CN220628978U - Motor rotor and motor - Google Patents

Abstract

The application provides a motor rotor and a motor. In the motor rotor, the carbon fiber sleeve sleeved on the rotor body provides effective protection for the rotor body, and particularly provides good protection for each rotor unit forming the rotor body under the high-rotation-speed condition. Therefore, the thickness of the magnetism isolating bridge of each rotor unit of the rotor main body is not required to be increased, the structural firmness of the motor rotor under the high-rotating-speed condition can be guaranteed, the rotor main body can stably work in the working state with a large rotating speed, and the magnetic flux performance of the motor rotor cannot be adversely affected. In addition, the sheet-like laminated bodies having the same structure and each having an integral structure can be manufactured by the same process, so that the degree of difficulty in manufacturing the rotor body and the manufacturing cost can be greatly reduced, which is advantageous for mass industrial production.

Description

Motor rotor and motor

Technical Field

The present application relates to the field of motors, and in particular to a motor rotor and a motor including the same.

Background

In existing electric drive systems for vehicles, the vehicle is typically driven with an electric motor (e.g., a permanent magnet synchronous motor), which requires a high rotational speed of the motor to provide good performance of the vehicle. However, as the rotational speed of the motor increases, the rotor laminate is subjected to a very large centrifugal force, which may cause deformation and breakage of the structure of the magnetic barrier bridge of the rotor.

In existing motors, the rotational speed of the rotor may reach 20000 revolutions per minute, so the structure of the rotor's magnetically isolated bridge needs to be designed thick enough to resist the centrifugal forces generated at high speeds. However, thicker magnetic barriers will lead to more flux leakage, which will lead to reduced flux utilization and efficiency of the overall motor. Thus, there is a need for an electric motor rotor that balances structural integrity and magnetic flux performance at high rotational speeds. For example, in chinese patent application publication No. CN 115917927A, entitled "permanent magnet motor with windings" (which is a chinese co-family application of international application WO 2021/225902 A1), a solution is disclosed for protecting a rotor with a wound fiber sleeve, but the rotor is difficult and costly to process, which is disadvantageous for large-scale industrial production.

Disclosure of Invention

The present application has been made in view of the state of the art described above. An object of the present application is to provide a motor rotor which is capable of balancing structural rigidity and magnetic flux performance under high rotation speed conditions, and which is easy to process and low in cost, and is advantageous for mass industrial production. Another object of the present application is to provide an electric machine comprising the above electric machine rotor.

In order to achieve the above object, the present application adopts the following technical solutions.

The application provides a motor rotor, including:

a rotor body integrally formed in a cylindrical shape, the rotor body including a plurality of rotor units arranged in a stacked manner in an axial direction, each of the rotor units being formed by stacking a plurality of sheet-like stacked bodies in the axial direction, each of the sheet-like stacked bodies having an integral construction and having the same structure, and each of the rotor units being formed with a plurality of grooves;

a plurality of magnets mounted in the plurality of slots and fixed relative to the rotor body; and

and a carbon fiber sleeve formed in a cylindrical shape and covering the entire outer peripheral surface of the rotor body.

In an alternative, the sheet-like laminate is a sheet formed by the same press working process.

In another alternative, the carbon fiber sleeve is a cylindrical body formed by winding a carbon fiber ribbon around the outer circumferential surface of the rotor body.

In another alternative, the plurality of grooves includes a plurality of first grooves arranged at intervals in a circumferential direction of the rotor body, each of the first grooves penetrating the rotor unit in the axial direction, the first grooves being arranged in pairs, each pair of the first grooves being arranged in a V-shape, and

the plurality of magnets includes a first magnet insertedly mounted in the first slot.

In another alternative, for each pair of the first grooves, the rotor unit is formed with a magnetic shielding bridge between radially inner ends of the two first grooves, such that the two first grooves are separated by the magnetic shielding bridge, and

each of the first grooves extends to the outer peripheral surface and has an opening on the outer peripheral surface such that a radially outer end of each of the first grooves is open toward a radially outer side of the rotor body.

In another alternative, each of the first grooves includes a mounting groove portion and a magnetism isolating groove portion that communicate with each other, the first magnet is located at the mounting groove portion, the magnetism isolating groove portion is located radially inward of the mounting groove portion, and the magnetism isolating bridge is disposed between the magnetism isolating groove portions.

In another alternative, the plurality of slots further includes a plurality of second slots, each of the second slots extending through the rotor unit in the axial direction, each of the second slots corresponding to a pair of the first slots, each of the second slots being located between and spaced apart from a corresponding pair of the first slots in the circumferential direction, and

the plurality of magnets includes a second magnet insertedly mounted in the second slot.

In another alternative, the second slot and the corresponding pair of first slots form a slot unit, the slot unit having a symmetrical structure,

and a plurality of second magnets are inserted into each of the second grooves, each of the second grooves having a width direction perpendicular to the axial direction and the extending direction of the symmetry line of the groove unit, and the plurality of second magnets being arranged along the width direction.

In another alternative, the motor further comprises a rotor shaft, and the rotor body is sleeved on the rotor shaft and fixed with the rotor shaft.

The application also provides a motor, which comprises the motor rotor according to any one of the technical schemes.

Through adopting above-mentioned technical scheme, this application provides a novel motor rotor and including this motor rotor's motor. In the motor rotor of the present application, a rotor body, a plurality of magnets, and a carbon fiber sleeve are assembled together. The rotor body is integrally formed in a cylindrical shape, and includes a plurality of rotor units arranged in a stacked manner in the axial direction, each rotor unit being formed by stacking a plurality of sheet-like stacked bodies in the axial direction, each sheet-like stacked body having a non-split integral construction and having the same structure. Each rotor unit is formed with a plurality of slots in which a plurality of magnets are insertedly mounted and fixed with respect to the rotor body. The carbon fiber sleeve is cylindrical and is coated on the outer peripheral surface of the rotor body.

In this way, on the one hand, the carbon fiber sleeve fitted over the rotor body provides an effective protection for the rotor body, in particular a good protection for the individual rotor units constituting the rotor body in high rotational speed conditions. Therefore, the thickness of the magnetism isolating bridge of each rotor unit of the rotor main body does not need to be increased, so that the structural firmness of the motor rotor under the high-rotating-speed condition can be ensured, the rotor main body can stably work in a working state with a large rotating speed (such as more than 23000 revolutions per minute), and the magnetic flux performance of the motor rotor is not adversely affected. On the other hand, the sheet-like laminated bodies having the same structure and each having an integral structure can be manufactured by the same process, and therefore, the degree of difficulty in manufacturing the rotor body and the manufacturing cost can be greatly reduced, which is advantageous for mass industrial production.

Drawings

Fig. 1A is a perspective view illustrating a motor rotor according to an embodiment of the present application.

Fig. 1B is a schematic front view showing the motor rotor in fig. 1A.

Fig. 2A is a perspective view showing an assembly of a rotor body, magnets (first and second magnets), and a rotor shaft of the motor rotor in fig. 1A.

Fig. 2B is a schematic front view showing the assembly in fig. 2A.

Fig. 2C is an enlarged schematic view showing a partial structure of the assembly in fig. 2A.

Fig. 2D is a perspective view illustrating a plurality of second magnets of the assembly of fig. 2A mounted in one second slot.

Fig. 3A is a perspective view illustrating a carbon fiber sleeve of the motor rotor in fig. 1A.

Fig. 3B is a schematic front view showing the carbon fiber sleeve of fig. 3A.

Description of the reference numerals

1a rotor body; a 1u rotor unit; 1u1 magnetic isolation bridge; 1h 1a first groove; 1h11 mounting groove parts; 1h12 magnetism isolating groove parts; 1h 2a second groove;

2. a first magnet;

3. a second magnet;

4. a carbon fiber sleeve;

5. a rotor shaft;

aaxial direction; c, circumferential direction; l symmetry line.

Detailed Description

Exemplary embodiments of the present application are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are merely illustrative of how one skilled in the art may practice the present application and are not intended to be exhaustive of all of the possible ways of practicing the present application nor to limit the scope of the present application.

In the present application, "axial", "radial", and "circumferential" refer to the axial direction, the radial direction, and the circumferential direction of the motor rotor (rotor body), respectively, unless otherwise specified. "radially outward" refers to the side radially away from the central axis of the motor rotor, and "radially inward" refers to the side radially toward the central axis of the motor rotor.

The structure of a motor rotor according to an embodiment of the present application is described below with reference to the drawings.

As shown in fig. 1A, 1B, 2A, a motor rotor according to an embodiment of the present application includes a rotor body 1, a first magnet 2, a second magnet 3, a carbon fiber sleeve 4, and a rotor shaft 5 assembled together. The first magnet 2 and the second magnet 3 are accommodated in different grooves 1h1, 1h2 of a rotor unit 1u of the rotor body 1, respectively, and the carbon fiber sleeve 4 is wrapped around the outer peripheral surface of the rotor body 1, and the rotor shaft 5 is inserted into and fixed to the rotor body 1.

In the present embodiment, as shown in fig. 2A, the rotor body 1 is formed in a cylindrical shape as a whole. The rotor body 1 includes a plurality of rotor units 1u arranged in a stacked manner in the axial direction a. The plurality of rotor units 1u have the same configuration and are arranged in a coaxial manner, the below-described slot units of the adjacent rotor units 1u are perfectly aligned in the circumferential direction C of the motor rotor, and the magnets mounted to the adjacent rotor units 1u are perfectly aligned, and the motor rotor formed by this configuration is a so-called straight slot motor rotor. Further, each rotor unit 1u is formed by stacking a plurality of sheet-like stacked bodies having the same structure in the axial direction a. The structures of the sheet-like laminated bodies in all the rotor units 1u are the same, and each sheet-like laminated body has an integral structure such that all the sheet-like laminated bodies are sheets formed by the same press working process, wherein a typical example of the sheet is a silicon steel sheet, but may also be a sheet made of other conductive materials.

In order to house and mount the first magnet 2 and the second magnet 3, as shown in fig. 2A to 2C, the rotor unit 1u is formed with a plurality of first grooves 1h1 and a plurality of second grooves 1h2 penetrating along the axial direction a.

As shown in fig. 2A to 2C, a plurality of first grooves 1h1 are arranged at intervals in the circumferential direction C, two adjacent first grooves 1h1 in the circumferential direction C are arranged in pairs and are grouped into one group, the two first grooves 1h1 in each pair of first grooves 1h1 are laid out in a V-shape and the angle formed by their extending directions may be an obtuse angle, where the opening of the V may be directed to the radially outer side of the rotor body 1, and the sharp corner or bottom of the V may be directed to the radially inner side or center of the rotor body 1. For each pair of first grooves 1h1, the rotor unit 1u is formed with a magnetism isolating bridge 1u1 between radially inner side ends of the two first grooves 1h1 such that the two first grooves 1h1 are separated by the magnetism isolating bridge 1u 1; each first groove 1h1 extends to the outer peripheral surface and has an opening on the outer peripheral surface such that a radially outer end portion of each first groove 1h1 is open toward the radially outer side of the rotor body 1, but is closed by the carbon fiber sleeve 4. Further, each first groove 1h1 includes a mounting groove portion 1h11 and a magnetism isolating groove portion 1h12 communicating with each other. The mounting groove portion 1h11 is for accommodating and mounting the first magnet 2. The magnetism isolating groove portion 1h12 is located radially inward of the mounting groove portion 1h11, and can effectively reduce magnetic leakage. Further, with respect to the first magnets 2 in the first slots 1h1 arranged in pairs, the magnetism isolating bridges 1u1 are provided only between the adjacent magnetism isolating slot portions 1h12, and the magnetism isolating bridges provided on the radially outer sides of the first magnets 2 are omitted with respect to the motor rotor of the related art. In this way, not only is the magnetic leakage reduced and the power density improved by the provision of the magnetic shield bridge 1u1, but also the sheet-like laminated bodies of the rotor unit 1u are each formed into a non-split integral structure, that is, a structural design in which the portions defining the first groove 1h1 are connected to each other without split, due to the structure of the magnetic shield bridge 1u 1.

As shown in fig. 2A to 2C, a plurality of second grooves 1h2 are arranged at intervals in the circumferential direction C. Each second groove 1h2 corresponds to a pair of first grooves 1h1, and each second groove 1h2 is located between the pair of first grooves 1h1 in the circumferential direction C and spaced apart from the first grooves 1h 1. Thus, the adjacent group of first grooves 1h1 and the corresponding one of the second grooves 1h2 constitute one groove unit. As shown in fig. 2C, for each slot unit, there is a symmetry line L extending along one radial direction, so that the slot unit as a whole has a line-symmetrical structure with respect to the symmetry line L. In each slot unit, the volume of the first slot 1h1 is larger than the volume of the second slot 1h2, so that the first slot 1h1 is used for mounting a larger magnet and the second slot 1h2 is used for mounting a smaller magnet. In the present embodiment, eight slot units are uniformly distributed in the circumferential direction C of the motor rotor.

In the present embodiment, as shown in fig. 2A to 2C, one first magnet 2 is accommodated and mounted in each first groove 1h 1. The first magnets 2 accommodated and mounted in these first grooves 1h1 have the same rectangular parallelepiped shape. In addition, a plurality of second magnets 3 are accommodated and mounted in each of the second grooves 1h2, and the plurality of second magnets 3 also have the same rectangular parallelepiped shape. Each of the second grooves 1h2 has a width direction perpendicular to the axial direction a and the extending direction of the symmetry line L of the groove unit, and the plurality of second magnets 3 are arranged along the width direction in each of the second grooves 1h2. Adjacent second magnets 3 in each second groove 1h2 are abutted against each other and bonded together by an adhesive such as epoxy resin, whereby a plurality of second magnets 3 in the same second groove 1h2 constitute a single body. The plurality of second magnets 3 thus disposed can reduce eddy current loss and also the stress resistance becomes strong. Providing a plurality of smaller-sized split second magnets 3 as described herein can reduce the chance of breakage of the magnets as compared to a magnet formed integrally with a larger size. In addition, epoxy exists between the plurality of second magnets 3 for isolating eddy currents. In the case where the motor rotor rotates at a high speed, the temperature at the second magnets 3 will be very high, and the plurality of second magnets 3 can reduce heat and prevent demagnetization. By forming the slot units laid out as above and installing the corresponding first magnet 2 and second magnet 3, the magnetic flux from the motor rotor to the motor stator can be increased. In order to avoid interference, the axial end faces of the first magnet 2 accommodated in the first groove 1h1 and the second magnet 3 accommodated in the second groove 1h2 are flush with the axial end face of the rotor unit 1u to which they are attached.

In the present embodiment, as shown in fig. 1A and 1B, the carbon fiber sleeve 4 is a cylindrical body formed by winding a carbon fiber ribbon around the outer peripheral surface of the rotor body 1. The carbon fiber sleeve 4 covers the entire outer peripheral surface of the rotor body 1 to limit deformation of the respective sheet-like laminated bodies of the rotor unit 1u of the rotor body 1 that may occur in a high rotation speed state. Based on the evaluation of the centrifugal force of the electronic rotor, the thickness of the carbon fiber sleeve 4 may be set to 0.5mm or more and 3mm or less. In addition, the pre-tightening force can be applied and performed in a low-temperature environment (for example, 20 ℃ below zero) in the process of winding the carbon fiber sleeve 4, so that the thickness of the carbon fiber sleeve 4 is reduced.

In this embodiment, as shown in fig. 1A and 1B, the rotor body 1 is sleeved on the rotor shaft 5 and fixed with the rotor shaft 5, and the rotor shaft 5 can be connected with a transmission of a vehicle so as to bidirectionally transmit torque.

It should be understood that the above-described embodiments are merely exemplary and are not intended to limit the present application. Those skilled in the art can make various modifications and changes to the above-described embodiments without departing from the scope of the present application. Further, the following supplementary explanation is made.

i. The present application also provides an electric machine comprising a motor rotor and a motor stator according to the present application. The motor stator may be located radially outward of the motor rotor and spaced apart from the motor rotor by a predetermined gap. In an alternative, the motor may further comprise a rotor support to which the motor rotor may be fixed from the radially outer side, the rotor support being mounted to the rotor shaft 5 from the radially outer side.

it is understood that the motor rotor of the present application is not limited to straight slot motor rotors. For example, the slot units of the adjacent rotor units 1u may be partially offset in the circumferential direction C of the motor rotor so that the magnets of the adjacent rotor units 1u are also partially offset, and the motor rotor formed by this configuration is a so-called skewed slot motor rotor.

it will be appreciated that the angle formed by the extension of the two first grooves 1h1 in each groove unit need not form an obtuse angle, but may also form a relatively large acute angle (e.g. close to 90 degrees). In the motor rotor of the present application, the number of the groove units is not limited to eight as described in the above embodiment, but the number of the groove units may be adjusted as needed.

Claims (10)

1. An electric motor rotor, comprising:

a rotor body integrally formed in a cylindrical shape, the rotor body including a plurality of rotor units arranged in a stacked manner in an axial direction, each of the rotor units being formed by stacking a plurality of sheet-like stacked bodies in the axial direction, each of the sheet-like stacked bodies having an integral construction and having the same structure, and each of the rotor units being formed with a plurality of grooves;

a plurality of magnets mounted in the plurality of slots and fixed relative to the rotor body; and

and a carbon fiber sleeve formed in a cylindrical shape and covering the entire outer peripheral surface of the rotor body.

2. The motor rotor according to claim 1, wherein the sheet-like laminated body is a sheet formed by processing in the same press working process.

3. The motor rotor according to claim 1, wherein the carbon fiber sleeve is a cylindrical body formed by winding a carbon fiber ribbon shape on an outer peripheral surface of the rotor body.

4. An electric motor rotor according to any one of claims 1 to 3, characterized in that,

the plurality of grooves includes a plurality of first grooves arranged at intervals in a circumferential direction of the rotor body, each of the first grooves penetrating the rotor unit in the axial direction, the first grooves being arranged in pairs, each pair of the first grooves being arranged in a V-shape, and

the plurality of magnets includes a first magnet insertedly mounted in the first slot.

5. The motor rotor according to claim 4, wherein,

for each pair of the first grooves, the rotor unit is formed with a magnetic shielding bridge between radially inner ends of the two first grooves, such that the two first grooves are separated by the magnetic shielding bridge, and

each of the first grooves extends to the outer peripheral surface and has an opening on the outer peripheral surface such that a radially outer end of each of the first grooves is open toward a radially outer side of the rotor body.

6. The motor rotor according to claim 5, wherein each of the first grooves includes a mounting groove portion and a magnetism isolating groove portion that communicate with each other, the first magnet being located at the mounting groove portion, the magnetism isolating groove portion being located radially inward of the mounting groove portion, the magnetism isolating bridge being disposed between the magnetism isolating groove portions.

7. The electric machine rotor of claim 4, wherein the plurality of slots further comprises a plurality of second slots, each second slot extending through the rotor unit along the axial direction, each second slot corresponding to a pair of the first slots, each second slot being located between and spaced apart from a corresponding pair of the first slots in the circumferential direction, and

the plurality of magnets includes a second magnet insertedly mounted in the second slot.

8. The motor rotor according to claim 7, wherein the second groove and the corresponding pair of the first grooves constitute a groove unit having a symmetrical structure,

and a plurality of second magnets are inserted into each of the second grooves, each of the second grooves having a width direction perpendicular to the axial direction and the extending direction of the symmetry line of the groove unit, and the plurality of second magnets being arranged along the width direction.

9. A motor rotor according to any one of claims 1 to 3, further comprising a rotor shaft, the rotor body being nested with and secured to the rotor shaft.

10. An electric machine comprising the electric machine rotor of any one of claims 1 to 9.