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Stator assembly
Most of our electric motor factories produce small motors using the external press fitting process.
Stator core in the embedded line after dipping and baking, pressed into the seat must ensure that the axial position in line with the requirements of the drawings.
Otherwise it will make one end of the coil stretched too much, resulting in total assembly difficulties, and will make the electric motor air gap magnetic potential increases, affecting the performance of the electric motor.
It will also increase the wear of the axial force on the rotor of electric motors.
The axial position of the stator core in the housing is generally ensured in the press-fit tire tool.
The size of the pressure cap is controlled so that the position of the core after press-fitting is in accordance with the requirements of the drawing.
To ensure that the stator core does not rotate in the housing, the contact between the inner circle of the housing and the outer circle of the stator core alone is not sufficient, so each electric motor is also fitted with a stop screw to completely fix the core in the housing.
Rotor assembly
The assembly of the rotor of an asynchronous motor includes the assembly of the rotor core and shaft, the assembly of the bearings and the assembly of the fan.
It is the key component of the electric motor production.
Assembly of the rotor core and shaft
When the electric motor is in operation, mechanical power is output through the rotor shaft, therefore, the reliability of the combination of rotor core and shaft is very important.
When the rotor outer diameter is less than 300mm, the rotor core is normally pressed directly onto the rotor shaft; when the rotor outer diameter is greater than 300mm to 400mm.
The rotor bracket is pressed into the core first, and then the rotor shaft is pressed into the rotor bracket.
The Y series electric motors adopts a structure where the rotor core is pressed directly onto the rotor shaft from most manufacturers
There are three basic forms of assembly between the rotor core and the shaft on the production line : knurled cold press fit, hot sleeve fit and key connection fit.
Knurling cold press fit In the knurling cold press fit, the shaft processing process is: finishing the core file a knurling a grinding, then pressed into the rotor core, and then finishing grinding shaft extension, bearing file and finishing the outer circle of the core.
When using the knurling process, excessive interference is also not permitted.
Omdat de grootte van de koude persdruk evenredig is met de hoeveelheid interferentie, kan het gebeuren dat de hoeveelheid interferentie niet wordt ingedrukt als de hoeveelheid interferentie te groot is, of dat het materiaal vervormd of beschadigd raakt als gevolg van overmatige interne spanning.
Hot-sleeving wordt doorgaans uitgevoerd door gebruik te maken van de restwarmte van de gegoten aluminium rotor (of door de rotor opnieuw te verwarmen).
Het hot sleeve-proces bespaart apparatuur voor koudpersen, terwijl de combinatie van rotorkern en as betrouwbaarder is.
Doordat de hete huls wordt verwarmd om de insluiting uit te zetten en vervolgens wordt afgekoeld, krimpt het gat van de insluiting om de insluiting vast te houden, wat zorgt voor voldoende interferentiewaarden en een hoge betrouwbaarheid.
The advantage of the key connection is that it ensures the reliability of the connection and facilitates the organisation of flow production.
The disadvantage is that the processing process increases and the keyway in the shaft reduces the strength of the shaft, especially in small electric motors.
When using a key connection, the width of the key is selected according to the specified requirements.
In order to simplify the process, it is usually possible to use the same keyway width with the shaft extension for electric machines.
Bearing assembly
In small and medium-sized asynchronous motors, rolling bearing construction is widely used. They are lighter than plain bearings, require less frequent maintenance during operation and consume less lubricating oil and grease.
At the same time, rolling bearings have a small radial clearance and are more suitable for asynchronous motors with a small air gap.
General assembly
The total assembly of small and medium-sized motors includes the rotor set into the stator, the installation of other components, such as end caps, junction boxes, external fans and brush devices, etc in many manufacturers.
After the total assembly, it is also necessary to carry out tests and the exterior finishing of the motor.
General assembly of rotor into stator for electric motor production
Sleeving the rotor into the stator is one of the key processes.
Improper operation can easily cause bruising of the windings and sometimes even deformation of the rotor shaft.
When inserting the rotor, it is necessary to pay attention to the corresponding position of the shaft extension and the junction box.
If the mass of the rotor is less than 35kg, it can be put into the stator by hand.
For larger rotors, lifting tools are required.
operating, first lift the tool at the lifting ring 2 and set it on the rotor shaft, then lift the rotor at the lifting ring 1 instead and hold the lever 3 to make the rotor penetrate into the stator horizontally and smoothly.
Installation of end cover
When installing the end cap, generally install the non-axle extension end first.
Apply a thin layer of oil on the assembly stop surface to prevent the mouth part from rusting.
After installing the end cap, tap around the end cap to tighten the end face of the end cap and the seat, and then tighten the bolts diagonally in turn.
When the second end cover is installed, the rotor needs to be lifted flat (small motor can not be lifted), then the end cover stop knocked together, tighten the bolt.
If the two end caps are installed with different axes, or the end surfaces are not parallel, the rotor may rotate stagnant, you need to use a hammer to knock around the end caps to eliminate the different axes, not parallel phenomenon, so that the rotor rotates flexibly.
Then install the outer bearing cover, tighten the bearing cover screws.
Air gap adjustment
For the whole round end cover rolling bearing of medium-sized motor, when the rotor is inserted into the stator, the end cover of the ball bearing end should be installed first, and then the end cover of the roller bearing end should be installed to prevent the rolling bearing from being damaged.
When the end cover of the ball bearing end must be installed first, the end cover screw should not be tightened, after the end cover of the ball end is installed, then tighten the screw.
After the end cover is installed, to adjust the air gap.
The method of adjustment is to use the jack (four at both ends) to adjust the relative position of the end cover.
Use the plug ruler in the mutual difference 120. position for measurement (both ends), until the air gap uniformity in line with the technical conditions of the standard.
After adjusting the air gap will be screw fastening, in the horizontal punching machine according to the location of the drawing drilling dumpling positioning pin hole, and play people positioning pin.
Assembly of brush system in power electronics
In the electric motor with slip ring contact (such as large and medium-sized winding rotor asynchronous motor).
The quality of brush assembly has a great impact on the situation of the conduction; in the motor with commutator, the commutation of the situation is good or bad, often closely related to the quality of the brush system assembly.
The brushes for collector ring and commutator are generally electrochemical graphite brushes and metal graphite brushes.
Electrochemical graphite brush is made of natural graphite after processing to remove impurities and then sintered.
According to the different ratios of raw materials, it can be divided into graphite-based, coke-based and carbon-black-based.
Carbon black-based brushes have higher resistance coefficient and contact voltage drop, and are suitable for motors with difficult commutation; graphite-based brushes are commonly used in normal motors.
Gegalvaniseerde grafietborstels hebben minder hardheid en langzamere slijtage, de stroomdichtheid is over het algemeen beschikbaar op 10-12A1cm2. metalen grafietborstels zijn geschikt voor motoren met lage spanning en hoge stroomsterkte. Het wordt gesinterd door toevoeging van 40% -50% koperpoeder in grafiet.
Het heeft een hoge dichtheid, lage hardheid, lage slijtagecoëfficiënt, lage weerstandscoëfficiënt, lage contactdrukval, langzame slijtage en de stroomdichtheid is over het algemeen beschikbaar bij 17-20A/cm2 voor hogere kwaliteit.
De borstelopstelling in de gelijkstroommotor, omdat bij de positieve en negatieve borstels onder de commutator de slijtagegraad inconsistent is, moet dus een redelijke opstelling van de borstelopstellingspositie zijn.
De borstels moeten verspringend op het commutatoroppervlak liggen.
Automation of small motor assembly for electric power trains
Om de arbeidsproductiviteit te verbeteren, de productiekosten te verlagen, de productontwikkeling of productiecyclus te verkorten, om het concurrentievermogen van producten op de markt te vergroten. De auto-industrie in binnen- en buitenland concurreert om de introductie van automatiseringstechnologie op het gebied van motorassemblage.
Het vroege automatiseringssysteem voor motorassemblage, vertegenwoordigd door de halfautomatische motorassemblagelijn, werd gebruikt voor de assemblage van kleine motoren met grote hoeveelheden en weinig specificaties.
Deze semi-automatische assemblagelijn omvat automatische assemblagemachines zoals rotorlaadmachine, lagerperspassingmachine, eindkapperspassingmachine en schroefaandraaimachine, waarvan de functies zijn: statorbelasting, rotorinbrenging in de stator, lagerperspassing, eindkapbelasting en vlinder- en spijkeraanscherping.
Het belangrijkste assemblageproces wordt machinaal uitgevoerd en het aanvullende werk wordt met de hand gedaan.
De uitrusting van deze halfautomatische assemblagelijn is vast en heeft een bepaald werktempo, en de werkefficiëntie is hoog, die 25-40s/set kan bereiken.
In order to meet the requirements of automatic assembly of multi-species and small-lot products, foreign countries have developed flexible assembly cells (FAC) and flexible assembly systems (FAS), both of which use computer-controlled robots as the core equipment and thus have a high level of automation.
The flexible assembly cell includes a handling robot and multiple assembly robots.
The handling robot is responsible for handling various parts and delivering the assembled parts to the workstation of the assembly robot in order, and then carrying the assembled parts to the conveyor belt to send them away.
Equipment such as workbenches and presses are equipped at the assembly robots, which are responsible for the assembly of various parts.
The flexible assembly cell can assemble different types of components, and the computer program can also be changed in order to assemble motor products with different specifications.
Based on the flexible assembly cell, a fully automated flexible assembly system has been further developed.
This system mainly includes several major parts such as programmable assembly unit, system storage warehouse and flexible logistics transfer system, whose core is the programmable assembly unit.
The programmable assembly unit realizes the control of the assembly robot by changing the computer program and assembles various motors with different specifications.
To ensure a hindrance-free supply of components to the assembly system and to act as a buffer in the event of a system failure, the flexible assembly system has a storage warehouse.
The warehouse is equipped with programmable shelf controls that enable the computer to provide random access to each storage unit.
The flexible logistics transfer system consists of a conveyor belt or automatic guided vehicle (AGV), which is responsible for the handling of materials and the exchange of logistics between processes inside and outside the system.
FAS systems usually use a hierarchical distributed computer control system to manage and control various automated equipment in the system.
The computer system includes a main computer, a FAS management computer, a logistics computer and multiple FAC computers.
Through these computers, the FAS system can easily change the program and control the assembly system to achieve automatic assembly of multi-spec motors.
As an example, an automatic assembly system developed abroad can automatically assemble 450 types of small motors with different specifications.
This shows that the FAS flexible assembly system is not only highly automated, but also highly adaptable, and is the direction of automation for small motor assembly today.
In addition to assembly automation, there are also automatic motor factory test lines and automatic electrostatic painting lines.
Het gebruik van deze automatische lijnen zal de arbeidsomstandigheden aanzienlijk verbeteren en de arbeidsproductiviteit verhogen, en kan gunstige omstandigheden creëren voor de realisatie van de meta-gepersonaliseerde productie van elektromotorfabrieken.
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