交流电机转子铜端环感应钎焊研究
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摘要
风力发电机、高速电力机车用牵引电机等,为达到大功率、小体积的使用效果,广泛使用高导电性和高强度的铜合金。交流电机端环与导条的焊接是大功率异步牵引电动机制造的一项关键技术,开展其焊接工艺研究具有重要的意义,中国南车电机公司将此课题作为解决交流电机制造的一个重点项目,本文结合交流电机转子端环焊接的课题,对铜及其合金的焊接进行了研究,主要研究结论如下:
1、通过氧乙炔火焰钎焊、感应钎焊、电阻钎焊等焊接方法的对比试验发现感应钎焊可获得优质的焊接接头,且感应钎焊的焊接效率也是最高的。
2、采用中频整体感应钎焊,一次加热完成大功率异步牵引电动机转子端环与导条的焊接,焊接周期短,导条和端环受焊接热影响小,转子冲片绝缘几乎不受影响,焊接的机械强度好、整体质量高。
3、为实现端环的整体焊接,保证焊接质量,感应线圈的设计是关键环节,通过试验研究,设计了不同大小的感应线圈,对于大型电机采用多段对称感应钎焊,从而解决了一机多用的焊接效果。
4、合理的焊接材料、钎剂的选择匹配,焊接加热程序的设计,焊接部位的彻底清理将对端环的焊接质量具有极大的影响。
采用端环的整体感应钎焊工艺,已成功焊接了上百台电机转子,并投入到风电、民用、铁路等行业营运的过程中,无一例出现问题。由此可见,该焊接工艺是安全可靠、切实可行的,同时也适合于工业化大批量生产。
Copper alloy with high conductivity and high strength is widely used for wind mill generator and pulling motor used for electric express locomotive to reach to high power and small in size. The welding of end ring of alternating current machine and the conducting bar is the key technology for manufacturing of asynchronous traction motor with high power. China South Locomotive and Rolling Stock Industry Corporation had taken this significative study as a key project for the manufacturing of alternating current machine. According to the welding of end ring of alternating current machine, the welding of copper and copper alloy is described in this paper. Results obtained in this study are as follows.
1.By the comparison of oxyacetylene gas brazing, induction brazing and resistance brazing, it was found that high-quality welding joint could be obtained by induction brazing, which also had the highest efficiency.
2.The welding of end ring of the high power synchronous traction motor once and for all using medium—frequency induction brazing ,which showed a variety of advantages, such as short circle, low heat affecting of conducting bar and end ring, without influence for rotor sheet insulation and with high mechanical strength and high quality.The design of an induction coil was the key point during integral welding of end ring in order to get high quality.
3.By the investigation, induction coils with different dimension were designed for large-scale electric machine using multi-symmetrical induction brazing, which solved the problem of a tractor serves several purposes.
4.Appropriate welding material, election of soldering acid, design of welding heat process and cleaning up influenced the welding quality significantly.
More than one hundred motor rotors have been welded using integral induction brazing of end ring, which just have been used successfully for the areas of wind power generation, civil using and railway and so on. It follows that this welding processing is reliable and practicable, and it is suited for large-lot production.
1、通过氧乙炔火焰钎焊、感应钎焊、电阻钎焊等焊接方法的对比试验发现感应钎焊可获得优质的焊接接头,且感应钎焊的焊接效率也是最高的。
2、采用中频整体感应钎焊,一次加热完成大功率异步牵引电动机转子端环与导条的焊接,焊接周期短,导条和端环受焊接热影响小,转子冲片绝缘几乎不受影响,焊接的机械强度好、整体质量高。
3、为实现端环的整体焊接,保证焊接质量,感应线圈的设计是关键环节,通过试验研究,设计了不同大小的感应线圈,对于大型电机采用多段对称感应钎焊,从而解决了一机多用的焊接效果。
4、合理的焊接材料、钎剂的选择匹配,焊接加热程序的设计,焊接部位的彻底清理将对端环的焊接质量具有极大的影响。
采用端环的整体感应钎焊工艺,已成功焊接了上百台电机转子,并投入到风电、民用、铁路等行业营运的过程中,无一例出现问题。由此可见,该焊接工艺是安全可靠、切实可行的,同时也适合于工业化大批量生产。
Copper alloy with high conductivity and high strength is widely used for wind mill generator and pulling motor used for electric express locomotive to reach to high power and small in size. The welding of end ring of alternating current machine and the conducting bar is the key technology for manufacturing of asynchronous traction motor with high power. China South Locomotive and Rolling Stock Industry Corporation had taken this significative study as a key project for the manufacturing of alternating current machine. According to the welding of end ring of alternating current machine, the welding of copper and copper alloy is described in this paper. Results obtained in this study are as follows.
1.By the comparison of oxyacetylene gas brazing, induction brazing and resistance brazing, it was found that high-quality welding joint could be obtained by induction brazing, which also had the highest efficiency.
2.The welding of end ring of the high power synchronous traction motor once and for all using medium—frequency induction brazing ,which showed a variety of advantages, such as short circle, low heat affecting of conducting bar and end ring, without influence for rotor sheet insulation and with high mechanical strength and high quality.The design of an induction coil was the key point during integral welding of end ring in order to get high quality.
3.By the investigation, induction coils with different dimension were designed for large-scale electric machine using multi-symmetrical induction brazing, which solved the problem of a tractor serves several purposes.
4.Appropriate welding material, election of soldering acid, design of welding heat process and cleaning up influenced the welding quality significantly.
More than one hundred motor rotors have been welded using integral induction brazing of end ring, which just have been used successfully for the areas of wind power generation, civil using and railway and so on. It follows that this welding processing is reliable and practicable, and it is suited for large-lot production.
引文
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[2] 李寿康. 铜及铜合金知识简介[J] . 金属世界, 2005, 4(4):39-41.
[3] Papanicolaou E, Jaluria Y. Computation of Turbulent Flow In Mixed Convection In A Cavity with A Localized Head Source [J]. Journal of Heat Transfer, 1995, 17(5):649～658.
[4] YUE Qiang, LU Zhong-wu. An Analysis of Contemporary Copper Recycling in China [J]. The Chinese Journal of Process Engineering, 2006,6(4):683-690.
[5] 赵九夷. 我国海洋耐蚀防污铜合金研究及其应用[J]. 特种铸造及有色合金, 2006,26(6):390-392.
[6] 方洪渊. 简明钎焊工手册[M]. 北京:机械工业出版社,2001:34-46.
[7] 陈爱国. 船用螺旋桨裂纹氩弧焊修复工艺探讨[J]. 科技,2006, 5(2):42-43.
[8] 申有才 . 大截面紫铜母线钨极氩弧焊焊接工艺 [J]. 化工建设工程 , 2001, 23(4):26-34.
[9] 朱军等. 浅谈铜与钢异种材料的氩弧钎焊[J]. 兵器材料科学与工程, 2000, 23(4):43-46.
[10] 马王哲,张善保,杨永波等. MIG钎焊堆焊铜带技术[J]. 焊接,2006,6(1): 53-56.
[11] 王芳. 火焰钎焊工艺在空调管路加工中的应用和研究[J]. 机电工程技术,2006,35(6):68-69.
[12] Matsuoka S I. Ultrasonic Welding of Ceramics/Metal U2 sing Inserts[J]. Journal of Materials Processing Technology,1994 , 47(5):185 – 196.
[13] H.Y. Wang and Z.J.Li. INVESTIGATION OF LASER BEAM WELDING PROCESS OF AZ61 MAGNESIUM-BASED ALLOY[J]. Acta Metall Sin, 2006, 19(4): 287- 294.
[14] ZHANG Qian , ZHU Xiaoqing , ZHANG Zhengwei. Lead isotop ic composition and lead source of the Tongchanghe basalt-type native copper-chalcocite deposit in Ninglang, western Yunnan,China[J]. CHINESE JOURNAL OF GEOCHEMISTRY, 2006,25(2): 112-122.
[15] 韩彩霞. 钢与铜及铜合金的焊接研究现状[J]. 热加工工艺,2003, 6(3):53-55.
[16] 何鹏, 刘多, 冯吉才. 高频感应钎焊中电源频率的优化选择[J]. 焊接学报,2002,26(11):27-28.
[17] 孙计生, 潘晖, 刘效方. 感应钎焊工艺对黄铜接头组织的影响[J]. 稀有金属,2001,25(3):211-213.
[18] 赵鹏飞, 康慧. Al2Ti异种合金真空钎焊的研究[J ] . 材料工程, 2001,33(4):25 – 28.
[19] 杨永福, 阎安军, 雷艳. 纯钛的高频感应钎焊[J] . 稀有金属材料与工程, 1998 , 27 (2):103 – 106.
[20] 吴铭方, 蒋成禹, 于治水等. Ti26Al - 4V 真空钎焊研究 [J]. 机械工程学报, 2002 , 38 (4) : 71 - 73
[21] 袁庆龙, 苏永安. Ti/ Cu/ Ti 火焰加热扩散钎焊界面组织分析[J]. 焊接学报, 2002, 25(4): 15-18.
[22] 王朱鑫,蒋爱国. 超厚度铜排的焊接工艺[J]. 化工建设工程, 2002, 24(5): 53-56.
[23] 郑淑敏. 焊接材料产品样本[M]. 北京: 机械工业部,1997,4(1): 571-626.
[24] 王一力. 金属焊接国家标准汇编[M]. 北京:中国标准出版社,1990: 394-398.
[25] 洪 梅, 韩爱林, 尚殿波.钎焊新材料在电冰箱铜管蒸发器上的应用[J]. 新技术新工艺, 2000, 11(3):28.
[26] Kreye H. Melting Phenomena in Solid-state Welding Processes [J]. Welding Research Supplement, 1975,20(5): 154 – 158.
[27] James E, Rzanowski K. A Transmission Electron Microscopy Study of Ultrasonic Wire Bonding[ J ]. Hybrids and Manufacturing Technology, 1990, 30(2): 176 – 181.
[28] Leng Xuesong, Zhang Guangjun, Gao Hongming. A study on twin-tungsten TIG welding method[J]. CHINA WELDING, 2006, 15(1): 49-52.
[29] 任露泉,邱小明,李建桥,徐德生. BCu50ZnMnNiSi 多元铜基钎料的研究[J]. 功能材料, 2000, 31(3): 313-315.
[30] 吴铭方, 蒋成禹, 于治水等. TC4/ 72Ag228Cu 钎焊组织及 Ti2Cu 化合物生长机理研究[J ] . 航空材料学报, 2001, 21 (3): 29 – 32.
[31] Anders EW Jarfors. The influence of carbon on the phases in the copper - titanium system and their precipitation[J]. Journal of Materials Science, 1999 , 34 : 4533 – 4544.
[32] 康辉, 邱小明, 丛茜等. 多元铜基钎料成分设计[J]. 农业机械学报,2001, 32(3):116-121.
[33] 吴曙明,张福东, 郭胜强. 电动机转子导条与端环中频感应钎焊工艺探讨[J]. 电机技术,2000, 3: 18-20.
[34] 汪永东, 史文卿,呼义通. 交直流电机转子铜条与端环中频感应钎焊工艺方法的研究[J]. 大电机技术,2002,6(3):5-7.
[35] 刘淑健,李凌宇. 铜散热器高频感应钎焊专机的研制[J]. 焊接技术, 2003, 23(3):37-38.
[36] 徐波等. 转子铜条与端环的焊接[J], 大电机技术, 2005, 32(1): 1
[37] 潘政权, 张庄生,于玉平. 特种屏蔽电机转子端环钎焊工艺的研究[J]. 防爆电机, 2000, 4(1):29-31.
[38] GB265-89,焊接接头拉伸试验方法[S]. 北京:中国标准出版社,1989.
[39] 美国金属学会[美]. 金属手册[M]. 北京:机械工业出版社,1994:78-100.
[40] 余永宁. 金属学原理[M] . 北京: 冶金工业出版社, 2000:198-199.
[41] 钱在中. 焊接技术手册[M]. 山西: 山西科学技术出版社,2000:849 – 854.
[42] 中国机械工程学会焊接学会. 焊接手册[M]. 北京: 机械工业出版社,2001
[43] 刘祖常, 程振江. 无损检测[M] . 1992, 14(2) : 45- 48.
[44] 谈育煦. 金属电子显微分析(第一版) [M] . 北京: 机械工业出版社, 1989: 109 – 111.
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[51] Bengtsson P. High productivity MIG/MAG welding processes. Welding&Metal Fabricatiaon[J], 1992,60(6):226-228.
[2] 李寿康. 铜及铜合金知识简介[J] . 金属世界, 2005, 4(4):39-41.
[3] Papanicolaou E, Jaluria Y. Computation of Turbulent Flow In Mixed Convection In A Cavity with A Localized Head Source [J]. Journal of Heat Transfer, 1995, 17(5):649～658.
[4] YUE Qiang, LU Zhong-wu. An Analysis of Contemporary Copper Recycling in China [J]. The Chinese Journal of Process Engineering, 2006,6(4):683-690.
[5] 赵九夷. 我国海洋耐蚀防污铜合金研究及其应用[J]. 特种铸造及有色合金, 2006,26(6):390-392.
[6] 方洪渊. 简明钎焊工手册[M]. 北京:机械工业出版社,2001:34-46.
[7] 陈爱国. 船用螺旋桨裂纹氩弧焊修复工艺探讨[J]. 科技,2006, 5(2):42-43.
[8] 申有才 . 大截面紫铜母线钨极氩弧焊焊接工艺 [J]. 化工建设工程 , 2001, 23(4):26-34.
[9] 朱军等. 浅谈铜与钢异种材料的氩弧钎焊[J]. 兵器材料科学与工程, 2000, 23(4):43-46.
[10] 马王哲,张善保,杨永波等. MIG钎焊堆焊铜带技术[J]. 焊接,2006,6(1): 53-56.
[11] 王芳. 火焰钎焊工艺在空调管路加工中的应用和研究[J]. 机电工程技术,2006,35(6):68-69.
[12] Matsuoka S I. Ultrasonic Welding of Ceramics/Metal U2 sing Inserts[J]. Journal of Materials Processing Technology,1994 , 47(5):185 – 196.
[13] H.Y. Wang and Z.J.Li. INVESTIGATION OF LASER BEAM WELDING PROCESS OF AZ61 MAGNESIUM-BASED ALLOY[J]. Acta Metall Sin, 2006, 19(4): 287- 294.
[14] ZHANG Qian , ZHU Xiaoqing , ZHANG Zhengwei. Lead isotop ic composition and lead source of the Tongchanghe basalt-type native copper-chalcocite deposit in Ninglang, western Yunnan,China[J]. CHINESE JOURNAL OF GEOCHEMISTRY, 2006,25(2): 112-122.
[15] 韩彩霞. 钢与铜及铜合金的焊接研究现状[J]. 热加工工艺,2003, 6(3):53-55.
[16] 何鹏, 刘多, 冯吉才. 高频感应钎焊中电源频率的优化选择[J]. 焊接学报,2002,26(11):27-28.
[17] 孙计生, 潘晖, 刘效方. 感应钎焊工艺对黄铜接头组织的影响[J]. 稀有金属,2001,25(3):211-213.
[18] 赵鹏飞, 康慧. Al2Ti异种合金真空钎焊的研究[J ] . 材料工程, 2001,33(4):25 – 28.
[19] 杨永福, 阎安军, 雷艳. 纯钛的高频感应钎焊[J] . 稀有金属材料与工程, 1998 , 27 (2):103 – 106.
[20] 吴铭方, 蒋成禹, 于治水等. Ti26Al - 4V 真空钎焊研究 [J]. 机械工程学报, 2002 , 38 (4) : 71 - 73
[21] 袁庆龙, 苏永安. Ti/ Cu/ Ti 火焰加热扩散钎焊界面组织分析[J]. 焊接学报, 2002, 25(4): 15-18.
[22] 王朱鑫,蒋爱国. 超厚度铜排的焊接工艺[J]. 化工建设工程, 2002, 24(5): 53-56.
[23] 郑淑敏. 焊接材料产品样本[M]. 北京: 机械工业部,1997,4(1): 571-626.
[24] 王一力. 金属焊接国家标准汇编[M]. 北京:中国标准出版社,1990: 394-398.
[25] 洪 梅, 韩爱林, 尚殿波.钎焊新材料在电冰箱铜管蒸发器上的应用[J]. 新技术新工艺, 2000, 11(3):28.
[26] Kreye H. Melting Phenomena in Solid-state Welding Processes [J]. Welding Research Supplement, 1975,20(5): 154 – 158.
[27] James E, Rzanowski K. A Transmission Electron Microscopy Study of Ultrasonic Wire Bonding[ J ]. Hybrids and Manufacturing Technology, 1990, 30(2): 176 – 181.
[28] Leng Xuesong, Zhang Guangjun, Gao Hongming. A study on twin-tungsten TIG welding method[J]. CHINA WELDING, 2006, 15(1): 49-52.
[29] 任露泉,邱小明,李建桥,徐德生. BCu50ZnMnNiSi 多元铜基钎料的研究[J]. 功能材料, 2000, 31(3): 313-315.
[30] 吴铭方, 蒋成禹, 于治水等. TC4/ 72Ag228Cu 钎焊组织及 Ti2Cu 化合物生长机理研究[J ] . 航空材料学报, 2001, 21 (3): 29 – 32.
[31] Anders EW Jarfors. The influence of carbon on the phases in the copper - titanium system and their precipitation[J]. Journal of Materials Science, 1999 , 34 : 4533 – 4544.
[32] 康辉, 邱小明, 丛茜等. 多元铜基钎料成分设计[J]. 农业机械学报,2001, 32(3):116-121.
[33] 吴曙明,张福东, 郭胜强. 电动机转子导条与端环中频感应钎焊工艺探讨[J]. 电机技术,2000, 3: 18-20.
[34] 汪永东, 史文卿,呼义通. 交直流电机转子铜条与端环中频感应钎焊工艺方法的研究[J]. 大电机技术,2002,6(3):5-7.
[35] 刘淑健,李凌宇. 铜散热器高频感应钎焊专机的研制[J]. 焊接技术, 2003, 23(3):37-38.
[36] 徐波等. 转子铜条与端环的焊接[J], 大电机技术, 2005, 32(1): 1
[37] 潘政权, 张庄生,于玉平. 特种屏蔽电机转子端环钎焊工艺的研究[J]. 防爆电机, 2000, 4(1):29-31.
[38] GB265-89,焊接接头拉伸试验方法[S]. 北京:中国标准出版社,1989.
[39] 美国金属学会[美]. 金属手册[M]. 北京:机械工业出版社,1994:78-100.
[40] 余永宁. 金属学原理[M] . 北京: 冶金工业出版社, 2000:198-199.
[41] 钱在中. 焊接技术手册[M]. 山西: 山西科学技术出版社,2000:849 – 854.
[42] 中国机械工程学会焊接学会. 焊接手册[M]. 北京: 机械工业出版社,2001
[43] 刘祖常, 程振江. 无损检测[M] . 1992, 14(2) : 45- 48.
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