a shaft hole at the first shaft hole station;

s3: the method comprises the following steps that plate raw materials are conveyed to a wire slot station step by step, and a plurality of wire slots which are uniformly distributed in the circumferential direction are punched in the wire slot station;

s5: the plate raw materials are conveyed to a buckling point station in a stepping mode, the buckling point station comprises a plurality of groups of matched buckling point male dies and buckling point female dies, the central axes of the corresponding buckling point male dies and the corresponding buckling point female dies horizontally deviate a preset distance, the buckling point male dies and the buckling point female dies are respectively arranged in a cylindrical mode, the central axes of the buckling point male dies horizontally deviate a preset distance relative to the central axes of the corresponding buckling point female dies, the depth of the buckling point male dies, which are punched into a rotor punching sheet, does not exceed the thickness of the rotor punching sheet, the buckling point station punches a plurality of cylindrical buckling points, each buckling point comprises a positioning groove and a positioning bulge, the positioning grooves and the positioning bulges are vertically arranged in a cylindrical mode and are respectively positioned on the upper side and the lower side of the rotor punching sheet, and the central axis of each buckling;

s6: the method comprises the following steps that a plate raw material is conveyed to a blanking station in a stepping mode, the blanking station punches the plate raw material into a round-sheet-shaped rotor punching sheet and is overlapped and riveted with a previous rotor punching sheet, and the latter rotor punching sheet rotates for a preset angle relative to the previous rotor punching sheet;

s7: and repeating the steps S1, S3, S5 and S6N times, and overlapping and riveting the N rotor punching sheets into the rotor body.

2. The method for manufacturing a large-rotation twisted round-buckled self-clinching rotor as claimed in claim 1, wherein the step S6: the blanking station comprises a blanking male die, a blanking female die and a torsion mechanism, wherein the blanking male die, the blanking female die and the torsion mechanism are matched, the torsion mechanism drives the blanking female die and the blanking female die to rotate by a preset angle, the torsion mechanism drives a plate raw material to be blanked into a round-sheet-shaped rotor punching sheet, the rotor punching sheet is pressed into the blanking female die and is overlapped and riveted with the previous rotor punching sheet through a fastening point, and after the overlapping and riveting, the torsion mechanism drives the blanking female die and the overlapped and riveted rotor.

3. The method for manufacturing a large-rotation twisted round-button self-clinching rotor as claimed in claim 2, further comprising, between the steps S1 and S3, the step S2 of: the plate raw materials are conveyed to a counting hole station in a stepping mode, and the counting hole station can selectively work;

s7: repeating the steps S1, S2, S3, S5 and S6N times, wherein in the 1 st time, the counting hole station works in the step S2, a plurality of counting holes are punched in the plate raw material, and a plurality of buckling point convex dies are correspondingly embedded into the plurality of counting holes in the step S5; and in the 2 nd time to the Nth time, the counting hole station does not work in the step S2, and a plurality of buckling points are punched on the plate raw material in the step S5.

4. The method for manufacturing a large-rotation twisted round-button self-clinching rotor as claimed in claim 3, further comprising, between the steps S3 and S5, the step S4 of: the plate raw materials are conveyed to a second shaft hole station step by step, and the shaft hole is corrected at the second shaft hole station.

5. The method for manufacturing the large-rotation skew round-button self-riveting rotor as claimed in claim 4, wherein the blanking male die is vertically inserted with a number of pressing rods corresponding to the number of the button points, and when the rotor punching sheet is blanked, the lower ends of the pressing rods are embedded into the button points and abut against the rotor punching sheet.

6. The method for manufacturing the large-rotation skew round-button self-riveting rotor according to claim 1, wherein the push rods with the number corresponding to the button points are inserted into the button-point female die, and the button-point male die, the button-point female die and the push rods are enclosed to form a button-point forming cavity.

7. The method for manufacturing a large-rotation twisted round-button self-clinching rotor as claimed in claim 4, wherein step S0 is further provided before step S1;

s0: the plate raw material is conveyed to a guide station step by step, a guide hole is punched in the plate raw material, and guide pins embedded in the guide hole are respectively arranged at the first shaft hole station, the counting hole station, the wire groove station, the second shaft hole station, the buckling point station and the blanking station.

8. The method for manufacturing a large-revolution skew round-button self-clinching rotor as claimed in claim 4, further comprising the step of S8: and (5) sending out the rotor body subjected to the stack riveting along the bottom of the blanking female die.

Technical Field

The invention belongs to the technical field of motor rotor manufacturing, and relates to a method for manufacturing a large-rotation skew round buckle self-riveting rotor.

Background

The rotor of the motor is subjected to a time-varying magnetic flux, which induces eddy currents therein, thereby generating energy losses. To reduce eddy current losses, the rotor is typically made up of a number of thin rotor laminations, i.e., laminations, which are stacked together in a known "skew" relationship.

For example, chinese patent application No. 95117706.0 discloses a method and apparatus for setting skew angle, including for assisting in determining the orientation of a skew pin of an apparatus having a central shaft for stacking motor rotor laminations. The skew pin is movable in at least one predetermined angular orientation relative to the axis of the central shaft. The tool comprises: a first member shaped to be positioned in a generally spatially expanded relationship with the central axis and having at least one location thereon corresponding to a predetermined rotor lamination stack height; and a second member disposed in a predetermined relationship on the first member at a location corresponding to a predetermined rotor lamination stacking height. The skew pin can be located on one or more scales corresponding to one or more locations on the second member to orient the skew pin at a corresponding angular orientation relative to the central axis.

However, the method and the equipment can only be suitable for small-angle skew of the rotor punching sheet, so that the problem of uneven rotor mass distribution is easily caused, and in order to solve the problem, the applicant provides a large-rotation skew self-riveting rotor with the publication number of CN204349609U, the self-riveting rotor comprises a body formed by overlapping a plurality of rotor punching sheets, a shaft hole is formed in the axis of each rotor punching sheet, four positioning salient points are uniformly distributed on each rotor punching sheet around the shaft hole, the positioning salient points are symmetrical along the radial center of each rotor punching sheet, an extending hole is formed in one end of each positioning salient point, the plurality of rotor punching sheets rotate in the same direction and the same angle one by one, and all the rotor punching sheets are riveted to.

However, in the rotor structure, in order to generate a skew guiding effect when the fastening point is self-riveted, the fastening point is designed to be long waist-shaped and provided with the extending hole, so that the pulling force is insufficient when the fastening point and the fastening point are overlapped and riveted, the rotor punching sheets are easily separated, and the yield of products is low. Moreover, the structure of the buckling point is complex, the requirement on the concentricity of the long waist-shaped buckling point and the rotor punching sheet is high, and the yield and the production efficiency of the product are also influenced. In addition, in some rotor products, due to factors such as size, the rotor punching sheet cannot adopt the long waist-shaped buckling point.

Disclosure of Invention

The invention aims to solve the problems in the prior art and provides a method for manufacturing a large-rotation skew round-button self-riveting rotor with strong drawing force and high yield.

The purpose of the invention can be realized by the following technical scheme: a manufacturing method of a large-rotation skew round buckle self-riveting rotor comprises the following steps:

s1: conveying the plate raw materials to a first shaft hole station in a stepping mode, and punching a shaft hole at the first shaft hole station;

s3: the method comprises the following steps that plate raw materials are conveyed to a wire slot station step by step, and a plurality of wire slots which are uniformly distributed in the circumferential direction are punched in the wire slot station;

s5: the plate raw materials are conveyed to a buckling point station in a stepping mode, the buckling point station comprises a plurality of groups of matched buckling point male dies and buckling point female dies, the central vertical shafts of the corresponding buckling point male dies and the corresponding buckling point female dies horizontally deviate a preset distance, the buckling point male dies and the buckling point female dies are respectively arranged in a cylindrical mode, the central vertical shafts of the buckling point male dies horizontally deviate a preset distance relative to the central vertical shafts of the corresponding buckling point female dies, the depth of the buckling point male dies, which are punched into a rotor sheet, does not exceed the thickness of the rotor sheet, a plurality of cylindrical buckling points are punched in the buckling point station, each buckling point comprises a positioning groove and a positioning bulge, the positioning grooves and the positioning bulges are vertically arranged in a cylindrical mode and are respectively located on the upper side and the lower side of the rotor sheet, and the central vertical shaft of each buckling point positioning groove horizontally deviates;

s6: the method comprises the following steps that a plate raw material is conveyed to a blanking station in a stepping mode, the blanking station punches the plate raw material into a round-sheet-shaped rotor punching sheet and is overlapped and riveted with a previous rotor punching sheet, and the latter rotor punching sheet rotates for a preset angle relative to the previous rotor punching sheet;

s7: and repeating the steps S1, S3, S5 and S6N times, and overlapping and riveting the N rotor punching sheets into the rotor body.

As a further improvement of the present invention, the step S6: the blanking station comprises a blanking male die, a blanking female die and a torsion mechanism, wherein the blanking male die, the blanking female die and the torsion mechanism are matched, the torsion mechanism drives the blanking female die and the blanking female die to rotate by a preset angle, the torsion mechanism drives a plate raw material to be blanked into a round-sheet-shaped rotor punching sheet, the rotor punching sheet is pressed into the blanking female die and is overlapped and riveted with the previous rotor punching sheet through a fastening point, and after the overlapping and riveting, the torsion mechanism drives the blanking female die and the overlapped and riveted rotor.

As a further improvement of the present invention, between the steps S1 and S3, there is further included step S2: the plate raw materials are conveyed to a counting hole station in a stepping mode, and the counting hole station can selectively work;

s7: repeating the steps S1, S2, S3, S5 and S6N times, wherein in the 1 st time, the counting hole station works in the step S2, a plurality of counting holes are punched in the plate raw material, and a plurality of buckling point convex dies are correspondingly embedded into the plurality of counting holes in the step S5; and in the 2 nd time to the Nth time, the counting hole station does not work in the step S2, and a plurality of buckling points are punched on the plate raw material in the step S5.

As a further improvement of the present invention, between the steps S3 and S5, there is further included step S4: the plate raw materials are conveyed to a second shaft hole station step by step, and the shaft hole is corrected at the second shaft hole station.

As a further improvement of the blanking device, the blanking male die is vertically inserted with the pressing rods with the number corresponding to the buckling points, and when the rotor punching sheet is blanked, the lower ends of the pressing rods are embedded into the buckling points and abut against the rotor punching sheet.

As a further improvement of the invention, the buckling point female die is internally inserted with a number of ejector rods corresponding to the buckling points, and the buckling point male die, the buckling point female die and the ejector rods are enclosed to form a buckling point forming cavity.

As a further improvement of the present invention, step S0 is further provided before step S1: the plate raw material is conveyed to a guide station step by step, a guide hole is punched in the plate raw material, and guide pins embedded in the guide hole are respectively arranged at the first shaft hole station, the counting hole station, the wire groove station, the second shaft hole station, the buckling point station and the blanking station.

As a further improvement of the present invention, the method further comprises a step S8 after the step S7: and (5) sending out the rotor body subjected to the stack riveting along the bottom of the blanking female die.

Based on the technical scheme, the embodiment of the invention can at least produce the following technical effects:

1. in the rotor manufacturing method, the positioning protrusions and the positioning grooves of the fastening points are skillfully arranged to be in a staggered eccentric structure, so that when the rotor punching sheets are overlapped and riveted up and down, the positioning protrusions above the positioning protrusions need to be circumferentially rotated by a certain angle to be embedded into the positioning grooves below the positioning protrusions, and then the rotor wire grooves are twisted, meanwhile, the positioning protrusions and the positioning grooves form tight fit with the same outline, the drawing force between the rotor punching sheets can be effectively guaranteed, and the yield of final products is high. In addition, the cylindrical buckling point of the rotor punching sheet can be formed by one-time punching, the structure is simpler, the requirement on machining precision is lower, the production efficiency and the yield are higher, and the applicable rotor product range is wider.

2. Through step S2 for body bottom rotor punching no longer overlaps with the rotor punching of preceding body and rivets, can realize autosegregation after the body is overlapped and rivets promptly and accomplish, and the knot of body is evagination not, and the later stage need not to carry out knot leveling process again, and production efficiency is higher. In addition, when the rotor is in stack riveting production, the counting hole is punched once, which is equivalent to a body completed by stack riveting, and further the production counting function can be realized.

3. Through step S4, the deformation of the shaft hole caused by the punching of the wire groove can be corrected, and the processing precision of the shaft hole is ensured.

Drawings

Fig. 1 is a schematic structural diagram of a rotor sheet.

Fig. 2 is a schematic structural diagram of a rotor punching sheet buckling point overlapping rivet.

Fig. 3 is a structural schematic diagram of a rotor riveting die.

Fig. 4 is a partially enlarged view of a portion a in fig. 3.

Fig. 5 is a structural schematic diagram of a male die part of the rotor riveting die.

In the figure, 100, a rotor sheet; 110. a shaft hole; 120. a wire slot; 130. buckling points; 131. a positioning groove; 132. positioning the projection; 140. counting the holes;

10. a first shaft hole station; 20. counting hole stations; 21. counting a hole male die; 22. counting a hole female die; 30. a trunking station; 40. a second shaft hole station; 50. a dotting station; 51. dotting a convex die; 52. buckling a point female die; 53. a top rod; 60. a blanking station; 61. blanking male dies; 62. blanking female dies; 63. a torsion mechanism; 64. a pressure lever; 70. and (6) guiding the station.

Detailed Description

The following are specific embodiments of the present invention and are further described with reference to the drawings, but the present invention is not limited to these embodiments.

As shown in fig. 1 to 5, the manufacturing method of the large-rotation skew round-button self-riveting rotor comprises the following steps:

s1: the plate raw materials are conveyed to a first shaft hole station 10 step by step, and a shaft hole 110 is punched at the first shaft hole station 10;

s2: the plate raw materials are conveyed to a counting hole station 20 in a stepping mode, and the counting hole station 20 can selectively work;

s3: the plate raw materials are conveyed to a wire casing station 30 step by step, and a plurality of wire casings 120 which are uniformly distributed in the circumferential direction are punched at the wire casing station 30;

s4: the plate raw materials are conveyed to a second shaft hole station 40 step by step, and the second shaft hole station 40 corrects the shaft hole 110;

s5: the plate raw material is delivered to a point-buckling station 50 step by step, the point-buckling station 50 comprises 4 groups of matched point-buckling male dies 51 and point-buckling female dies 52, and the central axes of the corresponding buckling point male die 51 and the corresponding buckling point female die 52 are horizontally deviated by a preset distance, the buckling point male die 51 and the buckling point female die 52 are respectively arranged in a cylindrical shape, and the central axis of the dotting punch 51 is horizontally offset by a preset distance with respect to the central axis of the corresponding dotting die 52, the punching depth of the buckling point male die 51 into the rotor punching sheet 100 does not exceed the thickness of the rotor punching sheet 100, 4 cylindrical buckling points 130 are punched at the buckling point station 50, each buckling point 130 comprises a positioning groove 131 and a positioning protrusion 132, the positioning grooves 131 and the positioning protrusions 132 are vertically arranged in a cylindrical shape and are respectively positioned on the upper side and the lower side of the rotor punching sheet 100, and the central axis of each buckling point 130 positioning groove 131 horizontally offsets a preset distance relative to the central axis of the corresponding positioning protrusion 132;

s6: the method comprises the following steps that plate raw materials are conveyed to a blanking station 60 in a stepping mode, wherein the blanking station 60 comprises a blanking male die 61, a blanking female die 62 and a torsion mechanism 63 which are matched with each other and drive the blanking female die 62 to rotate, the blanking station 60 punches the plate raw materials into a disc-shaped rotor punching sheet 100, the rotor punching sheet 100 is pressed into the blanking female die 62 and is overlapped and riveted with the previous rotor punching sheet 100 through a buckling point 130, and after the overlapping and riveting, the torsion mechanism 63 drives the blanking female die 62 and the overlapped and riveted rotor punching sheet 100 in the blanking female die 62 to rotate for 91-95 degrees;

s7: repeating the steps S1 to S6N times, and when the number 1 is reached, working at the counting hole station 20 in the step S2, punching 4 counting holes 140 in the plate raw material, and correspondingly embedding 4 counting holes 140 in 4 dotting convex dies 51 in the step S5; in the 2 nd to the nth time, the counting hole station 20 does not work in the step S2, and in the step S5, 4 fastening points 130 are punched on the plate material;

s8: the rotor body after the stack riveting is sent out along the bottom of the blanking female die 62.

In the rotor manufacturing method, the positioning protrusions 132 and the positioning grooves 131 of the fastening points 130 are skillfully arranged to be in a staggered eccentric structure, so that when the rotor sheets 100 are stacked and riveted up and down, the positioning protrusions 132 of the next rotor sheet 100 can be embedded into the positioning grooves 131 of the previous rotor sheet 100 only by rotating circumferentially by a certain angle, and further the skew of the rotor wire slots 120 is realized, and meanwhile, the positioning protrusions 132 and the positioning grooves 131 form a tight fit with a consistent contour, so that the drawing force between the rotor sheets 100 can be effectively ensured, and the yield of the final product is high. In addition, the cylindrical fastening point 130 of the rotor punching sheet 100 can be formed by one-time punching, the structure is simpler, the requirement on processing precision is lower, the production efficiency and the yield are higher, and the applicable rotor product range is wider.

It is worth mentioning that, through step S2, make body bottom rotor punching 100 no longer overlap with the rotor punching 100 of previous body and rivet, can realize autosegregation after the body overlap rivets the completion promptly, and the knot 130 of body is not outer protruding, and the later stage need not to carry out knot 130 flattening process again, and production efficiency is higher. In addition, when the rotor is in stack riveting production, the counting hole 140 is punched once, which is equivalent to completing one body in stack riveting, and further playing a role in production counting.

Further, step S0 is provided before step S1: the plate raw material is conveyed to a guide station 70 in a stepping mode, a guide hole is punched in the plate raw material, guide pins embedded in the guide hole are respectively arranged on a first shaft hole station 10, a counting hole station 20, a wire groove station 30, a second shaft hole station 40, a buckling point station 50 and a blanking station 60, and therefore positioning accuracy of the plate raw material during blanking is guaranteed.

As shown in fig. 1 to 2, the rotor manufactured by the method for manufacturing a large-rotation skew round-buckle self-riveting rotor includes a body formed by overlapping a plurality of rotor laminations 100, a shaft hole 110 is formed in the center of each rotor lamination 100, a wire casing 120 is formed on the periphery of the shaft hole 110 formed in the center of each rotor lamination 100, four buckle points 130 are circumferentially and uniformly distributed on each rotor lamination 100 by taking the shaft hole 110 as the center, each buckle point 130 includes a positioning groove 131 and a positioning protrusion 132, the positioning grooves 131 and the positioning protrusions 132 are vertically and cylindrically arranged and respectively located on the upper side and the lower side of each rotor lamination 100, the positioning protrusions 132 of the subsequent rotor lamination 100 are correspondingly embedded with the positioning grooves 131 of the previous rotor lamination 100 one by one, and the central axis of the positioning groove 131 of each buckle point 130 is horizontally offset by a preset distance relative to the central axis of the corresponding positioning protrusion 132.

Wherein, the rotation angle of the latter rotor punching sheet 100 relative to the former rotor punching sheet 100 is 91 ° to 95 °. And the rotor punching sheets 100 are overlapped and riveted after being rotated by a large angle, so that the balance deflection caused by uneven material thickness distribution can be avoided, the balance effect during the rotation of the rotor is improved, and the time for artificial correction is shortened.

According to the required skew angle of the wire groove 120 of the rotor body and the punching thickness of the positioning protrusion 132 of the fastening point 130, the required horizontal offset distance between the central axes of the positioning groove 131 and the positioning protrusion 132 of each fastening point 130 can be obtained through conversion.

In addition, set up first shaft hole station 10, count hole station 20 before wire casing station 30, can avoid the product deformation that leads to because of wire casing 120 punching technology, effectively guarantee the precision of shaft hole 110, count hole 140, and lie in that set up second shaft hole station 40 behind wire casing station 30, can correct the shaft hole 110 deformation that leads to because of wire casing 120 punching.

As shown in fig. 3 to 5, four pressing rods 64 corresponding to the fastening points 130 are vertically inserted into the blanking male die 61, and when the rotor punching sheet 100 is blanked, the lower ends of the pressing rods 64 are embedded into the fastening points 130 and abut against the rotor punching sheet 100. That is to say, during blanking, the blanking male die 61 is completely attached to the upper surface of the rotor sheet 100, and the buckling point 130 is not easily deformed during the blanking process, so as to ensure the drawing force of the rotor.

Similarly, four ejector rods 53 corresponding to the buckling points 130 are inserted into the buckling point female die 52, and a buckling point 130 forming cavity is formed by enclosing the buckling point male die 51, the buckling point female die 52 and the ejector rods 53. The ejector rod 53 is arranged so as to control the punching thickness of the positioning protrusion 132 of the buckling point 130, and the consistency of the shape and the size of the buckling point 130 is ensured.

The blanking female die 62 is internally provided with a locking ring with the inner diameter slightly smaller than the outer diameter of the rotor punching sheet 100, and when the rotor punching sheet 100 is riveted, the locking ring is in interference fit with the rotor punching sheet 100 to provide upward supporting force, so that the rotor punching sheets 100 are attached to each other up and down.

The blanking station 60 is designed by referring to a CN 108746322A-rotor sheet manufacturing method and a mold, controlling the structure of the counting hole punch 21 moving up and down, and referring to a CN201120372053.8 pneumatic device for selectively punching the mold, which is not described herein again.

The specific embodiments described herein are merely illustrative of the spirit of the invention. Various modifications or additions may be made to the described embodiments or alternatives may be employed by those skilled in the art without departing from the spirit or ambit of the invention as defined in the appended claims.