CN-122008495-A - Production die and method for new energy synchronous rotor

CN122008495ACN 122008495 ACN122008495 ACN 122008495ACN-122008495-A

Abstract

The application discloses a production die and a method for a new energy synchronous rotor, comprising an upper die assembly and a lower die assembly, wherein the upper die assembly sequentially comprises a main nozzle, a splitter plate, a plurality of branch nozzles, a path plate and a closed loop flow path plate, wherein the top end of the main nozzle is connected with a nozzle of an external injection molding machine to receive molten rubber, the splitter plate is internally provided with a plurality of branch channels which are radially distributed by taking an outlet of the main nozzle as a center, the inlets of the branch channels are communicated with the outlet of the main nozzle, the inlets of the branch nozzles are respectively and correspondingly connected with the outlets of the branch channels, the path plate is provided with an inner annular groove, an outer annular groove and a plurality of radial connecting grooves which are communicated with each other to form a closed loop flow path, and the rubber material from the center main nozzle is distributed into an inner annular path and an outer annular path which encircle the circumference of the rotor through the closed loop flow path plate, and the residual rubber volume solidified in a path plate channel system is greatly reduced in each injection molding cycle.

Inventors

ZHENG GUANGHUI
ZHAO PEIZHEN
LU SONG
ZHENG JINZE

Assignees

山东博源精密机械有限公司

Dates

Publication Date: 20260512
Application Date: 20260129

Claims (10)

1. The utility model provides a new forms of energy synchronous production mould for rotor, includes module and lower module, its characterized in that, go up the module and include in proper order from top to bottom: the top end of the main nozzle is used for being connected with a nozzle of an external injection molding machine so as to receive molten sizing material; The inside of the flow dividing plate is provided with a plurality of flow dividing channels which are radially distributed by taking the outlet of the main nozzle as the center, and the inlets of the flow dividing channels are communicated with the outlet of the main nozzle; the inlets of the branch nozzles are correspondingly connected with the outlets of the sub-runners respectively; the path plate is provided with an inner ring groove, an outer ring groove and a plurality of radial connecting grooves which are communicated with each other to form a closed loop flow path, and outlets of a plurality of branch nozzles are respectively communicated with a plurality of glue inlet points on the closed loop flow path; the lower die assembly comprises a lower die holder for placing the rotor core, and when the dies are assembled, all glue injection holes at the bottom of the path plate are aligned with gaps between each permanent magnet on the rotor core and the groove wall.
2. The production mold for the new energy synchronous rotor according to claim 1, wherein a plurality of circular sinking grooves are uniformly formed at the top of the inner ring groove of the path plate at intervals along the circumferential direction, the circular sinking grooves form glue inlet points for butt joint of the outlets of the branch nozzles, and the vertical projection of the glue inlet points is positioned in an area commonly covered by the inner ring groove and/or the outer ring groove.
3. The production die for the new energy synchronous rotor according to claim 1, wherein the glue injection holes formed in the path plate are gradually narrowed in cross section along a glue feeding direction and a glue discharging direction, hollow cone tables are integrally formed on the joint surface of the path plate facing the rotor core corresponding to the glue injection holes, and when the die is assembled, the lower end parts of the hollow cone tables are inserted and tightly matched with the gap inlets between the corresponding permanent magnets and the core slots on the rotor core.
4. The production mold for new energy synchronous rotors according to claim 1, wherein a hot runner system is integrated in the split plate, the hot runner system comprises heating elements embedded in the upper surface and the lower surface of the split plate, and the main nozzle, the split runner in the split plate and the branch nozzle are all positioned in a heating temperature zone of the hot runner system, so that the sizing material flowing through is always kept in a molten state.
5. The production mold for the new energy synchronous rotor according to claim 1, wherein the upper mold assembly further comprises an upper mold core fixedly arranged above the path plate, the lower surface of the upper mold core and the upper surface of the path plate jointly seal the top opening of the runner path groove, an upper base plate fixedly arranged above the upper mold core, each branch nozzle sequentially penetrates through the upper base plate and the upper mold core, the outlet of each branch nozzle is communicated with the glue inlet point of the path plate, a hollow ejector plate capable of moving along the opening and closing direction is sleeved on the periphery of the path plate, and the hollow ejector plate can eject and drive the path plate to be separated from the upper mold core after opening the mold under the action of a driving mechanism so as to open a closed loop runner path.
6. The production die for the new energy synchronous rotor is characterized in that the lower die holder comprises a central placing disc and clamping blocks symmetrically arranged on two sides of the placing disc and capable of moving radially, an inclined hole is formed in each clamping block, an inclined guide pillar is correspondingly arranged on the upper die assembly, in the die assembly process, the inclined guide pillars are inserted into the corresponding inclined holes, the two clamping blocks are driven to move in the opposite direction, and radial extrusion force is applied to a rotor core arranged on the placing disc to clamp and fix the rotor core.
7. The production mold for the new energy synchronous rotor according to claim 6, wherein an independent temperature control system is integrated inside the placing plate of the lower mold base, the temperature control system is configured to maintain the temperature of the rotor core within a set temperature range for not solidifying the sizing material during the sizing material injection process, and to synchronously and uniformly solidify the sizing material in the rotor core and the gap after all the sizing material injection is completed.
8. The production mold for the new energy synchronous rotor according to claim 6, wherein a closed vibration chamber is formed in the clamping block, a freely rolling impact body is arranged in the vibration chamber, and the impact body moves in the vibration chamber and generates impact, so that vibration is transmitted to the rotor core.
9. The production die for the new energy synchronous rotor is characterized in that two parallel pressing rails are arranged on the lower die holder, step sliding blocks transversely extend out of two sides of the clamping blocks, the pressing rails are located on the upper step surface of the step sliding blocks, a vertical gap is reserved between the pressing rails and the upper step surface, and a limiting part is further arranged on the lower die holder and located on the opposite side of the two clamping blocks and used for limiting the outward moving position of the clamping blocks.
10. A method of using the production mold for a new energy synchronous rotor according to any one of claims 1 to 9, comprising the steps of: s1, placing a rotor core which is preliminarily filled with a permanent magnet on a placing disc of a lower die holder by a mechanical arm, descending an upper die assembly, inserting an inclined guide pillar on the upper die assembly into an inclined hole of a clamping block, driving the clamping block to move along a pressing rail and a step sliding block in a guiding way, and radially supporting and fastening the rotor core in the center of the placing disc; s2, electrifying a hot runner system to heat to the melting temperature of the sizing material, starting a temperature control system of a placing disc, and preheating and maintaining a rotor iron core at a set temperature; S3, injecting glue by an external injection molding machine through a main nozzle, distributing molten glue to each branch nozzle through a diversion channel, injecting glue into an inner ring groove, a radial connecting groove and an outer ring groove of a path plate through a glue inlet point, and injecting all gaps from all glue injection holes through a hollow cone frustum; S4, the clamping block is internally provided with an impact body to impact the cavity wall, so that vibration is generated and transmitted to the rotor to assist in exhausting and filling; S5, maintaining pressure after the glue injection is completed, performing a preset program by a placing disc temperature control system, firstly preserving heat to enable glue materials to fully flow and fuse, and then starting cooling to enable the glue materials in all gaps to be synchronously and uniformly solidified; and S6, after solidification, all the heating systems are closed, the upper die moves upwards, the inclined guide pillar drives the clamping block to loosen the rotor, the hollow ejector plate moves, the path plate is ejected to be separated from the upper die core, the closed loop flow path is opened to take out the discharged cake, and the mechanical arm takes out the finished rotor.

Description

Production die and method for new energy synchronous rotor Technical Field The application belongs to the technical field of injection molds, and particularly relates to a production mold and a production method for a new energy synchronous rotor. Background In order to pursue higher power density and efficiency, a built-in permanent magnet synchronous rotor technology is generally adopted in the current high-performance new energy driving motor. Among them, the built-in V-shaped (or double-layer V-shaped) permanent magnet layout has become an industry-accepted advanced design solution. The design embeds the bar permanent magnet into the rotor core slot with a specific inclination angle to form a V-shaped arrangement (often comprising a combination of large V and small V), and has the core advantages that the magnetic resistance torque can be skillfully utilized, and the bar permanent magnet is overlapped with the permanent magnet torque, so that the total output torque is greatly improved, and meanwhile, the air gap magnetic field waveform is optimized, the torque pulsation and the iron loss are reduced, so that the key for realizing the high-power, high-efficiency and high-smoothness operation of the motor is realized. However, this complex magnetic circuit topology presents a serious challenge to its manufacturing process, particularly the fixing and insulating process of the magnetic steel. In order to firmly fix the magnetic steel in the V-shaped groove and ensure insulation reliability, the main current technology is to inject thermoplastic engineering plastics (hereinafter, collectively referred to as "sizing materials") into the precise gap between the magnetic steel and the iron core groove. The V-shaped magnetic steel grooves are distributed in multiple layers (generally, an inner layer and an outer layer) in the circumferential direction on the rotor, and each layer of groove body forms a non-standard annular cavity through the iron core, so that a cavity system needing to be filled with sizing materials is extremely complex. Existing filling methods commonly employ a single central injection cold runner system. Specifically, after the rubber material is injected from the main gate in the center of the mold, the rubber material is conveyed to a plurality of gate positions preset in the inner and outer annular cavities through a radial distribution runner system, and then enters a final magnetic steel gap from the gate to be filled. The process path has extremely long runner system, long sizing material flow, serious temperature drop and serious pressure loss, and the flow path of sizing material from the center to the far-end gate is tortuous and long. The magnetic steel gap at the end of the runner is very easy to be filled and is not full, a cavity or a weak interface is formed, a complex radial runner and an inner annular and outer annular distribution cavity are formed, the final product is not formed, and only the effect of conveying sizing materials is achieved. However, during each production cycle, the size that solidifies in these large runner systems becomes a "cake" that must be removed. Although the waste materials can be recycled, the cost and the energy consumption of crushing, sorting and reprocessing are increased, the addition proportion of recycled materials is influenced by the performance degradation of the waste materials, the comprehensive material cost is increased for a long time, and a large amount of solid waste is generated. It follows that there is a need for further improvements and enhancements in the art. Disclosure of Invention The present invention provides a new energy synchronous rotor production mold and method to at least solve or alleviate one or more technical problems in the prior art, or at least provide a beneficial option. In order to achieve the above purpose, the present invention provides the following technical solutions: the utility model provides a new forms of energy synchronous production mould for rotor, includes last module and lower module, go up the module and include in proper order from top to bottom: the top end of the main nozzle is used for being connected with a nozzle of an external injection molding machine so as to receive molten sizing material; The inside of the flow dividing plate is provided with a plurality of flow dividing channels which are radially distributed by taking the outlet of the main nozzle as the center, and the inlets of the flow dividing channels are communicated with the outlet of the main nozzle; the inlets of the branch nozzles are correspondingly connected with the outlets of the sub-runners respectively; the path plate is provided with an inner ring groove, an outer ring groove and a plurality of radial connecting grooves which are communicated with each other to form a closed loop flow path, and outlets of a plurality of branch nozzles are respectively communicated with a plurality of glue inlet points on th