WO2017202320A1 - 电机转子、电机和电动汽车 - Google Patents

电机转子、电机和电动汽车 Download PDF

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Publication number
WO2017202320A1
WO2017202320A1 PCT/CN2017/085592 CN2017085592W WO2017202320A1 WO 2017202320 A1 WO2017202320 A1 WO 2017202320A1 CN 2017085592 W CN2017085592 W CN 2017085592W WO 2017202320 A1 WO2017202320 A1 WO 2017202320A1
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WIPO (PCT)
Prior art keywords
rotor
magnetic steel
motor
electric machine
magnetic
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PCT/CN2017/085592
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English (en)
French (fr)
Inventor
马冰青
吴施汛
齐文明
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比亚迪股份有限公司
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Publication of WO2017202320A1 publication Critical patent/WO2017202320A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Definitions

  • the present invention relates to the field of motor technology, and in particular to a motor rotor and a motor having the same, and an electric vehicle having the same.
  • a motor mainly includes a housing, a stator assembly, and a rotor assembly.
  • the outer casing includes a cylinder having an opening at the front end, a stator assembly is disposed in the outer casing, the stator assembly includes a stator core and a core winding, and the rotor assembly includes a rotating shaft, a permanent magnet and a rotor core;
  • the core is set on the rotating shaft, and the rotor core is uniformly provided with a plurality of permanent magnets on the outer circumference;
  • the front end of the outer casing is provided with an end surface, and the upper end of the outer casing is provided with a junction box to supply power to the winding.
  • An object of the present invention is to provide a motor rotor, a motor having the same, and an electric vehicle having the same.
  • the present invention provides a motor rotor including a rotor core formed by stacking a plurality of rotor punches, the rotor punching plate including a punching body, and the punching body is formed There are magnetic steel grooves for magnetic steel insertion, and the plurality of magnetic steel grooves are formed, and the plurality of magnetic steel grooves form a magnetic steel groove group and the magnetic steel groove group constitutes a rotor magnetic pole.
  • the present invention also provides an electric machine including a housing and a motor rotor and a motor stator mounted in the housing, the motor rotor being the motor rotor provided by the present invention.
  • the present invention also provides an electric vehicle including a drive motor, which is a motor provided by the present invention.
  • the present invention adopts a V-shaped arrangement of outwardly opening V-shaped magnetic steel groove groups, which can be subjected to centrifugal force when the rotor is rotated at a high speed, especially when the rotor is rotated at an ultra-high speed.
  • the area will be reduced, thereby reducing the tensile stress inside the magnetic steel and improving the life of the magnetic steel, and is especially suitable for the driving motor of an ultra-high speed operation in an electric vehicle.
  • FIG. 1 is a first perspective view of a motor according to an embodiment of the present invention
  • FIG. 2 is a second perspective view of a motor according to an embodiment of the present invention.
  • FIG. 3 is an exploded perspective view of a motor according to an embodiment of the present invention.
  • FIG. 4 is a schematic structural view of a rotor of a motor according to an embodiment of the present invention.
  • FIG. 5 is a schematic structural view of a magnetic steel trough provided by an embodiment of the present invention, wherein in order to clearly show the angle, the angle is enlarged by several times when other features are unchanged;
  • Fig. 6 is a schematic structural view of an electric vehicle according to an embodiment of the present invention.
  • orientation words such as “up, down, left, and right” are generally defined on the basis of the drawing direction of the drawing, and the "inside and outside” means correspondingly. Inside and outside of the contour of the part.
  • the present invention provides at least an electric motor rotor punch, an electric motor rotor, an electric motor 1000, and an electric vehicle 2000.
  • the motor 1000 can be a two-pole motor, a permanent magnet synchronous motor, or a two-pole permanent magnet synchronous motor, and the motor of the present invention can also be other types of motors known in the art, such as an asynchronous motor or the like.
  • an ultra-high speed motor that is, a motor having a rotational speed of more than 20,000 rpm (revolutions per minute)
  • the various motors mentioned in the present invention are also particularly suitable for use in a drive motor of an electric vehicle.
  • two-pole and “permanent magnet synchronization” as used in the present invention are terms well known in the art.
  • two pairs of poles mean that two pairs of magnetic poles are disposed on the rotor of the motor.
  • the more the number of magnetic pole pairs, when the motor speed is high, especially when the motor in the present invention is an ultra-high speed motor the higher the alternating frequency of the magnetic field, the more heat generated by the motor, and the requirements for the cooling system are also The higher the speed, the higher the iron consumption of the motor. Therefore, the two-pole motor is suitable for use in drive motors that operate at very high speeds.
  • three pairs of poles or four pairs of poles may also be used.
  • the permanent magnet synchronous motor is also suitable for use in the drive motor of an electric vehicle. In terms of performance, it may include the advantages of high efficiency, high power factor, small volume, light weight, and low temperature rise.
  • a permanent magnet is used to establish a rotor magnetic field.
  • the motor has a sufficiently large starting torque and does not require a large starting current, and is suitable for a driving motor driven by a power battery pack.
  • the permanent magnet synchronous motor has high efficiency, the resistance loss in the rotor winding is low, and there is little or no reactive current in the stator winding, which makes the motor temperature rise low, and can also prolong the service life of the motor.
  • the advantages of other permanent magnet synchronous motors have not been done. More details.
  • the permanent magnet synchronous motor has a simple structure, which makes the permanent magnet synchronous motor processing and distribution cost less, and the operation is more reliable.
  • the permanent magnet synchronous motor uses the rare earth permanent magnet to increase the air gap magnetic density and raise the motor speed to The best, which significantly reduces the size of the motor, improves the power to mass ratio; in addition, because the excitation copper consumption is saved, the motor efficiency is significantly improved.
  • the motor provided by the embodiment of the present invention includes a housing 400, a motor rotor 300 and a motor stator 500 mounted in the housing 400.
  • the motor stator 500 is fixedly disposed within the housing 400, and the motor rotor 300 is rotatably disposed at the center of the motor stator 500.
  • the motor rotor 300 includes a rotor core 310 formed by stacking a plurality of rotor blades, and a rotating shaft 320 coupled to the rotor core 310.
  • the center of rotation of the punch body 100 of the rotor core is formed with a shaft hole 101, and a pair of keys 102 for cooperating with the rotating shaft, that is, a rotor, are symmetrically formed on the side wall of the shaft hole 101
  • the iron core 310 and the rotating shaft 320 are in a key connection manner.
  • the rotor core 310 and the rotating shaft 320 may also be connected by other transmission connections known to those skilled in the art, for example, using a non-circular cross-section connection.
  • an oil hole 103 may be formed in the rotor punch to form a part of the rotor oil passage, and the lubricating oil may be cooled by circulating the lubricating oil in the rotor.
  • the housing 400 has an end cover 800 away from the power output end.
  • the end cover 800 may be formed with a bearing chamber.
  • the inner end of the rotating shaft 320 is installed in the bearing chamber through the deep groove ball bearing 600, and protrudes from the outer end of the housing 400. It can be used as a power output.
  • the junction box 700 mounted on the housing can be externally connected to a power source, for example, electrically connected to the power battery pack to be able to generate a magnetic field by supplying power to the winding 900, thereby enabling operation of the motor.
  • an air gap is provided between the rotor and the stator of the motor to enable the motor to operate normally.
  • the motor rotor blank provided includes a punch body 100 having a magnetic steel groove 200 for magnetic steel insertion formed thereon, that is, using magnetic steel as
  • the permanent magnets form the rotor poles, that is, the permanent magnets in the embodiment adopt an embedded mounting manner, which can effectively ensure the stability of the rotor when rotating at an ultra-high speed, compared with the surface-mounted permanent magnet mounting method, embedded
  • the permanent magnet mounting method is more suitable for rotors that operate at very high speeds.
  • the magnetic steel accommodated in the magnetic steel tank will have a tendency to deform under the action of centrifugal force, that is, tensile stress is generated inside the magnetic steel, and at the same time, the pressure is resisted due to the resistance of the magnetic steel groove.
  • Stress in which the tensile strength of the magnetic steel is much lower than its compressive strength.
  • the tensile strength is only 85 MPa, and the compressive strength can be above 1000 MPa.
  • the resulting tensile stress can affect the life of the magnetic steel.
  • the groove shape of the magnetic steel groove is improved, and the manner may include converting the tensile stress received by the magnetic steel into a compressive stress.
  • the magnetic steel groove 200 has a straight groove section 201 and a dip angle section 202 on both sides of the straight groove section 201 along the surface direction of the punching body 100, and the dip angle section 202 is away from the center of rotation of the punching body 100.
  • the first side edge is inclined outward from the end of the straight groove section 201.
  • the straight groove section 201 and the inclined section 202 located on both sides of the straight groove section 201 together constitute a magnetic steel
  • the closed cross-sectional profile of the magnetic steel groove 200 at the surface of the punch body 100 is divided by a broken line into a straight groove segment 201 and a dip segment 202.
  • a buffer zone for generating a slight deformation can be provided for both ends of the magnetic steel in the magnetic steel groove 200, that is, the magnetic steel is allowed to be magnetic when the rotor rotates.
  • the steel groove 200 is slightly deformed to release the tensile stress generated inside the magnetic steel, which in turn increases the life of the magnetic steel.
  • an angle can be formed on the existing one-shaped magnetic steel groove.
  • the angle ⁇ between the first side edge of the inclined section 202 and the straight groove section 201 is 0.5 ° - 2 °, for example with a 1 ° tilt.
  • FIG. 5 is a view in which the angle ⁇ is enlarged several times in the case where other features are not changed, to clearly show the inclination section 202. This improvement in the magnetic steel tank 200 can effectively increase the life of the magnetic steel.
  • the punch body 100 is made of an amorphous alloy material, that is, the rotor core in the embodiment of the present invention is made of an amorphous alloy material, and the strength of the punch body 100 can be increased.
  • the tensile strength of the characteristics of the amorphous alloy material is several tens of times that of the ordinary silicon steel material, so that the improvement of the magnetic steel groove 200 causes the strength sacrificed by the punch body 100 to be compensated by the material, and its strength is greatly increased. It is higher than the strength of the rotor sheet of the prior art silicon steel material, thereby ensuring the life of the magnetic steel and ensuring the strength and life of the rotor core.
  • the rotor core is made of an amorphous alloy material
  • the rotor core has the characteristics of high magnetic permeability, high electrical conductivity, small eddy current loss, and the like, and the performance of the motor is greatly improved.
  • the use of amorphous alloy material to make the rotor core can not only improve the rotor capacity, but also solve the key problem of how to achieve high power output through a small volume, enabling the drive motor in the electric vehicle field. Great progress has been made.
  • the inventor of the present invention has a design idea that the inventors have found that in the field of electric vehicles, it is difficult to increase the volume of the motor due to the space layout, and thus it is difficult to increase the torque of the motor.
  • the inventors also considered that when the motor speed reached an ultra-high speed of 20,000 rpm, it was limited by the yield strength of ordinary silicon steel sheets, and the designed motor volume would be too small. When the motor volume is too small, although the rotation speed is high, it will directly affect the torque output of the motor, which cannot meet the requirements of the drive motor.
  • the inventors of the present application have adopted an amorphous alloy material to form a rotor to solve the problem that the outer diameter of the rotor is limited, that is, to ensure that the motor can be operated at an ultra-high speed while increasing the volume of the motor as much as possible to increase the torque. Further increase the motor power. Further, the motor provided by the present invention does not simply use all components to be amorphous. Made of gold materials. Except for the cost factor, the present invention also finds that under the current process conditions, the width of the amorphous alloy strip is limited. If the amorphous alloy strip is used as the motor stator, the produced motor is too small and affects the power of the motor. Output.
  • the various motors provided by the embodiments of the present invention only make the rotor core made of amorphous alloy material, and the stator can be made of silicon steel material. Therefore, in the embodiment of the present invention, the structure in which the rotor is made of an amorphous alloy material and the stator is made of the original silicon steel material is a result of comprehensive consideration of various factors, and the inventor needs a lot of creative labor.
  • the present invention skillfully uses an amorphous alloy material for the manufacture of a rotor, which not only achieves the beneficial effect of improving the life of the magnetic steel during ultra-high speed operation, but also enables the designed motor to be small in size without being too small, that is,
  • the use of amorphous alloy materials for the manufacture of rotor cores has also produced unexpected technical effects, achieving a variety of effects. Especially suitable for the requirements of high-power and small-volume drive motors, the performance of the drive motor has been greatly improved.
  • the two inclined sections 202 may be designed to be symmetrically disposed with respect to the central axis of the straight groove section 201. That is, the structure of the two dip segments 202 is substantially the same.
  • the second side edge of the inclined section 202 close to the center of rotation of the punch body 100 is arranged in line with the straight groove section 201. That is, only the outer first side edge line of the inclined section 202 is inclined with respect to the straight groove section 201, thereby ensuring the small deformation of the magnetic steel at both ends outward under the centrifugal force, and better accommodating the magnetic steel.
  • the length of the straight groove segment 201 may be designed to account for 1/2-3/4 of the length of the magnetic steel accommodated in the magnetic steel groove along the surface of the punching body 100. . Thereby, the deformation of the magnetic steel is better buffered, and the magnetic steel groove is prevented from exerting unnecessary destructive force on the magnetic steel.
  • the rotor magnetic pole there are a plurality of magnetic steel grooves 200, and the plurality of magnetic steel grooves 200 are formed to obtain a magnetic steel groove group constituting a rotor magnetic pole, that is, the plurality of magnetic steel grooves 200 are formed.
  • the magnetic steel groove group and the magnetic steel groove group constitute a rotor magnetic pole, wherein one magnetic steel groove group can form a rotor magnetic pole.
  • the magnetic steel groove group includes a first magnetic shape symmetrically arranged with respect to a first diameter of the punch body (as a case, the first diameter is a diameter in the vertical direction on the punch body 100, as shown in FIG.
  • the steel trough 210 and the second magnetic steel trough 220, the first magnetic steel trough 210 and the second magnetic steel trough 220 are arranged in a first V-shape that is open to the outside.
  • the magnetic steel of the present invention is arranged in a V-shaped configuration.
  • the magnetic steel groove group further includes a third magnetic steel groove 230 and a fourth magnetic steel groove 240 symmetrically arranged with respect to the first diameter, the third The magnetic steel groove 230 and the fourth magnetic steel groove 240 are arranged in a second V-shape that is open to the outside and are spaced apart from the radially inner side of the first magnetic steel groove 210 and the second magnetic steel groove 220.
  • the present invention One of the magnetic poles may include four magnetic steels, thereby making full use of the space of the punch body, which is especially suitable for a smaller drive motor.
  • the space is utilized reasonably, and optionally, the angle of the second V-shaped is smaller than the angle of the first V-shaped.
  • the outer magnetic steel can better utilize the space in the chord direction of the punch body, so that the inner magnetic steel can better utilize the space in the radial direction of the punch body, the layout is more reasonable, and the magnetic field is generated more effectively.
  • the plurality of magnetic steel groove groups are respectively configured to constitute a plurality of rotor magnetic poles, and the plurality of magnetic steel groove groups are evenly distributed and uniformly distributed on the punch body in the circumferential direction.
  • the magnetic steel groove group is four to constitute two pairs of poles of the motor rotor.
  • a different number of sets of magnetic steel slots may be provided depending on the number of pole pairs.
  • the punching body 100 is formed with oil holes 103 uniformly distributed in the circumferential direction, and the oil holes 103 are located between adjacent magnetic steel groove groups to fully utilize the punching
  • the sheet body space in addition to the oil hole 103, can reduce the weight of the rotor and reduce the rotor moment of inertia.
  • the center of rotation of the punching main body 100 is formed with a rotating shaft hole 101, and a pair of keys 102 for engaging with the rotating shaft are symmetrically formed on the side wall of the rotating shaft hole 101, and the key 102 is convex toward the center of the circle And the pair of keys 102 are located on the first diameter. That is, the key is a convex structure rather than a concave structure, thereby facilitating the torque transmission in cooperation with the keyway on the rotating shaft.
  • reinforcing ribs are disposed between the symmetrically arranged magnetic steel grooves to enhance the strength of the punch body.
  • a magnetic bridge or a magnetic isolation hole is disposed between the magnetic steel groove and the edge of the punch body.
  • the magnetic bridge can be as small as possible, which will reduce the magnetic flux leakage and increase the air gap magnetic density.
  • the magnetic isolation hole can improve the air gap magnetic density waveform, thereby improving the performance of the motor.
  • the motor provided by the invention is more suitable for the driving motor of the electric vehicle, wherein the iron consumption is relatively low, the output power is improved, and the problem of large noise caused by the amorphous motor is avoided.
  • the stator and rotor structures have been redesigned. Increasing the strength of the rotor structure can not only be made into an ultra-high-speed motor, but also has excellent electromagnetic performance. Only the rotor core uses an amorphous alloy, which reduces the processing difficulty and reduces the cost of the process.
  • the volume of the motor is not limited by the amorphous alloy material, so that it can exert greater torque and power.
  • the alternating frequency of the magnetic field is minimized, the iron loss is reduced, the heat dissipation is reduced, and the control of the motor is easily realized, so that the performance of the motor is significantly improved, and the performance of the electric vehicle is indirectly improved. More practical.

Abstract

一种电机转子（300）、电机（1000）和电动汽车（2000），电机转子包括由多个转子冲片叠置而成的转子铁芯（310），转子冲片包括冲片本体（100），冲片本体上形成有用于磁钢插入的磁钢槽（200），磁钢槽为多个，多个磁钢槽形成磁钢槽组，磁钢槽组构成转子磁极，磁钢槽组包括关于冲片本体的第一直径对称布置的第一磁钢槽（210）和第二磁钢槽（220），第一磁钢槽和第二磁钢槽呈向外开口的第一V型布置。电机转子采用呈向外开口的V型布置且形成磁极的磁钢槽组，能够在转子高速转动时，尤其是超高速转动时，磁钢槽中容纳的磁钢受离心力的受力面积会减低，从而减少磁钢内部的拉应力，延长了磁钢的寿命，尤其适用于电动汽车中超高速运转的驱动电机之用。

Description

电机转子、电机和电动汽车 技术领域
本发明涉及电机技术领域，具体地，涉及一种电机转子和具有该电机转子的电机以及具有该电机的电动汽车。
背景技术
电机作为驱动装置广泛应用于各种领域中。近年来随着电动汽车的兴起，用于驱动车辆行驶的驱动电机的重要性不言而喻。其中，公知地，电机主要包括外壳、定子组件及转子组件。例如在一些现有技术中，外壳包括前端具有开口的筒体，外壳内设置有定子组件，定子组件包括定子铁芯及铁芯绕组，转子组件则包括转轴、永磁体及转子铁芯；转子铁芯套装于转轴之上，转子铁芯外周均布有多个永磁体；外壳的前端设置有端面，外壳上端设置有接线盒以为绕组供电。从而实现电机的旋转驱动功能。其中作为电动汽车的驱动电机通常要求动力大而体积小，如何解决这一矛盾也是本领域内待研究的重要课题。
发明内容
本发明的目的是提供一种电机转子、具有该电机转子的电机和具有该电机的电动汽车。
为了实现上述目的，本发明提供一种电机转子，所述电机转子包括由多个转子冲片叠置而成的转子铁芯，所述转子冲片包括冲片本体，所述冲片本体上形成有用于磁钢插入的磁钢槽，所述磁钢槽为多个，所述多个磁钢槽形成磁钢槽组且所述磁钢槽组构成转子磁极。
本发明还提供一种电机，包括壳体以及安装在该壳体内的电机转子和电机定子，所述电机转子为本发明提供的电机转子。
本发明还提供一种电动汽车，包括驱动电机，所述驱动电机为本发明提供的电机。
通过上述技术方案，本发明采用向外开口的V型布置形成磁极的磁钢槽组，能够在转子高速转动时，尤其是超高速转动时，磁钢槽中容纳的磁钢受离心力的受力面积会减低，从而减少磁钢内部的拉应力，提升了磁钢的寿命，尤其适用于电动汽车中超高速运转的驱动电机之用。
本发明的其他特征和优点将在随后的具体实施方式部分予以详细说明。
附图说明
附图是用来提供对本发明的进一步理解，并且构成说明书的一部分，与下面的具体实施方式一起用于解释本发明，但并不构成对本发明的限制。在附图中：
图1是本发明具体实施方式提供的电机的第一视角立体图；
图2是本发明具体实施方式提供的电机的第二视角立体图；
图3是本发明具体实施方式提供的电机的分解示意图；
图4是本发明具体实施方式提供的电机转子冲片的结构示意图；
图5是本发明具体实施方式提供的磁钢槽的结构示意图，其中为了清楚显示夹角，在其他特征不变的情况下，该夹角被放大若干倍显示；
图6是本发明具体实施方式提供的电动汽车的结构简图。
具体实施方式
以下结合附图对本发明的具体实施方式进行详细说明。应当理解的是，此处所描述的具体实施方式仅用于说明和解释本发明，并不用于限制本发明。
在本发明中，在未作相反说明的情况下，使用的方位词如“上、下、左、右”通常是以附图的图面方向为基准定义的，“内、外”是指相应部件轮廓的内和外。
如图1至图6所示，本发明至少提供一种电机转子冲片、一种电机转子、一种电机1000以及一种电动汽车2000。其中电机1000可以为两对极电机、永磁同步电机、或两对极永磁同步电机，此外本发明的电机还可以为其他本领域内公知的电机种类，例如异步电机等等类型的电机，尤其是一种超高速电机，即转速在20000rpm(转/分钟)以上的电机，本发明提到的各种电机还尤其适用于电动汽车的驱动电机使用。
其中，本发明中所说的“两对极”、“永磁同步”是本领域公知的术语，例如，两对极是指电机转子上设置有两对磁极。其中由于磁极对数越多，当电机转速高时，尤其是本发明中的电机为超高速电机时，磁场的交变频率越高，电机所产生的热量就越多，对冷却系统的要求也就越高，另外电机的铁耗也会增大。因此，两对极电机适用于超高速运行的驱动电机使用。当然，在其他可能的实施方式中，也可以采用三对极或四对极等。
另外永磁同步电机也适用于电动汽车的驱动电机使用。在性能上，其可以包括效率高，功率因素高，体积小，重量轻，温升低的优点。具体地例如，永磁同步电机在转子上嵌了永磁体后，由永磁体来建立转子磁场，在正常工作时转子与定子磁场同步运行，转子中无感应电流，不存在转子电阻损耗，因此可大幅提高电机效率。另外，起动时，电机具有足够大的起动转矩，并且不需起动电流太大，适用于由动力电池包带动的驱动电机。此外，永磁同步电机的效率高，转子绕组中电阻损耗较低，定子绕组中较少有或几乎不存在无功电流，使电机温升低，也能够延长电机的使用寿命。其他永磁同步电机带来的优点不做过 多赘述。总之，永磁同步电机结构简单，使得永磁同步电机加工和配电费用减少，运行更加可靠，另外，永磁同步电机采用稀土永磁后增大了气隙磁密，并把电机转速提高到最佳，从而显著缩小了电机的体积，提高了功率质量比；另外由于省去了励磁铜耗，电机效率得以显著提高。
在结构上，如图1至图4所示，本发明实施方式提供的电机包括壳体400、安装在该壳体400内的电机转子300和电机定子500。电机定子500固定地设置在壳体400内，电机转子300可转动地设置在电机定子500的中心。其中电机转子300包括由多个转子冲片叠置而成的转子铁芯310，以及与转子铁芯310传动相连的转轴320。具体地，在本实施方式中，转子铁芯的冲片本体100的回转中心形成有转轴孔101，该转轴孔101的侧壁上对称地形成有用于与转轴配合的一对键102，即转子铁芯310和转轴320为键连接方式。在其他实施方式中，转子铁芯310和转轴320还可以采用其他本领域技术人员公知的传动连接方式进行连接，例如采用非圆剖面的型面连接方式。另外，在转子冲片上还可以形成有油孔103，以形成转子油路的一部分，通过使润滑油在转子中循环流动，可对转子进行冷却处理。
另外，壳体400远离动力输出端具有端盖800，该端盖800上可以形成有轴承室，转轴320的内端通过深沟球轴承600安装在该轴承室内，伸出壳体400的外端则可以作为动力输出端。另外，壳体上安装有接线盒700可以外接电源，例如与动力电池包电连接以能够通过为绕组900供电而产生磁场，从而能够实现电机的工作。另外，电机的转子和定子之间还设置有气隙以使得电机能够正常工作。
在本发明的实施方式中，如图4所示，所提供的电机转子冲片包括冲片本体100，该冲片本体100上形成有用于磁钢插入的磁钢槽200，即利用磁钢作为永磁体来形成转子磁极，即本实施方式中的永磁体采用嵌入式的安装方式，这样可以有效保证转子在超高速旋转时的稳定性，相比表贴式的永磁体安装方式，嵌入式的永磁体安装方式更适用于超高速运转的转子。其中，在转子高速尤其是超高速运转时，容纳在磁钢槽内的磁钢会在离心力作用下具有变形的趋势，即在磁钢内部产生拉应力，同时由于磁钢槽的阻力而承受压应力，其中磁钢的抗拉强度要远低于其抗压强度。一种磁钢的实施例中，其抗拉强度只有85Mpa，而抗压强度则可以达到1000Mpa以上。因此产生的拉应力会对磁钢的寿命造成影响。基于此，本实施方式中为了提高磁钢的寿命，对磁钢槽的槽型进行了改进，其方式可以包括将磁钢所受的拉应力转变为压应力。
其中，如图5所示，磁钢槽200沿冲片本体100的表面方向具有直槽段201和位于该直槽段201两侧的倾角段202，倾角段202远离冲片本体100回转中心的第一侧缘从直槽段201的端部向外倾斜。直槽段201与位于该直槽段201两侧的倾角段202共同构成磁钢 槽200在冲片本体100的表面的闭合横截轮廓。如图5所示，磁钢槽200在冲片本体100的表面的闭合横截轮廓由虚线分割为直槽段201和倾角段202。这样，通过在直槽段201两侧设置向外倾斜的倾角段202，可以为磁钢槽200内的磁钢两端提供产生微量变形的缓冲区，即在转子转动时，允许磁钢在磁钢槽200内微量变形从而释放磁钢内部产生的拉应力，继而提升磁钢的寿命。
具体地，在本实施方式中，为了实现磁钢槽200的改进，可以在现有的一字型磁钢槽上开角而成。其中，由于磁钢的变形较为微量，并且为了避免对转子冲片的强度造成过大影响，在本实施方式中，倾角段202的第一侧缘与直槽段201之间的夹角α为0.5°-2°，例如采用1°的倾斜。此处需要注意的是，图5是在其他特征不变的情况下，将该夹角α放大了若干倍后的视图，以示意地清楚显示该倾角段202。这种对磁钢槽200的改进能够有效增加磁钢的寿命。
在本发明的实施方式中，冲片本体100由非晶合金材料制成，即本发明实施方式中的转子铁芯由非晶合金材料制成，可以增加冲片本体100的强度。
公知地，非晶合金材料的特性中抗拉强度是普通硅钢材料的几十倍，因此对磁钢槽200的改进而导致冲片本体100所牺牲的强度能够由该材料弥补，并且其强度大大高于现有技术中硅钢材料的转子冲片的强度，从而既能够保证磁钢的寿命还能够保证转子铁芯的强度和寿命。
另外，本发明的实施方式中，由于转子铁芯由非晶合金材料制成，还会使得转子铁芯具有磁导率高、电导率高、涡流损耗小等特点，更大幅提升了电机的性能。其中，需要提及的是，使用非晶合金材料制成转子铁芯，不仅可以使得转子能力得到提升，还解决了如何通过小体积实现大功率输出的关键问题，能够使得电动汽车领域的驱动电机取得了巨大进步。
具体地，本发明的发明人的设计思路在于，发明人发现在电动汽车领域，出于空间布局的考虑，很难将电机的体积做大，因此很难提升电机的扭矩。这样为了提升功率，根据公式p＝T*n/9550可知，在体积一定的情况下，可以通过增加转速来实现大功率的输出。因此，本发明的发明人产生了使用小体积大转速的电机来作为电动汽车的驱动电机之用的动机。其中，发明人还考虑到当电机转速达到20000rpm的超高速以后，受到普通硅钢片屈服强度的限制，设计出来的电机体积会过小。当电机体积过小时，尽管转速较高但仍然会直接影响电机输出的转矩，从而不能满足驱动电机的要求。
考虑到这些因素，本申请发明人采用了非晶合金材料形成转子以解决转子外径受限的问题，即能够在保证电机可以超高速运转的同时，尽可能地增加电机的体积从而增加扭矩而进一步提升电机功率。进一步地，本发明提供的电机并非简单将所有部件均使用非晶合 金材料制造。将成本因素除外，本发明还发现在当前工艺条件下，非晶合金带材宽度受限，如果还用非晶合金带材做电机定子，也会造成所生产的电机过小而影响电机的功率输出。另外，由于非晶合金材料的磁致伸缩系数较大，这将会导致电机振动噪声较大。因此，本发明实施方式所提供的各种电机仅将转子铁芯使用非晶合金材料制成，而定子则可以选择使用硅钢材料制成。因此，本发明实施方式中采用将转子使用非晶合金材料、而定子采用原有硅钢材料的结构，是综合考虑各方面因素的结果，需要发明人进行大量创造性劳动。
并且进一步地，这正与上述采用非晶合金材料制造转子铁芯的从而提升超高速运转时磁钢寿命的想法不谋而合。这样，本发明巧妙地将非晶合金材料用于转子的制造，不仅能够达到在超高速运转时提高磁钢寿命的有益效果，还能够同时使得设计出来的电机体积较小而不过小，即通过采用非晶合金材料制造转子铁芯还产生了意料不到的技术效果，实现了一个特征的多种效果。尤其适用于需要大功率且小体积的驱动电机的要求，使得驱动电机的性能得到了大幅提升。
在本发明的实施方式中，如图5所示，为了保证磁钢两侧的变形一致，可以将两个倾角段202设计为关于直槽段201的中心轴线对称设置。即两个倾角段202的结构基本相同。另外，为了实现磁钢的结构，倾角段202接近冲片本体100回转中心的第二侧缘与直槽段201共线布置。即倾角段202中仅外侧的第一侧缘线相对于直槽段201倾斜，从而既能够保证磁钢在离心力作用下的两端向外的微量变形，还能够更好地使得磁钢容纳保持在磁钢槽200中。倾角段202的第一侧缘和第二侧缘通过弯折侧缘连接以与直槽段201配合形成闭合横截轮廓。具体的，进一步地，为了更好地适应磁钢的变形，可以设计直槽段201的长度占容纳在磁钢槽内的磁钢沿冲片本体100表面的长度的1/2-3/4。从而使得磁钢的变形得到更好的缓冲，而避免磁钢槽对磁钢施加不必要的破坏力。
上述介绍了磁钢槽200的槽型改进，下面对本发明实施方式中电机转子冲片中的磁极布置方面的改进进行描述。
其中，为了形成转子磁极，如图4所示，磁钢槽200为多个，该多个磁钢槽200形成得到构成转子磁极的磁钢槽组，即，所述多个磁钢槽200形成磁钢槽组且所述磁钢槽组构成转子磁极，其中一个磁钢槽组能够形成一个转子磁极。具体的，该磁钢槽组包括关于冲片本体的第一直径(作为一个示例，第一直径为冲片本体100上沿竖直方向的直径，如图4所示)对称布置的第一磁钢槽210和第二磁钢槽220，该第一磁钢槽210和第二磁钢槽220呈向外开口的第一V型布置。换言之，本发明的磁钢布置方式为V型结构。同样为了在较小的尺寸上产生较大的磁场，在本实施方式中，磁钢槽组还包括关于第一直径对称布置的第三磁钢槽230和第四磁钢槽240，该第三磁钢槽230和第四磁钢槽240呈向外开口的第二V型布置并且间隔设置于第一磁钢槽210和第二磁钢槽220的径向内侧。即本发明 中一个磁极可以包括四个磁钢，从而充分利用冲片本体的空间，这尤其适用于体积较小的驱动电机。为了优化同组中四个磁钢的布局，合理利用空间，可选地，第二V型的夹角小于第一V型的夹角。这样，能够使得外侧的磁钢更好地利用冲片本体弦线方向的空间，而使得内侧磁钢更好地利用冲片本体径向方向的空间，布局更加合理，更有效地产生磁场。
为了产生均匀的磁场，在本实施方式中，磁钢槽组为多个以分别构成多个转子磁极，该多个磁钢槽组为偶数个并沿周向均匀分布在冲片本体上。其中在本发明提供的两对极电机中，对应地，磁钢槽组为四个以构成电机转子的两对极。在其他实施方式中，随磁极对数的不同，可以设置不同数量的磁钢槽组。
在本实施方式中，为了保证冲片本体的强度，冲片本体100上形成有沿周向均匀分布的油孔103，该油孔103位于相邻的磁钢槽组之间，以充分利用冲片本体空间，另外开设油孔103可以对转子进行减重而减少转子转动惯量。另外，在本实施方式中，冲片本体100的回转中心形成有转轴孔101，该转轴孔101的侧壁上对称地形成有用于与转轴配合的一对键102，该键102朝向圆心凸出并该一对键102位于第一直径上。即，该键为凸出的结构而非凹入结构，从而方便与转轴上的键槽配合传递扭矩。
另外，为了保证冲片本体的强度，在本实施方式中，在磁钢槽组中，对称布置的磁钢槽之间设置有加强筋，以增强冲片本体的强度。另外，并且磁钢槽与冲片本体的边缘之间设置有隔磁桥或隔磁孔。其中的隔磁桥可以越小越好，从而会减小漏磁，增大气隙磁密。另外隔磁孔可以改善气隙磁密波形，从而提升电机性能。
本发明提供的电机更适用于电动汽车的驱动电机，其中铁耗比较低，输出功率得以提高，又避免了非晶电机带来的噪声大的问题。重新设计了定、转子结构。提高转子结构的强度，不仅可以做成超高转速电机，而且具有优异的电磁性能。只有转子铁芯使用非晶合金，降低了加工难度，降低了工艺的成本。电机体积不受非晶合金材料的制约，从而能发挥出更大的扭矩和功率。在高转速下，最小化了磁场的交变频率，降低了铁耗，减少了散热，并且易于实现对电机的控制，使得电机的性能得以显著提高，间接使得电动汽车的性能也得到大幅提升，实用性更好。
以上结合附图详细描述了本发明的优选实施方式，但是，本发明并不限于上述实施方式中的具体细节，在本发明的技术构思范围内，可以对本发明的技术方案进行多种简单变型，这些简单变型均属于本发明的保护范围。
另外需要说明的是，在上述具体实施方式中所描述的各个具体技术特征，在不矛盾的情况下，可以通过任何合适的方式进行组合，为了避免不必要的重复，本发明对各种可能的组合方式不再另行说明。
此外，本发明的各种不同的实施方式之间也可以进行任意组合，只要其不违背本发明 的思想，其同样应当视为本发明所公开的内容。

Claims (18)

  1. 一种电机转子，该电机转子(300)包括由多个转子冲片叠置而成的转子铁芯(310)，所述转子冲片包括冲片本体(100)，所述冲片本体(100)上形成有用于磁钢插入的磁钢槽(200)，其特征在于，所述磁钢槽(200)为多个，所述多个磁钢槽(200)形成磁钢槽组且所述磁钢槽组构成转子磁极。
  2. 根据权利要求1所述的电机转子，其特征在于，所述磁钢槽组包括关于所述冲片本体的第一直径对称布置的第一磁钢槽(210)和第二磁钢槽(220)，所述第一磁钢槽(210)和所述第二磁钢槽(220)呈向外开口的第一V型布置。
  3. 根据权利要求2所述的电机转子，其特征在于，所述磁钢槽组还包括关于所述第一直径对称布置的第三磁钢槽(230)和第四磁钢槽(240)，所述第三磁钢槽(230)和所述第四磁钢槽(240)呈向外开口的第二V型布置并且间隔设置于所述第一磁钢槽(210)和所述第二磁钢槽(220)的径向内侧。
  4. 根据权利要求3所述的电机转子，其特征在于，所述第二V型的夹角小于所述第一V型的夹角。
  5. 根据权利要求1-4中任意一项所述的电机转子，其特征在于，所述磁钢槽组为多个以分别构成多个转子磁极，所述多个磁钢槽组为偶数个并沿周向均匀分布在所述冲片本体上。
  6. 根据权利要求5所述的电机转子，其特征在于，所述磁钢槽组为四个以构成所述电机转子的两对极。
  7. 根据权利要求5或6所述的电机转子，其特征在于，所述冲片本体(100)上形成有沿周向均匀分布的油孔(103)，所述油孔位于相邻的所述磁钢槽组之间。
  8. 根据权利要求1-7中任意一项所述的电机转子，其特征在于，所述冲片本体(100)的回转中心形成有转轴孔(101)，所述转轴孔(101)的侧壁上对称地形成有用于与转轴配合的一对键(102)，所述键(102)朝向圆心凸出并且所述一对键(102)位于所述第一直 径上。
  9. 根据权利要求2或3所述的电机转子，其特征在于，在所述磁钢槽组中，对称布置的所述磁钢槽之间设置有加强筋，并且所述磁钢槽与所述冲片本体的边缘之间设置有隔磁桥或隔磁孔。
  10. 根据权利要求1-9中任意一项所述的电机转子，其特征在于，所述磁钢槽(200)沿所述冲片本体(100)的表面方向具有直槽段(201)和位于该直槽段(201)两侧的倾角段(202)，所述倾角段(202)远离所述冲片本体(100)回转中心的第一侧缘从所述直槽段(201)的端部向外倾斜。
  11. 根据权利要求10所述的电机转子，其特征在于，两个所述倾角段(202)关于所述直槽段(201)的中心轴线对称设置。
  12. 根据权利要求10或11所述的电机转子，其特征在于，所述倾角段(202)的所述第一侧缘与所述直槽段(201)之间的夹角为0.5°-2°。
  13. 根据权利要求10或11所述的电机转子，其特征在于，所述倾角段接近所述冲片本体(100)回转中心的第二侧缘与所述直槽段(201)共线布置。
  14. 根据权利要求10或11所述的电机转子，其特征在于，所述直槽段(201)占容纳在所述磁钢槽内的磁钢沿所述冲片本体(100)表面的长度的1/2-3/4。
  15. 根据权利要求1-14中任意一项所述的电机转子，其特征在于，所述冲片本体(100)由非晶合金材料制成。
  16. 根据权利要求1-15中任意一项所述的电机转子，其特征在于，所述电机转子为超高速电机转子。
  17. 一种电机，包括壳体(400)以及安装在该壳体(400)内的电机转子(300)和电机定子(500)，其特征在于，所述电机转子(300)为根据权利要求1-16中任意一项所述的电机转子。
  18. 一种电动汽车，包括驱动电机，其特征在于，所述驱动电机为根据权利要求17所述的电机。
PCT/CN2017/085592 2016-05-27 2017-05-23 电机转子、电机和电动汽车 WO2017202320A1 (zh)

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