TWI504105B - A rotor structure applied to motor and manufacture method thereof - Google Patents

Description

Rotor structure applied to motor and manufacturing method thereof

The invention relates to a rotor structure applied to a motor and a manufacturing method thereof, in particular to a rotor structure in which a metal core rod is firstly disposed on the inner side of the chip, and a metal injection material is injected on the outer side of the chip and Production method.

For a long time, induction motors such as motors are the mainstream of rotating electric machines. They have long been favored by practicality and sturdiness. They play a very important role in the manufacturing industry or the civilian production industry, making people's life and rotation. The motor is inseparable.

Among them, the rotor groove shape of the rotor and the material difference used in the groove are one of the important keys to the competitiveness of the motor market. In the prior art, the rotating motor has a copper rod placed in the rotor groove to improve the running efficiency of the motor, and achieve long-term performance. The purpose of running power saving, but it has the disadvantages of heavier weight and higher cost. Taking copper rotor as an example, it is a copper rod and a cast copper rotor. Its advantages are low resistivity, high efficiency during operation, and long-term use. Effectively reduce energy waste, the disadvantage is in high quality and high unit price materials.

On the contrary, the aluminum rotor is made by die-casting aluminum technology, which has the advantages of higher starting torque, lower weight and lower cost than the copper rotor, but has operational efficiency. The shortcoming is the aluminum rotor, which is an aluminum rod and a cast aluminum rotor. The high resistivity does not help the operation efficiency. When it is used for starting, it can get higher torque. In addition, it has low cost and low cost. Quality is also one of its competitiveness. The shortcoming in operation is the high loss caused by high resistance, resulting in low operating efficiency, and the energy consumed in long-term use is higher than that of copper rotor. Therefore, there is still no rotor in the prior art which has the advantages of both of the above materials, and thus has an improved space.

In addition, referring to the first and second figures, the first figure shows a first schematic diagram of a prior art rotor process, and the second figure shows a second schematic diagram of a prior art rotor process. As shown in the figure, in the existing rotor process, a plurality of materials such as copper or aluminum core rod PA12 (only one is shown) are inserted and fixed to the lower cover PA11, and after the fixing is completed, a plurality of steel bars are further fixed. The sheets PA13 (only one is shown and one is shown) are stacked on the lower cover PA11 through the mandrel PA12 (as shown in the first figure), and after stacking and completing the injection, the upper cover PA14 is further disposed. After stacking to the uppermost silicon steel sheet PA13, the rotor structure PA1 is completed by screwing or other means (as shown in the second figure).

However, in the above process for manufacturing the rotor, it is cumbersome and time consuming in the process of inserting the mandrel PA12 into the lower cover PA11 and locking the upper cover PA14, thereby causing a long manufacturing time and a short service life of the manufactured rotor. The existing technology still has room for improvement.

In view of the structure of the existing rotor, it is generally impossible to have the advantages of both the copper rotor and the aluminum rotor, and the manufacturing process has a long manufacturing time and a manufacturing rotation. The problem of short service life. Accordingly, the present invention mainly provides a rotor structure applied to a motor and a manufacturing method thereof, which mainly combines the advantages of both a copper rotor and an aluminum rotor, and proposes a new process method of the rotor material and a rotor structure thereof. The utility model can effectively retain the advantages of high efficiency of the copper rotor and high starting torque of the aluminum rotor, and improve the disadvantages of high cost of the copper rotor, thereby improving the competitiveness of the induction motor.

Based on the above objects, the main technical means adopted by the present invention is to provide a rotor structure for a motor, which comprises a plurality of chips, a plurality of metal core rods and a plurality of metal shots. The chips are provided with a plurality of fixed portions on the inner side and a plurality of injection portions on the outer side, and the stacks form a rotor core having a plurality of fixed grooves on the inner side and a plurality of injection grooves on the outer side. The metal core rods are disposed in the fixing grooves and have a first resistivity. The metal injection materials are injected into the injection grooves and have a second resistivity, and the second resistivity is greater than the first resistivity.

In addition, the main technical means adopted by the present invention also provides a manufacturing method for a rotor structure applied to a motor, which first stacks a plurality of chips having a plurality of fixed portions located on the inner side and a plurality of injection portions located on the outer side, thereby Forming a rotor core having a plurality of fixed grooves on the inner side and a plurality of injection grooves on the outer side; then, a plurality of metal core rods having a first resistivity are disposed in the fixed grooves; and finally a plurality of A second resistivity metal shot is injected into the injection slots, and the second resistivity is greater than the first resistivity.

In the above preferred embodiment of the rotor structure of the motor and the manufacturing method thereof, the chips are composed of one of an iron piece, a pure iron piece and a silicon steel piece, and the The chips are composed of at least one sub-chip, and the sub-chip includes one of the fixing portions and one of the injection portions, and includes at least one engaging recess and at least one engaging convex portion, and the card The recessed portion and the engaging convex portion are used to connect the chiplets to form the chips. In addition, the metal injection materials are die-cast aluminum, the metal core rods are pure copper rods, and the first resistivity and the second resistivity range from 1.7*10 ^-8 to 1.59*10 ^-7 ohm-meter. Between (Ω-m). In addition, among the chips, at the bottom of the rotor core, at least one stop portion is disposed on the fixing portions.

In addition, in the preferred embodiment of the above-mentioned auxiliary technical means for manufacturing the rotor structure of the motor, after the last step, a top cover can be formed on the top side of the rotor core, and simultaneously at the rotor core. A bottom cover is formed on the bottom side to create a rotor structure.

By using the main technical means of the rotor structure and the manufacturing method thereof for the motor adopted by the present invention, since the materials of the two different resistivities are applied to the single rotor slot, the advantages of the two materials, such as the copper rotor, can be maintained. High efficiency and the advantages of low cost and high starting torque of the aluminum rotor greatly increase the efficiency of the motor.

In addition, after the rotor structure of the motor and the manufacturing method thereof for the motor used in the present invention, the stopper can be further prevented to prevent the metal injection and the metal core rod from being mixed in the manufacturing process. There is interference, which in turn improves process yield.

The specific embodiments of the present invention will be further described by the following examples and drawings.

PA1‧‧‧ rotor structure

PA11‧‧‧Undercover

PA12‧‧‧ mandrel

PA13‧‧‧ steel sheet

PA14‧‧‧Upper cover

1‧‧‧Rotor structure applied to the motor

11‧‧‧Rotor core

111, 111a, 111b‧‧‧ chips

1111a‧‧‧stop

1112b‧‧‧Fixed Department

1113b‧‧‧Injection Department

1114b‧‧‧Clamping recess

1115b‧‧‧Snap convex

112‧‧‧fixed slot

113‧‧‧ injection trough

12‧‧‧Metal mandrel

13‧‧‧Metal injection

14‧‧‧Top cover

15‧‧‧ bottom cover

100,200‧‧‧ mould

The first diagram shows a first schematic diagram of a prior art rotor process; the second diagram shows a second schematic diagram of a prior art rotor process; and the third figure shows a rotor structure applied to a motor in accordance with a preferred embodiment of the present invention. 4 is a side view showing a rotor core of a preferred embodiment of the present invention; and FIG. 4A is a top view showing a rotor core of a preferred embodiment of the present invention; A metal core rod according to a preferred embodiment of the present invention is disposed on a side view of a rotor core; and a fifth diagram is a perspective view showing a metal core rod of a preferred embodiment of the present invention disposed on a rotor core; A partially enlarged view showing a metal core rod of a preferred embodiment of the present invention disposed on a rotor core; and a sixth view showing a metal shot of a preferred embodiment of the present invention in a rotor core; A schematic view showing a structure of a rotor applied to a motor according to a preferred embodiment of the present invention; an eighth diagram showing a schematic view of a chip of a bottommost layer of a rotor core according to a preferred embodiment of the present invention; and a ninth drawing showing the present invention Examples of his view on the chip embodiment.

Since the rotor structure applied to the motor and the method of manufacturing the same provided by the present invention, the combined implementation manner is numerous, so it is not repeated here. The description will be specifically described by exemplifying a preferred embodiment.

Referring to FIG. 3 to FIG. 7 together, FIG. 3 is a schematic flow chart showing a manufacturing method of a rotor structure applied to a motor according to a preferred embodiment of the present invention, and FIG. 4 is a view showing a rotor of a preferred embodiment of the present invention. A side view of the magnetic core, a fourth A diagram showing a top view of the rotor core of the preferred embodiment of the present invention, and a fifth view showing a side view of the metal core rod of the preferred embodiment of the present invention disposed on the rotor core. 5A is a perspective view showing a metal core rod of a preferred embodiment of the present invention disposed on a rotor core, and FIG. 5B is a partial enlarged view showing a metal core rod of the preferred embodiment of the present invention disposed on a rotor core. 6 is a view showing a metal injection of a preferred embodiment of the present invention taken on a rotor core, and a seventh view showing a schematic view of a rotor structure applied to a motor according to a preferred embodiment of the present invention.

As shown in the figure, in order to make the technical content of the present invention easier to understand by those skilled in the art, the manufacturing process is supplemented by a structural description, and the manufacturing method of the rotor structure 1 applied to the motor provided by the present invention is provided. The method includes the following steps: Step S101: stacking a plurality of chips to form a plurality of rotor cores having a plurality of inner fixed slots and a plurality of outer circumferential injection slots; and step S102: placing a plurality of metal core rods on the plurality of metal core rods a fixing groove; step S103: injecting a plurality of metal injection materials into the injection grooves; and step S104: forming a top cover on a top side of the rotor core, and simultaneously forming a bottom cover on a bottom side of the rotor core In order to create a rotor structure.

Among them, please refer to the fourth picture and the fourth picture A, after the step starts, Step S101 is performed to stack a plurality of chips, thereby forming a rotor core having a plurality of fixed grooves located on the inner side and a plurality of injection grooves located on the outer side. Specifically, a plurality of chips 111, 111a are stacked to form a rotor core 11, and the chip 111 can be composed of one of an iron piece, a pure iron piece and a silicon steel sheet, which is preferably implemented in the present invention. In the example, the silicon steel sheet is provided, and the chip 111 is provided with a plurality of fixing portions (not shown) and a plurality of injection portions (not shown), wherein the fixing portions are arranged on the inner side of the chip 111, and the injection portion is Arranged on the outer side of the chip 111 (the inner side and the outer side defined by the preferred embodiment of the present invention are relative concepts, that is, depending on the position of the fixed portion and the injection portion, as described hereinafter), in other words, the fixed portion is The hollow portion is distributed in the inner ring, and the injection portion is a hollow outer groove and distributed on the outer ring. In the preferred embodiment of the present invention, the fixing portion and the injection portion are integrally formed into a groove. In other embodiments it may be provided separately.

After the chips 111 are stacked, the fixing portions of the plurality of layers are stacked to form the fixing grooves 112 of the rotor core 11 as shown in FIG. 4A, and the plurality of filling portions are stacked to form a fourth drawing. Similarly, the injection groove 113 of the rotor core 11 is similar to the fixed groove 112, and the injection groove 113 is an outer groove. It should be noted that, since the fixing portion and the injection portion of the plurality of layers respectively form the fixing groove 112 and the injection groove 113, confusion is not avoided, and only the fourth A icon shows the fixing groove 112 and the injection groove 113, Bright.

After the step S101 is performed, please refer to the fifth figure, the fifth A picture, and the fifth B picture, and then step S102 is performed to set a plurality of metal core rods to the fixing grooves. Wherein, since the fixing groove 112 and the injection groove 113 are completed, in this step, a plurality of metal core rods 12 (only one is shown) are inserted in each of the fixing grooves 112 located inside, and the metal core The rod 12 has a first resistivity, and the metal mandrel 12 is a pure copper rod, and the first resistivity ranges from 1.7*10 ^-8 to 1.59*10 ^-7 ohm-meter (Ω-m). However, it is not limited to this in other embodiments.

After the step S102 is performed, please refer to the sixth figure together, and then step S103 is performed to inject a plurality of metal shots into the injection slots. Wherein, after the metal mandrel 12 is inserted, a plurality of metal shots 13 are injected into each of the injection grooves 113 located outside, and the metal injection 13 has a second resistivity and metal The injection 13 is die-cast aluminum, and the second resistivity ranges from 1.7*10 ^-8 to 1.59*10 ^-7 ohm-meter, but is not limited thereto in other embodiments. However, it should be noted that, in the selection of the material of the metal mandrel 12 and the metal injection material 13, the second resistivity of the metal shot 13 must be greater than the first resistivity of the metal mandrel 12.

After the step S103 is performed, please refer to the seventh figure, and then step S104 is performed to form a top cover on the top side of the rotor core, and a bottom cover is formed on the bottom side of the rotor core, thereby manufacturing Rotor structure. After the metal injection 13 is completed, a top cover 14 is formed on the top side of the rotor core 11 by using the mold 100, and a bottom cover 15 is formed on the bottom side of the rotor core 11 by using the mold 200. The rotor structure 1 applied to the motor is manufactured, and since the top cover 14 and the bottom cover 15 are simultaneously manufactured, and the top cover 14 and the bottom cover 15 are directly coupled to the metal core rod 12 during the manufacturing process, it can be largely reduce Process cumbersome and process time.

In addition, it is worth mentioning here that please refer to the eighth figure, which is a perspective view showing the chip of the bottommost layer of the rotor core of the preferred embodiment of the present invention. As shown in the eighth embodiment, the chip 111a is located at the bottom of the rotor core 11, and a stop portion 1111a (a plurality of other embodiments may be used) is provided in the fixing portions, and the stop is provided. The portion 1111a is for supporting the metal core rod 12 for preventing the metal shot 13 from being mixed with the metal core rod when the metal shot 13 is injected in step S103, thereby affecting the efficiency and yield of the rotor structure 1 applied to the motor. .

In addition, in the preferred embodiment of the present invention, each chip 111 is a single unit, and in other embodiments, please refer to the ninth diagram, and the ninth diagram shows a top view of the chip of other embodiments of the present invention. As shown in the ninth figure, the chip 111b may be composed of a plurality of sub-chips (not shown), and the sub-chips include one of the fixing portions in the preferred embodiment and one of the injection portions. And including at least one engaging recess 1114b and at least one engaging convex portion 1115b. Specifically, in other embodiments referred to in the ninth embodiment, the sub-chip includes a fixing portion 1112b on the inner side and one outer side. The injection portion 1113b, the one engagement recess 1114b, and the one engagement projection 1115b are provided on the two sides of the chiplet for connecting the other two chiplets to connect the plurality of sub-chips. The chip also constitutes a chip 111b.

In summary, after adopting the rotor structure applied to the motor and the manufacturing method thereof used in the present invention, since two materials with different resistivities are used in a single rotor slot, the advantages of the two materials can be maintained. Such as copper rotor high efficiency and aluminum rotor low cost and high starting torque The advantages, in turn, greatly improve the performance of the motor. In addition, the stopper portion can be further prevented from interfering with the metal mandrel and the metal mandrel during the manufacturing process, thereby improving the process yield.

The features and spirit of the present invention will be more apparent from the detailed description of the preferred embodiments. On the contrary, the intention is to cover various modifications and equivalents within the scope of the invention as claimed.

Claims (11)

A rotor structure for a motor, comprising: a plurality of chips, a plurality of fixed portions on the inner side and a plurality of injection portions on the outer side, and the stacking comprises a plurality of fixed grooves on the inner side and a plurality of located a rotor core of the outer injection groove; a plurality of metal core rods disposed in the fixing grooves and having a first resistivity; and a plurality of metal injection materials, which are placed in the injection grooves And having a second resistivity, the second resistivity being greater than the first resistivity; wherein the chips are composed of a plurality of sub-chips, the sub-chips including one of the fixed portions One of the injection portions, and comprising at least one engaging recess and at least one engaging convex portion, the engaging concave portion and the engaging convex portion are used for connecting the two sub-chips to form the plurality of sub-chips chip. The rotor structure applied to the motor according to claim 1, wherein the chips are one of an iron piece, a pure iron piece and a silicon steel piece. The rotor structure applied to the motor according to the first aspect of the invention, wherein the metal injection is a die-cast aluminum, and the metal core rods are pure copper rods. The rotor structure applied to the motor according to claim 1, wherein the first resistivity and the second resistivity range from 1.7*10 ^-8 to 1.59*10 ^-7 ohm-meter ( Between Ω-m). . The rotor structure applied to the motor according to claim 1, wherein the chips are located at the bottom of the rotor core, and the fixing portions are provided with at least one stopper. A manufacturing method for a rotor structure of a motor, comprising the steps of: (a) stacking a plurality of chips having a plurality of fixed portions on the inner side and a plurality of injection portions on the outer side, thereby forming a plurality of inner sides a fixed slot and a plurality of rotor cores located outside the injection slot; (b) a plurality of metal core rods having a first resistivity are disposed in the fixed slots; and (c) a plurality of having a second a metal injection of resistivity is injected into the injection grooves; wherein the second resistivity is greater than the first resistivity, and the chips are composed of at least one chip, the chip includes the One of the fixing portions and one of the injection portions, and comprising at least one engaging concave portion and at least one engaging convex portion, the engaging concave portion and the engaging convex portion are used for connecting the chiplets These chips are formed. The method for manufacturing a rotor structure for a motor according to claim 6, wherein the method further comprises: a step (d) forming a top cover on a top side of the rotor core, and simultaneously forming a top cover of the rotor core a bottom cover is formed on the bottom side, thereby The rotor structure is fabricated. The method for manufacturing a rotor structure for a motor according to claim 6, wherein the chips are one of an iron piece, a pure iron piece and a silicon steel piece. The method for manufacturing a rotor structure for a motor according to the sixth aspect of the invention, wherein the metal injection is a die-cast aluminum, and the metal core rods are pure copper rods. The method for manufacturing a rotor structure for a motor according to claim 6, wherein the first resistivity and the second resistivity range from 1.7*10 ^-8 to 1.59*10 ^-7 ohms - Between meters (Ω-m). The method for manufacturing a rotor structure for a motor according to claim 6, wherein at least one of the stoppers is disposed at the bottom of the rotor core.