电机转子整流子新型精车机床的开发与车削工艺

Turning process and development of motor rotor commutator new type precision lathe

为了提高电机转子整流子外圆的切削加工质量和效率,通过采用新型工件装夹方法,并应用Solidwords三维软件设计出新型工件装夹专用夹具,采用新的主运动传递方式与设计新型主轴传动机构,应用触摸屏人机界面的车削工艺参数数据写入技术、PLC步序控制技术、交流伺服电动机控制系统驱动技术、变频器主运动速度控制技术,开发出一种新型转子整流子外圆车削机床,改变了微电机行业转子整流子加工方法,并制定出新的车削工艺规程,使每个转子工件从装夹、车削、到卸料和清理切屑整个过程仅需时间4 s,加工效率得到极大的提高,其效率比传统车削方法提高达20倍以上,车削后整流子形位精度圆跳动≤0.005 mm,尺寸精度达到IT6,外圆表面粗糙度Ra≤0.4μm,车削后整流子圆柱面趋近镜面效果的光亮度,外圆表面无毛刺及其片间窄槽无嵌入的切屑。

In order to improve the rotor＇s commutator excircle machining quality and efficiency, a new type of workpiece clamping method was adopted and Solidworks 3 D software was utilized for mechanical design, so a new way of workpiece clamping fixture was designed. We also introduced a new main movement motion transfer mode and a new design of main shaft transmission mechanism. Turning process parameters write -in technology of touch screen man - machine interface technology, PLC program sequence control technology, AC servo motor control system drive technology, inverter motor main movement speed control technology were applied. We developed a innovative kind of rotor commutator excircle turning machine, made changes to the processing method for rotor commutator in micro motor industry, and regulated new turning procedure. As a result, the whole process of clamping, turning, discharge, and cleaning up scraps takes only 4 seconds for each rotor workpiece. Machining efficiency is greatly improved and its efficiency is at most 20 times higher than the traditional method of turning. After turning the position accuracy of commutator circular runout is less than or equal to 0.005 mm, size precision IT6, outer surface roughness Ra ≤ 0.4 μm. After turning, luminance in cylindrical surface of commutator is close to the luminance of mirror effect. The commutator excircle surface is without burr. Also, we found no embedding chips between the narrow grooves.