CN115940459A - Sinusoidal air gap flux density high-speed permanent magnet motor rotor and preparation method thereof - Google Patents
Sinusoidal air gap flux density high-speed permanent magnet motor rotor and preparation method thereof Download PDFInfo
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- CN115940459A CN115940459A CN202310220999.XA CN202310220999A CN115940459A CN 115940459 A CN115940459 A CN 115940459A CN 202310220999 A CN202310220999 A CN 202310220999A CN 115940459 A CN115940459 A CN 115940459A
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Abstract
The invention provides a high-speed permanent magnet motor rotor with a sinusoidal air gap flux density and a preparation method thereof. According to the invention, the magnetic powder adhesive film and the carbon fiber cloth are compounded to obtain the magnetic powder adhesive film carbon fiber composite structure, and then the magnetic powder adhesive film carbon fiber composite structure is rolled outside the permanent magnet layer by layer to improve the rotor strength, and the carbon fiber layer in the structure mainly bears load, so that the tensile strength is greatly improved; the permanent magnet material is in a discrete powder form, so that the concentrated load can be eliminated, and the loss of the rotor is reduced; the porosity is reduced by adjusting the grading of the hard magnetic particles, and the electromagnetic performance is improved; the Halbach array structure is wholly magnetized, so that sine air gap flux density is formed, power density is improved, harmonic loss and rotor eddy current loss are reduced, and torque pulsation is weakened; the cooling effect of the rotor is further improved through the design of the air duct in the rotor, so that the performance and the reliability of the motor are improved.
Description
Technical Field
The invention relates to the technical field of motors, in particular to a high-speed permanent magnet motor with a sinusoidal air gap flux density and a preparation method thereof.
Background
The high-speed motor has high rotating speed, small volume and high power density, can directly drive high-speed load and high-speed load (such as a compressor and an air blower) to form a high-speed direct drive system, greatly reduces the weight and the size, has the comprehensive energy-saving effect of 15 percent, greatly improves the efficiency and the reliability of the system, and is widely applied to important industrial fields of new energy automobiles, high-performance medical instruments, high-grade numerical control machines and robots, aerospace equipment, ocean engineering equipment and the like.
The high-speed permanent magnet motor has the advantages of simple structure, high force energy density, no excitation loss, high efficiency and the like, and is most suitable for the high-speed motor. The three high features of high speed, high frequency, and high power density make high speed motors face many difficulties and challenges in design. Firstly, the peripheral speed of the high-speed motor can generally reach more than 200m/s, the stator core loss, the rotor friction loss and the permanent magnet eddy current loss are very large under high speed and high frequency, and the high power density makes the rotor difficult to radiate heat and easily causes the permanent magnet to generate irreversible demagnetization; secondly, the tensile strength of the permanent magnet is only 30 to 80MPa, the rotor strength problem is more prominent under high rotating speed due to the action of centrifugal force, and a sheath is required to protect the permanent magnet. Therefore, the demagnetization caused by the mechanical strength and temperature rise of the permanent magnet rotor structure has become a major bottleneck problem restricting the development of the high-speed permanent magnet motor to high speed and high power.
Disclosure of Invention
The invention aims to solve the problems of low mechanical strength and easy loss of a permanent magnet rotor structure, and provides a high-speed permanent magnet motor rotor with a sinusoidal air gap magnetic density and a preparation method thereof, wherein on the premise of ensuring the magnetic field intensity, the rotor strength is improved by adopting a magnetic powder adhesive film carbon fiber composite structure, and a permanent magnet material is in a discrete powder form, so that the concentrated load is eliminated, and the rotor loss is reduced; the porosity is reduced by adjusting the grading of the hard magnetic particles, and the electromagnetic performance is improved; the Halbach array structure is wholly magnetized, so that sine air gap flux density is formed, power density is improved, harmonic loss and rotor eddy current loss are reduced, and torque pulsation is weakened; the cooling effect of the rotor is further improved through the design of the air duct in the rotor, so that the performance and the reliability of the motor are improved.
The invention provides a sinusoidal air gap flux density high-speed permanent magnet motor rotor, which comprises a rotating shaft, a Halbach array structure arranged outside the rotating shaft, flux-isolating end rings arranged at two ends of the Halbach array structure and a ventilation structure arranged inside the rotating shaft, wherein the Halbach array structure forms a plurality of magnetic poles, and the ventilation structure is a ventilation hole for reducing the temperature of the high-speed permanent magnet motor rotor;
the Halbach array structure comprises a permanent magnet layer, a magnetic powder glue film/carbon fiber unit and a carbon fiber sheath which are sequentially arranged on the outer side of a rotating shaft, wherein the permanent magnet layer comprises at least two permanent magnet blocks which are embedded and bonded on the outer side of the rotating shaft and are pre-oriented, the magnetic powder glue film/carbon fiber unit comprises at least two layers of magnetic powder glue film and carbon fiber composite structures which are wound on the outer side of the permanent magnet layer, each magnetic powder glue film and carbon fiber composite structure comprises a magnetic powder glue film and carbon fiber cloth which is compounded on the lower side of the magnetic powder glue film, and each magnetic powder glue film comprises magnetic powder and epoxy resin; the carbon fiber sheath is wound on the outer side of the magnetic powder adhesive film/carbon fiber unit;
the permanent magnet layer, the magnetic powder glue film/carbon fiber unit and the carbon fiber sheath are wholly Halbach magnetized, and the magnetism isolating end ring is arranged at the two ends of the magnetic powder glue film/carbon fiber unit and the carbon fiber sheath and outside the rotating shaft.
According to the high-speed permanent magnet motor rotor with the sinusoidal air gap magnetic density, as an optimal mode, magnetic powder is distributed in a magnetic powder adhesive film in a scattered mode, and the air gap magnetic density of the high-speed permanent magnet motor rotor is close to the sinusoidal property.
The invention relates to a high-speed permanent magnet motor rotor with sinusoidal air gap flux density, which is characterized in that as a preferred mode, a rotating shaft comprises a rotating shaft body and permanent magnet mounting grooves arranged on the outer surface of the rotating shaft body, and after permanent magnet blocks are mounted in the permanent magnet mounting grooves, the upper surfaces of the permanent magnet blocks are flush with the upper surfaces of two ends of the rotating shaft body;
the rotating shaft is made of non-magnetic conductive alloy material, and the surface of the rotating shaft is knurled;
the ventilation structure comprises an L-shaped ventilation hole which is arranged in the rotating shaft in a penetrating mode, the L-shaped ventilation hole comprises a straight hole which is arranged along the axis of the rotating shaft and an inclined hole which is communicated with the tail end of the straight hole, and the bending angle between the inclined hole and the straight hole is 30-60 degrees;
the volume ratio of the magnetic powder in the magnetic powder adhesive film/carbon fiber unit is 60-80%, the particle size of the magnetic powder is 50-200 μm, the particle size ratio is 3;
the magnetic powder adhesive film is directly laid on the carbon fiber cloth to be compounded into a complete layered composite material;
the outer end shaft end of the magnetic isolation end ring is of a conical structure, and the magnetic isolation end ring is in interference fit with the rotating shaft.
As an optimal mode, the high-speed permanent magnet motor rotor with the sinusoidal air gap magnetic density has the advantages that the particle size of magnetic powder is 100mm and 50mm, and the mass ratio is 3:1;
the magnetic powder is neodymium iron boron hard magnetic particles/or samarium cobalt hard magnetic particles;
the ventilation structure also comprises a central hole arranged in the center of the rotating shaft.
The invention provides a preparation method of a sinusoidal air gap flux density high-speed permanent magnet motor rotor, which comprises the following steps:
s1, preparing a magnetic powder adhesive film: mixing magnetic powder, epoxy resin and a solvent in proportion, uniformly stirring and pouring into a film drawing die, uniformly drawing a Cheng Denghou adhesive film by pulling a push rod at a uniform speed, and curing to obtain a magnetic powder adhesive film, wherein the solvent is a volatile solvent;
s2, rotating shaft processing: knurling the surface of the rotating shaft;
s3, installing a Halbach array structure: the Halbach array structure and the magnetism isolating end ring are sequentially arranged on the outer side of the rotating shaft and are solidified, the Halbach array structure comprises a permanent magnet layer, a magnetic powder adhesive film/carbon fiber unit and a carbon fiber sheath which are sequentially arranged, the magnetic powder adhesive film/carbon fiber unit comprises a magnetic powder adhesive film carbon fiber composite structure which is rolled layer by layer, and each layer of the magnetic powder adhesive film carbon fiber composite structure comprises a magnetic powder adhesive film and carbon fiber cloth;
s4, halbach magnetizing: and (3) carrying out integral Halbach magnetizing on the Halbach array structure by using a sinusoidal magnetic field to form a plurality of magnetic poles, and completing the preparation of the high-speed permanent magnet motor rotor with sinusoidal air gap flux density.
The invention relates to a preparation method of a sinusoidal air gap flux density high-speed permanent magnet motor rotor, and as a preferred mode, the step S3 comprises the following steps:
s31, pre-fetching the permanent magnet blocks and then uniformly bonding the pre-fetched permanent magnet blocks in the permanent magnet mounting grooves to obtain a permanent magnet layer;
s32, spreading a magnetic powder adhesive film on the upper layer of the carbon fiber cloth to obtain a magnetic powder adhesive film carbon fiber composite structure, then rolling the magnetic powder adhesive film carbon fiber composite structure on the outer side of the permanent magnet layer by layer, and curing to obtain a magnetic powder adhesive film/carbon fiber unit;
s33, winding a carbon fiber sheath on the magnetic powder adhesive film/carbon fiber unit and then curing;
and S34, assembling the magnetism isolating end rings on two sides of the Halbach array structure and on the outer side of the rotating shaft in an interference fit mode.
The invention relates to a preparation method of a high-speed permanent magnet motor rotor with sinusoidal air gap magnetic density, which is a preferable mode, in step S1, the particle size of magnetic powder is 50-200 μm, the particle size ratio is 3; the stirring time is 0.5 to 10 minutes, the film drawing speed is 20 to 50m/min, the curing mode of the equal-thickness adhesive film is normal-temperature curing, and the magnetic powder adhesive film and the carbon fiber cloth are cured by heating.
As an optimal mode, the preparation method of the high-speed permanent magnet motor rotor with the sinusoidal air gap magnetic density has the advantages that the grain diameter of the magnetic powder is 100mm and 50mm, and the grain diameter ratio is 3:1.
The invention relates to a preparation method of a sinusoidal air gap flux density high-speed permanent magnet motor rotor, and as a preferred mode, the step S2 further comprises the following steps: set up L shape ventilation hole in the pivot, L shape ventilation hole is along pivot axial evenly distributed.
The invention relates to a preparation method of a high-speed permanent magnet motor rotor with sinusoidal air gap flux density, which is a preferred mode, in step S31, a permanent magnet block comprises 16 permanent magnet blocks distributed along an X axis and a Y axis in a mirror image mode on a section perpendicular to a rotating shaft, and the permanent magnet blocks are numbered from 1 to 16 in a clockwise direction from the highest point;
in the step S4, after Halbach is magnetized, the magnetic field of the No. 1 permanent magnet is parallel to the Y axis, the magnetic field of the No. 2 permanent magnet forms an included angle of 70 degrees with the X axis, the magnetic field of the No. 3 permanent magnet forms an included angle of 45 degrees with the X axis, the magnetic field of the No. 4 permanent magnet forms an included angle of 20 degrees with the X axis, and the magnetic field of the No. 5 permanent magnet is parallel to the X axis.
A high-speed permanent magnet motor rotor with sine air gap flux density comprises a rotating shaft, a block-shaped permanent magnet arranged on the outer side of the rotating shaft, a magnetic powder/carbon fiber laminated structure arranged on the outer side of the permanent magnet, a carbon fiber sheath arranged on the outermost side, magnetic isolation end rings arranged at two ends of the structure, and a rotor inner air duct and a hollow shaft hole arranged in the rotating shaft; the magnetic isolation end ring is in interference fit with the rotating shaft and plays roles in axial positioning and magnetic isolation;
the block permanent magnet is divided into a plurality of blocks in the circumferential direction and the circumferential direction, and the permanent magnet blocks are uniformly adhered to the outer side of the rotating shaft; pre-orienting the permanent magnet blocks before installation;
and carrying out integral Halbach magnetizing on the permanent magnet, the magnetic powder/carbon fiber laminated structure and the carbon fiber sheath to form a Halbach composite array structure, so as to form a plurality of magnetic poles.
The rotating shaft is made of a non-magnetic conductive alloy material, and knurling processing is performed on the surface of the rotating shaft to increase friction and assist circumferential positioning of the magnetic steel.
The hard magnetic powder and the epoxy resin are uniformly mixed and drawn into a magnetic powder adhesive film. The smaller the diameter of the hard magnetic particles, the lower the porosity of the magnetic powder adhesive film, and the more stable the structure of the magnetic powder adhesive film.
One end of each L-shaped vent hole is a straight hole, the other end of each L-shaped vent hole is bent at an angle with the horizontal direction, so that the rotor can be cooled by itself under high-speed rotation conveniently, 4~6 air ducts are uniformly distributed in the circumferential direction, the diameters of the air ducts are designed according to the diameters of the rotors, and the bending angles are 30-60 degrees.
A high-speed permanent magnet motor rotor with sine air gap flux density is disclosed, and the preparation method of the motor rotor comprises the following steps:
s1, processing a rotating shaft: knurling the surface of the rotating shaft;
s2, mounting a permanent magnet: the permanent magnet is pre-fetched and then is uniformly adhered to the outer layer of the rotating shaft; the high-strength glue is sequentially adhered to the rotating shaft, and the surface of the assembled magnetic steel is ground to meet the requirement of cylindricity error;
s3, preparing a magnetic powder/carbon fiber laminated structure: mixing the hard magnetic powder with epoxy resin to form a magnetic powder adhesive film, and compounding the magnetic powder adhesive film with carbon fiber cloth to form a magnetic powder adhesive film/carbon fiber unit;
s4, preparing a composite magnetic material layer: uniformly rolling the magnetic powder adhesive film/carbon fiber unit on the outer layer of the permanent magnet to form a composite magnetic material layer;
s5, halbach magnetizing: and (3) carrying out integral Halbach magnetizing on the motor rotor by using a sinusoidal magnetic field to form a plurality of magnetic poles, realizing an integral Halbach array structure and finishing the preparation of the motor rotor.
And winding a carbon fiber sheath on the composite magnetic material layer.
Compared with the prior art, the invention has the advantages that:
(1) The permanent magnet in the invention keeps the advantage of high torque/power density of the traditional permanent magnet, and the Halbach magnetizing mode can reduce the using amount of the permanent magnet, improve the power density, ensure the magnetic field intensity of the rotor and reduce the stress of the permanent magnet.
(2) According to the invention, a magnetic powder adhesive film and carbon fiber cloth are compounded to obtain a magnetic powder adhesive film carbon fiber composite structure, and then the magnetic powder adhesive film carbon fiber composite structure is rolled on the outer side of a permanent magnet layer by layer to obtain a magnetic powder adhesive film/carbon fiber unit, and the magnetic powder adhesive film carbon fiber composite structure is used as a magnetic composite material, so that on one hand, excitation is provided to ensure the magnetic field intensity, and a Halbach level display structure is formed with a permanent magnet block, so that the sine of the rotor air gap flux density is greatly improved; on the other hand, the magnetic powder adhesive film carbon fiber composite structure mainly bears load by the carbon fiber layer, so that the tensile strength of the magnetic material is improved from 80MPa to 1450MPa, the strength of the rotor is greatly improved, and the linear speed of the rotor can be greatly improved; meanwhile, the hard magnetic material in the magnetic powder adhesive film carbon fiber composite structure is in a discrete powder state and has no concentrated load, so that the eddy current loss is avoided, and the loss of the rotor can be effectively reduced.
(3) The invention magnetizes the whole Halbach array structure in a Halbach magnetizing mode, further reduces the use amount of permanent magnets, improves the strength of the rotor, can greatly improve the sine of the rotor air gap magnetic density, reduces the harmonic content of back electromotive force, reduces the iron consumption of a stator, and solves the problem of large rotor loss.
Drawings
FIG. 1a is a front view of a rotor of a sinusoidal air gap high speed permanent magnet machine;
FIG. 1b is a side view of a sinusoidal air gap flux density high speed permanent magnet machine rotor;
FIG. 2 is a schematic diagram of Halbach magnetizing of a sinusoidal air gap flux density high-speed permanent magnet motor rotor;
FIG. 3 is a schematic diagram of a magnetic powder adhesive film carbon fiber composite structure of a high-speed permanent magnet motor rotor with a sinusoidal air gap magnetic density;
FIG. 4 is a flow chart of a method for manufacturing a sinusoidal air gap flux density high speed permanent magnet motor rotor;
FIG. 5 is a comparison graph of the Halbach array structure of a sinusoidal air gap flux density high-speed permanent magnet motor rotor and the air gap flux density of a conventional radial magnetizing high-speed motor;
FIG. 6 is a schematic view of the pre-orientation direction of the permanent magnets of a high-speed permanent magnet motor rotor with sinusoidal air gap flux density;
FIG. 7 is a schematic diagram showing the particle size and porosity of magnetic powder of a sinusoidal air gap flux density high-speed permanent magnet motor rotor;
FIG. 8 is a schematic diagram of the volume ratio and porosity of a sinusoidal air gap flux density high speed permanent magnet machine rotor;
FIG. 9 is a schematic diagram of the ratio of the thickness of the magnetic powder colloid film to the thickness of the carbon fiber and the residual magnetic induction of the high-speed permanent magnet motor rotor with sinusoidal air gap flux density;
FIG. 10 is a graph of the electromagnetic performance test results of magnetic materials of different thickness ratios of a sinusoidal air gap flux density high-speed permanent magnet motor rotor magnetic powder adhesive film and carbon fibers.
Reference numerals:
1. a rotating shaft; 11. A rotating shaft body; 12. A permanent magnet mounting groove; 2. A Halbach array structure; 21. A permanent magnet layer; 211. A permanent magnet block; 22. A magnetic powder adhesive film/carbon fiber unit; 221. A magnetic powder adhesive film carbon fiber composite structure; 2211. Magnetic powder glue film; 2212. Carbon fiber cloth; 23. A carbon fiber sheath; 3. A magnetic-isolating end ring; 4. A ventilation structure; 41. An L-shaped vent hole; 411. A straight hole; 412. An inclined hole; 42. A central bore.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.
Example 1
As shown in fig. 1a to 1b, a high-speed permanent magnet motor rotor with sinusoidal air gap flux density comprises a rotating shaft 1, a Halbach array structure 2 arranged outside the rotating shaft 1, magnetic isolation end rings 3 arranged at two ends of the Halbach array structure 2 and a ventilation structure 4 arranged inside the rotating shaft 1, wherein the Halbach array structure 2 forms a plurality of magnetic poles, and the ventilation structure 4 is a ventilation hole for reducing the temperature of the high-speed permanent magnet motor rotor;
as shown in fig. 2~3, the Halbach array structure 2 includes a permanent magnet layer 211, a magnetic powder adhesive film/carbon fiber unit 22 and a carbon fiber sheath 23 sequentially arranged outside the rotating shaft 1, the permanent magnet layer 211 includes at least two permanent magnet blocks 211 embedded and bonded outside the rotating shaft 1 and pre-oriented, the magnetic powder adhesive film/carbon fiber unit 22 includes at least two layers of magnetic powder adhesive film/carbon fiber composite structures 221 wound outside the permanent magnet layer 211, the magnetic powder adhesive film/carbon fiber composite structures 221 include magnetic powder adhesive films 2211 and carbon fiber cloth 2212 compounded on the lower side of the magnetic powder adhesive films 2211, and the magnetic powder adhesive films 2211 include magnetic powder and epoxy resin; the carbon fiber sheath 23 is wound on the outer side of the magnetic powder adhesive film/carbon fiber unit 22;
the permanent magnet layer 211, the magnetic powder adhesive film/carbon fiber unit 22 and the carbon fiber sheath 23 are wholly Halbach magnetized, and the magnetism isolating end ring 3 is arranged at the two ends of the magnetic powder adhesive film/carbon fiber unit 22 and the carbon fiber sheath 23 and outside the rotating shaft 1;
the magnetic powder is distributed in the magnetic powder adhesive film 2211 in a discrete way, and the air gap flux density of the rotor of the high-speed permanent magnet motor is close to the sine;
the rotating shaft 1 comprises a rotating shaft body 11 and permanent magnet mounting grooves 12 arranged on the outer surface of the rotating shaft body 11, and the upper surfaces of permanent magnet blocks 211 mounted in the permanent magnet mounting grooves 12 are flush with the upper surfaces of two ends of the rotating shaft body 11;
the rotating shaft 1 is made of a non-magnetic alloy material, and knurling is performed on the surface of the rotating shaft 1;
the ventilation structure 4 comprises an L-shaped ventilation hole 41 which is arranged in the rotating shaft 1 in a penetrating manner, the L-shaped ventilation hole 41 comprises a straight hole 411 arranged along the axis of the rotating shaft 1 and an inclined hole 412 communicated with the tail end of the straight hole 411, and the bending angle of the inclined hole 412 and the straight hole 411 is 30-60 degrees;
the volume ratio of the magnetic powder in the magnetic powder adhesive film/carbon fiber unit 22 is 60% -80%, the particle size of the magnetic powder is 50% -200 μm, the particle size ratio is 3;
the magnetic powder adhesive film 2211 and the carbon fiber cloth 2212 are directly paved for compounding;
the outer end shaft end of the magnetic isolation end ring 3 is of a conical structure, and the magnetic isolation end ring 3 is in interference fit with the rotating shaft 1;
the particle size of the magnetic powder is 100mm and 50mm, and the mass ratio is 3:1;
the magnetic powder is neodymium iron boron hard magnetic particles or samarium cobalt hard magnetic particles;
the ventilation structure 4 further comprises a central hole 42 arranged in the centre of the shaft 1.
Example 2
As shown in fig. 4, a method for manufacturing a sinusoidal air gap flux density high-speed permanent magnet motor rotor includes the following steps:
s1, preparing a magnetic powder adhesive film carbon fiber composite structure: mixing the magnetic powder, the epoxy resin and the solvent in proportion, uniformly stirring and pouring the mixture into a film drawing die, uniformly drawing a Cheng Denghou adhesive film by pulling a push rod at a uniform speed, and curing to obtain a magnetic powder adhesive film 2211, wherein the solvent is a volatile solvent;
the particle size of the magnetic powder is 50 to 200 mu m, the particle size ratio is 3 to 1, the solvent is acetone or toluene, the mass ratio of the solvent is 10 to 15 percent, the porosity of the magnetic powder adhesive film 2211 is 0.36 to 0.52, and the thickness of the carbon fiber cloth 2212 is 0.06 to 0.12mm;
the stirring time is 0.5 to 10 minutes, the film drawing speed is 20 to 50m/min, the curing mode of the constant-thickness adhesive film is normal-temperature curing, and the magnetic powder adhesive film 2211 and the carbon fiber cloth 2212 are cured and compounded by heating;
the grain diameter of the magnetic powder is 100mm and 50mm, and the grain diameter ratio is 3:1;
s2, rotating shaft processing: knurling the surface of the rotating shaft 1; the rotating shaft 1 is provided with L-shaped ventilation holes 41 and/or a central hole 42, and the L-shaped ventilation holes 41 are uniformly distributed along the axial direction of the rotating shaft 1;
s3, installing a Halbach array structure: the Halbach array structure 2 and the magnetism isolating end ring 3 are sequentially arranged on the outer side of the rotating shaft 1 and are solidified, the Halbach array structure 2 comprises a permanent magnet layer 21, a magnetic powder adhesive film/carbon fiber unit 22 and a carbon fiber sheath 23 which are sequentially arranged, the magnetic powder adhesive film/carbon fiber unit 22 comprises a magnetic powder adhesive film carbon fiber composite structure 221 which is rolled layer by layer, and each layer of magnetic powder adhesive film carbon fiber composite structure 221 comprises a magnetic powder adhesive film 2211 and a carbon fiber cloth 2212;
s31, pre-fetching the permanent magnet block 211, and uniformly adhering the pre-fetched permanent magnet block to the permanent magnet mounting groove 12 to obtain a permanent magnet layer 211;
the permanent magnet blocks 211 comprise 16 permanent magnet blocks which are distributed in a mirror image mode along the X axis and the Y axis on the section which is perpendicular to the rotating shaft 1;
s32, spreading the magnetic powder adhesive film 2211 on the upper layer of the carbon fiber cloth 2212 to obtain a magnetic powder adhesive film carbon fiber composite structure 221, rolling the magnetic powder adhesive film carbon fiber composite structure 221 on the outer side of the permanent magnet layer 21 layer by layer, and curing to obtain a magnetic powder adhesive film/carbon fiber unit 22;
s33, winding the carbon fiber sheath 23 on the magnetic powder adhesive film/carbon fiber unit 22, wherein in each layer of the magnetic powder adhesive film/carbon fiber composite structure 221, the carbon fiber cloth 2212 is located on the inner side, and the magnetic powder adhesive film 2211 is located on the outer side;
s34, assembling the magnetism isolating end rings 3 on two sides of the Halbach array structure 2 and on the outer side of the rotating shaft 1 in an interference fit mode;
s4, halbach magnetizing: and (2) carrying out integral Halbach magnetization on the Halbach array structure 2 by using a sinusoidal magnetic field, wherein after Halbach magnetization, the magnetic field of the No. 1 permanent magnet is parallel to the Y axis, the magnetic field of the No. 2 permanent magnet forms an included angle of 70 degrees with the X axis, the magnetic field of the No. 3 permanent magnet forms an included angle of 45 degrees with the X axis, the magnetic field of the No. 4 permanent magnet forms an included angle of 20 degrees with the X axis, the magnetic field of the No. 5 permanent magnet is parallel to the X axis, a plurality of magnetic poles are formed, and the preparation of the high-speed permanent magnet motor rotor with dense sinusoidal air gaps is completed.
Example 3
A high-speed permanent magnet motor rotor with sinusoidal air gap magnetic density and a manufacturing method thereof are shown in figures 1a to 1b, and the high-speed permanent magnet motor rotor with the sinusoidal air gap magnetic density comprises a rotating shaft 1, a permanent magnet layer 21 arranged on the outer side of the rotating shaft 1, a magnetic powder adhesive film/carbon fiber unit 22 arranged on the outer side of the permanent magnet layer 21, a carbon fiber sheath 23 arranged on the outer side of the magnetic powder adhesive film/carbon fiber unit 22, magnetic isolation end rings 3 arranged at two ends of the magnetic powder adhesive film/carbon fiber unit 22 and the carbon fiber sheath 3, and an L-shaped vent hole 41 arranged in the rotating shaft 1; the magnetic-isolating end ring 3 is arranged outside the rotating shaft; the magnetic-isolating end ring 3 is in interference fit with the rotating shaft 1 and plays roles in axial positioning and magnetic isolation; the shaft end of the outer end of the magnetism isolating end ring 3 is of a conical structure, L-shaped ventilation holes are uniformly distributed in the circumferential direction of the rotating shaft, one end of each L-shaped ventilation hole is a straight hole, and the other end of each L-shaped ventilation hole is bent by 60 degrees with the horizontal direction, so that self-cooling of the rotor under high-speed rotation is facilitated; the rotor shaft is a hollow shaft with a through hole 42.
The rotating shaft 1 is made of a non-magnetic alloy material, and the surface of the rotating shaft 1 is subjected to knurling treatment, like countless tiny pins are formed on the surface of a rotor, so that the friction force is increased, and the circumferential positioning is assisted;
the permanent magnet layer 21 comprises 16 permanent magnet blocks which are uniformly adhered to the outer side of the rotating shaft; pre-orienting the permanent magnet blocks before installation;
as shown in fig. 3, the magnetic powder adhesive film/carbon fiber unit 22 is prepared by mixing hard magnetic powder and epoxy resin to form a magnetic powder adhesive film, and then compounding the magnetic powder adhesive film with carbon fiber cloth, wherein the hard magnetic powder is neodymium iron boron hard magnetic particles. The magnetic powder adhesive film is composed of magnetic powder and epoxy resin, and the pores among the magnetic powder particles are filled with the epoxy resin. The particle size of the magnetic powder in this example is 100 μm and 50 μm; the particle size ratio of the particles is 3:1.
The thickness of the carbon fiber cloth 2212 is 0.1mm, and the magnetic powder film 2211T ex With carbon fiber 2212T cb The thickness ratio of (a) is 3:1, and the residual magnetic induction strengths of the novel composite magnetic material are 0.394T respectively.
Compared with the conventional radial magnetizing high-speed motor, the Halbach composite rotor structure manufactured by the optimized method has the advantages that the air gap magnetic density is closer to sine, the torque pulsation is small, the residual magnetic induction Br value of the air gap reaches 0.44T, and the requirement of the high-speed motor can be met as shown in figure 5.
But the tensile strength of the high-speed motor reaches 1460MPa, which is far higher than the tensile strength of 80MPa of the neodymium-iron-boron magnetic steel and the tensile strength of 30MPa of the samarium-cobalt magnetic steel, so that the maximum linear speed of the high-speed motor can be theoretically increased to 1200m/s from 200m/s, and the rotating speed of the high-speed motor is greatly increased.
The high-speed motor rotor prepared by the method can reduce the eddy current loss of the rotor due to the lower electrical conductivity of the novel composite magnetic material. Compared with the novel composite magnetic material rotor and the conventional high-speed motor rotor, the eddy current loss of the rotor can be reduced by 16.6%.
Magnetic powder/carbon fiber laminated structure 22 provides the excitation as compound magnetic material, through Halbach magnetization mode, makes rotor air gap magnetic density be close to sinusoidal characteristic, and the carbon fiber greatly increased magnetic material intensity in the magnetic material simultaneously, the discrete state of magnetic eliminates concentrated load, greatly reduced rotor eddy current loss, this novel rotor structure and preparation method have solved high-speed motor's intensity and the two major bottleneck problems of magnetic loss that high loss density leads to.
As shown in fig. 2, the permanent magnet layer 21, the magnetic powder adhesive film/carbon fiber unit 22 and the carbon fiber sheath 4 are wholly Halbach magnetized to form a Halbach array structure, so as to form a plurality of magnetic poles.
As shown in fig. 4, the method for manufacturing the motor rotor includes the following steps:
s1, processing a rotating shaft 1: knurling the surface of the rotating shaft 1;
s2, mounting of the permanent magnet layer 21: the permanent magnet layer 21 is pre-fetched and uniformly adhered to the outer layer of the rotating shaft 1; the permanent magnet layer 21 is divided into 16 pieces in the axial direction and the circumferential direction, and is sequentially bonded on the rotating shaft 1 by high-strength glue. And after assembly, the surface of the magnetic steel is ground, so that the requirement on cylindricity error is met.
S3, the rotor 1 is provided with air holes, and compared with a structure without holes, the surface temperature of the effective part of the rotor can be reduced by 20%. The number of the vent holes 41 is preferably and uniformly distributed with 4F 8, 4F 10 and 6F 6, the rotor strength and the processing process difficulty are comprehensively considered, the vent holes 41 are preferably and uniformly distributed with 4F 8 vent holes, the included angle between the vent holes 41 and the axial direction can be preferably 60 degrees, 45 degrees and 30 degrees, and the influence on the ventilation effect is small due to the included angle between the air duct and the axial direction, and the angle can not be limited.
S4, preparing a magnetic powder adhesive film/carbon fiber unit 22: mixing the selected magnetic powder particles with the particle sizes of 100mm and 50mm with epoxy resin according to the proportion of 3:1, adding volatile solvents such as acetone and toluene in the epoxy resin to ensure that the magnetic powder particles and the epoxy resin are fully fused and uniformly coated, and preferably selecting 10-15% of proportion through test comparison to reduce the viscosity of the epoxy resin at normal temperature.
Stirring the magnetic powder particles and the proportioned epoxy resin for more than 0.5 minute and less than 10 minutes, pouring the uniformly stirred raw materials into a special film-pulling die, pulling a push rod at a constant speed according to the preset film thickness, controlling the film-pulling speed to be more than 20m/min and less than 50m/min, uniformly pulling the raw materials into Cheng Denghou adhesive films, naturally curing, compounding the adhesive films 2211 and fiber cloth 2212 into a complete magnetic adhesive film/carbon fiber composite magnetic material 221, and then heating and curing;
s4, preparing a composite magnetic material layer: after knurling the rotating shaft 1, bonding the magnetic steel to the rotating shaft by using high-strength adhesive, rolling the magnetic powder/carbon fiber composite magnetic material 221 on the outer surface of the rotor 1 layer by layer, applying tension by adopting an equal stress method in the rolling process to ensure that the stress of each layer of the magnetic composite material is uniform, designing and determining the number of the rolled layers according to the requirement of the magnetic field intensity required to be provided, and then curing and processing to the axial size requirement to obtain a magnetic powder adhesive film/carbon fiber unit 22; finally, winding and curing the carbon fiber sheath 23;
s5, halbach magnetizing: the special magnetizing fixture is designed, the Halbach magnetizing effect is achieved by providing enough magnetic field intensity, the rotor permanent magnet layer 21, the magnetic powder adhesive film/carbon fiber unit 22 and the carbon fiber sheath 23 are subjected to integral Halbach magnetizing by adopting a sinusoidal magnetic field during magnetizing, and continuous magnetizing can be performed to guarantee the magnetizing intensity, so that the integral Halbach array structure of the rotor is finally realized, and the preparation of the motor rotor is completed.
In the step S2, the permanent magnet is pre-oriented according to the direction shown in the figure 6, after magnetizing, the magnetic field of the No. 1 permanent magnet is parallel to the Y axis of the coordinate, the No. 2 permanent magnet forms an included angle of 70 degrees with the X axis of the coordinate, the No. 3 permanent magnet forms an included angle of 45 degrees with the X axis of the coordinate, the No. 4 permanent magnet forms an included angle of 20 degrees with the X axis of the coordinate, and the No. 5 permanent magnet is parallel to the X axis. Other permanent magnets are respectively mirrored with No. 1, 2, 3, 4 and 5 permanent magnets in the directions of X axis, Y axis and 180 degrees as shown in FIG. 6.
Examples 4 to 10
The other contents of the rotor of the high-speed permanent magnet motor with the sinusoidal air gap magnetic density are the same as those of the embodiment 3, and the particle sizes of the magnetic powder are respectively as shown in figure 7 and table 1:
TABLE 1
Examples 11 to 13
The other contents of the high-speed permanent magnet motor rotor with the sinusoidal air gap flux density are the same as those in the embodiment 3, and the particle diameters of the magnetic powder are respectively as shown in fig. 8 and table 2:
TABLE 2
In example 11, the magnetic powder particles have particle sizes of 200 μm and 100 μm, and a volume ratio of 1: the tensile strength of the rotor of the high-speed permanent magnet motor is 1387MPa at 4 hours, and in the embodiment 12, the magnetic powder particle size is 200 mu m and 50 mu m, and the volume ratio is 3: at 2, the tensile strength of the rotor of the high-speed permanent magnet motor is 1489MPa, the particle size of magnetic powder particles is 200 mu m and 50 mu m, and the volume ratio is 1:4 hours, the tensile strength of the rotor of the fast permanent magnet motor is 1450MPa, in example 13, the particle size of the magnetic powder particles is 100 μm and 50 μm, and the volume ratio is 3:1, the tensile strength of the high-speed permanent magnet motor rotor is 1534MPa, the particle sizes of magnetic powder particles are 100 mu m and 50 mu m, the volume ratio is 1:1, and the tensile strength of the high-speed permanent magnet motor rotor is 1489MPa.
Example 14
The other contents are the same as in example 3, except that the thickness ratio of the magnetic powder adhesive film 2211 to the carbon fiber cloth 2212 is different, as shown in fig. 9 and 10, fig. 9 shows the magnetic powder adhesive film 2211 (thickness is shown in fig. 9)T sm ) With carbon fiber 2212 (thickness)T sc ) The relationship between the thickness ratio and the residual magnetic induction intensity, the magnetic powder component is the lowest when the thickness ratio is 1:1, the thickness ratio is larger than 4:1, the glue film preparation process difficulty is high, the stress is uneven after rolling, and the delamination is easy to occur at high speed, therefore, the thickness ratio of the magnetic powder glue film 2211 to the carbon fiber cloth 2212 is preferably 2:1 and 3:1, and is further preferably 3:1 through test comparison. FIG. 10 shows the magnetic properties of the magnetic powder film 2211T when the novel composite magnetic material is tested in different thickness ratios ex With carbon fiber 2212T cb Are 1:1, 2:1 and 3:1, the residual induction strengths of the novel composite magnetic material are 0.199T, 0.302T and 0.394T respectively.
Example 15
A sinusoidal air gap flux density high-speed permanent magnet motor rotor and a preparation method thereof are the same as embodiment 3 in other contents, and only a coil is arranged in a hollow hole of a rotating shaft, so that Halbach magnetizing efficiency is higher.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (10)
1. A high-speed permanent magnet motor rotor with sine air gap flux density is characterized in that: the high-speed permanent magnet motor rotor comprises a rotating shaft (1), a Halbach array structure (2) arranged on the outer side of the rotating shaft (1), magnetic isolation end rings (3) arranged at two ends of the Halbach array structure (2) and a ventilation structure (4) arranged in the rotating shaft (1), wherein the Halbach array structure (2) forms a plurality of magnetic poles, and the ventilation structure (4) is a ventilation hole used for reducing the temperature of the high-speed permanent magnet motor rotor;
the Halbach array structure (2) comprises a permanent magnet layer (21), a magnetic powder glue film/carbon fiber unit (22) and a carbon fiber sheath (23) which are sequentially arranged on the outer side of the rotating shaft (1), the permanent magnet layer (21) comprises at least two permanent magnet blocks (211) which are embedded and bonded on the outer side of the rotating shaft (1) and are pre-oriented, the magnetic powder glue film/carbon fiber unit (22) comprises at least two layers of magnetic powder glue film fiber composite structures (221) wound on the outer side of the permanent magnet layer (21), each magnetic powder glue film/carbon fiber composite structure (221) comprises a magnetic powder glue film (2211) and a carbon fiber cloth (2212) compounded on the lower side of the magnetic powder glue film (2211), and each magnetic powder glue film (2211) comprises magnetic powder and epoxy resin; the carbon fiber sheath (23) is wound on the outer side of the magnetic powder adhesive film/carbon fiber unit (22);
the permanent magnet layer (21), the magnetic powder glue film/carbon fiber unit (22) and the carbon fiber sheath (23) are wholly Halbach magnetized, and the magnetism isolating end ring (3) is arranged at the two ends of the magnetic powder glue film/carbon fiber unit (22) and the carbon fiber sheath (23) and at the outer side of the rotating shaft (1).
2. The sinusoidal air gap flux density high speed permanent magnet machine rotor of claim 1, wherein: the magnetic powder is distributed in the magnetic powder adhesive film (2211) in a discrete mode, and the air gap flux density of the high-speed permanent magnet motor rotor is close to sine.
3. The sinusoidal air gap flux density high speed permanent magnet machine rotor of claim 1, wherein: the rotating shaft (1) comprises a rotating shaft body (11) and permanent magnet mounting grooves (12) arranged on the outer surface of the rotating shaft body (11), and the rear upper surfaces of the permanent magnet blocks (211) mounted in the permanent magnet mounting grooves (12) are flush with the upper surfaces of the two ends of the rotating shaft body (11);
the rotating shaft (1) is made of a non-magnetic alloy material, and knurling is performed on the surface of the rotating shaft (1);
the ventilation structure (4) comprises an L-shaped ventilation hole (41) which is arranged in the rotating shaft (1) in a penetrating mode, the L-shaped ventilation hole (41) comprises a straight hole (411) which is arranged along the axis of the rotating shaft (1) and an inclined hole (412) which is communicated with the tail end of the straight hole (411), and the bending angle between the inclined hole (412) and the straight hole (411) is 30-60 degrees;
the volume ratio of the magnetic powder in the magnetic powder adhesive film/carbon fiber unit (22) is 60-80%, the particle size of the magnetic powder is 50-200 μm, the particle size ratio is 3;
the outer end shaft end of the magnetic isolation end ring (3) is of a conical structure, and the magnetic isolation end ring (3) and the rotating shaft (1) are in interference fit.
4. A sinusoidal air gap flux density high speed permanent magnet machine rotor according to claim 3, wherein: the particle size of the magnetic powder is 100mm and 50mm, and the mass ratio is 3:1;
the magnetic powder is neodymium iron boron hard magnetic particles or samarium cobalt hard magnetic particles;
the ventilation structure (4) further comprises a center hole (42) arranged in the center of the rotating shaft (1).
5. A preparation method of a high-speed permanent magnet motor rotor with a sinusoidal air gap flux density is characterized by comprising the following steps: the method comprises the following steps:
s1, preparing a magnetic powder adhesive film: mixing magnetic powder, epoxy resin and a solvent in proportion, uniformly stirring and pouring into a film drawing die, uniformly drawing a push rod at a uniform speed to uniformly draw Cheng Denghou adhesive films, and curing to obtain magnetic powder adhesive films (2211), wherein the solvent is a volatile solvent;
s2, rotating shaft processing: knurling the surface of the rotating shaft (1);
s3, installing a Halbach array structure: sequentially installing a Halbach array structure (2) and a magnetic isolation end ring (3) on the outer side of the rotating shaft (1) and curing the Halbach array structure, wherein the Halbach array structure (2) comprises a permanent magnet layer (21), a magnetic powder adhesive film/carbon fiber unit (22) and a carbon fiber sheath (23) which are sequentially arranged, the magnetic powder adhesive film/carbon fiber unit (22) comprises a magnetic powder adhesive film carbon fiber composite structure (221) which is rolled layer by layer, and each layer of the magnetic powder adhesive film carbon fiber composite structure (221) comprises a magnetic powder adhesive film (2211) and a carbon fiber cloth (2212);
s4, halbach magnetizing: and (3) carrying out integral Halbach magnetizing on the Halbach array structure (2) by using a sinusoidal magnetic field to form a plurality of magnetic poles, and completing the preparation of the high-speed permanent magnet motor rotor with sinusoidal air gap flux density.
6. The method for preparing the rotor of the high-speed permanent magnet motor with the sinusoidal air gap flux density according to claim 5, wherein the method comprises the following steps: step S3 includes the following steps:
s31, pre-fetching the permanent magnet blocks (211) and uniformly bonding the pre-fetched permanent magnet blocks in the permanent magnet mounting grooves (12) to obtain the permanent magnet layer (21);
s32, spreading the magnetic powder adhesive film (2211) on the upper layer of the carbon fiber cloth (2212) to obtain a magnetic powder adhesive film carbon fiber composite structure (221), then rolling the magnetic powder adhesive film carbon fiber composite structure (221) on the outer side of the permanent magnet layer (21) layer by layer, and curing to obtain the magnetic powder adhesive film/carbon fiber unit (22);
s33, winding a carbon fiber sheath (23) on the outer side of the magnetic powder adhesive film/carbon fiber unit (22) and then curing;
and S34, assembling the magnetism isolating end rings (3) on two sides of the Halbach array structure (2) and on the outer side of the rotating shaft (1) in an interference fit mode.
7. The method for preparing the rotor of the high-speed permanent magnet motor with the sinusoidal air gap flux density according to claim 5, wherein the method comprises the following steps: in the step S1, the particle size of the magnetic powder is 50 to 200 μm, the particle size ratio is 3 to 1, the solvent is acetone or toluene, the mass ratio of the solvent is 10 to 15%, the thickness of the carbon fiber cloth (2212) is 0.06 to 0.12mm, the stirring time is 0.5 to 10 minutes, the film drawing speed is 20 to 50m/min, the curing mode of the uniform-thickness adhesive film is normal-temperature curing, and the magnetic powder adhesive film (2211) and the carbon fiber cloth (2212) are cured by heating.
8. The method for preparing the rotor of the high-speed permanent magnet motor with the sinusoidal air gap flux density as claimed in claim 7, wherein the method comprises the following steps: the particle size of the magnetic powder is 100mm and 50mm, and the particle size ratio is 3:1.
9. The method for preparing the rotor of the high-speed permanent magnet motor with the sinusoidal air gap flux density as claimed in claim 5, wherein the method comprises the following steps: step S2 further includes: set up L shape ventilation hole (41) and/or centre bore (42) on pivot (1), L shape ventilation hole (41) are followed pivot (1) axial evenly distributed.
10. The method for preparing the rotor of the high-speed permanent magnet motor with the sinusoidal air gap flux density as claimed in claim 6, wherein the method comprises the following steps: in the step S31, the permanent magnet blocks (211) comprise 16 permanent magnet blocks which are distributed along an X axis and a Y axis in a mirror image mode on a section perpendicular to the rotating shaft (1), and the permanent magnet blocks are numbered from 1 to 16 in a clockwise direction from the highest point;
in the step S4, after Halbach is magnetized, the magnetic field of the permanent magnet No. 1 is parallel to the Y axis, the magnetic field of the permanent magnet No. 2 forms an included angle of 70 degrees with the X axis, the magnetic field of the permanent magnet No. 3 forms an included angle of 45 degrees with the X axis, the magnetic field of the permanent magnet No. 4 forms an included angle of 20 degrees with the X axis, and the magnetic field of the permanent magnet No. 5 is parallel to the X axis.
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| CN1761130A (en) * | 2004-10-11 | 2006-04-19 | 中国科学院电工研究所 | A kind of permanent magnet synchronous motor |
| CN203119650U (en) * | 2013-03-25 | 2013-08-07 | 山东颜山泵业有限公司 | Bidirectional positioning device for servo submersible motor rotor magnetic steel |
| CN112039240A (en) * | 2020-09-16 | 2020-12-04 | 沈阳工业大学 | Hybrid excitation type high-speed permanent magnet motor rotor and manufacturing method |
| CN112615450A (en) * | 2020-09-16 | 2021-04-06 | 山东大学 | Composite rotor suitable for high-speed permanent magnet motor |
| CN112615449A (en) * | 2020-09-16 | 2021-04-06 | 山东大学 | Multilayer structure hybrid excitation rotor and manufacturing method thereof |
| CN113270957A (en) * | 2021-07-19 | 2021-08-17 | 北京航空航天大学 | Novel high-speed motor multilayer carbon fiber-magnetic powder composite rotor and manufacturing method |
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2023
- 2023-03-09 CN CN202310220999.XA patent/CN115940459B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1761130A (en) * | 2004-10-11 | 2006-04-19 | 中国科学院电工研究所 | A kind of permanent magnet synchronous motor |
| CN203119650U (en) * | 2013-03-25 | 2013-08-07 | 山东颜山泵业有限公司 | Bidirectional positioning device for servo submersible motor rotor magnetic steel |
| CN112039240A (en) * | 2020-09-16 | 2020-12-04 | 沈阳工业大学 | Hybrid excitation type high-speed permanent magnet motor rotor and manufacturing method |
| CN112615450A (en) * | 2020-09-16 | 2021-04-06 | 山东大学 | Composite rotor suitable for high-speed permanent magnet motor |
| CN112615449A (en) * | 2020-09-16 | 2021-04-06 | 山东大学 | Multilayer structure hybrid excitation rotor and manufacturing method thereof |
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