KR100555769B1 - An electric motor rotor and a method for producing an electric motor rotor - Google Patents

Abstract

The present invention relates to an electric motor rotor and a motor rotor manufacturing method. The electric motor rotor includes a core 10 formed of a plurality of metal laminates 11 of magnetic material, polar peripheral parts 20 made of magnetic material and fixed around the core 10, and the polar peripheral parts 20 thereof. And the same number of magnet elements 30 held between the cores and the core 10, the rotor between each of the circumferentially spaced polar peripherals 20 and two adjacent polar peripherals 20, respectively. Having a circumferential side defined by intermediate peripherals 40 provided in said intermediate peripherals, said cores 10 in the region where their entirety of the extension extends at least two adjacent polar peripherals 20. Compared with reduced conductivity and reduced permeability. The rotor further includes a pair of end caps 50 for retaining the polar perimeters 20 in the core 10.

Description

An electric motor rotor and a method for producing an electric motor rotor}

The present invention relates to a structure of a brushless electric motor rotor having magnetic elements circumferentially disposed therein and radially spaced apart from the side of the rotor and a method of manufacturing such a rotor.

In the structure of the brushless motor rotor, permanent magnet elements are fixed to the core of the rotor so that they are mounted concentrically around the motor shaft. In this structure, the rotor is formed by longitudinally aligning a plurality of mutually overlapping metal stacks forming a lamination stack, each metal stack having a plurality of windows arranged in a circumferential direction. These windows are at the same angle from each other and from the motor shaft. In addition, these windows are aligned with respective windows of other metal stacks of the stack stack to form axial housings in which the magnet element is received and secured.

In the prior art construction, each metal stack of the stack of rotors has a central portion with a central hole mounted to the motor shaft, and radial ends, each radial end being outside of each window of the metal stack. It is formed at and incorporated in the central portion in the regions disposed outside of the two subsequent windows.

In this prior art structure, the windows of each metal laminate are formed so as to face towards the peripheral edge of the metal laminate at a position where each end edge of the window is away from the peripheral edge of the metal laminate, 2 An annular region connecting the two adjacent radial ends to one another and connecting the radial ends to the center of the metal stack via a gap existing between the adjacent end edges of the two subsequent windows.

The presence of the annular region enables the use of metal laminates made in one piece with windows which later form the axial housings for the magnetic elements in the formation of the laminate stack of the rotor.

This known structure for metal laminates is relatively easy to produce on a large scale at low cost and is suitable for producing highly reliable products, but has the drawback of causing a loss of effective magnetic flux, which is the use of the rotor. Not suitable for

In this structure, only a part of the total magnetic field of the rotor generated by the magnets interacts with the stator's magnetic field, and the rest of the total magnetic field is lost in the form of a dispersed magnetic field in both the rotor and the air gap. The magnetic field loss of the rotor occurs due to the presence of steel having the structural function of the metal laminate in the end region of the magnet. This region acts as a path to the magnetic flux lines of the dispersive magnetic field which represents the unused use of the rotor's total magnetic field.

Accordingly, an object of the present invention is to eliminate the magnetic flux loss due to the dispersive magnetic field of the rotor, achieve high energy efficiency and reliability, and obtain an easy, economical and industrially viable structure without compromising the integrity and strength of the rotor. It is to provide an electric motor rotor and a method of manufacturing the same.

The above and other objects are cores formed by a plurality of metal laminates which are axially superimposed and made of a magnetic material and which form a stack of stacks, and a polarity made of magnetic material and fixed around the core. A motor rotor comprising peripherals and an equal number of magnetic elements held between the polar peripherals and the core, the rotor between each of the two adjacent polar peripherals with the polar peripherals circumferentially spaced from each other; Has a circumferential side defined by intermediate peripheries provided in the intermediate periphery, the intermediate peripheries of which are reduced in conductivity relative to the core in an area where their entirety of the extension extends at least between two adjacent polar peripheries. And with reduced permeability, the rotor picks up the polar periphery. Is achieved by the electric motor rotor further comprises a pair of end caps for holding the core.

The present invention also provides a method of manufacturing the above-described electric motor rotor,
(a) providing each metal stack with a plurality of windows, each having end edges facing towards the peripheral edge of each metal stack, wherein the end edges of all windows are contained in the same circumference;
(b) in each metal stack, in an area radially aligned with the peripheral edges of at least two subsequent windows and from the peripheral edge of each metal stack, at each metal stack, its peripheral edge in the same plane as the peripheral edge; Providing a radial extension outside of the;
(c) stacking the metal stacks on the end caps by overlapping the metal stacks such that each window of the metal stacks is axially aligned with respective windows of the other metal stacks to form axial housings along the rotor with the end caps. Forming a sieve stack;
(d) inserting an adhesive into the axial housings;
(e) inserting a magnet element into each said axial housing;
(f) mounting and attaching another end cap to the laminate stack that already holds each of said magnetic elements in each of said axial housings;
(g) curing the adhesive to retain each of the magnetic elements in each of the axial housings; And
(h) removing each of said radial extensions such that the peripheral edges of said metal stacks define the transverse contour of the completed rotor.

Hereinafter, the present invention will be described with reference to the accompanying drawings.

1 is a schematic cross-sectional view of a rotor with a metal stack of a stack of stacks constructed in accordance with the prior art.

2 is a schematic cross-sectional view of a rotor with a metal stack of a stack of stacks constructed in accordance with a first embodiment of the present invention and in an unfinished state.

3 is a schematic cross-sectional view of a rotor with a metal stack of a stack of stacks constructed in accordance with a second embodiment of the present invention and in an incomplete state.

4 is a schematic enlarged cross-sectional view of the already completed rotor.

FIG. 5 is a longitudinal sectional view along line V-V of FIG. 4 showing an already completed rotor obtained in accordance with one of the first and second embodiments of the present invention. FIG.

6 is a longitudinal sectional view taken along the line V-V of FIG. 4 showing an already completed rotor obtained in accordance with another embodiment of the present invention.

7 is det. An enlarged plan view of a portion of the metal laminate indicated by a.

In the drawings, the electric motor rotor according to the present invention has a core 10 formed of a plurality of metal laminates 11 made of a magnetic material such as steel, and a polarity fixed around the core 10 ( A periphery 20, wherein the metal laminates 11 have a predetermined conductivity and a predetermined permeability, and overlap each other concentrically to form a laminate stack fixed around an extension of the motor shaft S. do. Between each polar periphery 20 and the core 10, an axial housing 12 is formed that extends over the entire longitudinal extension of the rotor 10, with a magnet in each axial housing 12. Element 30 is retained. Each magnet element 30 is usually in the form of, for example, an arcuate (or straight) longitudinal plate, the magnet elements being arranged in the same circumferential arrangement and spaced apart from each other. .

According to the prior art, each metal stack 11 is formed in the same circumferential direction with a central portion 13 having a central hole 14 mounted to the motor shaft S, from each other and the motor shaft. Radius formed at the same angle from (S) and the outside of each window 15, respectively, and incorporated in the central portion 13 by the area between two adjacent windows 15, respectively. It has directional ends 16.

The windows 15 of each metal stack have end edges 17 circumferentially included in the same circumference, the end edges 17 each forming a contour of the cross section of the finished rotor. Facing to the peripheral edge 18 of the metal laminate 11.

In order to form the stack stack, the windows 15 of each metal stack 11 are aligned with the windows 15 of the other metal stack 11, enabling assembly and fastening of the magnetic elements 30. Overlapping of the metal stacks 11 is done to form the axial housings 12 which make it easier. Once the stack stack is formed, the radial ends 16 are axially aligned to form each polar perimeter 20.

The magnet elements 30 are formed by the interface of the retaining adhesive, such as, for example, a curable polymer material, filling the gap existing between each magnet element 30 and each axial housing 12. 10) is retained. This adhesive has low conductivity and low permeability compared to the properties of the core's conductivity and permeability.

As shown in FIG. 1, the prior art structure allows the end edges 17 of the windows 15 of each metal stack 11 to be separated inward from the peripheral edge 18 of the metal stack 11. Spaced circumferentially aligned in the positioned position so that the two adjacent radial ends 16 of each metal stack 11 are on each other and between adjacent end edges of two subsequent windows 15. The structure forms a structural annular region 19 connected to the central portion 13. In this structure, the laminate stack forms the cylindrical side of the rotor that is metallic throughout the axial extension. Structural annular region 19 provides a structural connection that is sufficiently resistant to centrifugal forces on the magnet mass and the mass of steel material present in the magnet, but in this region the structural junction causes losses due to the distributed magnetic fields discussed above. Generates a flux line.

In order to solve the problem of magnetic flux loss due to the dispersion magnetic field existing in the prior art, the rotor according to the present invention, when completed, each of which a metal stack of the stack stack connects each of the two radial ends 16. It is configured not to have a structural annular region 19. The rotor has a cylindrical side, at least in this finished state, with metal regions circumferentially inserted in regions with reduced conductivity and permeability throughout the longitudinal extension as compared to the steel material forming the core.

According to the invention, as shown in FIG. 4, the cylindrical side of the rotor is connected to the core 10 in an area connecting at least two adjacent polar peripherals 20 between each of the two polar peripherals 20. In comparison, an intermediate peripheral portion 40 having a reduced conductivity and a reduced permeability is formed to be inserted in the circumferential direction. This intermediate periphery 40 comprises an end region 41 connecting the adjacent polar peripheries 20 and a central region 42.

According to the invention, each end region 41 of the intermediate periphery 40 is formed by a circumferential gap between each central region 42 and the adjacent polar periphery 20, the central region 42. Silver, for example, is defined by each periphery of the core 10 circumferentially away from adjacent polar peripheries 20, each end region 41 having an adhesive for retaining the magnetic elements 30. It is defined by the end of the filled axial housing 12 (see FIG. 4). This adhesive is a retention flocculating means such as resin, rubber, etc., which surrounds the magnet element to prevent chips from finally leaving it, and finishes on the side of the finished rotor at the end region 41 ( provide finishing.

In order to manufacture the rotor of the present invention, the stack of stacks is mounted on the end cap of one of the pair of end caps 50 forming the rotor. It is formed by wearing. This seating is preferably performed by applying resin to the upper surface of the end cap 50 located below the stack of rotors of the rotor. The end caps 50 are made of non-magnetic material to remove or minimize the magnetic field due to dispersion and the magnetic field passing through the end cap and the loss therefrom.
As shown in FIGS. 2, 3 and 5, according to the structural form of the invention, a finished rotor comprising a core 10 and polar periphery 20 is provided with at least two successive windows 15 each. In regions that are radially aligned with adjacent end edges 17, a stack of stamped metal stacks 11 is incorporated, incorporating a radial extension 60 to the peripheral edge 18. The radial extension 60 is on the outside of the peripheral edge in the same plane as the peripheral edge 18 and also on the circumference outside the circumference concentrically with respect to the circumference comprising the end edges 17. . In this embodiment, the end edges 17 penetrate radially through the peripheral edge 18 of each rotor stack in the region of the corresponding radial extension 60. The radial extension 60 may have any shape. In embodiments where the metal stack 11 is square, the regions are defined by the vertices of the stack. The dimensions of the metal laminate 11 are determined such that the laminate has a shape having an inner diameter of a stator as in the metal laminate shown in Fig. 2, or to use a small amount of raw material in its stamping process. In this case, the metal stack 11 has a shape in which the sides are defined by a polygon, for example a regular time, tangent to the excess material outside the peripheral edge 18.

2 and 3, each rotor stack is shaped with a single radial extension 60, which is annular, continuous, and already completed. The diameter of the rotor stack is determined by a diameter larger than the nominal diameter of the rotor.

The thickness of each radial extension 60 is such that during the manufacture of the metal laminate and the formation of the laminate stack and during the machining of the rotor, the thickness of the metal laminate without causing high losses of the material forming the laminate ( 11) to ensure completeness.

In the structure of the other embodiment shown in FIG. 3, additional reinforcement to a single radial extension 60 in each area radially aligned with adjacent end edges 17 of the two subsequent windows 15, respectively. 61 is incorporated and this additional reinforcement 61 is radially outward of it in the same plane as the single radial extension 60.

According to another embodiment of the present invention, as shown in FIG. 6, the core 10 is characterized in that the peripheral edge 18 has a radially inner edge of each axial housing 12 for the magnet element 30. It is produced by a laminate stack of metal laminates 11 stamped to form a shape. In this embodiment, the radially outer edge of each axial housing 12 is defined by the radially inner edge of each polar perimeter 20, with each polar perimeter 20 forming the core 10. It is then mounted radially spaced apart from the core 10 to form an axial housing 12 in which the gap is filled with an adhesive holding each magnetic element 30.

According to the present embodiment, after the formation of the rotor stack, each polar peripheral portion 20 is mounted adjacently at intervals from each portion of the peripheral edge of the stack. The polar periphery 20 is in the form of a bulk shoe or consists of an overlapping laminate which is attached to each other by, for example, adhesion, rivets, bolts or the like. In this embodiment, the shoes are due to the retention element 21 (hysteresis and Foucault currents) extending longitudinally through each polar periphery 20 to the pair of end caps 50. Bolts, rivets, and adhesive between each support and the cap, which are placed in a place that minimizes the loss, etc.). Each end cap 50 is mounted adjacent to the metal stack 11 provided at one of the ends of the stack stack. In order to form each axial housing 12 with a shoe, an apparatus or a mold for determining the shape of the end wall of each axial housing is provided to hold an adhesive for fixing the magnet element 30 in the axial housing. Need to use

According to the embodiment shown in FIGS. 2 to 5, to form a stack stack of rotors, the metal stacks 11 are superimposed (and at the end of each other) on an end cap 50 provided below the stack stack. To minimize losses due to hysteresis and fuco current), after forming the core 10, each axis formed by the longitudinal alignment of the windows 15 of the metal stacks 11 of the stack stack. The adhesive for securing the magnet element 30 in the directional housing 12 is received and then placed in the axial housing 12.

In this structure, after attaching the other end cap 50 and curing the adhesive retaining the magnetic element 30, the end edges 17 of the metal stack have a diameter at least equal to the diameter of the circumference surrounding the finished rotor. The rotor is subjected to a step of removing an excess of the material forming the metal laminate 11 by machining, for example, until it is included in the circumference having a diameter. Machining of the stack stack is performed until the desired final diameter of the rotor is obtained, obtaining the configuration shown in FIG. 4 with the core 10 and the polar periphery 20.

Attachment of the end caps to the stack of stacks and attachment of the end caps to each other can be made by a retaining element 21 such as rivets, bolts and the like. By machining the stack stack, the end edges 17 of the windows 15 of the metal stacks 11 forming the stack stack open at the cross-sectional contour of the rotor, in which region the axial housing 12 is opened. It is defined by the filled cured adhesive.

In this structure, each machined metal stack of the stack stack is formed on the outside of the adjacent magnet element 30 and is radially retained in the central portion 13 by an adhesive in each axial housing 12. With ends 16.

One or more radial extensions 60 are provided at the peripheral edges 18 of each metal stack coinciding with the circumference which determines the desired final diameter of the rotor, thereby ensuring that the metal stack 11 is secured during its manufacture. Mechanical stiffness, and can be industrially produced on a large scale.

Since the radial extension 60 is small in the metal stack shown in FIG. 2, the metal stack can be stamped at the same time as the stack of stators, thereby shortening the manufacturing time and removing excess. Material loss is minimized.

Metal laminates with additional reinforcements 61 as shown in FIG. 3 have the advantage of having strength while requiring low precision in tooling and production processes.

In an embodiment of manufacturing the rotor structure as shown in FIG. 6, after fabricating the stack of stacks forming the core 10, the end caps 50 are provided with the polar perimeters 20 provided below the stack of stacks. Lay out radially from the core 10 on the bed and hold by appropriate means. At that interval, an axial housing 12 is formed which is filled with an adhesive holding the magnet element 30. After the adhesive filling is completed, the magnet element 30 is received in each axial housing 12 and then the other end caps 50 and retaining elements 21 are installed to close the assembly. In this structure, the manufactured rotor is subjected to subsequent machining since the diameter of the rotor can be defined while relatively positioning between the polar periphery 20 and the core 10 to accommodate the magnetic elements 30. Do not need.

An adhesive used between the end caps 50 and the rotor stack can also be provided between the metal stacks of the stack stack, which adhesive edges of the axial housings for the magnetic elements formed in the rotor. Filling gaps between the magnet elements; Structurally retaining the magnet elements 30 in the axial housings to compensate for the centrifugal and rotational forces that the magnet elements 30 receive; Due to the damping effect or deformation of the adhesive layer, the high thermal stresses generated in the magnetic elements 30 and usually destructive (causing cracks, breaks, breaks, etc. of the chips), which are interconnected by the adhesive and the temperature fluctuations of the rotor Reducing the associated coefficient of expansion of materials); And sticking and retaining fragments caused by chips or chips from the magnetic elements 30. During manufacture of the rotor, if the adhesive is present in the axial housing 12 excessively, the excess is removed before curing of the adhesive is achieved. If the adhesive is not sufficient when introducing the magnet elements 30 in the axial housings 12, the axial housings are filled with additional adhesive after the magnetic elements have been introduced in the axial housings 12, Thereafter, the adhesive is cured.

End caps 50 adhering to the ends of the rotor stacks are provided to maintain the diameter of the rotor and to ensure the integrity of the rotor shape, because the magnetic elements 30 are brittle when subjected to tensile stress. Because it is a component, the structure formed by the magnet elements and the resin on which the magnet elements are immersed is not sufficient to ensure that the centrifugal force does not cause the magnet element 30 or the polar periphery 20 to break away or rupture. . The end caps 50 determine a portion of the contour of each axial housing that holds each magnetic element 30 and act as a sealing means for the adhesive contained within the housings.

In addition, the end caps 50 provide a uniform finish of the rotor to compensate for dimensional differences in the rotor components.

The present invention makes it possible to obtain a product which has the characteristics of high energy efficiency and high reliability at the same time, and which is suitable for large scale production at low cost in the product and its manufacturing process.

Claims (15)

A core 10 formed of a plurality of metal laminates 11 axially overlapping each other and made of a magnetic material, and forming a laminate stack, and made of magnetic material and secured around the core 10. An electric motor rotor comprising polar peripheries 20 and magnetic elements 30 retained between the polar peripheries 20 and the core 10, wherein the stack of stacks comprises an axial housing along the rotor. Formed by a plurality of metal stacks 11 concentrically superimposed with one another, each with a plurality of windows 15 axially aligned with respective windows of the other metal stacks 11 to form 12), each The window 15 of which has end edges 17 facing towards the peripheral edge 18 of each metal stack 11, wherein the end edges 17 of all the window 15 are contained in the same circumference. In the electric motor rotor, In each of the metal stacks 11, at the peripheral edges 18 of the metal stacks in areas radially aligned with adjacent end edges 17 of the at least two subsequent windows 15, the In the same plane as the peripheral edge 18, radial extensions 60 outside the peripheral edges are incorporated, the radial extensions 60 in which the magnetic elements 30 have their respective axial housings. After being mounted and secured to (12), it is machined to allow the peripheral edges 18 of the metal stacks to define the transverse contour of the finished rotor, with each of the windows 15 having its end edges 17 Motor rotor, characterized in that it is shaped to radially penetrate the peripheral edge (18) in the region of the corresponding radial extension (60). Motor rotor according to claim 1, characterized in that the end edges (17) of each of the windows (15) extend at least to the circumference surrounding the finished rotor before the rotor is mounted. 3. Electric motor rotor according to claim 2, characterized in that the end edges (17) of each said window (15) are open at the transverse contour of the finished rotor. 4. An electric motor rotor according to claim 3, wherein each said metal stack (11) has an annular and continuous single radial extension (60). 5. The single radius according to claim 4, wherein the single radial extension (60) is in each region radially aligned with adjacent end edges (17) of each of two subsequent windows (15). Motor rotor, characterized in that it has an additional reinforcement (61) on the same side as the directional extension (60) radially outward. 6. A peripheral periphery (40) according to claim 5, wherein the peripheral edge (18) of the laminate stack is provided between the polar periphery (20) circumferentially away from each other and each of two adjacent polar peripheries (20). Defining a cylindrical side, the intermediate perimeters 40 having reduced conductivity and reduction compared to the core 10 in an area where their entirety of the longitudinal extension connects at least two adjacent polar perimeters 20. Motor rotor, characterized in that the rotor further comprises a pair of end caps (50) for retaining the polar periphery (20) in the core (10). 7. The electric motor rotor according to claim 6, wherein each said polar periphery (20) is formed by overlapping stacks which are fixed to each other by one of means defined by adhesive, rivets and bolts. 7. The electric motor rotor according to claim 6, wherein each of said polar periphery portions is massive. A core 10 superimposed axially and formed by a plurality of metal laminates 11 made of magnetic material; Polar peripheries 20 made of magnetic material and fixed around the core 10; And the same number of magnet elements 30 retained between the polar periphery 20 and the core 10. (a) end edges 17 of all windows 15 with each of the metal stacks 11 each having end edges 17 facing towards the peripheral edge 18 of each metal stack 11. Providing a plurality of windows 15 contained in the same circumference; (b) from the peripheral edge 18 of each said metal stack 11 and in an area radially aligned with adjacent end edges 17 of at least two subsequent said windows 15, each of said said Providing a metal stack (11) with a radial extension (60) outside of the peripheral edge at the same plane as the peripheral edge (18); (c) the respective windows 15 of the metal stacks 11 are axially aligned with the respective windows of the other metal stacks to form the axial housings 12 along the rotor with the end cap 50. Superimposing the metal stacks (11) to form a stack stack on the end cap (50); (d) inserting an adhesive into the axial housings 12; (e) inserting a magnet element 30 into each said axial housing 12; (f) mounting and attaching another end cap (50) to the laminate stack that has already held each of said magnetic elements (30) in each of said axial housings (12); (g) curing the adhesive to retain each of the magnetic elements 30 in each of the axial housings 12; And (h) removing each of said radial extensions 60 such that the peripheral edges 18 of said metal stacks 11 define the transverse contour of the finished rotor. Manufacturing method. The method of claim 9, wherein Applying an adhesive on one side of said end cap (50) on which the first metal stack (11) of the stack stack is mounted; Applying an adhesive between metal stacks (11) of the stack stack; And And applying an adhesive between the last metal laminate (11) of the laminate stack and the other end cap (50). The method of claim 10, wherein Removing excess of said adhesive before said adhesive is cured; And securing the polar perimeters (20) through the end caps (50) to the core (10). delete delete delete delete

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