CN117791912A

CN117791912A - Rotor structure and rotor process

Info

Publication number: CN117791912A
Application number: CN202310436065.XA
Authority: CN
Inventors: 简嘉言; 徐子庭
Original assignee: Delta Electronics Inc
Current assignee: Delta Electronics Inc
Priority date: 2022-09-28
Filing date: 2023-04-21
Publication date: 2024-03-29
Also published as: TWI831679B

Abstract

The invention provides a rotor structure and a rotor process. The rotor structure comprises a silicon steel sheet laminated structure, an end plate, a rotating shaft and thermosetting plastic keys. The silicon steel sheet lamination structure comprises a plurality of silicon steel sheets, wherein each silicon steel sheet is provided with a shaft hole and at least one silicon steel sheet matching part, and the silicon steel sheet matching parts are connected with the shaft hole. The rotating shaft is arranged in the shaft holes in a penetrating way and is provided with at least one rotating shaft matching part which forms an axial injection molding runner for the at least one silicon steel sheet matching part. The end plate is provided with an injection molding port connected with an axial injection molding runner. The thermosetting plastic key is formed and configured in the axial injection molding runner, and the injection molding material fills the magnet groove and fixes the magnet. A rotor process is also provided.

Description

Rotor structure and rotor process

Technical Field

The invention relates to a motor rotor structure and a manufacturing method thereof.

Background

The assembly of motor rotor silicon steel sheet laminate structures with rotating shafts is generally known to use interference fit or metal bond fixation. The interference fit process requires heating the silicon steel sheet to a high temperature to expand the shaft hole or placing the rotating shaft into liquid nitrogen to reduce the shaft diameter. If the interference amount of the silicon steel sheet and the rotating shaft is too large, the silicon steel sheet is easy to deform and generate residual stress. The metal keys of the silicon steel sheets are matched with the key grooves of the rotating shaft, and because the metal keys are in sliding fit with each other, only one side is stressed when the rotor runs under the microcosmic condition, and at the moment, if the torque is too large when the rotor runs, the risk of failure of the metal keys can be generated.

In addition, a known motor rotor is formed by bonding magnets in magnet grooves of single silicon steel sheets by using magnet glue, and laminating a plurality of silicon steel sheets with magnets after the magnet glue is solidified to form a silicon steel sheet laminated structure. The technology is easy to cause overflow magnet glue to exist between the silicon steel sheets of each layer after the silicon steel sheets are overlapped, so that gaps among the silicon steel sheets are caused, and cooling oil overflows outwards when the rotor runs at a high speed.

Disclosure of Invention

The invention aims to provide a rotor structure and a rotor process, which solve the problems in the prior art.

According to an embodiment of the present invention, a rotor structure includes a laminated structure of silicon steel sheets, an upper end plate, a lower end plate, a rotating shaft, and a thermosetting plastic bond. The silicon steel sheet lamination structure is formed by stacking a plurality of silicon steel sheets, wherein each silicon steel sheet is provided with a shaft hole, at least one silicon steel sheet matching part and a plurality of magnet grooves for accommodating a plurality of magnets, and the silicon steel sheet matching parts are connected with the shaft holes. The upper end plate and the lower end plate are axially arranged at two opposite ends of the silicon steel sheet laminated structure, and the upper end plate or the lower end plate is concavely provided with an end plate shaft hole, at least one injection molding opening and at least one end plate injection molding runner. The rotating shaft penetrates through the shaft holes and the end plate shaft holes, the rotating shaft is provided with at least one rotating shaft matching part which forms an axial injection molding runner on the at least one silicon steel sheet matching part, at least one injection molding port is connected with at least one end plate injection molding runner and the axial injection molding runner, and at least one end plate injection molding runner is communicated with the axial injection molding runner and the magnetic stone grooves. The thermosetting plastic key is formed and configured in an axial injection molding runner formed by the aligned rotating shaft matching part and the silicon steel sheet matching part, and an injection molding material is filled between the magnet grooves and the magnets and is used for fixing the magnets after hardening.

According to an embodiment of the invention, the rotating shaft has at least one rotating shaft key slot extending along the axial direction, each silicon steel sheet has at least one metal key connected with the shaft hole, wherein a plurality of metal keys of a plurality of silicon steel sheets are clamped in the rotating shaft key slot, and a plurality of metal keys of a plurality of silicon steel sheets are aligned with each other.

According to an embodiment of the present invention, in the silicon steel sheet laminated structure, the plurality of magnet grooves of the plurality of silicon steel sheets are arranged offset from each other, and the plurality of silicon steel sheet mating portions of the plurality of silicon steel sheets are arranged in alignment with each other.

According to an embodiment of the invention, the end plate injection molding runner is provided with a circular runner, a plurality of tooth structures, a plurality of first pouring runners and a plurality of second pouring runners.

According to an embodiment of the present invention, the plurality of tooth structures are formed on a side of the annular flow channel away from the axial hole of the end plate, and are arranged along a circumferential direction of the plurality of end plates.

According to an embodiment of the present invention, the plurality of first pouring channels and the plurality of second pouring channels are located at one side of the annular channel near the axle hole of the end plate, and are connected with the annular channel.

According to an embodiment of the present invention, the respective plural magnet grooves in the laminated plural silicon steel sheets are partially connected to each other in the axial direction, wherein the plural magnet grooves in the outermost layer in the axial direction are connected to the annular flow passage, the plural tooth structures, the plural first pouring flow passages, and the plural second pouring flow passages.

According to an embodiment of the present invention, a plurality of the silicon steel sheet mating portions of the axially outermost layer are connected to a plurality of the second pouring channels.

According to an embodiment of the present invention, each of the silicon steel sheets has a plurality of cooling channels, which are located between each corresponding first pouring channel and each corresponding second pouring channel and are surrounded by the annular channel.

According to an embodiment of the present invention, the at least one injection molding opening is radially disposed between the plurality of magnet grooves and the plurality of silicon steel sheet mating portions, and is arranged along a circumferential direction of the upper end plate or the lower end plate.

According to an embodiment of the present invention, a rotor process comprises the steps of: (a) Sequentially stacking a plurality of silicon steel sheets to form a silicon steel sheet laminated structure, and stacking an upper end plate and a lower end plate along the axial direction at two ends of the silicon steel sheet laminated structure, wherein each of the plurality of silicon steel sheets is provided with a shaft hole, at least one silicon steel sheet matching part and a plurality of magnet grooves, the at least one silicon steel sheet matching part is connected with the shaft hole and is aligned with at least one rotating shaft matching part of a rotating shaft to form an axial injection molding runner, wherein the upper end plate or the lower end plate is concavely provided with an end plate shaft hole, at least one injection molding opening and at least one end plate injection molding runner, and the at least one injection molding opening is connected with the at least one end plate injection molding runner and the axial injection molding runner; (b) Placing a plurality of magnets into a plurality of corresponding magnet grooves, wherein the at least one end plate injection runner is communicated with the axial injection runner and the plurality of magnet grooves; (c) Preheating the silicon steel sheet laminated structure to reach a temperature suitable for injection molding; (d) Injecting an injection molding material from one end of the silicon steel sheet laminated structure along the axial direction to fill the axial injection molding runner, and hardening the injection molding material to form the axial injection molding runner formed by the at least one rotating shaft matching part and the plurality of silicon steel sheet matching parts, wherein the at least one rotating shaft matching part is aligned with the thermosetting plastic key; and (e) injecting injection molding materials to fill up between the magnet grooves and the magnets, and fixing the magnets after hardening.

According to an embodiment of the present invention, the step (a) is to insert a dummy shaft when stacking a plurality of the silicon steel sheets, and replace the dummy shaft with the rotating shaft after the step (b).

According to an embodiment of the present invention, a plurality of the magnets are magnetized after the step (e).

In summary, the rotor structure and the rotor process of the present invention are used for filling the magnet grooves and fixing the magnets by the characteristic that the thermosetting plastic can fill the gaps after being subjected to high-temperature injection molding and hardening. The rotor structure has a simpler process than the prior art that a single silicon steel sheet is glued and bonded with a magnet and then a plurality of silicon steel sheets are overlapped. The thermosetting plastic can fill the gaps of the magnet grooves, so that the risk of breaking the magnet is low, and the strength of the magnet is better than that of the magnet gel at high temperature. The rotor structure is made up through injection moulding and heating to hardening or solidifying by applying axial force to machine, so that it is less likely to overflow plastics to cause gaps between silicon steel sheets and the risk of oil leakage of cooling oil can be reduced. The process of the rotor structure can be used for injection molding a plurality of laminated silicon steel sheets at one time, and compared with the process of coating a single layer of magnetite glue and then laminating a plurality of layers of magnetite glue, the production time is greatly shortened. The thermosetting plastic keys of the rotor structure can be tightly filled in the rotating shaft matching part on the rotating shaft and the silicon steel sheet matching part of the silicon steel sheet, so that the problem that the metal keys are stressed in unilateral contact during the operation of the traditional rotor is solved, and in some embodiments, the torque during the operation of the motor can be dispersed by arranging a plurality of thermosetting plastic keys, so that the safety of the motor is improved. The thermosetting plastic bond can also replace the traditional metal bond, and reduces the design and processing difficulty.

The following description will make detailed description of the above description in terms of embodiments, and provide further explanation of the technical solution of the present invention.

Drawings

The foregoing and other objects, features, advantages and embodiments of the invention will be apparent from the following description taken in conjunction with the accompanying drawings in which:

fig. 1 is a perspective view showing a rotor structure of an embodiment of the present invention;

fig. 2 is an exploded view showing a rotor structure of an embodiment of the present invention;

fig. 3 is an end view showing an upper end plate of a rotor structure of an embodiment of the present invention;

fig. 4 is an end view of a single sheet of silicon steel showing the rotor structure of an embodiment of the present invention;

fig. 5 is an end view of a single sheet of silicon steel showing the configuration magnets of the rotor structure of the embodiment of the present invention;

fig. 6 is an end view showing a laminated structure of silicon steel sheets of a rotor structure configuring a rotation shaft of an embodiment of the present invention;

FIG. 7 is a schematic end view of an end plate injection runner illustrating rotor structure shaping in accordance with an embodiment of the present invention;

FIG. 8 is a schematic perspective view of an end plate injection runner and an axial injection runner illustrating rotor structure shaping in accordance with an embodiment of the present invention; and

fig. 9 is a flowchart illustrating a rotor process according to an embodiment of the present invention.

The reference numerals are as follows:

100 rotor structure

102 silicon steel sheet lamination structure

102a silicon steel sheet

102b end face

102c end face

103 lower end plate

103c end plate shaft hole

104 upper end plate

104a injection molding port

104b cooling flow path

104c end plate shaft hole

105 end plate injection molding runner

105a circular flow channel

105b tooth-like structure

105c first perfusion channel

105d second filling flow channel

106 rotating shaft

106a, shaft engaging portion

106b spindle keyway

112 shaft hole

113 magnet groove

113a first magnet slot

113b second magnet groove

113c air groove

114 magnet

114a first magnet

114b second magnet

115 silicon steel sheet mating part

116 metal bond

118 thermosetting plastic bond

AD: axial direction

900 process

902 step

904 step

906 step

908 step

910 step

Detailed Description

For a more complete and thorough description of the present invention, reference is made to the accompanying drawings and the various embodiments described below, wherein like reference numbers represent the same or similar elements. In other instances, well-known elements and steps have not been described in detail in order to not unnecessarily obscure the present invention. In the description and claims, unless the context clearly dictates otherwise, the terms "a" and "an" may refer to either a single or a plurality of.

Referring to fig. 1 and 2, fig. 1 is a perspective view illustrating a rotor structure according to an embodiment of the present invention, and fig. 2 is an exploded view illustrating the rotor structure according to the embodiment of the present invention. The rotor structure 100 of fig. 1 is obtained by combining the components of the rotor structure of fig. 2. The rotor structure 100 comprises a laminated structure of silicon steel sheets 102, a lower end plate 103, an upper end plate 104, a rotor shaft 106, injection molded material, and thermosetting plastic keys. The rotating shaft 106 penetrates through the shaft holes of the silicon steel sheet laminated structure 102, the lower end plate 103 and the upper end plate 104. The upper end plate 104 and the lower end plate 103 are disposed at two opposite ends of the laminated silicon steel sheet structure 102 in the axial direction AD, that is, the upper end plate 104 is disposed at an end face 102b of one end of the laminated silicon steel sheet structure 102, and the lower end plate 103 is disposed at an end face 102c of the other end of the laminated silicon steel sheet structure 102. The silicon steel sheet laminated structure 102 is made by laminating a plurality of silicon steel sheets 102 a. The thermosetting plastic bond will be described in detail later.

Referring to fig. 3, an end view of an upper end plate of a rotor structure according to an embodiment of the invention is shown. In this embodiment, the upper end plate 104 is a medium into which injection molding material is poured from above, so the upper end plate 104 is concavely provided with an end plate shaft hole 104c, at least one injection molding opening 104a and at least one end plate injection molding runner 105. At least one injection molding opening 104a is connected with at least one end plate injection molding runner 105 and the axial injection molding runner, and a plurality of injection molding openings 104a are through holes penetrating through the upper end plate 104. It should be noted that the lower end plate 103 may also be formed with the same injection port and end plate injection runner as the upper end plate 104, and the description and drawings mainly describe the structure of the end plate 104 for convenience of description and understanding, but are not intended to limit the invention. The end plate injection molding flow channel 105 comprises a circular ring flow channel 105a, a plurality of tooth-shaped structures 105b, a plurality of first injection flow channels 105c and a plurality of second injection flow channels 105d, wherein the design features of the circular ring flow channel 105a can enable the injection molding flow channel to be more uniform and reduce the flow channel resistance, in some embodiments of the invention, the tooth-shaped structures 105b are formed on the outer side (one side far away from an end plate shaft hole 104c in the radial direction) of the circular ring flow channel 105a and are arranged along the circumferential direction of the rotor structure, the tooth-shaped structures 105b are connected with the circular ring flow channel 105a, the tooth-shaped structures 105b are designed to enable the injection molding material to be easily guided to the edge of a magnet groove (such as an air groove 113c in fig. 5), the tooth-shaped structures 105b are designed to enable the injection molding flow channel of the end plate injection molding flow channel to be more uniform and are matched with the circular ring flow channel 105a, in some embodiments of the invention, the first injection flow channels 105c and the second injection flow channels 105d are positioned on the inner side (one side of the circular ring flow channel 105a and the other side close to the circular ring flow channel 105c, the first injection channels 105c and the other side of the circular ring flow channels 105c are connected with the circular ring flow channel 105c, and the other side of the circular ring flow channels 105c and the end plate injection flow channels are connected with the circular ring flow channels 105c in the embodiment of the invention, an injection port 104a is located in each of the first or second injection runners 105c, 105d. In some embodiments of the present invention, the upper end plate 104 is further provided with a cooling channel 104b between each pair of the first and second injection channels (105 c, 105 d), the cooling channel 104b and the end plate injection channel 105 are different in function, the cooling channel 104b is used for circulating cooling oil, and the end plate injection channel 105 is used for injecting injection molding material into the rotor structure, so that the two injection channels are not connected with each other. In some embodiments of the present invention, the sections of the plurality of tooth structures 105b that connect with the annular flow channel 105a and the sections of the first and second perfusion flow channels (105 c, 105 d) that connect with the annular flow channel 105a are not aligned with each other. In some embodiments of the present invention, the cooling flow passage 104b is located between each pair of the first and second pouring flow passages (105 c, 105 d) and is surrounded by the annular flow passage 105a, so that the cooling oil in the cooling flow passage 104b is less likely to leak out to the outer diameter during operation. In some embodiments of the present invention, the upper end plate 104 is only provided with at least one injection port 104a and the first and second injection channels (105 c, 105 d) through the annular channel 105a to fill the injection molding material into the whole silicon steel sheet laminated structure 102. In some embodiments of the present invention, the upper end plate 104 is provided with eight injection openings 104a for simultaneously filling injection molding material, so that the injection molding material can uniformly fill the space required for the rotor structure.

Referring to fig. 4, an end view of a single silicon steel sheet 102a of a rotor structure according to an embodiment of the invention is shown. Each of the silicon steel sheets 102a is provided with a plurality of magnet grooves 113 hollowed out in the axial direction to accommodate magnets. The magnet grooves 113 include a first magnet groove 113a having a large size and a second magnet groove 113b having a small size. In some embodiments of the present invention, the first magnet slot 113a is closer to the rotation shaft 106, and the second magnet slot 113b is farther from the rotation shaft 106. In some embodiments of the present invention, each of the silicon steel sheets 102a has a shaft hole 112 and at least one silicon steel sheet mating portion 115, and the silicon steel sheet mating portion 115 is connected to the shaft hole 112. In some embodiments of the present invention, the shaft hole 112 of each silicon steel sheet 102a is concavely provided with at least one silicon steel sheet mating portion 115 toward the center away from the silicon steel sheet 102a and at least one metal key 116 toward the center toward the silicon steel sheet 102 a. In some embodiments of the present invention, the shaft hole 112 of each silicon steel sheet 102a has two silicon steel sheet mating portions 115 and two metal keys 116, and the positions of the two silicon steel sheet mating portions 115 of the silicon steel sheet 102a are 180 degrees apart and the positions of the two metal keys 116 are 180 degrees apart when the silicon steel sheet 102a is viewed in the axial direction. In some embodiments of the present invention, the shaft hole 112 of each silicon steel sheet 102a is provided with two silicon steel sheet matching portions 115 and two metal keys 116, each silicon steel sheet matching portion 115 is located between two metal keys 116, each metal key 116 is located between two silicon steel sheet matching portions 115, that is, the silicon steel sheet matching portions 115 and the metal keys 116 are alternately staggered, and the adjacent silicon steel sheet matching portions 115 and the metal keys 116 of the silicon steel sheet 102a are observed to be 90 degrees different in axial direction. In some embodiments of the present invention, the silicon steel sheet fitting portion 115 is a groove formed in the shaft hole 112. In some embodiments of the present invention, the silicon steel sheet fitting portion 115 of the axially outermost two silicon steel sheets 102a is in direct communication with the second pouring spout 105d of the upper end plate 104 or the lower end plate 103 (refer to fig. 1 to 4 together). In some embodiments of the present invention, the magnet slots 113 of the axially outermost two-layer silicon steel sheet 102a are in direct communication with the annular runner 105a, the tooth structure 105b, the first pouring runner 105c, and the second pouring runner 105d of the upper end plate 104 or the lower end plate 103 (refer to fig. 1 to 4).

Referring to fig. 5, an end view of a single silicon steel sheet with magnets disposed thereon of a rotor structure according to an embodiment of the present invention is shown. Each of the silicon steel sheets 102a is provided with a plurality of magnet grooves 113 formed in the axial direction and arranged along the circumference of the silicon steel sheet 102a to accommodate a plurality of magnets 114. The magnet slots 113 include a first magnet slot 113a with a larger size for accommodating a first magnet 114a with a larger size, and a second magnet slot 113b with a smaller size for accommodating a second magnet 114b with a smaller size. In some embodiments of the present invention, each of the silicon steel sheets 102a has a shaft hole 112 and at least one silicon steel sheet mating portion 115, and the silicon steel sheet mating portion 115 is connected to the shaft hole 112. The cross-sectional area of the magnet groove 113 viewed in the axial direction is larger than the cross-sectional area of the magnet 114. In some embodiments of the present invention, air grooves 113c connected to the outside of the first and second magnet grooves (113 a, 113 b) may be used as injection molding runners penetrating through the inside of the laminated silicon steel sheet 102 a. In some embodiments of the present invention, the shaft hole 112 of each silicon steel sheet 102a has at least one silicon steel sheet mating portion 115 and at least one metal key 116. In some embodiments of the present invention, the shaft hole 112 of each silicon steel sheet 102a has two silicon steel sheet mating portions 115 and two metal keys 116. Specifically, the positions of the two silicon steel sheet mating portions 115 of the silicon steel sheet 102a are observed to be 180 degrees apart, the positions of the two metal keys 116 are observed to be 180 degrees apart, and the connecting line between the two silicon steel sheet mating portions 115 perpendicularly intersects with the connecting line between the two metal keys 116.

Referring to fig. 6, an end view of a laminated structure of silicon steel sheets of a rotor structure with a rotating shaft according to an embodiment of the present invention is shown. When the plurality of silicon steel sheets 102a are sleeved on the rotating shaft 106 and laminated, the silicon steel sheet laminated structure 102 is formed. The plurality of silicon steel sheet mating portions 115 of the plurality of silicon steel sheets 102a are positioned at the rotating shaft mating portion 106a of the rotating shaft 106 to form an axial injection molding runner in the axial direction. The plurality of metal keys 116 of the plurality of silicon steel sheets 102a are engaged with the shaft key grooves 106b of the shaft 106, and the shaft key grooves 106b are formed on the surface of the shaft 106 and extend in the axial direction. In some embodiments of the present invention, the silicon steel sheet engaging portion 115 is a groove on the shaft hole 112, and the rotating shaft engaging portion 106a is a groove on the rotating shaft 106. After the thermosetting plastic injection molding material is injected into the axial injection molding runner formed by the alignment of the silicon steel sheet matching portion 115 and the rotating shaft matching portion 106a and hardened or cured, the thermosetting plastic bond 118 is formed in the axial injection molding runner formed by the alignment, and is used as a rotation positioning bond between the silicon steel sheet laminated structure 102 and the rotating shaft 106. Unlike the rotary positioning key made of metal, which is formed by the metal key 116 of the silicon steel sheet 102a being engaged with the shaft key slot 106b of the shaft 106, the thermosetting plastic key 118 is arranged in the shaft 106 after the silicon steel sheet laminated structure 102 is sleeved with the silicon steel sheet, and is configured by transfer molding (transfer molding) to form an axial injection runner in the aligned silicon steel sheet matching portion 115 and the shaft matching portion 106a, so that the thermosetting plastic key 118 can be better adhered to the silicon steel sheet matching portion 115 and the shaft matching portion 106a, provide rotary positioning required during operation of the rotor structure, and reduce deformation and residual stress of the silicon steel sheet 102a when the interference amount between the silicon steel sheet laminated structure 102 and the shaft 106 is too large. In some embodiments of the present invention, there is a rotational detent bond provided by both the thermoset plastic bond 118 and the metal bond 116 between the spindle 106 and the silicon steel sheet laminate structure 102. In some embodiments of the present invention, only the rotational positioning key provided by the thermosetting plastic key 118 is present between the spindle 106 and the silicon steel sheet laminate structure 102, and the rotational positioning key provided by the metal key 116 is removed. In some embodiments of the present invention, there are two thermosetting plastic keys 118 between the shaft 106 and the silicon steel sheet laminated structure 102 and two rotational positioning keys provided by two metal keys 116, and the positions of the two thermosetting plastic keys 118 are 180 degrees different from each other and the positions of the two metal keys 116 are 180 degrees different from each other when the silicon steel sheet 102a is viewed in the axial direction.

Referring to fig. 7 and 8, fig. 7 is a schematic end view of an injection runner formed by a rotor structure according to an embodiment of the present invention, and fig. 8 is a schematic perspective view of an injection runner formed by a rotor structure according to an embodiment of the present invention. The schematic end faces of the end plate injection molding runners are shown with corresponding reference numerals in fig. 3-6. When the thermosetting plastic, i.e., the injection molding material, is injected into the injection molding runner of the end plate from the eight injection molding ports 104a of the end plate at the same time, the thermosetting plastic flows into the first injection runner 105c or the second injection runner 105d first, and a part of the thermosetting plastic directly flows into the first magnet groove 113a, the second magnet groove 113b and a part of the air groove 113c inside the annular runner 105a through the first injection runner 105c or the second injection runner 105d. In addition, another part of the thermosetting plastic flows outward through the annular runner 105a to the tooth-like structure 105b, and flows into the first magnet groove 113a, the second magnet groove 113b and a part of the air groove 113c outside the annular runner 105a through the tooth-like structure 105 b. In addition, a further part of the thermosetting plastic flows into the axial injection runner formed by co-alignment of the silicon steel sheet fitting portion 115 of the silicon steel sheet 102a and the rotation shaft fitting portion 106a of the rotation shaft 106 through the second injection runner 105d. Since the first magnet grooves 113a of the plurality of silicon steel sheets 102a are connected to each other in the axial direction, the second magnet grooves 113b are also connected to each other in the axial direction and to the end plate injection molding runner 105 of the upper and lower end plates. The magnet grooves 113 between the laminated silicon steel sheets 102a are arranged offset from each other based on the magnetic force distribution characteristics, and the magnet grooves 113 between the silicon steel sheets 102a of each layer are partially communicated to allow the injection molding material to pass through, so that the injection molding runners of the first and second magnet grooves (113 a, 113 b) in fig. 8 are also arranged offset from each other. Based on the first and second magnet grooves (113 a, 113 b) arranged in a staggered manner, the magnetic force expression of the magnet accommodated in the magnet groove can be improved. It should be noted that the silicon steel sheet mating portions 115 between the silicon steel sheets 102a are aligned (for example, the grooves of the silicon steel sheet mating portions 115 of the silicon steel sheets 102a are aligned with each other), that is, if viewed along the axial direction, the silicon steel sheet mating portions 115 between the silicon steel sheets 102a are aligned and penetrated, so that the rotating shaft mating portions 106a correspondingly form aligned and penetrated axial injection molding runners. In addition, the end plate injection molding runner 105 of the upper and lower end plates is also connected to an axial injection molding runner formed by the silicon steel sheet fitting portion 115 of the silicon steel sheet 102a and the rotation shaft fitting portion 106a of the rotation shaft 106. In some embodiments of the present invention, the injection molding openings 104a are radially disposed between the first and second magnet grooves (113 a, 113 b) and the silicon steel sheet mating portion 115, so that the injection molding material flows more uniformly.

Referring to fig. 9, a flow chart of a rotor process 900 according to an embodiment of the invention is shown. In step 902 (please refer to fig. 1 and 2 simultaneously), the rotor process sequentially stacks a plurality of silicon steel sheets 102a to form a silicon steel sheet laminated structure 102. In step 904, the rotor process places a plurality of magnets in a plurality of magnet slots 113 corresponding to each layer of silicon steel sheet 102 a. Wherein steps 902 and 904 are repeated alternately. The details of steps 902 and 904 may be that the rotating shaft 106 is vertically fixed on a base, and the lower end plate 103 is first inserted into the rotating shaft 106 through the end plate shaft hole 103 c. Then, the single silicon steel sheets 102a are sequentially threaded through the shaft holes 112 thereof on the rotating shaft 106 one by one (for example, the silicon steel sheets 102a are clamped by a mechanical arm for execution), and when each layer of silicon steel sheets 102a is stacked, the magnets 114 are placed in the magnet slots 113 corresponding to the layer of silicon steel sheets 102a, and the step is repeated for a plurality of times, so that the required number of the silicon steel sheets 102a are all threaded on the rotating shaft 106, and the silicon steel sheet laminated structure 102 is formed. In step 902 and step 904, an axial injection runner is formed by aligning the silicon steel sheet mating portion 115 of each silicon steel sheet 102a with the rotating shaft mating portion 106a of the rotating shaft 106. Finally, the upper end plate 104 is inserted through the end plate shaft hole 104c on the rotating shaft 106, so that the silicon steel sheets 102a with the magnets 114 are overlapped between the upper end plate 104 and the lower end plate 103 to form a rotor structure. In other embodiments, the steps 902 and 904 may be repeated alternately, for example, the silicon steel sheet laminated structure 102 is formed, and then an upper end plate 104 and a lower end plate 103 are stacked along the axial direction at two ends of the silicon steel sheet laminated structure 102. In some embodiments of the present invention, the upper and lower end plates, the silicon steel plates and the rotating shaft may be interference fit, for example, the upper and lower end plates or the silicon steel plates are heated to a higher temperature to expand the shaft holes, or the rotating shaft is put into liquid nitrogen to reduce the shaft diameters, so that the upper and lower end plates, the silicon steel plates pass through the shaft holes. When the upper end plate or the lower end plate or the silicon steel sheet and the rotating shaft return to normal temperature, the upper end plate or the lower end plate or the silicon steel sheet and the rotating shaft form interference fit to be fixed, and the shaft entering process is realized.

Next, in step 906 (please refer to fig. 1 and 2), the rotor process preheats the silicon steel sheet laminate structure 102 to a temperature suitable for injection molding. The details of step 906 may be performed by pressing the laminated plurality of silicon steel sheets 102a axially through the upper end plate 104 and the lower end plate 103, and preheating the rotor structure 100 and the silicon steel sheet laminated structure 102 thereof by the inner and outer heating coils. When the silicon steel sheet 102a and the rotating shaft 106 are restored to normal temperature by the action of pressing in the axial direction, the gap between the silicon steel sheets 102a can be reduced as much as possible.

In some embodiments of the present invention, step 902 may be performed by first inserting a dummy shaft (not shown) when stacking a plurality of silicon steel sheets 102a, and replacing the dummy shaft with the rotating shaft 106 after step 904.

Next, in step 908 (please refer to fig. 2-8), the rotor process injects the injection molding material from one end of the silicon steel sheet lamination structure 102 along the axial direction to fill the axial injection molding runner, and hardens the injection molding material to form a thermosetting plastic bond 118 in the axial injection molding runner. The details of step 908 may be that the molding jig is used to inject the injection molding material into the axial injection runner formed by aligning the silicon steel sheet mating portion 115 with the rotating shaft mating portion 106a through the injection port 104a of the upper end plate 104 and the end plate injection runner 105, and the injection molding material is injected into the silicon steel sheet laminated structure 102 by a transfer molding process to harden the injection molding material to form a hardened thermosetting plastic bond 118 to fill the axial injection runner. Next, in step 910 (please refer to fig. 2-8), an injection molding material is injected through the injection port 104a, the end plate injection runner 105 and the magnet groove 113 to fill the gap between the magnet groove and the magnet, and then the injection molding material is hardened, so as to form a hardened thermosetting plastic to bond and fix the magnet 114 in the magnet groove 113.

The rotor process also includes magnetizing the magnet 114 so that the magnet 114 has magnetic poles and forces that meet the requirements of the rotor structure. The step of magnetizing the magnet may be performed before step 904 (pre-magnetizing process), or after step 910 (post-magnetizing process), wherein the post-magnetizing process is easier to fill the magnet slot when stacking the silicon steel sheets.

The rotor process further comprises driving the rotor to rotate for a moving balance test to test whether the injection molding material is uniformly filled into the rotor, wherein the moving balance test is performed after the thermosetting plastic is completely hardened or cured to fix the magnet 114 to the magnet slot 113 (after step 910).

The rotor process also includes dimensional measurements of the rotor that have completed the dynamic balance test, such as measuring whether the axial length of the rotor and/or the diameter of the laminated structure of silicon steel sheets meets the requirements.

The rotor structure of the invention is used for filling the magnet groove and fixing the magnet through the characteristic that the gap can be filled after the thermosetting plastic is subjected to high-temperature injection molding and hardening or solidification. The rotor structure has a simpler process than the prior art that a single silicon steel sheet is glued and bonded with a magnet and then a plurality of silicon steel sheets are overlapped. The thermosetting plastic can fill the gaps of the magnet grooves and fix the magnets, so that the risk of breaking the magnets is low, and the strength of the thermosetting plastic at high temperature is better than that of the magnet. The process of the rotor structure is to complete the injection molding and heating to hardening or solidifying steps under the condition of applying axial force by the machine table, so that the situation that gaps are generated between silicon steel sheets due to plastic overflow is less prone to occur, and the risk of oil leakage of cooling oil during the running of the rotor can be reduced. The process of the rotor structure can be used for injection molding a plurality of laminated silicon steel sheets at one time, and compared with the process of coating a single layer of magnetite glue and then laminating a plurality of layers of magnetite glue, the production time is greatly shortened. The thermosetting plastic keys of the rotor structure can be tightly filled in the key groove matching parts on the shaft, the problem of unilateral contact stress of the metal keys is avoided, and in some embodiments, the motor torque can be dispersed through a plurality of thermosetting plastic keys, so that the motor safety is improved. The thermosetting plastic bond can also replace a metal bond, and reduces design difficulty.

While the present invention has been described with reference to the embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention, and it is intended that the scope of the invention be limited only by the appended claims.

Claims

1. A rotor structure comprising:

the silicon steel sheet lamination structure is formed by stacking a plurality of silicon steel sheets, wherein each silicon steel sheet is provided with a shaft hole, at least one silicon steel sheet matching part and a plurality of magnet grooves for accommodating a plurality of magnets, and the at least one silicon steel sheet matching part is connected with the shaft hole;

the upper end plate or the lower end plate is concavely provided with an end plate shaft hole, at least one injection molding opening and at least one end plate injection molding runner;

the rotating shaft is arranged in the shaft holes of the plurality of shaft holes and the plurality of end plate shaft holes in a penetrating way, and is provided with at least one rotating shaft matching part which forms an axial injection molding runner on the plurality of silicon steel sheet matching parts of the plurality of silicon steel sheets, wherein the at least one injection molding opening is connected with the at least one end plate injection molding runner and the axial injection molding runner, and the at least one end plate injection molding runner is communicated with the axial injection molding runner and the plurality of magnet grooves; and

and the thermosetting plastic key is formed and configured in the axial injection molding flow channel formed by the at least one rotating shaft matching part and the silicon steel sheet matching parts which are aligned, and the injection molding material is filled between the magnet grooves and the magnets and fixes the magnets after hardening.

2. The rotor structure of claim 1, wherein the shaft further has at least one shaft key slot extending in an axial direction, each of the silicon steel plates has at least one metal key connected to the shaft hole, wherein a plurality of the metal keys of a plurality of the silicon steel plates are engaged in the at least one shaft key slot, and a plurality of the metal keys of a plurality of the silicon steel plates are aligned with each other.

3. The rotor structure according to claim 1, wherein a plurality of the magnet grooves of a plurality of the silicon steel sheets are arranged offset from each other, and a plurality of the silicon steel sheet mating portions of a plurality of the silicon steel sheets are arranged in alignment with each other.

4. The rotor structure of claim 1, wherein the at least one end plate injection molding runner comprises an annular runner, a plurality of tooth structures, a plurality of first injection runners and a plurality of second injection runners.

5. The rotor structure of claim 4, wherein a plurality of the tooth structures are formed at a side of the circular flow passage away from the shaft hole of the end plate and are arranged along a circumferential direction of the upper end plate or the lower end plate.

6. The rotor structure of claim 5, wherein the first perfusion channels and the second perfusion channels are located at one side of the annular channel near the shaft hole of the end plate and are connected with the annular channel.

7. The rotor structure according to claim 6, wherein a plurality of said magnet grooves corresponding to a plurality of said silicon steel sheets are partially connected to each other in an axial direction, wherein a plurality of said magnet grooves in an axially outermost layer are connected to the annular flow passage, a plurality of said tooth structures, a plurality of said first pouring flow passages, and a plurality of said second pouring flow passages.

8. The rotor structure of claim 6, wherein the at least one silicon steel sheet mating portion of the plurality of silicon steel sheets of the axially outermost layer is connected to the plurality of second pouring channels.

9. The rotor structure of claim 6, wherein each of the silicon steel plates has a plurality of cooling channels between each of the corresponding first and second filling channels and is surrounded by the annular channel.

10. The rotor structure of claim 1, wherein the at least one injection molding opening is disposed between the plurality of magnet grooves and the plurality of silicon steel sheet mating portions in a radial direction and is arranged along a circumferential direction of the upper end plate or the lower end plate.

11. A rotor process comprising the steps of:

(a) Sequentially stacking a plurality of silicon steel sheets to form a silicon steel sheet stacking structure, and stacking an upper end plate and a lower end plate along the axial direction at two ends of the silicon steel sheet stacking structure, wherein each of the plurality of silicon steel sheets is provided with a shaft hole, at least one silicon steel sheet matching part and a plurality of magnet grooves, the at least one silicon steel sheet matching part is connected with the shaft hole, the plurality of silicon steel sheet matching parts in the plurality of silicon steel sheets are aligned with at least one rotating shaft matching part of a rotating shaft to form an axial injection runner, the upper end plate or the lower end plate is concavely provided with an end plate shaft hole, at least one injection port and at least one end plate injection runner, and the at least one injection port is connected with the at least one end plate injection runner and the axial injection runner;

(b) Placing a plurality of magnets into a plurality of corresponding magnet grooves, wherein the at least one end plate injection runner is communicated with the axial injection runner and the plurality of magnet grooves;

(c) Preheating the silicon steel sheet laminated structure to reach a temperature suitable for injection molding;

(d) Injecting an injection molding material from one end of the silicon steel sheet laminated structure along the axial direction to fill the axial injection molding runner, and hardening the injection molding material to form the axial injection molding runner formed by the at least one rotating shaft matching part and the plurality of silicon steel sheet matching parts, wherein the at least one rotating shaft matching part is aligned with the thermosetting plastic key; and

(e) Injecting injection molding materials to fill the gaps between the magnet grooves and the magnets, and fixing the magnets after hardening.

12. The rotor process according to claim 11, wherein the step (a) is to insert a dummy shaft when stacking a plurality of the silicon steel sheets, and replace the dummy shaft with the rotating shaft after the step (b).

13. The rotor process of claim 11, wherein a plurality of the magnets are magnetized after the step (e).