CN117458751A - Rotor core and injection molding rotor - Google Patents
Rotor core and injection molding rotor Download PDFInfo
- Publication number
- CN117458751A CN117458751A CN202311500601.4A CN202311500601A CN117458751A CN 117458751 A CN117458751 A CN 117458751A CN 202311500601 A CN202311500601 A CN 202311500601A CN 117458751 A CN117458751 A CN 117458751A
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- Prior art keywords
- rotor core
- bridge
- rotor
- permanent magnet
- injection molding
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- 238000001746 injection moulding Methods 0.000 title claims abstract description 54
- 238000004080 punching Methods 0.000 claims abstract description 84
- 239000012778 molding material Substances 0.000 claims abstract description 14
- 238000002347 injection Methods 0.000 claims description 18
- 239000007924 injection Substances 0.000 claims description 18
- 238000003475 lamination Methods 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 8
- 238000000465 moulding Methods 0.000 claims description 5
- 239000003822 epoxy resin Substances 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 4
- 230000008093 supporting effect Effects 0.000 description 25
- 238000003780 insertion Methods 0.000 description 20
- 230000037431 insertion Effects 0.000 description 20
- 230000009286 beneficial effect Effects 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 230000005291 magnetic effect Effects 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 238000004378 air conditioning Methods 0.000 description 4
- 238000013461 design Methods 0.000 description 4
- 238000009434 installation Methods 0.000 description 4
- 238000012797 qualification Methods 0.000 description 4
- 230000002093 peripheral effect Effects 0.000 description 3
- 230000000903 blocking effect Effects 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 239000003302 ferromagnetic material Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000005415 magnetization Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000006223 plastic coating Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
Classifications
-
- 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
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Permanent Field Magnets Of Synchronous Machinery (AREA)
Abstract
The invention discloses a rotor core and an injection molding rotor, and relates to the technical field of motors, wherein the rotor core comprises a plurality of rotor punching sheets which are overlapped along the axial direction, at least one rotor punching sheet is arranged as an outer connecting bridge punching sheet, an outer connecting bridge is connected between every two adjacent outer sector areas of the outer connecting bridge punching sheet, the outer connecting bridge can limit the permanent magnet to move towards the radial outer direction of a mounting groove, the permanent magnet is restrained from being separated from the mounting groove, and the mounting stability of the permanent magnet is improved; the structure of the externally connected bridge type punching sheet can improve the structural stability of the rotor core; the pressure release groove is formed in one side of the outer connecting bridge, which faces the mounting groove, and injection molding materials are circulated through the spacing space formed by the pressure release groove while the limit function of the outer connecting bridge to the permanent magnet is met, so that pressure is released when the rotor core is injected, and the injection molding quality of the injection molding rotor is improved.
Description
The invention relates to a divisional application with the application date of 2020.01.21, the application number of 202010072308.2 and the application name of rotor core and injection molding rotor with the same.
Technical Field
The invention relates to the technical field of motors, in particular to a rotor core and an injection molding rotor.
Background
Along with the continuous upgrading of energy efficiency requirements, the design and manufacture of the motor are continuously optimized, and the requirements on cost and performance are also continuously improved. In the related art, in the manufacturing process of the injection molding rotor of the motor, the stability and the injection molding quality of the injection molding rotor can be affected due to the fact that the injection molding material has larger pressure in the cavity.
Disclosure of Invention
The present invention aims to solve at least one of the technical problems existing in the prior art. Therefore, the invention provides the rotor core, which can improve the structural stability.
The invention also provides an injection molding rotor with the rotor core.
According to an embodiment of the first aspect of the present invention, a rotor core includes a plurality of rotor laminations stacked in an axial direction, the rotor laminations include an inner annular region and a plurality of outer sector regions, the plurality of outer sector regions are disposed around the inner annular region, and a mounting groove for mounting a permanent magnet is formed between two adjacent outer sector regions in a circumferential direction of the rotor core; at least one of the rotor punching sheets is an outer broken bridge type punching sheet, and the outer broken bridge type punching sheet is broken between every two adjacent outer fan-shaped areas; each outer sector area is provided with an outer baffle bridge on two sides of the circumference of the rotor core on at least one outer broken bridge type punching sheet, and the outer baffle bridge is positioned in the mounting groove to stop the outer side of the permanent magnet along the radial direction of the rotor core; and at least one of the rotor punching sheets is an outer bridge type punching sheet, an outer bridge is connected between every two adjacent outer fan-shaped areas of the outer bridge type punching sheet, and a pressure release groove is formed in one side of the outer bridge, facing the mounting groove.
The rotor core according to the embodiment of the invention has at least the following beneficial effects:
by setting at least one rotor punching sheet as an outer connecting bridge type punching sheet, an outer connecting bridge is connected between every two adjacent outer sector areas of the outer connecting bridge type punching sheet, the outer connecting bridge can limit the permanent magnet to move towards the radial outer side of the mounting groove, the permanent magnet is prevented from being separated from the mounting groove, and the mounting stability of the permanent magnet is improved; the structure of the externally connected bridge type punching sheet can improve the structural stability of the rotor core; the pressure release groove is formed in one side of the outer connecting bridge, which faces the mounting groove, and injection molding materials are circulated through the spacing space formed by the pressure release groove while the limit function of the outer connecting bridge to the permanent magnet is met, so that pressure is released when the rotor core is injected, and the injection molding quality of the injection molding rotor is improved.
According to some embodiments of the invention, a notch of the relief groove faces the inner annular region, the relief groove communicating with the mounting groove through the notch.
According to some embodiments of the invention, the pressure relief groove is used to fill injection molding material to relieve pressure when the rotor core is injection molded.
According to some embodiments of the invention, the number of externally connected bridge punches is less than or equal to one third of the number of rotor punches.
According to some embodiments of the invention, the two ends of the rotor core employ the outer bridge type punching sheet, and the middle portion of the rotor core includes the outer bridge type punching sheet.
According to some embodiments of the invention, the outer bridge cut-off punching sheet comprises: full-connection-outer-break bridge type punching sheets, wherein an inner connecting bridge is connected between each outer sector area and each inner annular area; and an inner connecting bridge is connected between only half of the outer sector area and the inner annular area of the half-connecting-outer bridge-breaking punching sheet, and the other half of the outer sector area and the inner annular area are disconnected.
According to some embodiments of the invention, the rotor punching sheet comprises at least one full-connection-outer bridge-cut punching sheet and a plurality of half-connection-outer bridge-cut punching sheets, wherein at least one full-connection-outer bridge-cut punching sheet is arranged at the end parts of the plurality of half-connection-outer bridge-cut punching sheets.
According to some embodiments of the invention, at least part of the rotor punching sheet is provided with a support bridge corresponding to the mounting groove, and the support bridge is connected to the outer periphery of the inner annular region to stop the inner side of the permanent magnet along the radial direction of the rotor core.
According to some embodiments of the invention, the rotor punching sheets at two ends of the rotor core are provided with supporting bridges, and the rest of the rotor punching sheets cancel the supporting bridges.
According to some embodiments of the invention, at least two of the rotor blades are provided with compensation holes on the outer sector area, said compensation holes being used for filling the compensation blocks.
According to some embodiments of the invention, the rotor core is provided with a receiving hole.
An injection molded rotor according to a second aspect of the present invention includes a rotor core, which is the rotor core described in the above embodiment; the permanent magnets are respectively matched in the mounting grooves; and the injection molding body is molded by injection molding materials to mold the permanent magnet and the rotor core into a whole.
The injection molding rotor provided by the embodiment of the invention has at least the following beneficial effects:
by adopting the rotor core of the embodiment of the first aspect, the rotor core adopts at least one rotor punching sheet as an outer connecting bridge punching sheet, and an outer connecting bridge is connected between every two adjacent outer sector areas of the outer connecting bridge punching sheet, and the outer connecting bridge can limit the movement of the permanent magnet towards the radial outer side of the mounting groove, inhibit the detachment of the permanent magnet from the mounting groove and improve the mounting stability of the permanent magnet; the structure of the externally connected bridge type punching sheet can improve the structural stability of the rotor core; the pressure release groove is formed in one side of the outer connecting bridge, which faces the mounting groove, and injection molding materials are circulated through the spacing space formed by the pressure release groove while the limit function of the outer connecting bridge to the permanent magnet is met, so that pressure is released when the rotor core is injected, and the injection molding quality of the injection molding rotor is improved.
According to some embodiments of the invention, the injection molded body is an unsaturated resin material piece or an epoxy resin piece.
According to some embodiments of the invention, the permanent magnet is formed by molding the permanent magnet and the rotor core into a whole by the injection molding body and then magnetizing.
Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
Drawings
The invention is further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a perspective view of a rotor core according to an embodiment of the present invention;
FIG. 2 is a front view of a rotor sheet (wherein the rotor sheet is an externally connected bridge sheet) according to an embodiment of the present invention;
FIG. 3 is a front view of a rotor sheet according to an embodiment of the present invention (wherein the rotor sheet is an outer bridge sheet, and the outer bridge has a pressure release groove on a side facing the mounting groove);
fig. 4 is a front view of a rotor sheet according to an embodiment of the present invention (wherein the rotor sheet is an outer broken bridge type sheet, and the support bridge is a straight support bridge);
FIG. 5 is a front view of a rotor sheet in an embodiment of the present invention (wherein the rotor sheet is an outer broken bridge type sheet, and the support bridge is a curved support bridge);
FIG. 6 is a front view of a rotor blade (wherein the rotor blade is a full-bridge-to-outer-break blade) in an embodiment of the present invention;
FIG. 7 is a front view of a rotor blade (wherein the rotor blade is a semi-continuous-external bridge-cut blade) in accordance with an embodiment of the present invention;
FIG. 8 is a schematic cross-sectional view of a rotor core according to an embodiment of the present invention;
fig. 9 is a schematic structural view of a rotor core and a permanent magnet according to an embodiment of the present invention (wherein the rotor core and the permanent magnet are cut away to show an internal assembly relationship);
FIG. 10 is a perspective view of a rotor according to an embodiment of the present invention;
FIG. 11 is an exploded view of a rotor according to an embodiment of the present invention;
fig. 12 is an optimized plan view of a rotor core according to an embodiment of the present invention;
FIG. 13 is a simulated and measured back emf waveform of the rotor using a submerged outer bridge scheme;
FIG. 14 is a graph showing a comparison of the actual measured counter potential harmonic content when a conventional outer bridge and a sinking outer bridge are provided on a rotor core;
FIG. 15 is a diagram showing a noise test for a sweep test of noise over the full rotational speed operating range of an air conditioning fan system when a motor having a rotor core is applied to the air conditioning fan with a conventional outer bridge disposed on the rotor core;
FIG. 16 is a noise test chart of a sweep test of noise over the full rotational speed operating range of an air conditioning fan system when a submerged outer bridge is provided on a rotor core and a motor containing the rotor core is applied to the air conditioning fan;
fig. 17 is a graph comparing the noise amplitude of a rotor at 6 times frequency using a common external gear scheme and a submerged external gear scheme in a full rotation speed range.
Reference numerals:
injection molding rotor 1000;
a rotor core 100;
rotor punching sheet 1; an inner annular region 11; a shaft hole 111; an outer sector 12; a mounting groove 121; an outer bridge 122; a pressure release groove 1221; an outer bridge 123; an outer bridge type punching sheet 13; an outer bridge cut-off punching sheet 14; full-on-off bridge type punching sheet 141; semi-continuous-external broken bridge type punching sheet 142; an inner connecting bridge 143; a support bridge 15; a straight strut 151; a curved strut bridge 152; a compensation hole 16; an embedding port 161; a receiving hole 17; a suction port 171;
a permanent magnet 200; an injection molding body 300; rotor shaft 400.
Detailed Description
Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are illustrative only and are not to be construed as limiting the invention.
In the description of the present invention, it should be understood that the direction or positional relationship indicated with respect to the description of the orientation, such as up, down, etc., is based on the direction or positional relationship shown in the drawings, is merely for convenience of describing the present invention and simplifying the description, and does not indicate or imply that the apparatus or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present invention.
In the description of the present invention, plural means two or more. The description of the first and second is for the purpose of distinguishing between technical features only and should not be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated or implicitly indicating the precedence of the technical features indicated.
In the description of the present invention, unless explicitly defined otherwise, terms such as arrangement, installation, connection, etc. should be construed broadly and the specific meaning of the terms in the present invention can be reasonably determined by a person skilled in the art in combination with the specific contents of the technical scheme.
A rotor core 100 according to an embodiment of the present invention is described below with reference to fig. 1 to 11.
According to the rotor core 100 of the embodiment of the present invention, as shown in fig. 1 to 7, the rotor core 100 is provided with a shaft hole 111 and a plurality of mounting grooves 121, the plurality of mounting grooves 121 being provided around the shaft hole 111 to mount a plurality of permanent magnets 200. The rotor core 100 may be of an integral structure, and the rotor core 100 may be formed by stacking a plurality of rotor punching sheets 1.
In some embodiments, as shown in fig. 8, the rotor core 100 is provided with a compensation hole 16 for mounting a compensation block (not shown in the drawing), the compensation hole 16 is located between two adjacent mounting slots 121 of the rotor core 100 (as the compensation hole 1 may be provided in a sector area in fig. 1), at least one end of the compensation hole 16 in the axial direction is an insertion opening 161 so that a part of the compensation block is inserted from the insertion opening 161, and the insertion opening 161 is a shrinkage opening so that the compensation block and the rotor core 100 form a snap-fit connection at the insertion opening 161.
It should be noted that, in other embodiments, the compensation block is also referred to as a balance block, and the rotor is provided with the compensation block for improving the rotation balance of the rotor during rotation, and the balance principle of the compensation block is the prior art and will not be described herein.
When the compensation holes 16 are provided in the above-described structure, the compensation block may be provided in various structures to form a snap-fit connection with the rotor core 100. Taking fig. 8 as an example, assume that the compensating hole 16 is a cylindrical hole, the insertion opening 161 is a conical opening having a diameter slightly smaller than that of the cylindrical hole, and assume that the portion of the compensating block inserted into the compensating hole 16 is a cylinder. In one form of the compensation block, the cylindrical portion of the compensation block is formed as a standard cylinder having the same diameter as the cylindrical hole, and the cylindrical portion of the compensation block may be pressed into the compensation hole 16 from the insertion opening 161 by punching or the like, and the cylindrical portion of the compensation block and the insertion opening 161 may be slightly deformed during the pressing, but the portion of the rotor core 100 surrounding the insertion opening 161 may be clamped to the cylindrical portion of the compensation block after the pressing. In another embodiment, the portion of the cylindrical portion of the compensation block located at the insertion opening 161 may deform out of the groove, making it difficult for the cylindrical portion of the compensation block to come out of the rotor. In another form of the compensation block, a groove is directly formed in the outer peripheral wall of the cylindrical portion of the compensation block, and when the compensation block is inserted into the compensation hole 16, a portion of the rotor core 100 surrounding the insertion opening 161 may be clamped in the groove, and the diameter of the groove may be slightly larger than the diameter of the insertion opening 161 or slightly smaller than the diameter of the insertion opening 161.
The shape of the compensation hole 16 is not particularly limited in this embodiment, nor is the shape of the insertion opening 161. The insertion opening 161 may be a tapered opening or a stepped opening.
Therefore, in the rotor core 100 according to the embodiment of the present invention, the insertion opening 161 at one end of the compensation hole 16 is configured as a shrinkage cavity, so that the compensation block and the rotor core 100 form a snap-fit connection at the insertion opening 161, thereby clamping the compensation block, and the compensation block can be firmly connected to the rotor core 100 after the rotor rotates at a high speed.
In the embodiment of the present invention, the compensation hole 16 may be provided as the insertion port 161 (the shrinkage port) at both axial ends, and thus the rotor core 100 may be provided with the compensation block at both axial end surfaces. The compensation hole 16 may be provided with an insertion opening 161 (a shrinkage opening) only at one axial end, and the rotor core 100 may be provided with a compensation block only at the end surface where the insertion opening 161 is provided.
In some embodiments, as shown in fig. 8, the rotor core 100 is provided with a suction hole 17 for absorbing the chips, the suction hole 17 is located between two adjacent mounting slots 121 of the rotor core 100 (as in fig. 1, the suction hole 17 may be disposed in a fan-shaped area), at least one end of the suction hole 17 in the axial direction is a suction port 171, and the suction port 171 is a flaring. The suction holes 17 may form a negative pressure region when the rotor rotates at a high speed, thereby sucking away debris. The suction inlet 171 of the suction hole 17 is formed into a flaring shape, which is beneficial to expanding the dust suction range and improving the cleanliness of the working environment of the rotor.
The shape of the suction hole 17 is not particularly limited in this embodiment, nor is the shape of the suction port 171. The suction port 171 may be a flaring of a gradual flaring or a stepwise flaring. In the rotor core 100 stacked by the plurality of rotor sheets 1, the compensation hole 16 is formed in at least two rotor sheets 1, at least one of which rotor sheets 1 is formed with an insertion hole 161.
In some embodiments, as shown in fig. 1, the rotor core 100 includes a plurality of rotor laminations 1 stacked in the axial direction, the rotor laminations 1 including an inner annular region 11 and a plurality of outer sector regions 12, the plurality of outer sector regions 12 being disposed around the inner annular region 11, the center of the inner annular region 11 constituting a shaft hole 111 of the rotor core 100, and a mounting groove 121 for mounting the permanent magnet 200 being formed between two adjacent outer sector regions 12 in the circumferential direction.
The structure is a built-in tangential magnetizing structure, which is beneficial to improving the magnetic focusing capability of the permanent magnet 200 matched with the rotor core 100.
In some embodiments, as shown in fig. 1, the rotor sheet 1 includes at least one outer bridge sheet 13, and as shown in fig. 2 and 3, the outer bridge sheet 13 has an outer bridge 122 connected between each adjacent two of the outer sector areas 12, the outer bridge 122 being located radially outward of the mounting slot 121, for example, between the outer peripheral walls of the adjacent two of the outer sector areas 12, or between the opposite side walls of the adjacent two of the outer sector areas 12 and adjacent to the outer peripheral wall of the outer sector area 12. The outer bridge 122 may be configured to limit the permanent magnet 200. When the permanent magnet 200 is adapted to the rotor core 100, the outer bridge 122 can restrict the movement of the permanent magnet 200 in the direction of the radial outside of the mounting groove 121, and can suppress the detachment of the permanent magnet 200 from the mounting groove 121, so that the mounting and working stability of the permanent magnet 200 can be improved.
In some embodiments, as shown in fig. 1, the rotor blade 1 includes at least one outer bridge-cut blade 14, as shown in fig. 4 and 5, the outer bridge-cut blade 14 being disconnected between each adjacent two outer scalloped regions 12, allowing for release of rotor internal pressure.
In other embodiments, the rotor punching sheet 1 comprises an outer bridge punching sheet 13 and an outer bridge punching sheet 14, and the combined structure of the outer bridge punching sheet 13 and the outer bridge punching sheet 14 can achieve the multiple purposes of both positioning and pressure release.
Because the rotor punching sheet 1 only adopts the design of the outer broken bridge type punching sheet superposition, the burrs can appear in the production process, the product performance is affected, and the qualification rate is low. Thus, in some embodiments, the rotor core 100 is formed into an injection-molded rotor by injection molding, and the rotor punching sheet 1 corresponding to the mold clamping position of the injection-molded rotor is the externally connected bridge punching sheet 13. Therefore, the injection molding burrs can be reduced at the die assembly position, so that the performance of the product, such as noise reduction, can be improved, the product qualification rate is high, and the production operability is strong. For example, patent No.: CN201810552685 discloses a motor with a brand new structure by arranging different inner magnetic bridges, claim 9 of the motor defines the plastic coating structure of the rotor core, and particularly, the rotor punching sheets of the patent are all outer broken bridge punching sheets, and burrs can appear in production and implementation, thus influencing the product performance and having low qualification rate.
In some embodiments, the number of outer bridge punches 13 is less than or equal to one third of the number of rotor punches 1. The magnetizing of the rotor core 100 can be facilitated, and the outer bridge type punching sheet 13 can be arranged at the die clamping position, and the outer bridge 122 can also improve the working stability of the product after magnetizing.
In some embodiments, as shown in fig. 1, at least one end of the rotor core 100 employs an externally bridged lamination 13, for example, one of the ends of the rotor core 100 employs an externally bridged lamination 13, or both ends of the rotor core 100 employ externally bridged laminations 13. The outer bridge type punching sheet 13 at the end of the rotor core 100 may be one or more pieces. The middle portion of the rotor core 100 includes the outer bridge cut-off punched sheet 14 or the outer bridge cut-off punched sheet 13. The middle portion of the rotor core 100 is a portion from which both end portions are removed. The outer bridge 122 can play a role of sealing materials, improve the stability of the injection molding process and improve the injection molding quality of the injection molding rotor.
In some embodiments, as shown in fig. 3, the outer bridge 122 is provided with a pressure relief groove 1221 at a side facing the mounting groove 121, the pressure relief groove 1221 being used to fill injection molding material to relieve pressure when the rotor core 100 is injection molded. It will be appreciated that the non-pressure release groove of the outer bridge 122 facing the mounting groove 121 may be used to limit the permanent magnet 200, and the pressure release groove 1221 of the outer bridge 122 facing the mounting groove 121 may be formed with a space between the permanent magnet 200 for circulating injection molding material and releasing pressure, thereby improving the injection molding quality of the injection molding rotor.
In some embodiments, as shown in fig. 4 and 5, on at least one outer break-off bridge die 14, each outer sector 12 is provided with outer stop bridges 123 on both sides in the circumferential direction, the outer stop bridges 123 being located radially outside the mounting slots 121 to stop against the permanent magnets 200. The outer bridge 123 may be provided to fix the permanent magnet 200, and a gap formed between two adjacent outer bridges 123 may be filled with injection molding material to release pressure when the rotor core 100 is injection-molded. When the permanent magnet 200 is adapted to be engaged with the rotor core 100, the outer bridge 123 can restrict the movement of the permanent magnet 200 toward the radially outer side of the mounting groove 121, and can reduce the detachment of the permanent magnet 200 from the mounting groove 121, thereby further improving the mounting and operation stability of the permanent magnet 200.
In some embodiments, as shown in fig. 1, at the junction of the outer bridge 123 and the outer sector 12, the distance between the radially outer side of the outer bridge 123 and the shaft aperture 11 is less than the distance between the radially outer side of the outer sector 12 and the shaft aperture 111. That is, the outer bridge 123 forms a submerged outer bridge with respect to the center of the shaft hole 11, and the distance of the radially outer side edge of the outer bridge 123 is close to the distance of the radially outer side edge of the outer sector 12.
Specifically, in the present embodiment, in order to optimize the magnetic circuit, a multi-directional search study is performed for optimizing the outer shape profile of the rotor core 100. According to simulation and actual measurement results, the common outer baffle bridge on the rotor core is optimized to be a sinking outer baffle bridge as shown in fig. 12, so that the optimized magnetic circuit is adapted to a high-impulse stator, a lower counter potential distortion rate is obtained, torque fluctuation is reduced, and noise is improved.
Fig. 13 shows that the rotor adopting the sinking type outer gear bridge simulates and actually measures counter potential waveforms, and the waveforms can be seen to be chordal waves tending to standards, so that waveform distortion is small.
Fig. 14 shows a comparative graph of the measured counter potential harmonic content when the rotor core is provided with a normal outer bridge and with a submerged outer bridge. The figure shows that the harmonic content of the sunk external gear bridge scheme is greatly reduced in 5 times and 7 times compared with that of the common external gear bridge scheme, and the sunk external gear bridge scheme also proves that the sunk external gear bridge scheme is effective for the optimal design of the rotor structure on the basis of considering the edge effect.
Fig. 15 and 16 show the noise test diagrams of the rotor core when the rotor core is provided with a common outer baffle bridge and a sinking outer baffle bridge, and the motor with the rotor core is applied to an air conditioner fan, and the noise is swept in the whole rotating speed operation range of the air conditioner fan system at the moment. As can be seen from a comparison of fig. 15 and 16, the 6-fold noise line of the sinking external bridge scheme is obviously dull, the common external bridge scheme taking the impulse shear stress into account has a bright band in the full frequency band, the sinking external bridge scheme has a resonance local bright spot only in the individual rotating speed, and the noise amplitude is obviously reduced. In addition, other secondary noise levels of the sinking type external baffle bridge scheme are also reduced, and the noise of the air conditioner fan is obviously improved.
Fig. 17 shows a comparison of the noise amplitudes of the common external gear scheme and the sunk external gear scheme at 6 times in the full rotation speed range, and it can be seen that the 6 times noise of the sunk external gear scheme is significantly lower than the 6 times noise of the common external gear scheme when the motor rotation speed enters the high rotation speed region.
Therefore, the scheme of the application utilizes the sinking type gear bridge, so that the distortion rate of counter electromotive force can be reduced, torque fluctuation is reduced, and vibration noise is reduced.
In some embodiments, as shown in fig. 6 and 7, the outer bridge cut-off die 14 comprises: full-on-off bridge punch 141 and half-on-off bridge punch 142. As shown in fig. 6, the full-bridge-to-outer-break punch 141 has an inner bridge 143 connected between each outer sector 12 and the inner annular region 11. As shown in fig. 7, an inner bridge 143 is connected between only half of the outer sector 12 and the inner annular region 11 of the half-connected-outer bridge-cut-off punched sheet 142, and the other half of the outer sector 12 is disconnected from the inner annular region 11. It can be appreciated that, in the full-connection-outer bridge-cut-off punching sheet 141, the inner connection bridge 143 is connected between each outer sector area 12 and the inner annular area 11, so that the connection strength between the outer sector area 12 and the inner annular area 11 can be improved, and the working stability of the rotor core 100 can be improved. In the half-continuous-outer bridge-cut-off punched sheet 142, the inner connecting bridge 143 is connected between half of the outer sector area 12 and the inner annular area 11, so that the connection strength between the outer sector area 12 and the inner annular area 11 can be further improved, and the working stability of the rotor core 100 can be improved. The other half of the outer sector area 12 is disconnected from the inner sector area 11, so that materials can be saved, the assembly flexibility is improved, and the release of the internal pressure is facilitated. Thus, the outer bridge cut-off punched sheet 14 includes: the full-connection-outer-break bridge type punching sheet 141 and the half-connection-outer-break bridge type punching sheet 142 can not only improve the structural strength of the rotor core 100, but also save materials.
Alternatively, in the half-continuous-external bridge-cut-off punched sheet 142, the internal connection bridges 143 are axially rotated and arranged at a rotation angle ((2k+1) 180/N) °, where k is a natural number and N is the number of internal connection bridges 143. The semi-continuous-external broken bridge type punching sheet 142 has reasonable layout and high structural strength, and is beneficial to further improving the working stability of the rotor core 100.
In some embodiments, as shown in fig. 1 and 8, at least part of the rotor sheet 1 is provided with a support bridge 15 corresponding to the mounting groove 121, and the support bridge 15 is connected to the outer periphery of the inner annular region 11 so as to be supported against the permanent magnet 200. The supporting bridge 15 can play a role in limiting and supporting the permanent magnet 200, and can further improve the installation and working stability of the permanent magnet 200.
Specifically, as shown in fig. 1 and 8, corresponding to the same permanent magnet 200, the supporting bridge 15 of part of the rotor core 100 is a straight supporting bridge 151, and the supporting bridge 15 of part of the rotor core 100 is a curved supporting bridge 152. As shown in fig. 4 and 9, the radial length of the straight strut 151 is equal to the interval between the inner annular region 11 and the permanent magnet 200 to support the permanent magnet 200. As shown in fig. 5 and 9, the radial length of the bent bridge 152 is greater than the interval between the inner annular region 11 and the permanent magnet 200 to support the permanent magnet 200 in a bent deformed state. It will be appreciated that the radial length of the straight bridge 151 is equal to the distance between the inner annular region 11 and the permanent magnet 200, and the supporting bridge 15 can serve to support the permanent magnet 200 and also improve the positioning accuracy of the permanent magnet 200. The radial length of the curved stay bridge 152 is greater than the interval between the inner annular region 11 and the permanent magnet 200 to support the permanent magnet 200 in a curved deformation state, so that the compression force between the permanent magnet 200 and the curved stay bridge 152 can be increased, and the installation and working stability of the permanent magnet 200 can be further improved under the action of the force.
Further, the rotor punching sheet 1 at both ends of the rotor core 100 is provided with a straight supporting bridge 151, and the rotor core 100 is provided with a curved supporting bridge 152 on only part of the rotor punching sheet 1 in the middle, and the supporting bridges 15 are omitted from the rest of the rotor punching sheets 1. The design is convenient for assembling the permanent magnet 200, can have good supporting effect on the permanent magnet 200, and can further save materials.
Of course, in the embodiment of the present invention, the combination manner of the supporting bridges 15 of each rotor sheet 1 is not limited to the above example, and the straight supporting bridges 151, the curved supporting bridges 152 and the bridgeless rotor sheet may be arbitrarily combined in a reasonable state.
A rotor core 100 in one embodiment of the present invention is described below with reference to fig. 1 to 8.
According to the rotor core 100 of the embodiment of the present invention, the rotor core 100 includes a plurality of rotor laminations 1 stacked in the axial direction, the rotor laminations 1 including an inner annular region 11 and a plurality of outer sector regions 12, the plurality of outer sector regions 12 being disposed around the inner annular region 11, the center of the inner annular region 11 constituting a shaft hole 111 of the rotor core 100, and a mounting groove 121 for mounting the permanent magnet 200 being formed between two adjacent outer sector regions 12 in the circumferential direction. The outer sector 12 of at least two rotor blades 1 is provided with compensation holes 16, the compensation holes 16 being used for filling compensation blocks. The rotor core 100 is provided with a receiving hole 17, and the receiving hole 17 is reamed at one axial end.
The rotor punching sheet 1 comprises an externally connected bridge punching sheet 13 and an externally disconnected bridge punching sheet 14.
Wherein the outer bridge type punching sheet 13 is connected with an outer bridge 122 between every two adjacent outer fan-shaped areas 12, and the outer bridge 122 is positioned at the radial outer side of the mounting groove 121. The outer bridge 122 is provided with a pressure release groove 1221 at a side facing the mounting groove 121, the pressure release groove 1221 being used to fill injection molding material to release pressure when the rotor core 100 is injection molded. The rotor core 100 is used for injection molding of the rotor 1000, and the rotor punching sheet 1 corresponding to the injection mold of the injection molding rotor 1000 at the mold clamping position is an externally connected bridge punching sheet 13. One end of the rotor core 100 employs an externally connected bridge type punching sheet 13. The number of the outer bridge type punching sheets 13 is less than or equal to one third of the number of the rotor punching sheets 1.
The outer bridge-cut punches 14 are disconnected between each adjacent two of the outer sector areas 12. On the outer bridge cut-off type punched sheet 14, each outer sector area 12 is provided with outer blocking bridges 123 on both circumferential sides, the outer blocking bridges 123 being located radially outside the mounting grooves 121 to stop the permanent magnets 200. The outer bridge-cut punched sheet 14 includes: full-on-off bridge punch 141 and half-on-off bridge punch 142. The full-bridge-to-outer-break punching sheet 141 has an inner bridge 143 connected between each outer sector 12 and the inner annular region 11. An inner connecting bridge 143 is connected between only half of the outer sector 12 and the inner annular region 11 of the half-connecting-outer bridge-breaking punched piece 142, and the other half of the outer sector 12 is disconnected from the inner annular region 11.
At least part of the rotor sheet 1 is provided with a support bridge 15 corresponding to the mounting groove 121, the support bridge 15 being connected to the outer circumference of the inner annular region 11 so as to be supported against the permanent magnets 200. Corresponding to the same permanent magnet 200, the supporting bridge 15 of part of the rotor core 100 is a straight supporting bridge 151, the supporting bridge 15 of part of the rotor core 100 is a curved supporting bridge 152, the radial length of the straight supporting bridge 151 is equal to the interval between the inner annular region 11 and the permanent magnet 200 to support the permanent magnet 200, and the radial length of the curved supporting bridge 152 is greater than the interval between the inner annular region 11 and the permanent magnet 200 to support the permanent magnet 200 in a curved deformation state. The rotor punching sheet 1 at both ends of the rotor core 100 is provided with a straight supporting bridge 151, and the rotor core 100 is provided with a curved supporting bridge 152 on only part of the rotor punching sheet 1 in the middle, and the supporting bridges 15 are canceled on the rest of the rotor punching sheets 1.
Of course, in other embodiments of the present invention, the above-described features may be formed on the rotor core 100 in any combination, without being particularly limited thereto.
An injection molded rotor 1000 according to an embodiment of the present invention is described below with reference to the accompanying drawings.
An injection molded rotor 1000 according to an embodiment of the present invention includes: as shown in fig. 10 and 11, a rotor core 100, a plurality of permanent magnets 200, and an injection-molded body 300. The rotor core 100 is the rotor core 100 according to the above embodiment of the present invention, and the specific structure of the rotor core 100 has been described in detail above, and will not be described again here. The plurality of permanent magnets 200 are fitted in the plurality of mounting grooves 121, respectively. After the plurality of permanent magnets 200 are fitted to the rotor core 100, the injection molded body 300 is overmolded with an injection molding material to overmold the permanent magnets 200 and the rotor core 100 into an integral piece.
According to the injection molding rotor 1000 of the embodiment of the present invention, a plurality of outer sector areas 12 are arranged around the inner annular area 11, and a mounting groove 121 for mounting the permanent magnet 200 is formed between two adjacent outer sector areas 12 in the circumferential direction, so that the injection molding rotor 1000 is of a built-in tangential magnetization structure, which is beneficial to improving the magnetic focusing capability of the permanent magnet 200. By providing the rotor sheet 1 with the sunk outer bridge, the back electromotive force distortion rate can be reduced, the torque ripple can be reduced, and the vibration noise can be reduced.
In some embodiments, the injection molded body 300 is an unsaturated resin material or an epoxy resin member, so that the hardness and strength of the injection molded body are high, and thus the working stability of the injection molded rotor 1000 can be improved.
Optionally, the injection molding body 300 may be a PBT piece, which has the characteristics of light weight, high strength, insulation and corrosion resistance, and also has the advantages of high utilization rate, high molding rate, stable product quality, convenient operation and the like, so that the injection molding piece is convenient to mold, and the stability of the injection molding piece is improved. Of course, in other embodiments, the injection molding body 300 may be a BMC, which has excellent electrical insulation, heat resistance, flame resistance, high mechanical strength, dimensional stability, shrinkage stability, easy processing, smooth molding surface, and is advantageous for improving the performance of the injection molding rotor 1000. The specific form of the injection molded body 300 is not limited herein.
Alternatively, the rotor 1000 may be assembled with the stator. The stator assembly adopts chain ferromagnetic materials to axially arrange and combine, the stator assembly is required to be bent and spliced after being vertically arranged, the stator assembly comprises a plurality of stator teeth, the stator teeth are wound with conductors, and the current phases of the conductors at two sides of the same stator teeth are the same.
In some embodiments, the rotor 1000 further comprises: the compensation block is embedded into the compensation hole 16 from the embedded opening 161, the compensation block and the rotor core form a buckle connection at the embedded opening 161, the projection area of the part of the compensation block outside the compensation hole 16 is larger than the projection area of the part inside the compensation hole 16, and the projection area of the part of the compensation block outside the compensation hole 16 is the projection area of the corresponding part of the compensation block on the end face of the rotor core. By adopting the arrangement, the position of the compensation block is further limited, and the installation stability of the compensation block is improved.
The rotor 1000 in one embodiment of the present invention is described below with reference to the accompanying drawings.
The rotor 1000 according to an embodiment of the present invention includes: a rotor core 100, a plurality of permanent magnets 200, and an injection molded body 300. The rotor core 100 is the rotor core 100 according to the above-described embodiment of the present invention. The plurality of permanent magnets 200 are fitted in the plurality of mounting grooves 121, respectively. After the plurality of permanent magnets 200 are fitted to the rotor core 100, the injection molded body 300 is overmolded with an injection molding material to overmold the permanent magnets 200 and the rotor core 100 into an integral piece. The injection molding body 300 is an unsaturated resin material or an epoxy resin material. The permanent magnet 200 is formed by molding the permanent magnet 200 and the rotor core 100 into a whole by the injection molding body 300 and magnetizing the same. The invention solves the pain point in the current industry, greatly improves the one-time qualification rate of production, and has the characteristics of simple and reasonable structure, simplified process and high consistency of product performance.
The embodiments of the present invention have been described in detail with reference to the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge of one of ordinary skill in the art without departing from the spirit of the present invention.
Claims (14)
1. A rotor core, characterized in that the rotor core comprises a plurality of rotor punching sheets which are overlapped along the axial direction, the rotor punching sheets comprise an inner annular area and a plurality of outer sector areas, the outer sector areas are arranged around the inner annular area, and a mounting groove for mounting a permanent magnet is formed between two adjacent outer sector areas in the circumferential direction of the rotor core; wherein,
at least one of the rotor punching sheets is an outer broken bridge type punching sheet, and the outer broken bridge type punching sheet is broken between every two adjacent outer fan-shaped areas; wherein,
each outer sector area is provided with an outer baffle bridge on the two circumferential sides of the rotor core on at least one outer broken bridge type punching sheet, and the outer baffle bridge is positioned in the mounting groove to stop the outer side of the permanent magnet along the radial direction of the rotor core;
and at least one of the rotor punching sheets is an outer bridge type punching sheet, an outer bridge is connected between every two adjacent outer fan-shaped areas of the outer bridge type punching sheet, and a pressure release groove is formed in one side of the outer bridge, facing the mounting groove.
2. The rotor core according to claim 1, wherein a notch of the pressure relief groove faces the inner annular region, the pressure relief groove communicating with the mounting groove through the notch.
3. The rotor core according to claim 1 or 2, wherein the pressure relief groove is used to be filled with an injection molding material to release pressure when the rotor core is injection molded.
4. The rotor core of claim 1, wherein the number of outer bridge laminations is less than or equal to one third of the number of rotor laminations.
5. The rotor core of claim 1, wherein the two ends of the rotor core employ the externally connected bridge type laminations, and wherein the intermediate portion of the rotor core includes the externally disconnected bridge type laminations.
6. The rotor core as recited in claim 1, wherein the outer bridge-cut stamped sheet comprises:
full-connection-outer-break bridge type punching sheets, wherein an inner connecting bridge is connected between each outer sector area and each inner annular area;
and an inner connecting bridge is connected between only half of the outer sector area and the inner annular area of the half-connecting-outer bridge-breaking punching sheet, and the other half of the outer sector area and the inner annular area are disconnected.
7. The rotor core of claim 6, wherein the rotor core comprises at least one of the full-bridge-cut-off sheet and a plurality of the half-bridge-cut-off sheets, the at least one of the full-bridge-cut-off sheets being disposed at ends of the plurality of the half-bridge-cut-off sheets.
8. The rotor core according to claim 1, wherein at least part of the rotor sheet is provided with a support bridge corresponding to the mounting groove, the support bridge being connected to an outer periphery of the inner annular region to stop an inner side of the permanent magnet in a radial direction of the rotor core.
9. The rotor core of claim 8, wherein the rotor laminations at both ends of the rotor core are provided with support bridges, and the remaining rotor laminations eliminate the support bridges.
10. A rotor core according to any one of claims 1-9, characterized in that at least two of the rotor laminations are provided with compensation holes on the outer sector area, which are used for filling the compensation blocks.
11. The rotor core according to any one of claims 1 to 9, wherein a receiving hole is provided on the rotor core.
12. An injection molded rotor comprising:
a rotor core, which is the rotor core according to any one of claims 1 to 11;
the permanent magnets are respectively matched in the mounting grooves;
and the injection molding body is molded by injection molding materials to mold the permanent magnet and the rotor core into a whole.
13. The rotor of claim 12, wherein the injection molded body is an unsaturated resin material piece or an epoxy resin piece.
14. The rotor of claim 12, wherein the permanent magnets are formed by molding the permanent magnets and the rotor core as one body by the injection molding body and then magnetizing the molded body.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311500601.4A CN117458751A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311500601.4A CN117458751A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor |
| CN202010072308.2A CN113224873A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor with same |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202010072308.2A Division CN113224873A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor with same |
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| Publication Number | Publication Date |
|---|---|
| CN117458751A true CN117458751A (en) | 2024-01-26 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311491325.XA Pending CN117458750A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor |
| CN202311500601.4A Pending CN117458751A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor |
| CN202010072308.2A Pending CN113224873A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor with same |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202311491325.XA Pending CN117458750A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202010072308.2A Pending CN113224873A (en) | 2020-01-21 | 2020-01-21 | Rotor core and injection molding rotor with same |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115995895A (en) * | 2021-10-18 | 2023-04-21 | 江苏雷利艾德思电机有限公司 | Rotor core, method for manufacturing rotor core, and motor rotor |
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2020
- 2020-01-21 CN CN202311491325.XA patent/CN117458750A/en active Pending
- 2020-01-21 CN CN202311500601.4A patent/CN117458751A/en active Pending
- 2020-01-21 CN CN202010072308.2A patent/CN113224873A/en active Pending
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| CN113224873A (en) | 2021-08-06 |
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