Guji nisantar zanen takardar a cikin jerin gwal 1070 Tsarkakakkun fayafai na alumin: Ingantaccen tsari jagora

1. Shigowa da: Bayanan Aikace-aikacen da Core Lasin Tsarin 1070 Tsarkakakkun fayafai na alumin

Matsakaicin masu canzawa su ne ainihin abubuwan da ke canza wutar lantarki, da karfin maganadisu da asarar su kai tsaye suna tabbatar da ingancin gidan wuta. 1070 tsantsar fayafai na aluminum don muryoyin wuta (Al abun ciki ≥99.7%) sun zama madaidaitan ma'auni don ƙanana da matsakaitan ma'aunin wutar lantarki saboda ƙarfin wutar lantarki (≥62% IACS a 20 ℃), low maganadisu hasãra (asarar hysteresis ≤0.3W/kg a 50Hz), da kyau kwarai ductility-musamman dace da high-mita, ƙananan hasara al'amuran (e.g., sabon makamashin abin hawa mai hawa tafsiri).

Yawanci, irin wannan cores ɗin sun ɗauka “Multi-sheet blanking da lamination” shiga jerin gwano: nada kayan na 1070 tsarkakakkun fa'idodin aluminum ga masu canza launi (0.3mm kauri) an barsu a cikin fayafai masu diamita na 50-200mm, sannan laminated (10-50 zanen gado ta lamination) don samar da ginshiƙai ko yokes. Alamar ingancin ainihin anan shine lamination factor ≥0.95 (ƙarin buƙatun GB/T 13789-2022 Sanyi-Roll Silicon Karfe Sheets don Transformers da Reactors; lamination factor = ainihin lamination density / theoretical density, nuna lamination tightness).

A cikin aikin masana'antu, 35% na lamination factor rashin yarda mai tushe daga takardar dislocation- i.e., ɓarkewar gefe tsakanin fayafai masu kusa >0.03mm. Wannan yana haifar da gibin iska a cikin ainihin, ƙara ƙarfin maganadisu ta hanyar 15%-20% kuma babu-load asara ta 8%-12%. Binciko tushen dalilin, Rashin kulawa tsakanin fil ɗin jagora da bushings na mutuwar bargo shine farkon fararwa: wuce gona da iri yana rage daidaiton jagora, haifar da rashin daidaituwa tsakanin babba da ƙasa ya mutu yayin da ba kowa; rashin isasshen izini, da bambanci, yana haifar da lalacewa da cunkoson fil ɗin jagora da bushings, samar da tarkacen karfe wanda ke gurɓatar da wuri. Saboda haka, dangane da kayan Properties na 1070 tsantsar fayafai na aluminum don muryoyin wuta da 0.3mm bakin ciki-sheet blanking tsari, ya zama dole a ƙayyade madaidaicin kewayon izini don fil ɗin jagora da bushings don guje wa ɓarkewar takarda a tushen.

2. Basic Halaye na Analysis na 1070 Fayafai na Aluminum Tsabta don Maɓalli masu Canzawa da Lamination Multi-Sheet

(1) Halayen Abu da Kauri na 1070 Tsarkakakkun fayafai na alumin (0.3mm)

1. Tasirin kaddarorin inji akan sakawa mara kyau: 1070 tsantsar fayafai na aluminum don muryoyin wuta suna da ƙananan taurin kawai HV25-30, Module na roba E=70GPa, da elongation δ5≥35%. A bayyane, bakin ciki zanen gado (0.3mm) suna da wuya ga nakasawa na roba saboda karkatar da jagora yayin blanking, kuma wannan nakasawa ba zai iya jurewa ba - kai tsaye yana haifar da ɓarna a gefen lamination. Misali, idan izinin tsakanin fil ɗin jagora da bushings ya wuce kima, Ƙarfin da ba shi da komai (kusan 8-12kN, dangane da diamita na diski) zai canza babban mutu ta 0.02mm, yana haifar da nakasar filastik 0.015mm a gefen diski. Ragewar da aka tara yayin lamination zai wuce 0.03mm.

2. Yanayin saman da lamination adhesion: Bugu da kari, Layer oxide na halitta (Tono ani) na 2-5nm sauƙi siffofi a saman 1070 tsantsar fayafai na aluminum don muryoyin wuta. Ko da yake ba ya shafar rufi, yana ƙara juriya a lokacin lamination. Idan wuce gona da iri tsakanin fil ɗin jagora da bushings yana haifar da bursu (>0.01mm) a gefen diski, wadannan burrs za su kara lalata mannewa, rage lamination factor daga 0.96 zuwa kasa 0.93.

(2) Mahimman Bukatun Don Lamination Multi-Sheet (Lamination Factor ≥0.95)

1. Ƙididdigar ma'anar lamination factor: Lamination factor K = (ainihin lamination kauri /(kauri-sheet ɗaya × lambar laminated)) × 100%. Domin 20 zanen gado na 1070 tsantsar fayafai na aluminum don muryoyin wuta (0.3mm kauri), kauri na lamination = 6.0mm. Idan ainihin kauri = 5.7mm, K=95%; idan akwai 0.03mm dislocation da takardar, da tara dislocation na 20 zanen gado = 0.6mm, kuma ainihin kauri mai inganci = 5.4mm - sakamakon K = 90% (rashin yarda).

2. Dangantaka tsakanin dislocation da lamination factor: Ƙaƙƙarfan simintin gyare-gyare (ABAQUS) kara nuna cewa lokacin da dislocation na guda diski ≤0.02mm, lamination factor 20 Farashin ≥0.95; lokacin dislocation >0.02mm, K yana raguwa a layi tare da ƙara raguwa (gangara -1.67%/0.01mm), kamar yadda aka nuna a teburin da ke ƙasa:

3. Injiniyanci da Nazari mai ƙididdigewa na Tasirin Tasirin Tsare-tsare na Pin-Bushing akan Rarraba Sheet

Matsakaicin jagorar da bushings na ɓarkewar mutuwa sune ainihin abubuwan da ke tabbatar da daidaito tsakanin manyan mutuwa da na ƙasa. Amincewar su (d) An ƙaddara ta hanyar diamita fil ɗin jagora (d) da bushing ciki diamita (D), i.e., d=(D-d)/2. Dukansu wuce gona da iri da rashin isasshen izini suna haifar da rarrabuwar kawuna 1070 tsantsar fayafai na aluminum don muryoyin wuta, tare da takamaiman hanyoyin kamar haka:

(1) Wucewa mai yawa (d>0.015mm): “Tsagewar Matsala” Asarar Daidaitaccen Jagoran da Ya Haihu

Na farko kuma mafi mahimmanci, wuce gona da iri yana lalata daidaitaccen jagora, kai ga “m dislocation.”

1. Samfurin injina: A lokacin blanking, babban mutun yana fuskantar rashin ƙarfi F (kN), samar da karfi na gefe F_side = F×tanθ akan fil ɗin jagora (θ ita ce kusurwa mara kyau, yawanci 5°-8°). Domin 1070 tsantsar fayafai na aluminum don muryoyin wuta tare da diamita na 100mm, F≈10kN da θ=6°, sune F_side≈10×tan6°≈1.05kN.

2. Lissafin ƙaura: Filayen jagora yawanci ana yin su da SUJ2 (dauke da karfe, E=206GPa). Don fil ɗin jagora mai diamita d=20mm da tsayi L=150mm, bisa ga dabarar karkatar da makanikai:

Δ= F_side×L³/(3×E×I)

ku = πd⁴/64 (lokacin inertia). Sauya bayanan: Δ≈1.05×10³×(150)³/(3×206×10³×π×20⁴/64)0.008mm.

Idan jagorar fil-bushing share δ=0.02mm, jimlar ƙaura na babba mutu = Δ+δ≈0.028mm. Wannan yana haifar da wargajewar gefen mara komai 1070 tsantsar fayafai na aluminum don muryoyin wuta ya zama kusan 0.028mm, ya haifar da lamination factor K≈93.8% don 20 zanen gado (rashin yarda).

(2) Rashin Isasshen Tsara (d<0.005mm): “Ragewar Tsayawa” Sakamakon Ciwo da Jamming

Akasin haka, rashin isasshen sharewa yana haifar da lalacewa da cunkoso, kai ga “tsauri mai tsauri.”

1. Tsarin sawa: Fil ɗin jagora da bushings suna ɗaukar dacewa H7/h6 (juriya aji). Idan sharewa <0.005mm, mara kyau lubrication (blanking na wadannan aluminum zanen gado a sauƙi haifar da aluminum kwakwalwan kwamfuta da cewa gurbata maiko) kai zuwa “bushewar gogayya,” haifar da scratches a kan jagora fil fil (zurfin >0.003mm).

2. Ayyukan kawarwa: Wuraren jagorori da aka sawa suna nuni da bushings “tsalle-tsalle” hali: na sama ya fara matsewa yayin motsi ƙasa, sa'an nan kuma ba zato ba tsammani. Wannan yana haifar da juzu'in jeri nan take na 0.02-0.03mm tsakanin babba da na ƙasa da ke mutuwa yayin ɓarna., kuma karkacewar bazuwar-yana sa ya yi wahala a gyara yayin lamination na 1070 tsantsar fayafai na aluminum don muryoyin wuta.

(3) Rage Rage Madaidaicin Rage Ragewa: Ƙarfin Ƙarfin Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙarƙashin Ƙarƙwara

Dangane da hanyoyin biyu na sama, Madaidaicin kewayon izini dole ne ya daidaita “guje wa m dislocation” kuma “hana tsauri mai tsauri.” Musamman, wajibi ne a gamsar “jimlar ƙaurawar mutuƙar babba ≤0.02mm” (tabbatar da rabuwar guda ɗaya 1070 tsantsar diski na aluminum don muryoyin wuta ≤0.02mm da K≥0.95), i.e.:

Δ+δ≤0.02mm

An ba da Δ≈0.008mm (karkatar da fil ɗin jagora sakamakon rashin ƙarfi), ≤0.012mm.

Mai ma'ana, don gujewa sawa saboda rashin isasshen sharewa, yana nufin GB/T 12444-2016 Abubuwan da suka mutu – Jagora Fil, Mafi ƙarancin izinin izini don fil ɗin jagora da bushings shine 0.005mm (don H7/h6 dace da d=20mm, jagora pin haƙuri h6=0/-0.013mm, jure juriya H7=+0.021/0mm, mafi ƙarancin izini = 0.005mm).

a takaice, Ya kamata a sarrafa sharewa tsakanin fil ɗin jagora da bushings a cikin 0.005-0.012mm. Wannan kewayon yana tabbatar da rabuwar guda ɗaya 1070 tsantsar diski na aluminum don muryoyin wuta ≤0.02mm da lamination factor ≥0.95.

4. Taimakawa Maganganun Fasaha don Kula da Tsare-tsare (Mutu + Tsari)

Sarrafa kawai jagorar share-bushing bai isa ba don kaucewa ɓarkewar takarda gaba ɗaya 1070 tsantsar fayafai na aluminum don muryoyin wuta. Wajibi ne a haɗa ingantaccen tsarin mutun da daidaita tsarin siga don samar da haɗin kai “jagora-matsayi-blanking” tsarin sarrafawa:

(1) Die Haɓaka Tsarin Jagora

Don farawa da, inganta tsarin ja-gorar mutu yana kafa harsashin kula da tsayayyen sharewa.

1. Material da daidaito na fil ɗin jagora da bushings:

• • fil jagora: SUJ2 ya mutu (Saukewa: HRC58-62), Rarraba saman Ra≤0.4μm, Silindricity ≤0.002mm;

• • Bushings: SUJ2 ya mutu (Saukewa: HRC55-58), ramin ciki Ra≤0.2μm, coaxiality ≤0.003mm;

• • Haƙuri mai dacewa: H7 / h6 dacewa an karɓa don tabbatar da izinin farko a cikin 0.005-0.012mm, adapting zuwa blanking daidaito bukatun na 1070 tsantsar fayafai na aluminum don muryoyin wuta.

2. Lamba da tsari na fil ɗin jagora:

• • Domin 1070 tsantsar fayafai na aluminum don muryoyin wuta tare da diamita na 50-200mm, biyu jagora fil (16-20mm) ana amfani da su, daidaitacce a waje da gefen da ba kowa (nisa daga gefen ≥15mm) don guje wa tsoma baki da karfi kan jagora;

• • “Jagoran taimako” (e.g., stripper farantin jagora fil) an ƙara shi don ƙarin jujjuyawar daidaitawa tsakanin babba da ƙananan mutuwa tsakanin 0.005mm.

(2) Daidaita Tsari Tsara Tsari

Na gaba, dangane da sigogin tsari, daidaitattun yanayi mara kyau tare da kulawar sharewa yana haɓaka kwanciyar hankali.

1. Gudun mara nauyi: Sarrafa a 100-150 bugun jini/min don gujewa girgiza fil ɗin jagora da bushings da ke haifar da barna mai sauri (lokacin da amplitude vibration >0.003mm, an ƙara tasirin sharewa), tabbatar da daidaiton matsayi na 1070 tsantsar fayafai na aluminum don muryoyin wuta A lokacin gurbata;

2. Hanyar shafawa: “Fesa lubrication” ana karba (samfurin man mai lubricating: ISO VG32, tare da takamaiman kayan aikin rigakafin riga-kafi na aluminum). Ana yin feshi kowane lokaci 500 blanking bugun jini don rage aluminum guntu tsara da jagora lalacewa, kare gefen ingancin 1070 tsantsar fayafai na aluminum don muryoyin wuta;

3. Matsayin lamination: Bayan yin komai, “injin tsotsa + saka fil” ana amfani da matsayi biyu. Matsakaicin fil suna da diamita na φ3-5mm, da yarda tare da pre-bushi ramukan na 1070 tsantsar fayafai na aluminum don muryoyin wuta ≤0.01mm don tabbatar da daidaitawar axial yayin lamination da yawa.

(3) Kulawa da Kulawa da Kulawa

Bayan saitin farko, ci gaba da sa ido da kulawa suna da mahimmanci daidai don dorewar aikin sharewa.

1. Sa idanu akan layi: Na'urar firikwensin motsi ta Laser (daidaito 0.001mm) an shigar da shi a wajen daji don saka idanu na ainihin lokacin radial na fil ɗin jagora. Lokacin gudu >0.008mm (yana nuna wuce gona da iri), injin yana tsayawa ta atomatik don gujewa yawan samar da rashin yarda 1070 tsantsar fayafai na aluminum don muryoyin wuta;

2. Kulawa na yau da kullun: Bayan yin komai 100,000 1070 tsantsar fayafai na aluminum don muryoyin wuta, an wargaza fil ɗin jagora da bushings, kuma ana auna sharewa da micrometer. Idan sharewa >0.015mm, an maye gurbin bushing (fil ɗin jagora yawanci suna da ƙarancin lalacewa kuma ana iya sake amfani da su).

5. Tabbatar da Masana'antu da Binciken Harka

(1) Tabbatar da Laboratory (Gwajin Bayanai daga Mai Haɓakawa Mai Sauƙi)

Don tabbatar da kewayon cirewa da gwaji, An gudanar da gwaje-gwajen dakin gwaje-gwaje tare da daidaitattun samfurori.

Dauke “φ120mm × 0.3mm 1070 tsantsar fayafai na aluminum don muryoyin wuta, 20-takardar lamination” a matsayin abin gwaji, Jagora daban-daban an saita share share-bushing don gwada yanayin lamination da tarwatsewa:

Ƙarshe: Lokacin sharewa yana cikin 0.005-0.012mm, lamination factor 1070 tsantsar fayafai na aluminum don muryoyin wuta ≥95% da asarar nauyi ≤1.05W/kg, yarda da GB/T 6451-2015 Ma'auni na Fasaha da Abubuwan Bukatu don Masu Canza Wutar Lantarki Na Mai.

(2) Shari'ar Aikace-aikacen Masana'antu (Sabuwar Aikin Motar Mota Mai Makamashi)

Don kwatanci mai amfani na waɗannan binciken a cikin saitunan masana'antu, an gabatar da wani bincike na sabon aikin wutar lantarki da ke hawa wuta.

A cikin samar da na'urorin taswira masu hawa abin hawa ta masana'antar kera motoci, jagorar farko mara sarrafawa fil-bushing share (0.02-0.025mm) ya haifar da lamination factor na kawai 92%-93% domin 1070 tsantsar fayafai na aluminum don muryoyin wuta kuma 30% wuce kima core asarar. Bayan yin amfani da mafita a cikin wannan takarda:

1. An maye gurbin fil ɗin jagora da bushings tare da dacewa H7/h6, ikon sarrafawa tsakanin 0.008-0.010mm;

2. An ƙara ja-gorar taimako da matsayar injin;

3. An aiwatar da sa ido kan cirewa akan layi.

Bayan ingantawa, lamination factor 1070 tsantsar fayafai na aluminum don muryoyin wuta daidaita a 95.5%-96.2%, kuma babban hasara ya ragu zuwa 1.03W/kg - saduwa da ƙananan buƙatun asara na masu canjin abin hawa.. Adadin cancantar samfur ya ƙaru daga 75% ku 99%.

6. Kammalawa da Outlook

(1) Core ƙarshe

Takaita mahimman binciken, don Multi-sheet blanking da lamination na 1070 tsantsar fayafai na aluminum don muryoyin wuta (0.3mm kauri) tare da lamination factor ≥0.95, Dole ne a sarrafa tsattsauran ra'ayi tsakanin fil ɗin jagora da bushings na kashe-kashe 0.005-0.012mm. Wannan kewayon yana guje wa duka tsattsauran rarrabuwar kawuna sakamakon wuce gona da iri (babba mutu ƙaura >0.02mm) da tsautsayi mai tsauri wanda ya haifar da rashin isasshen izini (lalacewa da cunkoso), tabbatar da rabuwar diski guda ≤0.02mm da ma'aunin lamination mai yarda.

(2) Hannun Ci gaban Gaba

Neman gaba ga ci gaban gaba, yankunan mayar da hankali guda uku suna fitowa don ƙara inganta aiki:

1. Tsarin jagoranci na hankali: Haɗa algorithms na AI da na'urori masu auna firikwensin piezoelectric don daidaita ainihin lokacin share fil ɗin jagora da bushings. (e.g., sa ramuwa ta hanyar haɓakar thermal), gane tsauri yarda ingantawa da kuma kara inganta lamination daidaito na 1070 tsarki aluminum fayafai ga masu canza launi;

2. Fasaha jagora mara gata: Ci gaba “Jagoran levitation Magnetic” (rashin tuntuɓar fitilun jagora da bushings ta amfani da ƙarfin lantarki) don kawar da tasirin sharewa gaba ɗaya akan daidaiton jagora, adapting zuwa mafi girma-daidaici blanking bukatun na 1070 tsantsar fayafai na aluminum don muryoyin wuta;

3. Gyara kayan aiki: Gashi saman 1070 tsantsar fayafai na aluminum don muryoyin wuta tare da 0.5-1μm TiN Layer don ƙara taurin saman (Saukewa: HV300-400), rage ɓarke ​​​​burrs da lamination gogayya, da kuma ƙara faɗaɗa kewayon juriya na kulawar sharewa.

(3) Babban Ka'ida

Daga karshe, Babban ka'idar da ke tattare da wannan aikin ita ce ɓarkewar zane-zane da yawa da lamination na bakin ciki 1070 tsantsar fayafai na aluminum don muryoyin wuta dole ne a mayar da hankali a kan synergy na “jagorar daidaito-kayan kaddarorin-lamination bukatun”. Sarrafa jagorar share-bushing shine tushe, amma dole ne a haɗa shi tare da tsarin mutuƙar da haɓaka aiki don cimma ingantaccen aiki, ƙananan hasara na samar da wutar lantarki.