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CN104967226A - 一种定子磁芯及其制造工艺和包含该定子磁芯的无刷电机 - Google Patents

一种定子磁芯及其制造工艺和包含该定子磁芯的无刷电机 Download PDF

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CN104967226A
CN104967226A CN201510455964.XA CN201510455964A CN104967226A CN 104967226 A CN104967226 A CN 104967226A CN 201510455964 A CN201510455964 A CN 201510455964A CN 104967226 A CN104967226 A CN 104967226A
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梁洪炘
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Priority to JP2017549511A priority patent/JP6924700B2/ja
Priority to PCT/IB2016/001200 priority patent/WO2017017526A2/en
Priority to KR1020187006082A priority patent/KR102270098B1/ko
Priority to DE112016000213.0T priority patent/DE112016000213T5/de
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D6/00—Heat treatment of ferrous alloys
    • C21D6/007—Heat treatment of ferrous alloys containing Co
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D6/00—Heat treatment of ferrous alloys
    • C21D6/008—Heat treatment of ferrous alloys containing Si
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/12—Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium, or niobium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C22C45/02—Amorphous alloys with iron as the major constituent
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/02—Details of the magnetic circuit characterised by the magnetic material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/04—Details of the magnetic circuit characterised by the material used for insulating the magnetic circuit or parts thereof
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/02—Details
    • H02K21/04—Windings on magnets for additional excitation ; Windings and magnets for additional excitation
    • H02K21/046—Windings on magnets for additional excitation ; Windings and magnets for additional excitation with rotating permanent magnets and stationary field winding
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information

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Abstract

一种定子磁芯及其制造工艺和包含该定子磁芯的无刷电机，其特征在于：定子磁芯由含钴和钒的铁基非晶材料制成，所述铁基非晶材料的组成按重量百分比为：钴0.8-1.4％、钒0.6-1.2％、硼2.7-3.3％、硅6.5-8％，余量为铁。一种直流无刷电机，包括转子轴、前端盖、外壳、定子磁芯和后端盖，定子磁芯装配外壳内，定子磁芯内设置有定子线圈，定子磁芯与定子线圈互不接触，彼此之间形成有绝缘层。本发明的定子磁芯由含钴和钒的铁基非晶材料制成，通过增加钴和钒元素，细化了晶粒并增加了材料的韧性，其不但克服了以往加工成型困难的问题，而且提高了含该定子磁芯的直流无刷电机的效率，获得突破性的进步。

Description

一种定子磁芯及其制造工艺和包含该定子磁芯的无刷电机
技术领域
本发明涉及一种定子磁芯及其制造工艺和包含该定子磁芯的无刷电机，
特别涉及一种用铁基非晶材料制作的直流无刷电机定子磁芯。
背景技术
目前的电机，不论是交流还是直流，不论功率大小。全部都是用矽钢片做，随着应用领域的扩大，电机的发展越来越向高速大功率方面发展。众所周知，矽钢片的电磁特性使它只能使用在最高300HZ的交变频率，超过这个上限，由于它的铁损会造成矽钢片发热，效率急剧下降，甚至于烧坏线圈。
铁基非晶材料因具有优异的高频特性，极低的铁损，尤其是他的可叠加性，使得其应用范围不断扩大。在大功率方面大有取代铁氧体的趋势，然而由于非晶态带材的极薄特点以及他对温度和应力的敏感性，铁基非晶材料制造电机的转子和定子，在加工工艺方面有很大的困难挑战。因为铁基非晶材料通常只有20-26um厚度，在加工成型，热处理以及粘结等工艺上稍有不慎就会破坏其电磁性能，如：电火花加工因为局部的“火花”温度使得非晶态材料发生“再结晶”而丧失非晶特性，至使“加工”失败；固化“粘结”产生的应力也是使得非晶态材料变坏的重要因素，“热处理”工艺也一样，稍有不慎就会前功尽弃。目前成功的铁基非晶材料转子只有少部分，但对已形状复杂的定子则尚未见报导。为此，有必要克服上述问题，对传统定子作进一步改进。
发明内容
本发明的目的旨在提供一种由含钴和钒的铁基非晶材料制成的定子磁芯及其制造工艺，其细化了晶粒和增加了材料的韧性，以克服现有技术铁基非晶材料加工困难的不足之处；此外，包含该定子磁芯的直流无刷电机效率大大提高。
按此目的设计的一种定子磁芯，其特征在于：定子磁芯由含钴和钒的铁基非晶材料制成，所述铁基非晶材料的组成按重量百分比为：钴0.8-1.4％、钒0.6-1.2％、硼2.7-3.3％、硅6.5-8％，余量为铁。
按照上述重量百分比的取值范围，优选方案为：钴1％、钒0.8％、硼3.2％、硅7.5％，以及铁87.5％。
定子磁芯的真空热处理工艺为：首先加温至310℃保温20-25分钟，随后加温至345℃保温15-20分钟，然后加温至385℃保温30-35分钟，最后断电随炉冷却至120℃出炉。
定子磁芯热处理成型后的固化工艺为：加温至80-90℃后，进入真空浸漆箱，固化剂为V852-12A/B纳米聚合环氧胶，5小时后放进110℃烘箱中2小时结束。
定子磁芯采用冷却乳化液保护下3500Ypm的金钢砂轮切割。
一种包含上述定子磁芯的直流无刷电机，包括转子轴、前端盖、外壳、上述的定子磁芯和后端盖，其特征在于定子磁芯装配外壳内，定子磁芯内设置有定子线圈，定子磁芯与定子线圈互不接触，彼此之间形成有绝缘层。
转子轴、定子磁芯和定子线圈的轴线彼此重合。
转子轴一端设置有转子轴承。
本发明的定子磁芯由含钴和钒的铁基非晶材料制成，通过增加钴和钒元素，细化了晶粒并增加了材料的韧性，其不但克服了以往加工成型困难的问题，而且提高了含该定子磁芯的直流无刷电机的效率。经测试，电机转速由过去的每分钟12000～15000转，提高到28000～35000转，稳定在30000转，电机不发烫，获得突破性的进步。
附图说明
图1为本发明一实施例的剖视结构示意图。
图2为本发明一实施例的立体结构示意图。
具体实施方式
下面结合附图及实施例对本发明作进一步描述。
本定子磁芯的制造工艺，定子磁芯4由含钴(Co)和钒(V)的铁基非晶材料制成，所述铁基非晶材料的组成按重量百分比为：钴(Co)0.8-1.4％、钒(V)0.6-1.2％、硼(B)2.7-3.3％、硅(Si)6.5-8％，余量为铁(Fe)。
按照上述重量百分比的取值范围，本实施例优选钴(Co)1％、钒(V)0.8％、硼(B)3.2％、硅(Si)7.5％，以及铁(Fe)87.5％。
本定子磁芯4的真空热处理工艺为：首先加温至310℃保温20-25分钟，随后加温至345℃保温15-20分钟，然后加温至385℃保温30-35分钟，最后断电随炉冷却至120℃出炉。
定子磁芯4经热处理成型后的固化工艺为：加温至80-90℃后，进入真空浸漆箱，固化剂为V852-12A/B纳米聚合环氧胶，5小时后放进110℃烘箱中2小时结束。
由于定子磁芯4的机械加工除了要求保证其尺寸的精度以外，还需要保证在整个加工过程中，铁基非晶材料的任何部位的温度均不能超过80℃，因此，本定子磁芯4采用冷却乳化液保护下3500Ypm的金钢砂轮切割。
参见图1-图2，本含有上述定子磁芯4的无刷电机为直流无刷电机，包括转子轴1、前端盖2、外壳3、上述的定子磁芯4、定子线圈5、转子轴承7和后端盖8。外壳3呈外径为26mm的圆筒，其上下端分别装配前端盖2和后端盖8，前端盖2中心设有供转子轴1突出的圆孔，后端盖8封闭设置；定子磁芯4装配于外壳3内，定子线圈5设置于定子磁芯4内，转子轴1、定子磁芯4和定子线圈5的轴线彼此重合，其中，定子磁芯4与定子线圈5互不接触，彼此之间形成有绝缘层6，绝缘层6为空气层；转子轴1下侧大部分插设于外壳3内，其底端装配转子轴承7，顶端通过前端盖2上的圆孔外露，整个无刷电机的长度为65mm。
以本30W功率的无刷电机为例，通过电源控制电路给出直流的电压和电流分别为DC24V和DC1.43A，可知输入功率为34.32W(P＝U·I)。同时在无刷电机的输出端测出其读数为电压24V和电流1.25A，即实际功率为30W(P’＝U’·I’)，再通过比对得到本无刷电机的效率可达87％(Q＝P’/P)。
上述为本发明的优选方案,本领域普通技术人员对其简单的变型或改造，均落在本发明的保护范围之内。

Claims (8)

1.一种定子磁芯，其特征在于：定子磁芯由含钴和钒的铁基非晶材料制成，所述铁基非晶材料的组成按重量百分比为：钴0.8-1.4％、钒0.6-1.2％、硼2.7-3.3％、硅6.5-8％，余量为铁。
2.根据权利要求1所述的定子磁芯，其特征在于所述铁基非晶材料的组成按重量百分比优选为：钴1％、钒0.8％、硼3.2％、硅7.5％，以及铁87.5％。
3.根据权利要求1所述定子磁芯的制造工艺，其特征在于所述定子磁芯的真空热处理工艺为：首先加温至310℃保温20-25分钟，随后加温至345℃保温15-20分钟，然后加温至385℃保温30-35分钟，最后断电随炉冷却至120℃出炉。
4.根据权利要求3所述定子磁芯的制造工艺，其特征在于所述定子磁芯热处理成型后的固化工艺为：加温至80-90℃后，进入真空浸漆箱，固化剂为V852-12A/B纳米聚合环氧胶，5小时后放进110℃烘箱中2小时结束。
5.根据权利要求4所述定子磁芯的制造工艺，其特征在于所述定子磁芯采用冷却乳化液保护下3500Ypm的金钢砂轮切割。
6.一种直流无刷电机，包括转子轴(1)、前端盖(2)、外壳(3)、后端盖(8)和权利要求1所述的定子磁芯(4)，其特征在于定子磁芯(4)装配外壳(3)内，定子磁芯(4)内设置有定子线圈(5)，定子磁芯(4)与定子线圈(5)互不接触，彼此之间形成有绝缘层(6)。
7.根据权利要求6所述的直流无刷电机，其特征在于所述转子轴(1)、定子磁芯(4)和定子线圈(5)的轴线彼此重合。
8.根据权利要求7所述的直流无刷电机，其特征在于所述转子轴(1)一端设置有转子轴承(7)。
CN201510455964.XA 2015-07-28 2015-07-28 一种定子磁芯及其制造工艺和包含该定子磁芯的无刷电机 Pending CN104967226A (zh)

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CN201510455964.XA CN104967226A (zh) 2015-07-28 2015-07-28 一种定子磁芯及其制造工艺和包含该定子磁芯的无刷电机
US15/221,526 US10498180B2 (en) 2015-07-28 2016-07-27 Stator magnetic core brushless motor apparatus, system and methods
JP2017549511A JP6924700B2 (ja) 2015-07-28 2016-07-28 ステータ磁心ブラシレスモータ装置、システム及び方法
PCT/IB2016/001200 WO2017017526A2 (en) 2015-07-28 2016-07-28 Stator magnetic core brushless motor apparatus, system and methods
KR1020187006082A KR102270098B1 (ko) 2015-07-28 2016-07-28 스테이터 자기 코어 브러시리스 모터 기구, 시스템 및 방법
DE112016000213.0T DE112016000213T5 (de) 2015-07-28 2016-07-28 Vorrichtung mit bürstenlosem motor mit stator-magnetkern; system und verfahren

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