CN116404777B - Rotor without main magnetic bridge and manufacturing method of rotor - Google Patents
Rotor without main magnetic bridge and manufacturing method of rotor Download PDFInfo
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- CN116404777B CN116404777B CN202310186845.3A CN202310186845A CN116404777B CN 116404777 B CN116404777 B CN 116404777B CN 202310186845 A CN202310186845 A CN 202310186845A CN 116404777 B CN116404777 B CN 116404777B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 10
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 84
- 239000010959 steel Substances 0.000 claims abstract description 84
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 26
- 239000011810 insulating material Substances 0.000 claims abstract description 26
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 25
- 239000004917 carbon fiber Substances 0.000 claims abstract description 25
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 24
- 230000002093 peripheral effect Effects 0.000 claims abstract description 19
- 239000000853 adhesive Substances 0.000 claims description 18
- 230000001070 adhesive effect Effects 0.000 claims description 18
- 230000005389 magnetism Effects 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 7
- 230000000694 effects Effects 0.000 abstract description 8
- 230000004907 flux Effects 0.000 abstract 1
- 238000002955 isolation Methods 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 229910000976 Electrical steel Inorganic materials 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 229920006351 engineering plastic Polymers 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 238000007142 ring opening reaction Methods 0.000 description 1
- 238000010408 sweeping Methods 0.000 description 1
Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
- H02K1/2753—Inner 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
- H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
Abstract
The application relates to the technical field of motors and discloses a rotor without a main magnetic bridge and a manufacturing method of the rotor, wherein the rotor comprises one or more rotor subunits and a carbon fiber sleeve surrounding the periphery of the rotor subunits, and the rotor subunits comprise an iron core part and a magnetic steel subunit; the iron core part comprises a first part positioned at the center and a plurality of second parts positioned at the periphery, the first part and the second parts are arranged at intervals, so that an inner side groove is formed between the first part and the second part, the inner side groove comprises an inner side first groove, an inner side second groove and an inner side third groove, and the inner side third groove is communicated with the inner side first groove and the inner side second groove; the inner third groove is formed in a semi-annular shape open toward an outer peripheral side of the core portion, the second portion includes a hook portion partially formed by the inner third groove, and a first filling region is formed between the hook portion and the inner third groove, and is filled with an insulating material. The rotor magnetic flux leakage problem relieving effect is achieved.
Description
Technical Field
The present application relates to the field of electric machines, and in particular to a rotor without a main magnetic bridge.
Background
For permanent magnet motors with high rotational speeds, such as drive motors for new energy vehicles, the rotor of the motor has to withstand very high centrifugal forces at high rotational speeds, which puts high demands on the mechanical strength of the rotor core.
One common method of increasing the strength of the rotor core in the prior art is to increase the thickness of the magnetic isolation bridge, however, as the thickness of the magnetic isolation bridge increases, the magnetic leakage will also increase, and the power density of the motor is affected.
Tesla patent application WO2021225902A1 discloses a motor rotor using carbon fiber windings without magnetic bridges. By winding carbon fibers around the outer periphery of the motor rotor, the rotor core is pre-pressed against the centrifugal force, and the mechanical strength of the rotor can be increased.
However, in order to meet the high rotational speed of the motor, the winding thickness of the carbon fiber layer is not negligible. The thickness of the carbon fiber layer is increased, so that the cost is increased; moreover, as the thickness of the carbon fiber layer increases, for certain motors, the gap between the rotor and the stator becomes smaller, and too small a gap may affect smooth rotation of the rotor in the stator, and even "sweeping" may occur, which is undesirable in production and application.
Disclosure of Invention
In order to alleviate the problem of rotor magnetic leakage on the premise of guaranteeing the mechanical strength of a rotor core, the application provides a rotor without a main magnetic bridge.
The application provides a rotor without main magnetic bridge, adopts following technical scheme:
a rotor without a main magnetic bridge, comprising one or more rotor subunits and a carbon fiber sleeve surrounding the periphery of the rotor subunits, wherein the rotor subunits comprise an iron core part and a magnetic steel subunit; the core part comprises a first part positioned at the center and a plurality of second parts positioned at the periphery, wherein the first part and the second parts are arranged at intervals, so that an inner side groove is formed between the first part and the second part, the inner side groove comprises an inner side first groove, an inner side second groove and an inner side third groove, and the inner side third groove is communicated with the inner side first groove and the inner side second groove; the inner third groove is formed in a semi-annular shape with an opening facing the outer peripheral side of the core portion, the second portion includes a hook portion partially formed by the inner third groove, a first filling area is formed between the hook portion and the inner third groove, and an insulating material is filled in the first filling area.
By adopting the technical scheme, the iron core part of the rotor subunit is split and comprises a first part positioned in the center and a plurality of second parts positioned at the periphery, so that the rotor is not provided with a main magnetic isolation bridge, and the magnetic leakage phenomenon is greatly reduced; the hook part which has magnetism isolation and connection functions and is surrounded by the semicircular inner side third groove is arranged on the second part, a first filling area is formed between the hook part and the inner side third groove, insulating materials are filled in the first filling area, the hook part acts as a function similar to a hook or an anchor through the insulating materials filled in the inner side third groove, the first part and the second part are tightly connected, and therefore the phenomenon of structural strength reduction caused by cancellation of the main magnetism isolation bridge is greatly improved.
Optionally, the rotor subunits are plural, the plural rotor subunits are stacked together in the axial direction, and the magnetic steel subunits of at least two rotor subunits are not aligned in the axial direction.
By adopting the technical scheme, the magnetic steel subunits of at least two rotor subunits are not aligned in the axial direction, so that the rotor forms oblique poles, and the harmonic influence of the rotor is reduced.
Optionally, the core portion is formed by stacking a plurality of core pieces in a single piece.
Optionally, the magnetic steel subunit includes an inner first magnetic steel disposed in the inner first slot and an inner second magnetic steel disposed in the inner second slot, and an adhesive is disposed at least in a region located radially inward of the core portion at a portion where the inner first magnetic steel contacts the wall of the inner first slot; and the part of the inner second magnetic steel, which is contacted with the wall of the inner second groove, is provided with an adhesive at least in the area positioned at the radial inner side of the iron core part.
By adopting the technical scheme, the inner first magnetic steel and the inner second magnetic steel are bonded and fixed with the first part by using the adhesive, so that part of centrifugal force of the inner first magnetic steel and the inner second magnetic steel which are subjected to centrifugal force action under a rotating state and have a tendency of moving towards the peripheral side is restrained.
Optionally, a second filling area is arranged between the first portion and the second portion, the second filling area is located at one side of the magnetic steel subunit away from the first filling area, and insulating materials are poured into the second filling area.
By adopting the technical scheme, insulating materials are filled in the second filling area, so that the magnetic leakage phenomenon is reduced.
Optionally, the hook portion includes a connecting portion and a clamping portion, the connecting portion extends along a radial direction of the core portion, the clamping portion is located at an end of the connecting portion, which is close to an inner peripheral side of the core portion, in a circumferential direction of the core portion, a size of the clamping portion is larger than a size of the connecting portion.
By adopting the technical scheme, the connecting part has a certain extension length in the radial direction, and a bridge which is long enough and connects the two side areas is created; the clamping part forms a certain width in the circumferential direction, so that the connecting force born by the clamping part is shared in all circumferential directions, and the first part and the second part are more firmly connected.
Optionally, the second part is provided with an outer groove symmetrical in the circumferential direction, and the outer groove comprises an outer first groove and an outer second groove which are communicated with each other; the magnetic steel subunit further comprises outer first magnetic steel arranged in the outer first groove and outer second magnetic steel arranged in the outer second groove; the outer groove is positioned on the outer peripheral side of the inner groove, and the middle part of the outer groove is opposite to the hook part along the radial direction of the rotor.
Optionally, the carbon fiber sleeve has a thickness of no more than 1.5mm.
The application also provides a manufacturing method of the rotor without the main magnetic bridge, which comprises the following steps:
step S1, providing a certain number of iron core single sheets, and superposing a plurality of iron core single sheets to form an iron core part;
s2, inserting the magnetic steel subunit into the inner groove;
s3, filling insulating materials into the first filling area to obtain a rotor subunit;
and S4, stacking a plurality of rotor subunits together, and sleeving the carbon fiber sleeve on the outer side of the rotor subunits to form the rotor.
By adopting the technical scheme, the iron core single sheets are designed in a split mode, a plurality of iron core single sheets are stacked together by means of a tool, and the structural characteristics of the iron core single sheets for inserting the magnetic steel subunit are ensured to be aligned in the axial direction; and after the magnetic steel subunits are fixed, insulating materials are poured into the first filling area and the second filling area, so that a rotor subunit formed by splicing a plurality of parts forms a firm whole.
Optionally, the step S4 further includes: the magnetic steel subunits of at least two rotor subunits are not aligned in the axial direction.
By adopting the technical scheme, at least one rotor subunit is rotated, so that the magnetic steel subunits of at least two rotor subunits are not aligned in the axial direction, the rotor is inclined, and the harmonic influence of the rotor is weakened.
In summary, the present application includes at least one of the following beneficial technical effects:
1. the rotor is not provided with a main magnetism isolating bridge, the magnetic leakage phenomenon is greatly reduced, the second part is provided with the hook part which has magnetism isolating and connecting functions and is surrounded by the semicircular inner side third groove, a first filling area is formed between the hook part and the inner side third groove, the first filling area is filled with insulating materials, the hook part acts as a function similar to a hook or an anchor through the insulating materials filled in the inner side third groove, and the first part and the second part are tightly connected together, so that the phenomenon of reduced structural strength caused by cancellation of the main magnetism isolating bridge is greatly improved;
2. the magnetic steel subunits of at least two rotor subunits are arranged in an unaligned manner in the axial direction, so that the rotor forms an oblique pole, and the harmonic influence of the rotor is weakened;
3. the first inner magnetic steel and the second inner magnetic steel are bonded and fixed to the first portion by an adhesive, so that a part of centrifugal force of the first inner magnetic steel and the second inner magnetic steel, which tend to move toward the outer periphery due to centrifugal force in a rotating state, is restrained.
Drawings
FIG. 1 is a schematic view of a core portion of a rotor in an embodiment of the present application (with some structural features omitted);
FIG. 2 is a schematic structural view of a monolithic portion of a core in an embodiment of the present application;
FIG. 3 is a schematic structural view of a first portion in an embodiment of the present application;
FIG. 4 is an enlarged partial schematic view of FIG. 2;
FIG. 5 is a schematic cross-sectional view of a rotor in an embodiment of the present application;
fig. 6 is a schematic structural diagram of a rotor unit in an embodiment of the present application.
Reference numerals: s, a rotor; SU, rotor subunits; 10s, iron core part; 10. a single iron core; 11. a first portion; 111. a center portion; 112. a peak; 113. a valley portion; 114. an outer side portion; 115. an inner side portion; 116. a neck; 12. a second portion; 121. a main body portion; 122. a hook portion; 123. a connection part; 124. a clamping part; 20. a magnetic steel subunit; 21. an inner first magnetic steel; 22. an inner second magnetic steel; 23. an outer first magnetic steel; 22. outer second magnetic steel; 30. an inner groove; 31. an inner first groove; 32. an inner second groove; 33. an inner third groove; 40. an outer groove; 41. an outer first groove; 42. an outer second groove; 50. a carbon fiber sleeve; a1, a first filling area; a2, a second filling area; a3, a third filling area; ag. And (5) an adhesive area.
Detailed Description
The present application is described in further detail below in conjunction with figures 1-6.
The embodiment of the application discloses a rotor without a main magnetic bridge, wherein the radial direction in the embodiment is the radial direction of a motor rotor S, and the circumferential direction is the circumferential direction of the motor rotor S unless specifically stated.
Referring to fig. 1 and 2, a rotor without a main magnetic bridge includes a plurality of rotor sub-units SU stacked together, the plurality of rotor sub-units SU are coaxially disposed, a carbon fiber cover 50 is coated on the outer circumference of the rotor sub-units SU, and the carbon fiber cover 50 applies pre-compression to the rotor sub-units SU to resist centrifugal force, thereby increasing the mechanical strength of the rotor S.
Referring to fig. 1 to 3, the rotor subunit SU includes an iron core portion 10s, and the iron core portion 10s is formed by stacking a plurality of iron core single pieces 10, also called silicon steel sheets. Each core segment 10 in this embodiment is identical.
Referring to fig. 2 and 3, the core portion 10s includes a first portion 11 at the center and a plurality of (six in the present embodiment) second portions 12 at the periphery, the plurality of second portions 12 being arranged at equal intervals in the circumferential direction. The first portion 11 and the second portion 12 are provided separately.
The first portion 11 includes a central portion 111 and a plurality of (6 in the present embodiment) peak portions 112 protruding toward the outer peripheral side in the radial direction of the motor rotor S, the plurality of peak portions 112 being disposed at equal intervals in the circumferential direction of the central portion 111. A valley 113 is formed between two adjacent peaks 112, and the valley 113 has a funnel-shaped structure.
The funnel-shaped valley portion 113 includes an outer side portion 114 on the outer peripheral side, an inner side portion 115 on the inner peripheral side, and a neck portion 116 connecting the outer side portion 114 and the inner side portion 115. The outer side portion 114 is formed as a trumpet-shaped channel, and the inner side portion 115 is formed as a groove opening toward the outer peripheral side. In the circumferential direction, the width of the neck 116 is smaller than the width of the outer side 114 and the inner side 115.
The second portion 12 includes a fan-shaped main body portion 121 and a hook portion 122, the hook portion 122 includes a connecting portion 123 and a click portion 124, the connecting portion 123 extends in the radial direction of the core portion 10s, and the click portion 124 is located at one end of the connecting portion 123 near the inner peripheral side of the core portion 10s. The dimension of the catching portion 124 is larger than the dimension of the connecting portion 123 in the circumferential direction of the core portion 10s. When the first portion 11 and the second portion 12 are assembled, the body portion 121 extends into the outer side portion 114; the hook 122 extends partially into the inner portion 115 through the neck 116, wherein the connecting portion 123 extends through the neck 116, and the engaging portion 124 is received in the inner portion 115.
Referring to fig. 4 and 5, there is a certain gap between the first portion 11 and the second portion 12 such that, in a cross section of the core portion 10s perpendicular to the axial direction, an inner groove 30 symmetrical in the circumferential direction is formed between the first portion 11 and each of the second portions 12, the inner groove 30 being substantially V-shaped.
The inner side groove 30 includes an inner side first groove 31 and an inner side second groove 32 which are symmetrically disposed, the inner side first groove 31 and the inner side second groove 32 being communicated through an inner side third groove 33, the inner side third groove 33 being located between the inner side first groove 31 and the inner side second groove 32. The inner third groove 33 has a meandering course in the cross-section shown in the drawing, so that it forms a semi-ring shape in this cross-section, the semi-ring opening facing in the peripheral direction.
The inside third groove 33 is filled with an insulating material such as a resin or reinforced engineering plastic so as to form a first filling area A1. For example, when the insulating material is selected from reinforced engineering plastics, it may be selected from, for example, nylon and fiberglass.
Referring to fig. 4 to 6, the rotor subunit SU further includes a magnetic steel subunit 20, and the magnetic steel subunit 20 includes an inner first magnetic steel 21 and an inner second magnetic steel 22 arranged in a splayed shape. The inner first groove 31 and the inner second groove 32 are for accommodating the inner first magnetic steel 21 and the inner second magnetic steel 22, respectively.
The above-described structure is such that the rotor S does not have a main magnetic shield (the so-called main magnetic shield is located at a position occupied by a second filling area A2 described later) by devising the core portion 10S to include the first portion 11 at the center and the plurality of second portions 12 at the periphery in a split manner, and the magnetic leakage phenomenon is greatly reduced.
Meanwhile, the second part 12 is provided with the hook part 122 which has magnetism isolating and connecting functions and is surrounded by the semicircular inner side third groove 33, and the insulating material in the first filling area A1 at the periphery of the hook part 122 is equivalent to one part of a magnetism isolating bridge on one hand, so that the magnetism leakage limiting function is realized; on the other hand, it also serves as a structural connection. The insulating material in the first filling area A1 can connect the hook 122 with the first portion 11 of the core portion 10s located at the inner periphery of the inner third slot 33 in terms of structural connection. In other words, the hook 122 serves as a hook or anchor by way of the insulating material filled in the inner third groove 33, closely connecting the first portion 11 and the second portion 12 together, so that the phenomenon of the reduction in structural strength due to the elimination of the main magnetic barrier bridge is greatly improved.
Referring to fig. 4 and 5, a second filling area A2 is provided between the first portion 11 and the second portion 12. The second filling area A2 is positioned on one side of the inner side first magnetic steel 21 and the inner side second magnetic steel 22, which is far away from the first filling area A1, and insulating materials are filled in the second filling area A2. The insulating material in the second filling area A2 reduces the magnetic leakage phenomenon and simultaneously increases the integral structural strength of the rotor.
Referring to fig. 5 and 6, the second portion 12 is provided with an outer groove 40 having a substantially V-shape, and the outer groove 40 is located on the outer peripheral side of the inner groove 30. The outer side groove 40 comprises an outer side first groove 41 and an outer side second groove 42 which are communicated, wherein the outer side first groove 41 is internally provided with the outer side first magnetic steel 23, the outer side second groove 42 is internally provided with the outer side second magnetic steel 24, and the outer side first magnetic steel 23 and the outer side second magnetic steel 24 are arranged in a splayed shape. The hook 122 is radially opposed to the intermediate region of the outer first magnetic steel 23 and the outer second magnetic steel 24 (or the outer groove 40) located on the outer peripheral side thereof, and the outer groove 40 maintains air insulation in the region between the outer first magnetic steel 23 and the outer second magnetic steel 24.
Referring to fig. 4 and 5, the outside first groove 41 and the outside second groove 42 are each provided with a third filling area A3, the third filling area A3 is located at one end of the outside first magnetic steel 23 and the outside second magnetic steel 24 away from the hook 122, and the third filling area A3 is filled with an insulating material. The insulating material in the third filling area A3 reduces the magnetic leakage phenomenon and simultaneously increases the integral structural strength of the rotor.
Referring to fig. 2, 4 and 5, an adhesive is provided between the inner peripheral side surface of the inner first magnetic steel 21 facing the core portion 10s and the wall of the inner first slot 31, and an adhesive is provided between the inner peripheral side surface of the inner second magnetic steel 22 facing the core portion 10s and the wall of the inner second slot 32, that is, an adhesive area Ag is formed between the inner first magnetic steel 21 and the first portion 11 of the core portion and between the inner second magnetic steel 22 and the first portion 11 of the core portion. In this embodiment, the adhesive is a magnetic steel adhesive. The adhesive area Ag can bind a part of centrifugal force of the inner first magnetic steel 21 and the inner second magnetic steel 22 which are subject to centrifugal force action in a rotating state and have a tendency to move to the outer peripheral side; on the other hand, similar to the effect of the hooks 122, the adhesive area Ag connects the second portion 12 with weak structural strength with the first inner magnetic steel 21 and the second inner magnetic steel 22 together with the first portion 11.
The thickness of the carbon fiber sheath 50 may not exceed 1.5mm on the basis of structural reinforcement of the core portion 10s by the hook 122 and the inner third groove 33 filled with an insulating material. In the present embodiment, the carbon fiber sheath 50 has a thickness of 0.7mm.
It should be understood that the above-described effects of the structural strength of the reinforcing core portion 10s exerted by the carbon fiber cover 50, the hook 122 and the inner third slot 33 filled with the insulating material complement each other. That is, not only the presence of the hook portion 122 allows the thickness of the carbon fiber cover 50 to be small, but also the presence of the carbon fiber cover 50 allows the connection effect of the hook portion 122 to the core portion 10s to be sufficient. The effect "sufficient" here means that, for example, the third filling area A3 may also be filled with no insulating material; for another example, the structure of each silicon steel sheet in the present embodiment is the same, and it is not necessary to provide a differential structure between adjacent silicon steel sheets to further improve the structural strength of the motor rotor S.
Referring to fig. 1, the magnetic steel subunits 20 of each rotor subunit SU are not aligned in the axial direction. In this way, the magnetic field of the rotor S forms a skewed pole, so that the harmonic effect of the rotor S can be reduced. It should be appreciated that in other possible embodiments, the magnet steel subunits 20 of at least two adjacent rotor subunits SU are not axially aligned.
The application also discloses a manufacturing method for manufacturing the rotor without the main magnetic bridge, which comprises the following steps:
step S1, a core segment 10S corresponding to the single rotor subunit SU is fabricated. A number of core segments 10 are prepared according to the machining requirements, for example by means of a tooling, a plurality of core segments 10 are stacked coaxially and in axial alignment, and it is ensured that the structural features of the core segments 10 for inserting the magnetic steel subunits 20 are aligned in the axial direction.
And S2, inserting magnetic steel. The inner first magnetic steel 21 and the inner second magnetic steel 22 are respectively inserted into the corresponding inner grooves 30, the outer first magnetic steel 23 and the outer second magnetic steel 24 are respectively inserted into the corresponding outer grooves 40, and the magnetic steel sub-units 20 are adhered to the adhesive areas Ag of the iron core part 10s by adding adhesives. Due to the split design of the core single piece 10, the operation of setting the adhesive in the adhesive area Ag is easy to realize in the assembly process.
Step S3, a rotor subunit SU is formed. Insulating material is poured into the first filling area A1 and the second filling area A2, so that a rotor subunit SU formed by splicing a plurality of parts forms a firm whole.
And S4, forming a rotor. A plurality of rotor subunits SU are stacked together, and a carbon fiber sleeve 50 is sleeved on the outer side of the rotor subunits SU to form a rotor S. Preferably, the magnetic steel subunits 20 of at least two rotor subunits SU are axially misaligned so that the rotor S forms a skewed pole, reducing the harmonic effects of the rotor S.
In contrast to the tesla disclosure mentioned in the background section of the present application, the hook 122 and the first filling area A1 in the present application are configured such that the first portion 11 and the second portion 12 can form a complete whole with a certain structural strength during the assembly process, and thus the intermediate piece, i.e. the rotor subunit SU, provided in the present application is not provided with the carbon fiber sheath 50. In a subsequent assembly process, one or more rotor subunits SU may be stacked as desired and then covered with carbon fiber jacket 50 to form the final rotor S.
The assembly process is carried out in a segmented manner, so that the assembly difficulty is reduced; in addition, in the production practice, the rotor subunits SU may be manufactured in batch in advance as components, and then, according to the needs of different rotors S, a plurality of rotor subunits SU may be selected to be spliced, and then, the carbon fiber sheath 50 is wrapped.
However, the two parts of the rotor lamination in tesla publication cannot form a whole with a certain structural strength during the assembly process, so that the lamination assembly and the carbon fiber layer coating must be performed simultaneously, which not only increases the assembly difficulty, but also cannot form a bevel pole.
The foregoing are all preferred embodiments of the present application, and are not intended to limit the scope of the present application in any way, therefore: all equivalent changes in structure, shape and principle of this application should be covered in the protection scope of this application. For example:
in other possible embodiments, the rotor S may not include the outer magnetic steel, or the rotor S may include the outer magnetic steel forming more layers in the radial direction.
Claims (10)
1. A rotor without a main magnetic bridge, characterized by: comprises one or more rotor Subunits (SU) and a carbon fiber sleeve (50) surrounding the periphery of the rotor Subunits (SU), wherein the rotor Subunits (SU) comprise an iron core part (10 s) and a magnetic steel subunit (20);
the core part (10 s) comprises a first part (11) positioned at the center and a plurality of second parts (12) positioned at the periphery, wherein the first part (11) and the second parts (12) are arranged at intervals so as to form an inner side groove (30) between the first part (11) and the second part (12), the inner side groove (30) comprises an inner side first groove (31), an inner side second groove (32) and an inner side third groove (33), and the inner side third groove (33) is communicated with the inner side first groove (31) and the inner side second groove (32);
the inner third groove (33) is formed in a semi-annular shape with an opening facing the outer peripheral side of the iron core part (10 s), the second part (12) comprises a hook part (122) which is partially surrounded by the inner third groove (33), the hook part (122) and the main body part of the second part (12) are integrally formed, a first filling area (A1) is formed between the hook part (122) and the inner third groove (33), and an insulating material is filled in the first filling area (A1) in a filling mode to serve as a magnetism isolating area.
2. A rotor without a main magnetic bridge according to claim 1, wherein: the rotor Subunits (SU) are stacked together in an axial direction, and the magnetic steel subunits (20) of at least two of the rotor Subunits (SU) are not aligned in the axial direction.
3. A rotor without a main magnetic bridge according to claim 1, wherein: the core part (10 s) is formed by stacking a plurality of core single pieces (10).
4. A rotor without a main magnetic bridge according to claim 2, characterized in that: the magnetic steel subunit (20) comprises an inner first magnetic steel (21) arranged in the inner first groove (31) and an inner second magnetic steel (22) arranged in the inner second groove (32), wherein an adhesive is arranged at least in a region positioned radially inside the iron core part (10 s) at a part where the inner first magnetic steel (21) is contacted with the wall of the inner first groove (31); the portion of the inner second magnetic steel (22) in contact with the wall of the inner second groove (32) is provided with an adhesive at least in a region located radially inward of the core portion (10 s).
5. A rotor without a main magnetic bridge according to claim 1, wherein: a second filling area (A2) is arranged between the first part (11) and the second part (12), the second filling area (A2) is positioned at one side of the magnetic steel subunit (20) away from the first filling area (A1), and insulating materials are filled in the second filling area (A2).
6. A rotor without a main magnetic bridge according to claim 1, wherein: the hook portion (122) comprises a connecting portion (123) and a clamping portion (124), the connecting portion (123) extends along the radial direction of the iron core portion (10 s), the clamping portion (124) is located at one end, close to the inner peripheral side of the iron core portion (10 s), of the connecting portion (123), in the circumferential direction of the iron core portion (10 s), and the size of the clamping portion (124) is larger than that of the connecting portion (123).
7. A rotor without a main magnetic bridge according to claim 1, wherein: the second part (12) is provided with outer grooves (40) symmetrical in the circumferential direction, and the outer grooves (40) comprise an outer first groove (41) and an outer second groove (42) which are communicated with each other; the magnetic steel subunit (20) further comprises an outer first magnetic steel (23) arranged in the outer first groove (41) and an outer second magnetic steel (24) arranged in the outer second groove (42); the outer groove (40) is located on the outer peripheral side of the inner groove (30), and the middle part of the outer groove (40) is opposite to the hook part (122) along the radial direction of the rotor (S).
8. A rotor without a main magnetic bridge according to claim 1, wherein: the carbon fiber sheath (50) has a thickness of not more than 1.5mm.
9. A method of manufacturing a rotor without a main magnetic bridge as claimed in any one of claims 1 to 8, comprising the steps of:
step S1, providing a certain number of iron core single sheets (10), and superposing a plurality of iron core single sheets (10) to form an iron core part (10S);
s2, inserting the magnetic steel subunit (20) into the inner groove (30);
s3, filling insulating materials into the first filling area (A1) to obtain a rotor Subunit (SU);
and S4, stacking a plurality of rotor Subunits (SU), and sleeving a carbon fiber sleeve (50) on the outer side of the rotor Subunits (SU) to form the rotor (S).
10. The method for manufacturing a rotor without a main magnetic bridge according to claim 9, wherein: step S4 further includes: the magnetic steel subunits (20) of at least two of the rotor Subunits (SU) are axially misaligned.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310186845.3A CN116404777B (en) | 2023-03-01 | 2023-03-01 | Rotor without main magnetic bridge and manufacturing method of rotor |
| PCT/CN2023/141276 WO2024120543A1 (en) | 2022-12-29 | 2023-12-22 | Motor rotor and method for manufacturing motor rotor |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310186845.3A CN116404777B (en) | 2023-03-01 | 2023-03-01 | Rotor without main magnetic bridge and manufacturing method of rotor |
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| CN116404777A CN116404777A (en) | 2023-07-07 |
| CN116404777B true CN116404777B (en) | 2024-03-05 |
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| WO2024120543A1 (en) * | 2022-12-29 | 2024-06-13 | 天蔚蓝电驱动科技(江苏)有限公司 | Motor rotor and method for manufacturing motor rotor |
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| CN209896884U (en) * | 2019-03-29 | 2020-01-03 | 郑州智驱科技有限公司 | Sectional type permanent magnet synchronous motor rotor |
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| CN116404777A (en) | 2023-07-07 |
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