CN113054817B - Electric tool, brushless motor and rotor - Google Patents

Electric tool, brushless motor and rotor Download PDF

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Publication number
CN113054817B
CN113054817B CN201911375260.6A CN201911375260A CN113054817B CN 113054817 B CN113054817 B CN 113054817B CN 201911375260 A CN201911375260 A CN 201911375260A CN 113054817 B CN113054817 B CN 113054817B
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rotor
magnetic
brushless motor
magnets
magnet
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CN113054817A (en
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朱锦斌
方承志
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Bosch Power Tools China Co Ltd
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Bosch Power Tools China Co Ltd
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K29/00Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • H02K1/27Rotor cores with permanent magnets
    • H02K1/2706Inner rotors
    • H02K1/272Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/278Surface mounted magnets; Inset magnets

Abstract

The present disclosure provides a power tool, a brushless motor and a rotor thereof. The rotor includes a rotor core and magnets disposed on an outer circumferential surface of the rotor core and constituting 1 or more pairs of magnetic poles in which N poles and S poles of the rotor are alternately arranged. The rotor further comprises an outer cover, the outer cover is arranged outside the magnets, the peripheral wall of the outer cover comprises a magnetic conduction part and a magnetic isolation part, the magnetic conduction part comprises a plurality of parts which respectively cover at least parts of the magnets of the magnetic poles, and the magnetic isolation part corresponds to the circumferential interval between the magnets of two adjacent magnetic poles in the circumferential direction. The peripheral wall of the outer cover further comprises a connecting part used for connecting all parts of the magnetic conduction part together.

Description

Electric tool, brushless motor and rotor
Technical Field
The present disclosure relates to a rotor for a brushless motor, a brushless motor including the rotor, and a power tool including the brushless motor.
Background
The brushless motor cancels a carbon brush reversing mechanism, and has the advantages of low cost, long service life and high reliability in engineering application. Therefore, brushless motors are widely used in the field of electric tools. One common form of brushless motor is the use of a surface-mounted rotor, i.e. magnets on the surface of the rotor core. Thus, the rotor has the advantages of simple manufacturing process, low cost and easy vector control. However, the surface-mounted rotor has the problem that when the surface-mounted rotor runs at a high speed, the magnet cannot bear a very large self centrifugal force to be broken and fly out, so that the motor fails.
In order to solve the above problems, one conventional scheme is to use a non-magnetic stainless steel ring to cover the surface of the magnet or use a non-magnetic fiber string to bind the surface of the magnet to protect the magnet, but the non-magnetic materials can greatly increase the magnetic resistance, resulting in poor performance of the motor.
Therefore, it is desirable to provide a solution to the above technical problem.
Disclosure of Invention
In view of the above problems in the prior art, the present disclosure aims to provide an improved rotor for a brushless motor, a brushless motor including the rotor, and a power tool including the brushless motor, which are capable of improving the mechanical strength of the rotor and reducing the rotor leakage flux.
According to an aspect of the present invention, there is provided a rotor for a brushless motor, characterized in that the rotor includes a rotor core and magnets which are provided on an outer peripheral surface of the rotor core and constitute 1 or more pairs of magnetic poles of which N poles and S poles are alternately arranged, wherein the rotor further includes a housing which is provided outside the magnets, a peripheral wall of the housing including a magnetic conductive portion including portions respectively covering at least parts of the magnets of the respective magnetic poles and a magnetic barrier portion corresponding to a circumferential interval between the magnets of circumferentially adjacent two magnetic poles, and wherein the peripheral wall of the housing further includes a connecting portion provided in the magnetic barrier portion for connecting the portions of the magnetic conductive portion together.
According to another aspect of the present invention, there is provided a brushless motor including: a stator; and the rotor as described above, which is rotatably provided at the center of the stator.
According to yet another aspect of the present invention, there is provided an electric power tool including the brushless motor as described above.
As can be seen from the above description, the rotor according to the present disclosure has sufficient mechanical strength. In addition, the rotor according to the present disclosure can make full use of the magnetic flux that can be provided by the magnet, and can reduce the magnetic flux leakage of the rotor.
Drawings
Fig. 1 is a perspective view of a brushless motor according to one possible embodiment of the present disclosure.
Fig. 2 is a perspective view schematically illustrating a rotor of the brushless motor of fig. 1.
Fig. 3A and 3B are exploded views of the rotor of fig. 2.
Fig. 4A-4C show extensions of portions of the peripheral wall of the outer housing of the rotor of fig. 2, illustrating some embodiments of the pattern of openings in the peripheral wall.
Fig. 5A and 5B schematically illustrate some embodiments of the end wall of the rotor in fig. 2.
Detailed Description
The present disclosure provides, in one aspect, an improved rotor for a brushless motor. The present disclosure provides, in another aspect, a brushless motor including the rotor. The present disclosure provides, in yet another aspect, a power tool including the brushless motor.
In the present disclosure, "power tool" may include various types of power tools, for example, gardening implements such as a weeder or a hedge trimmer; hand-held power tools such as angle grinders, screwdrivers, electric drills, or hammer drills; a measuring tool such as a laser rangefinder.
In the present disclosure, "brushless motor" refers to a brushless motor that can power an electric power tool. The brushless motor in the present disclosure may be a brushless direct current motor (BLDC).
Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.
Fig. 1 schematically illustrates a brushless motor 100 according to one possible embodiment of the present disclosure. Fig. 2 schematically shows the rotor 20 of the brushless motor in fig. 1.
Referring to fig. 1 and 2, a brushless motor 100 mainly includes a stator 10 and a rotor 20. In the brushless motor 100 according to the present disclosure, the stator 10 is implemented as an outer stator, and the rotor 20 is implemented as an inner rotor, that is, the stator 10 is sleeved outside the rotor 20 and coaxial with the rotor 20. The coils of the stator 10 may be energized by power electronics (not shown) to cause the rotor 20 to rotate. Since the present disclosure mainly relates to the improvement of the rotor 20, a detailed description of the stator 10 is omitted.
Rotor 20 mainly includes rotor shaft 21, rotor core 23, magnets 25A-25D, and housing 27. The rotor core 23 has a columnar shape, for example, a cylinder or a prism. A center hole 29 is formed at the center of the rotor core 23. The rotor shaft 21 passes through the central hole 29. The magnets 25A to 25D are attached to the outer peripheral surface of the rotor core 23 and constitute 1 or more pairs of magnetic poles of the rotor 20 in which N poles and S poles are alternately arranged.
In one embodiment, magnets 25A-25D include a plurality of magnets circumferentially spaced (e.g., at equal circumferential intervals) from the outer surface of core 23, wherein each magnet constitutes one pole of the rotor, and the plurality of magnets form 1 or more pairs of poles with alternating N and S poles. It should be understood that each of the plurality of magnets may be formed of one or more pieces of magnets, i.e., one piece of magnet may be provided or two or more pieces of magnet may be provided at the position of each of the plurality of magnets 25A-25D.
The cover 27 surrounds the outer peripheries of the magnets 25A to 25D, and serves to prevent the magnets from being broken or flying out. The housing 27 is shaped and sized to fit over the magnets 25A-25D. For example, the length of the housing 27 in the axial direction is substantially equal to the length of the magnets 25A-25D in the axial direction, e.g., the axial length of the housing 27 is equal to, or slightly greater than, or slightly less than the axial length of the magnets 25A-25D. The inner diameter of the cover 27 is equal to the outer diameter of the circumference enclosed by the magnets 25A-25D, whereby the cover 27 can just surround the magnets 25A-25D. The peripheral wall of the housing 27 includes a magnetic conductive portion 271, a magnetic shield portion 272, and a connecting portion 273.
The magnetic conductive portion 271 surrounds the magnets 25A to 25D constituting the respective magnetic poles. The magnetic conductive part is made of a material having good magnetic conductivity, such as soft iron, silicon steel, low carbon steel, and alloy. The magnetic conductive part 271 may include a plurality of portions each of which surrounds the magnet of one magnetic pole and constitutes a part of a magnetic circuit together with the magnet. For example, referring to fig. 2, one portion 271B of the plurality of portions of the magnetically permeable portion encases the magnet 25B.
Each of the portions of the magnetically permeable portion 271 may be configured to cover just the magnet of a pole, may cover portions of the surface of the magnet of the pole, or may extend slightly beyond the magnet of the pole. In other words, each of the plurality of portions of the magnetic conductive portion 271 may be configured to surround the magnet outer circumferential surface in complete coincidence with the magnet of one magnetic pole. Each of the portions of the magnetic permeable portion 271 may also be configured to have a surface area smaller than that of the magnet of the covered magnetic pole. Each of the portions of the magnetic permeable portion 271 may also be configured to have a surface area greater than that of the magnet of the covered magnetic pole.
In order to make the magnetic flux of the magnet fully utilized and the cover can better function to protect the magnet, the surface coverage of each of the plurality of portions of the magnetic conductive part to the magnet of the magnetic pole covered by the magnetic conductive part is in the range of 80% -120%. It will be appreciated that where the surface coverage is other than 100%, each of the portions of the magnetically permeable section may be axially shorter or longer than the magnet it covers, or may be circumferentially narrower or wider than the magnet it covers.
The magnetism blocking portion 272 corresponds in position to the circumferential interval between the magnets of two circumferentially adjacent magnetic poles for blocking an undesired magnetic path between the magnets of the two magnetic poles, for example, a magnetic path between circumferentially opposite ends of the two adjacent magnets. The magnetism blocking portion may be implemented as a plurality of opening portions that respectively expose at least a portion of one of the plurality of circumferential intervals. Each opening portion may be implemented as one or more openings, wherein each opening may be configured in a rectangular pattern as seen from the front, and the width of each opening is associated with the motor air gap, e.g. the width of each opening is larger than 2 times the motor air gap.
It should be understood that the "width" of each opening refers to the linear distance between the two sides of the rectangular-shaped opening in the axial direction.
It should be understood that "motor air gap" refers to the air gap between the stator and rotor of the motor. That is, a gap between the stator 10 and the rotor 20 of the brushless motor 100.
It should be understood that while each opening of the magnetic shield satisfies a width 2 times greater than the air gap of the motor, it is also necessary to satisfy the above-mentioned 80% -120% magnet surface coverage requirement of the magnetic conductive portion.
For ease of machining, the opening portions corresponding to each circumferential interval are configured in the same pattern. Each opening may be implemented in various patterns in shape and layout, for example, the shape of the opening may include a straight line segment, a curved line segment, a broken line segment, or a combination thereof. That is, the shape of the opening may be implemented in any suitable shape. Fig. 4A-4C show an extension of a portion of the peripheral wall of the cover 27, showing some embodiments of the pattern of the opening. Referring to fig. 4A, each opening portion may be implemented to include continuously extending openings 272A and 272B. Referring to fig. 4B and 4C, each opening portion may be implemented to include a discrete distribution of openings, e.g., discrete openings 272a1-272a2 and 272B1-272B2 as shown in fig. 4B. Referring to FIG. 4C, each of the openings may be implemented as one or more rows of openings discretely distributed along the axial direction, such as openings 272A1-272A6 and 272B1-272B 6.
The connecting portion 273 connects the respective portions of the magnetically permeable portion together so that the housing 27 is formed as one body. The axial length of the connection portion 273 should be as narrow as possible in terms of electromagnetic performance of the brushless motor, and the axial length of the connection portion 273 should not be too narrow in terms of mechanical strength of the rotor. In addition, the connection portion 273 may be made of the same magnetic conductive material as the magnetic conductive portion in consideration of convenience of processing and cost, so that the entire housing 27 may be formed by a punching process or a punching process in combination with a welding process.
The connecting portion 273 includes a plurality of portions, each portion corresponding to one of a plurality of circumferential intervals, and an axial length of each portion is associated with an axial length of the outer cover 27 and a thickness of the outer cover 27 in the radial direction. Referring to fig. 3B, each portion of the connecting portion 273 includes a first connecting portion 2731 at a periphery at one axial end and a second connecting portion 2732 at a periphery at the other axial end.
During rotation of the rotor 20, the magnets generate centrifugal forces that cause them to fly radially, as do the portions of the housing that cover them. Thus, during rotation of the rotor, the radial constraint that the housing can provide to the rotor needs to be greater than the sum of the two centrifugal forces. The principle by which the enclosure can provide this restraining force is described below.
The case is exemplified in which the magnet and the housing of each magnetic pole are symmetrically designed, that is, the magnets of the respective magnetic poles are uniformly arranged on the outer circumferential surface of the rotor. The mass of the magnet of one pole is m1, the rotation speed of the rotor is v, the radial distance between the center of mass of the magnet and the rotor shaft is r1, the mass of the housing part covering the magnet (i.e. the part of the magnetic conducting part covering the magnet) is m2, the radial distance between the center of mass of the housing part and the rotor shaft is r2, and the centrifugal force F1 generated by the magnet can be obtained by the following formula (r):
Figure BDA0002340780840000071
the centrifugal force F2 of the cover part can be given by the following formula (ii):
Figure BDA0002340780840000072
the shear stress of the housing material is τ, the radial thickness of the housing is h, the axial length of the housing 27 is L, and the axial length of the first connection portion 2731 is L1And the second connection portion 2730 has an axial length L2. The stress concentration coefficient of the outer cover material is k, and the radial binding force F3 provided by the outer cover can be obtained by the following formula:
Figure BDA0002340780840000081
as described above, during the rotation of the rotor, the condition F needs to be satisfied1+F2<F3Namely, the following formula (iv) is satisfied:
Figure BDA0002340780840000082
the constraint conditions of the axial length L1 of the first connection portion and the axial length L2 of the second connection portion of each connection portion can be derived from the above formula (r).
In addition, in consideration of the magnetic flux leakage coefficient, a certain condition must be satisfied between the sum (L1+ L2) of the axial length L1 of the first connecting portion and the axial length L2 of the second connecting portion and L, in other words, the ratio of (L1+ L2) in the axial length of the housing must not be excessively large, nor excessively small. Experience, experiment and calculation show that the following formula (v) needs to be satisfied between (L1+ L2) and L:
L>3(L1+L2) ⑤
it should be appreciated that in embodiments of the present disclosure, the rotational speed of the rotor should be less than 50000 rpm.
It will be appreciated that the connecting portion may also include portions disposed at other locations in the circumferential spacing, for example, portions for spacing two or more openings corresponding to one circumferential spacing from each other may also be part of the connecting portion, constructed of the same magnetically permeable material as the magnetically permeable portion.
The housing 27 may be realized without the end wall and only with the circumferential wall, i.e. both ends of the housing in the axial direction are realized as free ends. The housing 27 may also be realized to comprise one end wall, i.e. one of the two ends in the axial direction is realized as a free end, and the other end is formed with an end wall, which at least partly covers said end, and which can function to limit the movement of the magnets and the rotor core in the axial direction.
In embodiments where the housing 27 is formed with one end wall, the rotor shaft, rotor core and magnets may be loaded into the housing from the free end (i.e., the end without the end wall) and abutted against the end wall after they are assembled.
In the embodiment in which the housing 27 is formed with one end wall, the end wall should not cover the entire end portion but partially from the electromagnetic performance aspect of the motor as long as the above-described axial restraining effect can be exerted.
Referring to FIG. 5A, in one embodiment, the end cap is configured as a ring around the circumference of the end. In this embodiment, the sum (d + L1+ L2) of the radial width d of the end cap, the axial length L1 of the first connecting portion, and the axial length L2 of the second connecting portion and the axial length L of the outer shield satisfy the following formula (i):
(d+L1+L2)<L*1/3 ⑥
referring to fig. 5B, in another embodiment, the end cap may also be configured in a star shape.
It should be understood that the end wall may be configured in other suitable patterns, but is not limited thereto.
Therefore, according to the technical scheme of the disclosure, the mechanical strength of the rotor is improved, the magnetic flux of the magnet of each magnetic pole can be fully utilized, and an unexpected magnetic circuit can be blocked. In addition, the magnets of the rotor are protected by the outer cover, reducing the risk of damage to the magnets themselves. Also, even in the event of a break in the magnet, any broken portion is not thrown into the environment at a high speed, thereby protecting the motor from further damage.
While the foregoing describes certain embodiments, these example embodiments are presented by way of example only, and are not intended to limit the scope of the present disclosure. The appended claims and their equivalents are intended to cover all modifications, substitutions and changes made within the scope and spirit of the present disclosure.

Claims (11)

1. A rotor (20) for a brushless motor, comprising a rotor core and magnets disposed on an outer circumferential surface of the rotor core and constituting 1 or more pairs of magnetic poles of which N-poles and S-poles are alternately arranged,
wherein the rotor further comprises an outer cover (27) covering the outside of the magnets, the peripheral wall of the outer cover comprises a magnetic conductive part (271) and a magnetic isolation part (272), the magnetic conductive part comprises a plurality of parts respectively covering the magnets of each magnetic pole, the magnetic isolation part corresponds to the circumferential interval between the magnets of two adjacent magnetic poles in the circumferential direction,
wherein, the peripheral wall of the outer cover also comprises a connecting part (273) arranged in the magnetic isolation part and used for connecting all parts of the magnetic conduction part together, and
the magnetic conduction part is made of magnetic conduction materials, each part of the magnetic conduction part and the magnet covered by the magnetic conduction part form a part of a magnetic circuit, and the surface coverage rate of each part of the magnetic conduction part to the magnet covered by the part is 80% -120%.
2. The rotor (20) for a brushless motor according to claim 1, wherein the magnetism blocking portion includes a plurality of opening portions each corresponding to one of a plurality of circumferential intervals for exposing at least a part of the circumferential interval so as to block a magnetic path between circumferentially opposite ends of the magnets of two circumferentially adjacent magnetic poles.
3. The rotor (20) for a brushless motor according to claim 2, wherein each opening portion is configured in a rectangular pattern as viewed from the front, and a width of each opening portion is greater than twice an air gap of the brushless motor, the width of the opening portion being a linear distance between two opposite sides of the opening portion in an axial direction.
4. The rotor (20) for a brushless motor according to claim 2, wherein each opening portion has one of the following features:
comprises straight line segments, curved line segments, broken line segments or the combination thereof;
comprising continuously extending openings or discretely distributed openings;
comprises one or more openings extending in an axial direction; and
comprising one or more rows of openings distributed discretely in the axial direction.
5. Rotor (20) for a brushless electric motor according to claim 1,
the connecting part is made of the same magnetic conduction material as the magnetic conduction part;
the connecting portion comprises a plurality of portions, each portion corresponding to one of a plurality of circumferential spacings; and is
Each of the portions of the connecting portion includes at least a first connecting portion at a periphery of one end in the axial direction and a second connecting portion at a periphery of the other end in the axial direction.
6. The rotor (20) for a brushless motor according to claim 5, wherein an axial length L1 of the first connection portion and an axial length L2 of the second connection portion of each portion of the connection portion satisfy the following formula:
Figure FDA0003606958220000031
where v is the rotational speed of the rotor, m1 is the mass of the magnet of one pole, r1 is the radial distance between the center of mass of the magnet and the rotor shaft, m2 is the mass of the portion of the magnetically permeable section covering the magnet, r2 is the radial distance between the center of mass of the portion of the magnetically permeable section covering the magnet and the rotor shaft, τ is the shear stress of the housing material, h is the radial thickness of the housing, and k is the stress concentration coefficient of the housing material.
7. The rotor (20) for a brushless motor according to claim 5 or 6, wherein an axial length L1 of the first connection portion and an axial length L2 of the second connection portion of each portion of the connection portion satisfy the following formula:
L>3(L1+L2),
wherein L is the axial length of the housing.
8. The rotor (20) for a brushless motor according to claim 5, wherein the housing further includes an end wall at one end portion in the axial direction, partially covering the one end portion, for restraining the rotor core and each magnet from moving in the axial direction.
9. The rotor (20) for a brushless motor according to claim 8, wherein the end wall is configured as an annular end wall surrounding a periphery of the one end portion, a radial width d of the annular end wall satisfying the following formula:
(d+L1+L2)<L*1/3,
where L is the axial length of the housing, L1 is the axial length of the first coupling portion, and L2 is the axial length of the second coupling portion.
10. A brushless electric machine (100), comprising:
a stator (10); and
a rotor (20) according to any of claims 1-9, rotatably arranged in the centre of the stator.
11. An electric tool, characterized by comprising the brushless motor (100) according to claim 10.
CN201911375260.6A 2019-12-27 2019-12-27 Electric tool, brushless motor and rotor Active CN113054817B (en)

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CN107154692A (en) * 2017-06-16 2017-09-12 浙江迪贝电气股份有限公司 A kind of permanent-magnet ferrite rotor
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