WO2020019868A1 - 磁极模块、电机转子及制造该电机转子的方法 - Google Patents

磁极模块、电机转子及制造该电机转子的方法 Download PDF

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Publication number
WO2020019868A1
WO2020019868A1 PCT/CN2019/089553 CN2019089553W WO2020019868A1 WO 2020019868 A1 WO2020019868 A1 WO 2020019868A1 CN 2019089553 W CN2019089553 W CN 2019089553W WO 2020019868 A1 WO2020019868 A1 WO 2020019868A1
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WO
WIPO (PCT)
Prior art keywords
magnetic pole
substrate
cover
holes
rotor
Prior art date
Application number
PCT/CN2019/089553
Other languages
English (en)
French (fr)
Inventor
孙杨
宋佺
Original Assignee
北京金风科创风电设备有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 北京金风科创风电设备有限公司 filed Critical 北京金风科创风电设备有限公司
Priority to EP19841331.2A priority Critical patent/EP3709482A4/en
Priority to AU2019310830A priority patent/AU2019310830B2/en
Priority to US16/958,583 priority patent/US11509205B2/en
Publication of WO2020019868A1 publication Critical patent/WO2020019868A1/zh

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Classifications

    • 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
    • H02K1/2786—Outer rotors
    • H02K1/2787—Outer rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/2789—Outer rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2791—Surface mounted magnets; Inset 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
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/278—Surface mounted magnets; Inset 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
    • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H02K29/03—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/12—Machines characterised by the modularity of some components
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
    • H02K7/1807—Rotary generators
    • H02K7/1823—Rotary generators structurally associated with turbines or similar engines
    • H02K7/183—Rotary generators structurally associated with turbines or similar engines wherein the turbine is a wind turbine
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
    • H02K7/1807—Rotary generators
    • H02K7/1823—Rotary generators structurally associated with turbines or similar engines
    • H02K7/183—Rotary generators structurally associated with turbines or similar engines wherein the turbine is a wind turbine
    • H02K7/1838—Generators mounted in a nacelle or similar structure of a horizontal axis wind turbine
    • 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
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction

Definitions

  • the present disclosure relates to the technical field of motors, and more particularly, to a magnetic pole module, a motor rotor including the magnetic pole module, and a method of manufacturing the motor rotor.
  • the current common solution in the design of motors is that the motor adopts the stator inclined groove method or the rotor inclined pole method. If the motor stator chute method is adopted, not only will the coil be difficult to manufacture due to the angle of the chute, but also it will increase the coil length and the winding resistance, which will cause the copper loss of the motor to increase and the heating to increase.
  • the motor rotor oblique pole method referring to FIG.
  • the motor rotor oblique pole method may also be that a plurality of segments of conventional magnetic poles 11 in the axial direction of the motor are staggered by a certain angle in the axial direction (ie, segmented oblique poles).
  • segmented oblique poles a certain angle in the axial direction
  • Strict requirements are imposed on the accuracy of the size control, which reduces the yield of the magnetic pole 11 and the assembly efficiency, thereby reducing the production efficiency.
  • the design life of the generator usually requires 20 or even 25 years. This requires the rotor pole fixing and protection technology to provide higher mechanical fatigue resistance and Corrosion resistance.
  • the surface-mount magnetic pole fixing process is to fix the magnetic pole to the surface of the rotor yoke by resin bonding.
  • the surface-mounted magnetic pole fixing process is because the magnetic pole is completely fixed to the surface of the rotor yoke by the resin adhesive force. Once a weak point of the seal appears during the process of the process, the magnetic pole is easily damaged due to the high temperature and high humidity operating conditions of the wind turbine for a long time.
  • the pulverization reduces the excitation magnetic flux of the rotor poles and the air gap magnetic induction intensity of the generator, thereby reducing the power generation of the wind turbine.
  • a magnetic pole offset structure feature with a magnetic pole offset structure feature that takes into account generator performance (cogging torque, torque ripple), magnetic pole protection, and magnetic pole mechanical fixation is provided.
  • generator performance cogging torque, torque ripple
  • magnetic pole protection magnetic pole protection
  • magnetic pole mechanical fixation is provided.
  • a magnetic pole module capable of achieving good sealing and protection of a magnetic pole or a magnetic pole unit and being easily mechanically fixed is provided.
  • a method of manufacturing the above-mentioned motor rotor is provided.
  • a motor rotor includes a rotor yoke and a plurality of magnetic pole modules provided on the rotor yoke, each magnetic pole module including a substrate, a casing, and a receiving space formed in the substrate and the casing.
  • adjacent magnetic pole units in different circumferentially adjacent magnetic pole modules may be spaced apart from each other by a second distance along a circumferential direction of the rotor yoke, wherein the first distance may be different from the second distance.
  • different magnetic pole modules adjacent in the circumferential direction may be spaced apart from each other by a predetermined distance along the circumferential direction of the rotor yoke.
  • a protrusion may be provided on the substrate, and the protrusion may be provided on the front surface of the substrate along the axial direction.
  • Each magnetic pole unit of the pair of magnetic pole units may be respectively closely disposed on the two protrusion portions.
  • each magnetic pole unit may include a plurality of magnetic poles aligned in the axial direction, and the plurality of magnetic poles in each magnetic pole unit may have the same polarity.
  • each magnetic pole unit may be adhered to the inner surface of the casing by an adhesive.
  • each gap between the case, the substrate, and the pair of magnetic pole units may be filled with a resin.
  • a plurality of substrate through holes may be provided on the substrate, a plurality of cover through holes corresponding to the plurality of substrate through holes may be provided on the cover, and a threaded hole may be provided on the rotor yoke. Holes, multiple casing through holes, and threaded holes can be aligned with each other, and the magnetic pole module can be mechanically driven by passing fasteners through the multiple substrate through holes, the multiple casing through holes, and the threaded holes. It is fixed on the rotor yoke.
  • a plurality of magnetic pole modules may be arranged on the rotor yoke in a row along a circumferential direction of the rotor yoke, and each of the magnetic pole modules in the row may be aligned with each other in a circumferential direction of the rotor yoke.
  • a plurality of magnetic pole modules may be arranged in rows on the rotor yoke along an axial direction parallel to the central rotation axis of the motor rotor, and each of the magnetic pole modules in the rows may be parallel to the center of the motor rotor. The rotation axes are aligned with each other in the axial direction.
  • the polarities of circumferentially adjacent magnetic pole units in different magnetic pole modules may be opposite, and the polarities of axially adjacent magnetic pole units in different magnetic pole modules may be the same.
  • a magnetic pole module includes: a substrate; a first magnetic pole unit and a second magnetic pole unit, which are disposed on a front surface of the substrate, and the first magnetic pole unit and the second magnetic pole unit have opposite polarities and are spaced apart from each other. A first distance; the cover is buckled on the first magnetic pole unit, the second magnetic pole unit and the substrate.
  • the magnetic pole module may further include a protruding portion, and the protruding portion may be disposed on the front surface of the substrate and located between the first magnetic pole unit and the second magnetic pole unit.
  • first magnetic pole unit and the second magnetic pole unit may be bonded to the inner surface of the casing by an adhesive.
  • the substrate may include a plurality of substrate through holes provided on both sides of the substrate
  • the cover may include a plurality of cover through holes provided on both sides of the cover, wherein the plurality of substrate through holes may be connected with Multiple housing through-holes are aligned.
  • each gap between the cover, the substrate, the first magnetic pole unit, and the second magnetic pole unit may be filled with a resin.
  • first magnetic pole unit and the second magnetic pole unit may be spaced apart from each other in the width direction, and each magnetic pole unit may include a plurality of magnetic poles aligned in the length direction, and the plurality of magnetic poles in each magnetic pole unit have the same polarity.
  • a method of manufacturing a rotor of a motor comprising: arranging a pair of magnetic pole units of opposite polarities in parallel on a substrate and spacing the pair of magnetic pole units apart by a first distance; The cover is buckled on a pair of magnetic pole units and the substrate and forms a sealed space between the cover and the substrate; the sealed space formed by the cover and the substrate is filled with resin to form a magnetic pole module; a plurality of magnetic pole modules are arranged on the rotor On the yoke, adjacent magnetic pole units in different magnetic pole modules adjacent to each other are spaced apart from each other by a second distance along the circumferential direction of the rotor yoke, and the first distance is different from the second distance.
  • the method may further include: before the pair of magnetic pole units are disposed on the substrate, a protrusion may be provided in a middle portion of the substrate, and the pair of magnetic pole units may be disposed on both sides of the protrusion.
  • an adhesive may be applied to the front surface of each magnetic pole unit of the pair of magnetic pole units for adhering the front surface to the cover; After the pair of magnetic pole units, the front surfaces of the case and the pair of magnetic pole units can be pressed so that the adhesive between the case and the front surfaces of the pair of magnetic pole units is completely spread; The outer seams are sealed to form a sealed space between the cover and the substrate.
  • the casing may further include a vacuum suction nozzle and a glue injection nozzle respectively disposed on two end surfaces of the casing, and the method may further include the following steps: The inside of the sealed space formed with the substrate is filled with resin so that each gap between the cover, the substrate and the pair of magnetic pole units is filled with the resin. After the resin is poured, the vacuum nozzle and the injection nozzle are removed, and Apply the sealant to the position after the nozzle and the vacuum nozzle to seal.
  • multiple substrate through-holes may be opened on the substrate, multiple cover through-holes may be opened on the cover, and multiple threaded holes may be opened on the rotor yoke.
  • the method may further include the following steps: Passing multiple fasteners through multiple substrate through holes, multiple housing through holes, and multiple threaded holes to mechanically fix multiple magnetic pole modules to the rotor yoke, and making the circumferential directions in different magnetic pole modules adjacent The polarity of the magnetic pole unit is opposite, and the polarity of the axially adjacent magnetic pole units in different magnetic pole modules is the same.
  • the cogging torque and torque ripple of the generator can be reduced, and at the same time, the magnetic pole or the magnetic pole unit is reliably fixed on the rotor yoke, and the reliable sealing of the magnetic pole or the magnetic pole unit is achieved, thereby taking into account
  • the performance of the generator cogging torque, torque ripple), magnetic pole protection and magnetic pole mechanical fixing are described.
  • the magnetic pole or the magnetic pole unit can be effectively sealed reliably, and the mechanical fixing of the magnetic pole or the magnetic pole unit is facilitated.
  • the manufacturing man-hours of a magnetic pole module can be reduced, and reliable sealing protection and fixing of the magnetic poles can be achieved, and a magnetic pole arrangement method capable of reducing cogging torque and torque ripple of a generator can be provided.
  • FIG. 1 is a schematic diagram showing a part of a rotor of a motor employing a rotor inclined pole method in the prior art
  • FIG. 2 is a schematic diagram showing a part of a rotor of a motor employing a rotor segmented slant pole method in the prior art
  • FIG. 3 is a schematic structural view showing a substrate of a magnetic pole template according to a first embodiment of the present disclosure
  • FIG. 4 is a schematic structural diagram illustrating a substrate and a magnetic pole unit of a magnetic pole module according to a first embodiment of the present disclosure
  • FIG. 5 is a schematic structural diagram illustrating a cover of a magnetic pole module according to a first embodiment of the present disclosure
  • FIG. 6 is a schematic structural diagram illustrating a substrate, a magnetic pole unit, and a cover of a magnetic pole module according to a first embodiment of the present disclosure
  • FIG. 7 is a schematic structural diagram illustrating a magnetic pole module (including a glue injection nozzle and a vacuum nozzle) according to a first embodiment of the present disclosure
  • FIG. 8 is a schematic structural diagram showing a magnetic pole module (removing an injection nozzle and a vacuum nozzle) according to a first embodiment of the present disclosure
  • FIG. 9 is a schematic structural view showing a part of a rotor of a motor according to a first embodiment of the present disclosure.
  • FIG. 10 is a schematic structural diagram illustrating a substrate, a magnetic pole unit, and a cover of a magnetic pole module according to a second embodiment of the present disclosure
  • FIG. 11 is a schematic structural view showing a bead according to a second embodiment of the present disclosure.
  • FIG. 12 is a schematic structural view showing a part of a rotor of a motor according to a second embodiment of the present disclosure
  • FIG. 13 is a schematic structural view showing a part of a motor rotor according to a second embodiment of the present disclosure.
  • Axial mentioned in this article refers to the axial direction parallel to the central axis of rotation of the rotor of the motor, “peripheral” refers to the circumferential direction along the direction of rotation of the rotor, and “radial” refers to the radial direction of the motor .
  • the magnetic pole module 100 may mainly include a substrate 110, a pair of magnetic pole units (a first magnetic pole unit 120 and a second magnetic pole unit 130), and a cover 140.
  • a pair of magnetic pole units are disposed on the substrate 110 and are spaced a predetermined distance from each other.
  • a cover 140 covers the pair of magnetic pole units to seal the pair of magnetic pole units.
  • the plurality of magnetic pole modules 100 will be fixed on the surface of the rotor yoke 150 to form a motor rotor 1000.
  • the structure of the magnetic pole module 100 will be described using terms indicating directions such as “axial”, “circumferential”, and “radial”.
  • the substrate 110 may be a rectangular or square plate having a certain thickness.
  • the substrate 110 may have a front surface 111 a and a back surface 111 b in a thickness direction.
  • the first magnetic pole unit 120 and the second magnetic pole unit 130 may be disposed on the front surface 111 a of the substrate 110.
  • the substrate 110 may further have first and second side surfaces 112a and 112b in the width direction and first and second end surfaces 113a and 113b in the length direction.
  • the substrate 110 may be made of a magnetically permeable material.
  • the protruding portion 114 may be disposed on the front surface 111 a of the substrate 110 along the length direction, and is used to separate the first magnetic pole unit 120 and the second magnetic pole unit 130.
  • the protrusion 114 may be fixed on a symmetrical centerline of the substrate 110.
  • the protruding portion 114 may be an elongated boss provided on the substrate 110.
  • the protruding portion 114 may be adhered to the front surface 111a of the substrate 110 by an adhesive (for example, a structural adhesive), and the protruding portion 114 may be formed integrally with the substrate 110. As shown in FIG.
  • the length of the protrusion 114 is equal to the length of the substrate 110, that is, both ends of the protrusion 114 and the end surface of the substrate 110 are aligned with each other, but the embodiment of the present disclosure is not limited thereto.
  • the length of the protruding portion 114 may also be different from the length of the substrate 110.
  • the protruding portion 114 may have any suitable shape.
  • the protruding portion 114 may also be composed of a plurality of discontinuous portions such as a columnar body, as long as the protruding portion 114 can be provided.
  • the two rows of magnetic pole units 120 and 130 may be separated by two rows of magnetic pole units 120 and 130.
  • the first magnetic pole unit 120 and the second magnetic pole unit 130 may be respectively disposed on both sides of the protruding portion 114 in close contact with the protruding portion 114.
  • the first magnetic pole unit 120 and the second magnetic pole unit 130 are separated by the protruding portion 114, so that the two rows of magnetic pole units are physically separated, thereby preventing the first magnetic pole unit 120 and the second magnetic pole unit from being operated for a long time by the motor. 130 moves relative to each other (for example, because of a magnetic field).
  • the first magnetic pole unit 120 and the second magnetic pole unit 130 may be spaced apart from each other in a width direction.
  • Each of the first magnetic pole unit 120 and the second magnetic pole unit 130 may include a magnetic pole, respectively, and the first magnetic pole unit 120
  • Each of the second and second magnetic pole units 130 may also include a plurality of magnetic poles aligned in the length direction, respectively. Multiple magnetic poles in each magnetic pole unit may have the same polarity. As shown in FIG. 4, each magnetic pole unit includes three magnetic poles.
  • the first magnetic pole unit 120 and the second magnetic pole unit 130 have opposite polarities, thereby forming a pair of magnetic pole units.
  • the first magnetic pole unit 120 may be an N pole (that is, the polarity of each magnetic pole in the first magnetic pole unit 120 Both are N), and the second magnetic pole unit 130 may be an S pole (that is, the polarity of each magnetic pole in the second magnetic pole unit 130 is S).
  • the first magnetic pole unit 120 may have a front surface 121 a and a back surface 121 b in a thickness direction, a first side surface 122 a and a second side surface 122 b in a width direction, and a first end surface 123 a in a length direction. And second end surface 123b.
  • the second magnetic pole unit 130 may have a front surface 131a and a back surface 131b in a thickness direction, a first side surface 132a and a second side surface 132b in a width direction, and a first end surface 133a and a second end surface 133b in a length direction. .
  • the back surface 121b of the first magnetic pole unit 120 and the back surface 131b of the second magnetic pole unit 130 may be adhered to the front surface 111a of the substrate 110 by an adhesive (for example, a structural adhesive).
  • the width of the protruding portion 114 can be represented by d 1. Therefore, a distance d 1 can be maintained between the two rows of magnetic pole units, which is hereinafter referred to as a first distance d 1 .
  • the first magnetic pole unit may be spaced apart distances d 1 between the first side surface 132a of the second unit 122b and the second magnetic pole portion 114 in contact with the protrusion portion 114 in contact with the protrusion 130 of the first side surface 120.
  • both ends of the first magnetic pole unit 120 and the second magnetic pole unit 130 may be aligned with the substrate 110, that is, the first end surface 123a of the first magnetic pole unit 120 and the first end of the second magnetic pole unit 130.
  • the surface 133a may be aligned with the first end surface 113a of the substrate 110
  • the second end surface 123b of the first magnetic pole unit 120 and the second end surface 133b of the second magnetic pole unit 130 may be aligned with the second end surface 113b of the substrate 110.
  • this setting is merely an example, and a case where the two ends of the magnetic pole unit and the two ends of the substrate are slightly misaligned or staggered from each other can also be considered.
  • the substrate 110 may further include a plurality of substrate through holes 115 provided on both sides of the substrate 110.
  • the plurality of substrate through-holes 115 may be provided at positions where no magnetic pole unit is placed on the substrate 110.
  • the plurality of substrate through-holes 115 may be provided near the first side surface 112a and the second side surface 112b of the substrate 110, respectively.
  • each substrate 110 may be provided with four substrate through-holes 115, and two substrate through-holes 115 may be respectively provided on both sides of the substrate 110.
  • the cover 140 may be fastened on the substrate 110, the first magnetic pole unit 120 and the second magnetic pole unit 130 to seal and surround the first magnetic pole unit 120 and the second magnetic pole unit 130 on the substrate 110.
  • the cover 140 may cover the substrate 110 and form a receiving space between the cover 140 and the substrate 110.
  • the first magnetic pole unit 120 and the second magnetic pole unit 130 may be located and sealed in the receiving space.
  • the cover 140 may have an outer surface of the structure following the structure where the magnetic pole units 120 and 130 are installed behind the substrate 110. Shape to closely contact the outer surfaces of the first magnetic pole unit 120, the second magnetic pole unit 130, and the substrate 110.
  • the cover 140 may have a “convex” shape.
  • the cover 140 may include a first portion 141 a covering the outer surfaces of the first and second magnetic pole units 120 and 130, and a second portion 141 b and a third portion located on both sides of the first portion 141 a and covering the substrate 110.
  • 141c The first portion 141 a may contact the front surface 121 a of the first magnetic pole unit 120 and the front surface 131 a of the second magnetic pole unit 130 provided on the substrate 110.
  • the second portion 141b and the third portion 141c may cover portions of the substrate 110 located on both sides of the magnetic pole units 120 and 130.
  • One side of the cover 140 may be open to provide an entrance for the substrate 110, the first magnetic pole unit 120, and the second magnetic pole unit 130. Therefore, after the cover 140 covers the first and second magnetic pole units 120 and 130 and the substrate 110, the first and second magnetic pole units 120 and 130 are sealed in the cover 140 as a whole, and the side surfaces and ends of the substrate 110 are sealed. The surface is also covered, and only the back surface 111b of the substrate 110 is exposed.
  • the inner surface of the cover 140 may be bonded to the first magnetic pole unit 120, the second magnetic pole unit 130, and the substrate 110 by an adhesive. Close contact and bonding.
  • the following methods can be used to ensure that the first magnetic pole unit 120 and the second magnetic pole unit 130 are in close contact with and firmly combined with the cover 140: Before the cover 140 is fastened, the front surface 121a of the first magnetic pole unit 120 and An adhesive is applied to the front surface 131a of the second magnetic pole unit 130 (for example, an adhesive layer is applied by spot coating or by a glue line).
  • the cover 140 is buckled on the first magnetic pole unit 120 and the second magnetic pole unit 130, and the cover 140 and the first magnetic pole unit 120 and the second magnetic pole unit 130 are pressed tightly to ensure that the inner surface of the cover 140 and the first magnetic pole unit 130
  • the adhesive between the front surface of one magnetic pole unit 120 and the second magnetic pole unit 130 is completely spread, so as to fully fill the gap between the cover 140 and the first magnetic pole unit 120 and the second magnetic pole unit 130, avoiding the gap between them. Air pockets appeared in between. After that, the adhesive is heated to cure.
  • the front surface of the cover 140 and the first magnetic pole unit 120 and the second magnetic pole unit 130 should be closely adhered by applying glue (for example, applying an adhesive).
  • glue for example, applying an adhesive.
  • the method of spreading the adhesive layer (for example, the adhesive layer) close to the cover 140 not only guarantees that the place is 100% filled with glue, but will not cause a cavity when the resin is vacuum filled due to the small gap (described in more detail below) It does not affect the air gap.
  • an external joint between the cover 140 and the substrate 110 may be sealed with a sealant, thereby forming a housing for the first magnetic pole unit 120 and the second magnetic pole unit 130 between the cover 140 and the substrate 110. Seal the space.
  • the cover 140 may further include a glue injection nozzle 149 and an evacuation nozzle 148 provided on both end surfaces of the cover 140.
  • the glue injection nozzle 149 and the vacuum nozzle 148 may be provided to vacuum-fill the sealed space formed by the cover 140 and the substrate 110 so as to fill the cover 140 and the substrate 110 and the cover 140 and the first magnetic pole unit 120 and All gaps between the second magnetic pole units 130.
  • the gap between the cover 140 and the side surface and the end surface of the magnetic pole unit, and between the cover 140 and the outer surface of the substrate 110 can be designed to a large value (because it does not affect the air gap), thereby ensuring that the resin
  • the gaps are filled with 100% glue.
  • the glue injection nozzle 149 and the vacuum extraction nozzle 148 may be removed.
  • a sealant is applied to the position after the glue injection nozzle 149 and the vacuum suction nozzle 148 are removed to seal, for example, the bare glue injection opening and vacuum Vacuum port.
  • the glue injection nozzle 149 and the vacuum nozzle 148 are cut off and polished flat, so that the end surface of the cover 140 is flat.
  • the case 140 may further include a plurality of case through holes 145 provided on both sides of the magnetic pole unit.
  • the positions of the cover through holes 145 on the cover 140 correspond to the positions of the substrate through holes 115 provided on the substrate 110.
  • the cover 140 is fastened on the substrate 110, the first magnetic pole unit 120, and the second magnetic pole unit 130, the plurality of cover through holes 145 on the cover 140 and the plurality of substrate through holes 115 on the substrate 110 are aligned one by one. .
  • the substrate through hole 115 and the cover through hole 145 can be formed when the substrate 110 and the cover 140 are manufactured respectively. After the cover 140 is fastened on the substrate 110 and the magnetic pole units 120 and 130, the cover 140 and the substrate are aligned. In order to prevent the substrate through hole 115 and the cover through hole 145 from affecting the formation of the sealed space when the resin is vacuum-filled in the sealed space formed by 110, and to prevent the substrate through hole 115 and the cover through hole 145 from being blocked by the injected resin, the magnetic pole module may be filled.
  • the substrate through-hole 115 and the cover through-hole 145 may be formed when the substrate 110 and the cover 140 are respectively manufactured, it is not limited thereto.
  • the substrate 110 and the cover 140 without through holes may be formed first, and after the resin is poured, the through holes are opened in the magnetic pole module 100.
  • the cover 140 may be made of a non-magnetically permeable material.
  • the magnetic pole unit magnetic pole
  • the substrate 110 made of a magnetically conductive material
  • an adhesive to cover the cover 140 of the non-magnetically conductive material
  • the outer joint, the joint between the cover through hole 145 and the substrate through hole 115 is sealed with a sealant, and the sealed space containing the magnetic pole unit formed by the cover 140 and the substrate 110 is vacuum filled with resin, which is effective. Ground to achieve hermetic protection of magnetic poles.
  • the motor rotor 1000 can be formed by mounting the magnetic pole module 100 on the inner surface of the rotor yoke 150.
  • FIG. 9 illustrates a structural diagram of a part of a motor rotor 1000 according to an embodiment of the present disclosure.
  • the motor rotor 1000 may include a rotor yoke 150 and a plurality of magnetic pole modules 100 provided on the rotor yoke 150, and a back surface 111 b of the substrate 110 of the magnetic pole module 100 may contact a radial direction of the rotor yoke 150.
  • the inner surface is a structural diagram of a part of a motor rotor 1000 according to an embodiment of the present disclosure.
  • the motor rotor 1000 may include a rotor yoke 150 and a plurality of magnetic pole modules 100 provided on the rotor yoke 150, and a back surface 111 b of the substrate 110 of the magnetic pole module 100 may contact a radial direction of the rotor yoke 150.
  • the rotor yoke 150 may be provided with a plurality of screw holes (not visible in the figure).
  • the plurality of threaded holes on the rotor yoke 150 may correspond to the plurality of substrate through holes 115 on the substrate 110 of the magnetic pole module 100 and the plurality of case through holes 145 on the housing 140 and are mounted on the rotor yoke in the magnetic pole module 100. Align 150 with each other so that fasteners 170 (with additional gaskets 160 can be added) pass through the substrate through-holes 115, housing through-holes 145, and threaded holes on the rotor yoke 150, so that the magnetic pole module 100 Mechanically fixed to the rotor yoke 150.
  • a plurality of magnetic pole modules 100 may be arranged in a row on a rotor yoke 150 in an axial direction (ie, an axial direction) parallel to a central rotation axis of a motor rotor 1000.
  • Each of the magnetic pole modules 100 in 100 is aligned with each other in an axial direction (ie, an axial direction) parallel to the central rotation axis of the motor rotor 1000, and the first magnetic pole unit 120 and the second magnetic pole unit in each magnetic pole module 100 130 are respectively aligned with each other in the axial direction.
  • the axially adjacent magnetic pole units in different magnetic pole modules have the same polarity, that is, magnetic pole units of the same polarity are aligned along the axial direction.
  • the aligned magnetic pole modules 100 are vertically arranged as a whole along the axial direction, and the magnetic pole modules 100 are not shifted or inclined from each other.
  • a plurality of magnetic pole modules 100 may be disposed on the rotor yoke 150 in a row along a circumferential direction (ie, a circumferential direction) of the rotor yoke 150, and each of the magnetic pole modules 100 in the row of the magnetic pole modules 100 is magnetically mounted on the rotor.
  • the yoke 150 is aligned with each other in the circumferential direction (ie, the circumferential direction), and the first magnetic pole unit 120 in each magnetic pole module 100 is adjacent to the second magnetic pole unit 130 in the adjacent magnetic pole module 100.
  • the polarities of circumferentially adjacent magnetic pole units in the same magnetic pole module or in different magnetic pole modules are opposite, that is, magnetic pole units having different polarities in the circumferential direction are alternately disposed.
  • the polarities of the first magnetic pole unit 120 and the second magnetic pole unit 130 in a magnetic pole module 100 may be opposite.
  • the second magnetic pole unit 130 (the polarity is S) of the one magnetic pole module 100 in the row of the magnetic pole modules 100 and the first magnetic pole of the adjacent magnetic pole module 100
  • the units 120 (the polarity is N) are adjacent, that is, a magnetic pole unit arrangement of alternating NSNS polarities is formed in the circumferential direction of the rotor yoke 150.
  • a pair of magnetic pole units 120 and 130 in each magnetic pole module 100 are spaced apart from each other by a first distance d 1 along the circumferential direction of the rotor yoke 150.
  • the plurality of magnetic pole modules 100 are also arranged such that adjacent magnetic pole units in different circumferentially adjacent magnetic pole modules 100 are spaced apart from each other by a second distance d 2 along the circumferential direction of the rotor yoke 150, as shown in FIG. 9.
  • the first side surface 122 a of the first magnetic pole unit 120 may be spaced apart from the first side surface 112 a of the substrate 110 by a third distance d 3 .
  • the second side surface 132 b of the second magnetic pole unit 130 may be spaced from the second side surface 112 b of the substrate 110 by a fourth distance d 4 .
  • a fifth distance d 5 may be separated between two adjacent magnetic pole modules 100.
  • the second distance d 2 may be approximately equal to the sum of the third distance d 3 , the fourth distance d 4, and the fifth distance d 5 (considering the distance between the cover 140 and the substrate 110 and the magnetic pole units 120 and 130). Each gap).
  • a module between two poles of the magnetic pole unit (the first pole and a second pole unit 120, unit 130) 100 spaced apart a first distance is a distance d 1
  • the distance between two adjacent columns of magnetic pole units is a second distance d 2
  • d 1 is not equal to d 2 .
  • d 1 ⁇ d 2 .
  • each pair of magnetic pole units that is, a pair of magnetic pole units in one magnetic pole module
  • This type of magnetic pole offset structure can reduce cogging torque and torque ripple of a permanent magnet direct drive generator.
  • a resin vacuum infusion can be performed on all the magnetic pole modules 100 as a whole to achieve the gap between the magnetic pole module 100 and the rotor yoke 150, the fastener 170, the gasket 160, and Respective gaps in the through holes 115 of the substrate, the through holes 145 of the casing, and the screw holes on the rotor yoke 150 are effectively filled and sealed.
  • the motor rotor may further include other components (for example, a structural member such as a rotor bracket).
  • a structural member such as a rotor bracket.
  • each magnetic pole module 100 is manufactured separately, and each magnetic pole module 100 includes a pair of magnetic pole units (a first magnetic pole unit 120 and a second magnetic pole unit of opposite polarities). 130), compared with the traditional "each magnetic pole module includes a substrate, a row of magnetic poles, a cover", the man-hour is greatly reduced.
  • magnetic pole shift can be effectively realized to reduce cogging torque and torque pulsation, and each resin is bonded and vacuum-filled by an adhesive method.
  • each resin is bonded and vacuum-filled by an adhesive method.
  • the magnetic pole module 100 and the motor rotor 1000 described above not only the magnetic pole offset structure type can be realized, the cogging torque and torque ripple of the permanent magnet direct drive generator can be effectively reduced, but also the magnetic pole (magnetic pole Unit) to effectively seal and mechanically fix it on the rotor yoke 150, so as to achieve effective sealing of the magnetic poles and secure and reliable fixation of the magnetic pole module 100, thereby ensuring that the magnetic poles have a high temperature and high temperature during the entire life cycle of the generator. Reliability under humidity conditions. Therefore, the magnetic pole module 100 provided in the present disclosure and the motor rotor 1000 including the magnetic pole module 100 having a magnetic pole offset structure feature take into consideration generator performance (cogging torque, torque ripple), magnetic pole protection, and magnetic pole mechanical fixing.
  • a method of manufacturing the magnetic pole module 100 and the motor rotor 1000 according to the first embodiment of the present disclosure will be described below with reference to FIGS. 3 to 9.
  • a substrate 110 having a plurality of substrate through holes 115 is manufactured. Then, a protruding portion 114 is provided in a middle portion of the substrate 110 (preferably, at a center line of symmetry), and the protruding portion 114 may be adhered to the front surface 111 a of the substrate 110 by an adhesive.
  • the substrate 110 provided with the plurality of substrate through-holes 115 and the protruding portion 114 may be formed integrally.
  • a pair of magnetic pole units (the first magnetic pole unit 120 (N pole) and the second magnetic pole unit 130 (S pole)) of opposite polarities are arranged in parallel on the substrate 110, and the pair of magnetic poles The units are spaced apart by a first distance d 1 .
  • the first magnetic pole unit 120 and the second magnetic pole unit 130 can be closely arranged on both sides of the protruding portion 114 in close contact with the protruding portion 114, and the back surface 121 b of the first magnetic pole unit 120 and the second magnetic pole unit 130 can be adhered by an adhesive.
  • the back surface 131b is pasted on the front surface 111a of the substrate 110.
  • the first magnetic pole unit 120 and the second magnetic pole unit 130 may be separated by the protruding portion 114 and symmetrically distributed on both sides of the protruding portion 114.
  • the cover 140 may be fastened on the substrate 110, the first magnetic pole unit 120 and the second magnetic pole unit 130, and a sealed space may be formed between the cover 140 and the substrate 110.
  • the front surface 121 a of the first magnetic pole unit 120 and the front surface 131 a of the second magnetic pole unit 130 may be coated with an adhesive (for example, spot coating or coating by a glue line). Adhesive) for adhering the front surface 121a and the front surface 131a to the cover 140.
  • the cover 140 is fastened on the substrate 110, the first magnetic pole unit 120, and the second magnetic pole unit 130, so that the first portion 141a of the cover 140 covers the first magnetic pole unit 120 and the second magnetic pole unit 130, and the The second portion 141b and the third portion 141c cover portions of the substrate 110 on both sides of the magnetic pole units 120 and 130.
  • the cover shell 140 and the first magnetic pole unit 120 and the second magnetic pole unit 130 may be pressed to make the cover 140
  • the adhesive between the first part 141a and the front surface 121a of the first magnetic pole unit 120 and the front surface 131a of the second magnetic pole unit 130 is completely and uniformly spread, thereby filling the cover 140, the first magnetic pole unit 120, and the second
  • the gap between the magnetic pole units 130 is heated to cure the adhesive.
  • the first and second magnetic pole units 120 and 130 are sealed in the cover 140 as a whole, and a side surface of the substrate 110 is sealed.
  • the end surface is also covered, and only the back surface of the substrate 110 is exposed.
  • the outer joint between the cover 140 and the substrate 110 may be sealed with a sealant, and then the sealant is cured, thereby forming a sealed space for housing the magnetic pole units 120 and 130.
  • the cover 140 may further include a vacuum suction nozzle 148 and a glue injection nozzle 149 respectively disposed on both end surfaces of the cover 140.
  • the magnetic pole module 100 shown in FIG. 6 is placed in a vertical position, and the vacuum nozzle 148 is connected to the vacuum pipe to evacuate the inside of the magnetic pole module 100.
  • the injection nozzle 149 from the axial bottom of the casing 140 is connected to the injection pipe, and the inside of the sealed space formed by the casing 140 and the substrate 110 is vacuum-filled with resin so that the resin is completely filled between the casing 140 and the substrate 110.
  • Each gap between the cover 140 and the magnetic pole units 120 and 130 is heated to cure the resin after the resin is vacuum-filled.
  • a vacuum-filled resin is used to seal and fill the sealed space formed by the cover 140 and the substrate 110.
  • this method can ensure that the cover 140 and the magnetic pole unit 120, 130 Volts.
  • other injection methods may also be used. For example, if the cover 140 is thicker and has greater rigidity, a positive pressure injection method may be used.
  • the vacuum nozzle 148 and the glue injection nozzle 149 on the cover 140 may be removed or cut off, and then both end surfaces of the cover 140 may be polished and flattened to remove burrs, and A sealant is applied to the position after the glue injection nozzle 149 and the vacuum suction nozzle 148 are removed for sealing, for example, the bare glue injection port and the vacuum suction port are sealed with a sealant.
  • the sealant is cured by heating to complete the sealing of the magnetic pole module 100, thereby completing the manufacture of the single magnetic pole module 100.
  • a plurality of magnetic pole modules 100 are assembled to a rotor yoke 150 provided with a screw hole (not visible in the figure).
  • the magnetic pole module 100 is positioned by a tooling or a mechanical arm, so that the substrate through hole 115 and the cover through hole 145 of the magnetic pole module 100 correspond to the screw holes on the rotor yoke 150 one by one.
  • a plurality of magnetic pole modules are passed through a plurality of fasteners 170 (possible to add a gasket 160) through a plurality of substrate through holes 115, a plurality of casing through holes 145, and a plurality of threaded holes on the rotor yoke 150, respectively.
  • the exposed fasteners 170, gaskets 160, substrate through holes 115, housing through holes 145, and threaded holes on the rotor yoke 150 can be covered with a sealant and cured by heating to achieve this. Office seal.
  • adjacent magnetic pole units in different circumferentially adjacent magnetic pole modules 100 may be spaced apart from each other by a second distance d 2 along the circumferential direction of the rotor yoke 150.
  • circumferentially adjacent magnetic pole modules 100 may be spaced apart from each other along the circumferential direction of the rotor yoke 150 by a certain distance (for example, the fifth distance d 5 as described above). At the same time, during assembly, it is necessary to ensure that the polarities of circumferentially adjacent magnetic pole units in different magnetic pole modules are opposite, and the polarities of axially adjacent magnetic pole units in different magnetic pole modules are the same.
  • the magnetic pole module 200 according to the second embodiment is different from the magnetic pole module 100 according to the first embodiment in that the substrate 210 and the cover 240 of the magnetic pole module 200 are not provided with through holes.
  • other structural features Can be the same.
  • the motor rotor 2000 is different from the motor rotor 1000 according to the first embodiment in that the motor rotor 2000 further includes a bead 280, and the magnetic pole module 200 is mechanically fixed to the rotor yoke 250 through the bead 280. Therefore, in the following description, these differences will be described in detail, and the same or similar parts as the first embodiment will be briefly described or omitted. Those skilled in the art should understand that the first embodiment and the second implementation Examples can be used in combination.
  • the magnetic pole module 200 may mainly include a substrate 210, a pair of magnetic pole units (a first magnetic pole unit 220 and a second magnetic pole unit 230), and a cover 240.
  • a pair of magnetic pole units 220 and 230 are disposed on the substrate 210 and are spaced apart from each other by a predetermined distance (the first distance d 1 as described above).
  • the cover 240 covers the pair of magnetic pole units 220 and 230 and seals the pair of magnetic pole units 220. , 230.
  • the two end surfaces of the cover 240 are respectively provided with a glue injection nozzle 249 and a vacuum suction nozzle 248 (removed after the resin is vacuum-filled).
  • the magnetic pole module 200 is not provided with a through hole. As shown in FIG. 13, the plurality of magnetic pole modules 200 may be mechanically fixed to the rotor yoke 250 by a bead 280 and a fastener 270.
  • the bead 280 may include a protruding portion 281 and first and second edge portions 282 and 283 located on both sides of the protruding portion 281.
  • the thickness of the protruding portion 281 may be larger than the thickness of the first edge portion 282 and the second edge portion 283 to match the shape of the magnetic pole module 200.
  • the bead 280 may further include a plurality of through holes 284 provided along the length direction. Preferably, the plurality of through holes 284 may be provided along the axial centerline of the bead 280.
  • the rotor yoke 250 may be provided with a plurality of screw holes 251, and the distances between the screw holes 251 along the circumferential direction of the rotor yoke 250 may be greater than the width of the magnetic pole module 200.
  • the magnetic pole module 200 may be disposed on both sides of the axially-threaded screw holes 251.
  • the pitch in the axial direction of each screw hole 251 on the rotor yoke 250 is equal to the pitch between the through holes 284 on the bead 280 shown in FIG. 11.
  • a plurality of magnetic pole modules 200 can be positioned on the rotor yoke 250 through a tooling or a mechanical wall, and two circumferentially adjacent magnetic pole modules 200 can be separated by a predetermined distance (as described above).
  • a fifth distance d 5 ), the predetermined distance may be equal to or slightly larger than the width of the protruding portion 281 of the bead 280.
  • a bead 280 may be disposed between two rows of the magnetic pole modules 200, and a protruding portion 281 of the bead 280 may be disposed in two columns of the magnetic pole modules 200 adjacent in the circumferential direction.
  • the first edge portion 282 and the second edge portion 283 of the bead 280 are respectively pressed on the adjacent magnetic pole modules 200, and the plurality of through holes 284 on the bead 280 and the rotor yoke 250 are simultaneously pressed.
  • the plurality of threaded holes 251 are aligned one by one, and a fastener 270 (a gasket 260 may be added) is passed through the through hole 284 and the threaded hole 251 to mechanically fix the magnetic pole module 200 to the rotor yoke 250.
  • the length of the bead 280 shown in the figure may correspond to the length of the two magnetic pole modules 200.
  • the present disclosure is not limited thereto, and the bead 280 may have a length capable of holding a plurality of magnetic pole modules 200 at the same time, which may be adjusted through practical applications.
  • the number of through holes 284 on the bead 280 can also be adjusted according to the actual application, as long as it corresponds to the screw holes 251 provided on the rotor yoke 250.
  • the sealed magnetic pole module 200 can be mechanically fixed to the rotor yoke 250 efficiently.
  • the separation distance between two columns of magnetic pole units (the first magnetic pole unit 220 and the second magnetic pole unit 230) in one magnetic pole module 200 Is a first distance d 1
  • a distance separated between two adjacent columns of magnetic pole units in two adjacent magnetic pole modules 200 is a second distance d 2
  • d 1 is not equal to d 2 .
  • d 1 ⁇ d 2 .
  • the magnetic pole module 200 is similar to the manufacturing method of the magnetic pole module 100 according to the first embodiment, except that no through holes are provided in the substrate 210 and the cover 240. Therefore, the manufacturing method of the magnetic pole module 200 (for example, the structural features, assembly, or spatial relationship of the substrate 210, the magnetic pole units 220 and 230, and the cover 240) will not be described in detail here.
  • the first embodiment and the second embodiment can be combined with each other, resulting in an embodiment that is not described in detail.
  • a plurality of magnetic pole modules 200 are positioned on the rotor yoke 250 by a tooling or a mechanical arm, and the rotor yoke 250 is provided with a plurality of screw holes 251.
  • the magnetic pole module 200 may be arranged on both sides of the screw holes 251 in the axial row, as shown in FIG. 12.
  • the bead 280 may be disposed between the two columns of the magnetic pole modules 200, the protruding portion 281 of the bead 280 may be disposed in a gap between the two columns of the magnetic pole modules 200 adjacent in the circumferential direction, and the first edge portion 282 of the bead 280 and The second edge portions 283 are respectively pressed on the adjacent magnetic pole modules 200, and at the same time, the plurality of through holes 284 on the bead 280 and the plurality of threaded holes 251 on the rotor yoke 250 are aligned one by one.
  • a washer 260) is additionally inserted through the through hole 284 and the threaded hole 251 to mechanically fix the magnetic pole module 200 to the rotor yoke 250.
  • pole module 200 After the pole module 200 is assembled between the two magnetic pole unit (the first pole and a second pole unit 220, unit 230) in a pole module 200 is spaced apart from the first distance d 1, the two adjacent The distance separated between two adjacent columns of magnetic pole units in the magnetic pole module 200 is the second distance d 2 , and d 1 is not equal to d 2 . In this embodiment, d 1 ⁇ d 2 .
  • a resin vacuum infusion can be performed on all the magnetic pole modules 200 as a whole to achieve the gap between the magnetic pole module 200 and the rotor yoke 250, the fastener 270, the gasket 260, and Each gap in the through hole 284 on the bead 280 and the threaded hole 251 on the rotor yoke 250 is effectively filled and sealed.
  • the motor rotor 2000 according to the second embodiment can more efficiently mechanically fix the reliably sealed magnetic pole module 200 to the rotor yoke 250 by using a “strip + fastener fixing” method.
  • a through hole is provided on 100 or a magnetic pole module 100 or 200 is mechanically fixed to the rotor yoke by using a bead 280, but the present disclosure is not limited thereto, and other mechanical fixation may be considered without departing from the technical concept and scope of the present disclosure.
  • the method enables the motor rotor according to the present disclosure to take into consideration generator performance (cogging torque, torque ripple), magnetic pole protection, and magnetic pole mechanical fixing.

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  • Permanent Field Magnets Of Synchronous Machinery (AREA)

Abstract

本公开涉及磁极模块、电机转子及制造该电机转子的方法。所述电机转子包括转子磁轭和设置在所述转子磁轭上的多个磁极模块，每个磁极模块包括基板、罩壳和容纳在由所述基板和所述罩壳形成的容纳空间中的极性相反的一对磁极单元，其中，每个磁极模块内的一对磁极单元沿着所述转子磁轭的圆周方向彼此间隔开第一距离。根据本公开的电机转子能够兼顾发电机性能(齿槽转矩、转矩脉动)、磁极的防护和磁极的机械固定。

Description

磁极模块、电机转子及制造该电机转子的方法 技术领域
本公开涉及电机技术领域，更具体地，涉及磁极模块、包括该磁极模块的电机转子以及制造该电机转子的方法。
背景技术
对于大型风力发电机组的永磁直驱发电机，两项重要设计指标在于减小发电机的齿槽转矩和转矩脉动。发电机的齿槽转矩越小，意味着风力发电机组具有越低的切入风速，扩大了机组的转速运行范围，提高了风能利用率和机组发电量。发电机的转矩脉动越小，风力发电机组的运行稳定性越高，轴承等旋转部件的使用寿命越长。
为了减小发电机的齿槽转矩和转矩脉动，目前在电机设计中通常的解决方案为电机采用定子斜槽方式或者转子斜极方式。若采用电机定子斜槽方式，不但会使线圈因斜槽角度等问题而难于制造，还会使线圈长度增加，绕组电阻增大，导致电机的铜损耗增大，发热增大。对于电机转子斜极方式，参照图1，若采用将转子磁轭上的每个磁极沿轴向倾斜的方式，需要将转子磁轭2上的每个磁极1沿电机轴向倾斜，意味着磁极1或转子磁轭2须做成异形(即，除了诸如长方体等常规磁极形状之外的其他形状)，这不但增加了磁极1或转子磁轭2的制造难度，也增加了在生产和装配磁极1时所需模具和工装的加工制造难度，极大降低了磁极1或转子磁轭2的成品率，导致产品成本增加。此外，参照图2，电机转子斜极方式也可以是将电机轴向上的多段常规的磁极11沿轴向错开一定的角度(即，分段斜极)，但是，这对磁极11装配时的尺寸控制精度提出了严格要求，降低了磁极11的成品率和装配效率，进而降低了生产效率。
此外，尤为重要的是，风力发电机组的运行工况复杂多变，发电机的设计寿命通常要求20年甚至25年，这就要求转子磁极的固定和防护工艺提供更高的耐机械疲劳性能和耐腐蚀性能。转子磁极的固定方式主要有表贴式和插入式两种。表贴式磁极固定工艺是将磁极通过树脂粘接固定在转子磁轭表 面。表贴式磁极固定工艺由于磁极完全通过树脂粘接力固定于转子磁轭表面，一旦工艺执行过程中出现密封薄弱点，在风力发电机组长时间高温度、高湿度运行条件下，磁极极易由于密封不足出现锈蚀粉化，进而造成树脂对磁极的粘贴失效，最终发生锈蚀的磁极在磁极之间相互排斥力的作用下脱离转子并发生跳出现象，导致定子与转子磨损乃至发电机故障下塔事故。插入式磁极固定工艺，将磁极插入到位于转子铁心的槽中，再通过端板固定磁极轴向两端，实现对磁极的固定。虽然插入式磁极固定工艺通过插槽固定式结构实现了对磁极的可靠固定，但仍然存在着磁极密封不足的隐患，在风力发电机组长时间高温度、高湿度运行条件下，磁极极易出现锈蚀粉化，从而削弱了转子磁极的励磁磁通和发电机的气隙磁感应强度，进而降低了风力发电机组的发电量。
发明内容
为解决现有技术中存在的上述问题，根据本公开的一个方面，提供一种兼顾发电机性能(齿槽转矩、转矩脉动)、磁极防护和磁极机械固定的具有磁极偏移结构特征的电机转子。
根据本公开的另一方面，提供一种能够实现对磁极或磁极单元的良好密封和防护，且易于机械固定的磁极模块。
根据本公开的另一个方面，提供一种制造上述电机转子的方法。
根据本公开的一个方面，一种电机转子括转子磁轭和设置在转子磁轭上的多个磁极模块，每个磁极模块包括基板、罩壳和容纳在由基板和罩壳形成的容纳空间中的极性相反的一对磁极单元，其中，每个磁极模块内的一对磁极单元沿着转子磁轭的圆周方向彼此间隔开第一距离。
可选地，周向相邻的不同磁极模块中的相邻的磁极单元可沿着转子磁轭的圆周方向彼此间隔开第二距离，其中，第一距离可与第二距离不同。
可选地，周向相邻的不同磁极模块可沿着转子磁轭的圆周方向彼此间隔开预定距离。
可选地，基板上可设置有突起部，突起部可沿着轴向设置在基板的正表面上，一对磁极单元中的每个磁极单元可分别紧贴着突起部设置在突起部的两侧，每个磁极单元可包括在轴向上对齐的多个磁极，每个磁极单元中的多个磁极可具有相同的极性。
可选地，每个磁极单元的正表面可通过粘结剂被粘接在罩壳的内表面上。
可选地，罩壳、基板和一对磁极单元之间的各个间隙可被树脂填充。
可选地，基板上可设置有多个基板通孔，罩壳上可设置有与多个基板通孔对应的多个罩壳通孔，转子磁轭上可设置有螺纹孔，多个基板通孔、多个罩壳通孔、螺纹孔可彼此对齐，并可通过使紧固件穿过所述多个基板通孔、所述多个罩壳通孔和所述螺纹孔而将磁极模块机械固定在转子磁轭上。
可选地，多个磁极模块可沿着转子磁轭的圆周方向成排地设置在转子磁轭上，成排的磁极模块中的每个磁极模块可在转子磁轭的圆周方向上彼此对齐，并且，多个磁极模块可沿着平行于电机转子的中心旋转轴线的轴向方向成列地设置在转子磁轭上，成列的磁极模块中的每个磁极模块可在平行于电机转子的中心旋转轴线的轴向方向上彼此对齐。
可选地，不同磁极模块中的周向相邻的磁极单元的极性可相反，不同磁极模块中的轴向相邻的磁极单元的极性可相同。
根据本公开的另一方面，一种磁极模块包括：基板；第一磁极单元和第二磁极单元，设置在基板的正表面上，第一磁极单元和第二磁极单元的极性相反并彼此间隔开第一距离；罩壳，扣装在第一磁极单元、第二磁极单元和基板上。
可选地，磁极模块还可包括突起部，突起部可设置在基板的正表面上，并位于第一磁极单元和第二磁极单元之间。
可选地，第一磁极单元和第二磁极单元可与罩壳的内表面之间通过粘结剂粘接在一起。
可选地，基板可包括设置在基板的两侧上的多个基板通孔，罩壳可包括设置在罩壳的两侧上的多个罩壳通孔，其中，多个基板通孔可与多个罩壳通孔对齐。
可选地，罩壳、基板、第一磁极单元和第二磁极单元之间的各个间隙可被树脂填充。
可选地，第一磁极单元和第二磁极单元可在宽度方向上彼此间隔开，每个磁极单元可包括在长度方向上对齐的多个磁极，每个磁极单元中的多个磁极具有相同的极性。
根据本公开的另一方面，提供一种制造电机转子的方法，所述方法包括：将极性相反的一对磁极单元并列设置在基板上，并使一对磁极单元间隔开第 一距离；将罩壳扣装在一对磁极单元和基板上并在罩壳与基板之间形成密封空间；对由罩壳和基板形成的密封空间灌注树脂，从而形成磁极模块；将多个磁极模块设置在转子磁轭上，以使周向相邻的不同磁极模块中的相邻的磁极单元沿着转子磁轭的圆周方向彼此间隔开第二距离，第一距离与第二距离不同。
可选地，所述方法还可包括：在将一对磁极单元设置在基板上之前，可在基板的中部设置突起部，并可将一对磁极单元设置在突起部的两侧。
可选地，在扣装罩壳之前，可在一对磁极单元的每个磁极单元的正表面上涂覆粘结剂，用于使正表面粘接到罩壳上；在将罩壳扣装在一对磁极单元之后，可压紧罩壳和一对磁极单元的正表面，以使罩壳和一对磁极单元的正表面之间的粘结剂完全铺开；可对罩壳与基板之间的外部接缝进行密封，以使罩壳和基板形成密封空间。
可选地，罩壳还可包括分别设置在罩壳的两个端表面上的抽真空嘴和注胶嘴，所述方法还可包括如下步骤：通过抽真空嘴和注胶嘴对由罩壳与基板形成的密封空间的内部灌注树脂，以使罩壳、基板和一对磁极单元之间的各个间隙被树脂填充，在灌注树脂完成后，去除抽真空嘴和注胶嘴，并对去除注胶嘴和抽真空嘴后的位置涂覆密封剂以进行密封。
可选地，在基板上可开设多个基板通孔、在罩壳上可开设多个罩壳通孔并可在转子磁轭上开设多个螺纹孔，所述方法还可包括如下步骤：通过使多个紧固件分别穿过多个基板通孔、多个罩壳通孔和多个螺纹孔而将多个磁极模块机械地固定到转子磁轭上，并使不同磁极模块中的周向相邻的磁极单元的极性相反，不同磁极模块中的轴向相邻的磁极单元的极性相同。
通过采用本公开的电机转子，可降低发电机的齿槽转矩和转矩脉动，同时确保磁极或磁极单元可靠地固定在转子磁轭上，并实现对磁极或磁极单元的可靠密封，从而兼顾了发电机性能(齿槽转矩、转矩脉动)、磁极防护和磁极机械固定。
通过采用本公开的磁极模块，可以有效地将磁极或磁极单元可靠地密封，并利于对磁极或磁极单元的机械固定。
通过采用本公开的制造电机转子的方法，可减少磁极模块制造工时并实现磁极的可靠密封防护和固定，同时提供能够降低发电机的齿槽转矩和转矩脉动的磁极排布方式。
附图说明
图1是示出现有技术中的采用转子斜极方式的电机转子的一部分的示意图；
图2是示出现有技术中的采用转子分段斜极方式的电机转子的一部分的示意图；
图3是示出根据本公开的第一实施例的磁极模板的基板的结构示意图；
图4是示出根据本公开的第一实施例的磁极模块的基板和磁极单元的结构示意图；
图5是示出根据本公开的第一实施例的磁极模块的罩壳的结构示意图；
图6是示出根据本公开的第一实施例的磁极模块的基板、磁极单元和罩壳的结构示意图；
图7是示出根据本公开的第一实施例的磁极模块(包括注胶嘴和抽真空嘴)的结构示意图；
图8是示出根据本公开的第一实施例的磁极模块(去除注胶嘴和抽真空嘴)的结构示意图；
图9是示出根据本公开的第一实施例的电机转子的一部分的结构示意图；
图10是示出根据本公开的第二实施例的磁极模块的基板、磁极单元和罩壳的结构示意图；
图11是示出根据本公开的第二实施例的压条的结构示意图；
图12是示出根据本公开的第二实施例的电机转子的一部分的结构示意图；
图13是示出根据本公开的第二实施例的电机转子的一部分的结构示意图。
附图标号说明：
1-磁极；2-转子磁轭；11-磁极；100-磁极模块；110-基板；111a-正表面；111b-背表面；112a-第一侧表面；112b-第二侧表面；113a-第一端表面；113b-第二端表面；114-突起部；115-基板通孔；120-第一磁极单元；121a-正表面；121b-背表面；122a-第一侧表面；122b-第二侧表面；123a-第一端表面；123b-第二端表面；130-第二磁极单元；131a-正表面；131b-背表面；132a-第一侧表面；132b-第二侧表面；133a-第一端表面；133b-第二端表面；140-罩壳； 141a-第一部分；141b-第二部分；141c-第三部分；145-罩壳通孔；148-抽真空嘴；149-注胶嘴；150-转子磁轭；160-垫片；170-紧固件；1000-电机转子；200-磁极模块；210-基板；220-第一磁极单元；230-第二磁极单元；240-罩壳；248-抽真空嘴；249-注胶嘴；250-转子磁轭；251-螺纹孔；260-垫片；270-紧固件；280-压条；281-突出部分；282-第一边缘部分；283-第二边缘部分；284-通孔；2000-电机转子。
具体实施方式
为了使本领域技术人员能够更好地理解本公开的技术构思，下面将结合附图对本公开的具体实施例进行详细描述，在附图中，相同的标号始终表示相同的部件。
在本文中提及的“轴向”是指平行于电机转子的中心旋转轴线的轴向方向，“周向”是指沿着转子旋转方向的圆周方向，“径向”是指电机的半径方向。
图3至图9示出了根据本公开的第一实施例的磁极模块100以及包括该磁极模块100的电机转子1000。参照图3至图8，磁极模块100可主要包括基板110、一对磁极单元(第一磁极单元120和第二磁极单元130)和罩壳140。一对磁极单元设置在基板110上，并相互间隔预定距离，罩壳140覆盖在一对磁极单元上，密封一对磁极单元。
多个磁极模块100将固定在转子磁轭150的表面上，从而形成电机转子1000。在下面的描述中，为了便于描述，将用“轴向”、“周向”、“径向”等指示方向的术语来描述磁极模块100的结构。
如图3和图4所示，基板110可以是具有一定厚度的矩形或方形的板。基板110在厚度方向上可具有正表面111a和背表面111b。第一磁极单元120和第二磁极单元130可设置在基板110的正表面111a上。基板110还可具有宽度方向上的第一侧表面112a和第二侧表面112b以及长度方向上的第一端表面113a和第二端表面113b。基板110可以由导磁材料制成。
突起部114可沿着长度方向设置在基板110的正表面111a上，用于将第一磁极单元120和第二磁极单元130分隔开。优选地，突起部114可固定在基板110的对称中心线上。如图3所示，突起部114可以是设置在基板110上的细长形的凸台。突起部114可通过粘结剂(例如，结构胶)粘贴在基板 110的正表面111a上，突起部114也可以与基板110一体地形成。如图3中所示，突起部114的长度与基板110的长度相等，也就是突起部114的两端与基板110的端表面彼此对齐，但本公开的实施例并不限于此。突起部114的长度也可以与基板110的长度不同，突起部114可以具有任何适合的形状，突起部114还可以由多个不连续的部分(诸如，柱状体)组成，只要突起部114能够设置在两列磁极单元120、130之间，以隔开两列磁极单元120、130即可。
在宽度方向上，第一磁极单元120和第二磁极单元130可分别紧贴着突起部114设置在突起部114的两侧。第一磁极单元120和第二磁极单元130通过突起部114分隔开，从而使两列磁极单元在物理上隔离开，进而防止由于电机长时间工作而使第一磁极单元120和第二磁极单元130相对于彼此移动(例如，因为磁场作用)。
第一磁极单元120和第二磁极单元130可在宽度方向上彼此间隔开，第一磁极单元120和第二磁极单元130中的每个磁极单元可分别包括一个磁极，并且，第一磁极单元120和第二磁极单元130中的每个磁极单元也可分别包括在长度方向上对齐的多个磁极。每个磁极单元中的多个磁极可具有相同的极性。如图4所示，每个磁极单元分别包括3个磁极。第一磁极单元120和第二磁极单元130的极性相反，从而组成一对磁极单元，例如，第一磁极单元120可以是N极(即，第一磁极单元120中的每个磁极的极性均为N)，第二磁极单元130可以是S极(即，第二磁极单元130中的每个磁极的极性均为S)。
如图4所示，第一磁极单元120可具有厚度方向上的正表面121a和背表面121b、宽度方向上的第一侧表面122a和第二侧表面122b、长度方向上的第一端表面123a和第二端表面123b。第二磁极单元130可具有厚度方向上的正表面131a和背表面131b、宽度方向上的第一侧表面132a和第二侧表面132b、长度方向上的第一端表面133a和第二端表面133b。
第一磁极单元120的背表面121b和第二磁极单元130的背表面131b可通过粘结剂(例如，结构胶)粘接在基板110的正表面111a上。突起部114的宽度可用d 1表示，因此，两列磁极单元之间可保持距离d 1，下面称为第一距离d 1。换言之，第一磁极单元120的与突起部114接触的第二侧表面122b和第二磁极单元130的与突起部114接触的第一侧表面132a之间可间隔开第 一距离d 1。
此外，在长度方向上，第一磁极单元120以及第二磁极单元130的两端可以与基板110对齐，即，第一磁极单元120的第一端表面123a和第二磁极单元130的第一端表面133a可以与基板110的第一端表面113a对齐，第一磁极单元120的第二端表面123b和第二磁极单元130的第二端表面133b可以与基板110的第二端表面113b对齐。然而，该设置仅为示例，也可以考虑使磁极单元的两端与基板的两端略微不对齐或彼此错开的情况。
基板110还可具有设置在基板110的两侧的多个基板通孔115。多个基板通孔115可设置在基板110上未放置磁极单元的位置处，例如，多个基板通孔115可分别靠近基板110的第一侧表面112a和第二侧表面112b设置。如图4所示，每个基板110上可设置有四个基板通孔115，在基板110的两侧可分别设置两个基板通孔115。
如图5所示，罩壳140可扣装在基板110、第一磁极单元120和第二磁极单元130上，以将第一磁极单元120和第二磁极单元130密封包围在基板110上。
具体地，罩壳140可覆盖在基板110上，并在罩壳140与基板110之间形成容纳空间，第一磁极单元120和第二磁极单元130可位于并密封在该容纳空间中。
为了将第一磁极单元120和第二磁极单元130密封并固定在基板110上，以及保持结构的紧凑性，罩壳140可具有与磁极单元120和130安装在基板110之后的结构的外表面随形的形状，以紧密接触第一磁极单元120、第二磁极单元130以及基板110的外表面。
例如，罩壳140可以具有“凸”字形的形状。沿着宽度方向，罩壳140可包括覆盖第一磁极单元120和第二磁极单元130的外表面的第一部分141a、以及位于第一部分141a两侧并覆盖基板110的第二部分141b和第三部分141c。第一部分141a可接触设置在基板110上的第一磁极单元120的正表面121a和第二磁极单元130的正表面131a。第二部分141b和第三部分141c可以覆盖基板110的位于磁极单元120和130两侧的部分。
罩壳140的一侧可以是敞开的，以为基板110、第一磁极单元120和第二磁极单元130提供入口。因此，在罩壳140覆盖第一磁极单元120和第二磁极单元130以及基板110之后，第一磁极单元120、第二磁极单元130整 体密封在罩壳140中，并且基板110的侧表面、端表面也被覆盖，仅露出基板110的背表面111b。
当罩壳140扣装在基板110、第一磁极单元120和第二磁极单元130上时，罩壳140的内表面可以通过粘结剂与第一磁极单元120、第二磁极单元130以及基板110紧密接触和粘接固定。
可以通过下述方法来确保第一磁极单元120和第二磁极单元130与罩壳140的紧密接触和牢固结合：在扣装罩壳140之前，可以先在第一磁极单元120的正表面121a和第二磁极单元130的正表面131a上涂覆粘结剂(例如，通过点涂或通过打胶线涂覆粘结剂层)。之后，将罩壳140扣装在第一磁极单元120和第二磁极单元130上，并压紧罩壳140与第一磁极单元120和第二磁极单元130，确保罩壳140的内表面与第一磁极单元120和第二磁极单元130的正表面之间的粘结剂完全铺开，从而充分填充罩壳140与第一磁极单元120和第二磁极单元130之间的间隙，避免在它们之间出现气穴。之后，加热固化粘结剂。
为了尽量降低对转子和定子之间的气隙的影响，罩壳140与第一磁极单元120和第二磁极单元130的正表面应紧密贴附，通过打胶(例如，涂覆粘结剂)并紧贴罩壳140铺开胶层(例如，粘结剂层)的方式既保证该处100％填胶，不会因间隙小在真空灌注树脂时出现空腔(下文将更详细地描述)，也不影响气隙。
在扣装罩壳140之后，可以利用密封剂对罩壳140和基板110的外部接缝进行密封，从而在罩壳140和基板110之间形成容纳第一磁极单元120和第二磁极单元130的密封空间。
罩壳140还可包括设置在罩壳140的两个端表面上的注胶嘴149和抽真空嘴148。注胶嘴149和抽真空嘴148可被设置用于对由罩壳140与基板110形成的密封空间进行真空灌注树脂，从而填充罩壳140与基板110以及罩壳140与第一磁极单元120和第二磁极单元130之间的所有间隙。
罩壳140与磁极单元的侧表面以及端表面之间、罩壳140与基板110的外表面之间的间隙可设计较大值(因为不会影响气隙)，由此保证真空灌注时树脂对该处各间隙100％填胶。
在对磁极模块100完成真空灌注树脂之后，可去除注胶嘴149和抽真空嘴148。在去除注胶嘴149和抽真空嘴148之后，对去除注胶嘴149和抽真 空嘴148后的位置涂覆密封剂以进行密封，例如，可使用密封胶封堵裸露的注胶口和抽真空口。如图8所示，在磁极模块100被制造完成之后，切除注胶嘴149和抽真空嘴148并打磨平整，从而罩壳140的端表面是平整的。
罩壳140还可包括设置在磁极单元的两侧上的多个罩壳通孔145。罩壳140上的罩壳通孔145的位置与设置在基板110上的基板通孔115的位置相对应。当罩壳140扣装在基板110、第一磁极单元120和第二磁极单元130上时，罩壳140上的多个罩壳通孔145与基板110上的多个基板通孔115一一对齐。
基板通孔115和罩壳通孔145可在分别制造基板110和罩壳140时形成，当将罩壳140扣装在基板110和磁极单元120、130上之后，在对由罩壳140和基板110形成的密封空间进行真空灌注树脂时，为避免基板通孔115和罩壳通孔145影响形成密封空间以及为了防止基板通孔115和罩壳通孔145被所灌注树脂堵塞，可以将磁极模块(未完成)安装在特定的工装上，以将基板通孔115和罩壳通孔145设置到工装的特定部件上，暂时堵塞基板通孔115和罩壳通孔145，从而使基板110和罩壳140形成密封空间，进而执行后续的抽真空和灌注树脂操作。此外，可选地，在将罩壳140扣装在基板110和磁极单元120、130上之后，可使用密封剂对罩壳通孔145和基板通孔115之间的接缝进行密封，从而使基板110和罩壳140形成密封空间。
此外，虽然以上参照附图描述了基板通孔115和罩壳通孔145可在分别制造基板110和罩壳140时形成，但并不限于此。也可以首先形成无通孔的基板110和罩壳140，并在完成树脂灌注之后，再在磁极模块100上开设通孔。
罩壳140可以由非导磁材料制成。通过将磁极单元(磁极)粘接在由导磁材料制成的基板110上，再涂覆粘结剂并覆盖非导磁材料的罩壳140，对罩壳140的边缘与基板110的边缘的外部接缝、罩壳通孔145与基板通孔115之间的接缝涂覆密封胶进行密封，并对由罩壳140和基板110形成的容纳磁极单元的密封空间进行真空灌注树脂，可以有效地实现对磁极的密封防护。
通过将上述磁极模块100安装在转子磁轭150的内表面上，可形成电机转子1000。图9示出了根据本公开的实施例的电机转子1000的一部分的结构示意图。如图9中所示，电机转子1000可包括转子磁轭150和设置在转子磁轭150上的多个磁极模块100，磁极模块100的基板110的背表面111b可 接触转子磁轭150的径向内表面。
转子磁轭150上可设置有多个螺纹孔(图中不可见)。转子磁轭150上的多个螺纹孔可以与磁极模块100的基板110上的多个基板通孔115和罩壳140上的多个罩壳通孔145对应并在磁极模块100安装在转子磁轭150上时彼此一一对齐，以使紧固件170(可加设垫片160)穿过各个基板通孔115、罩壳通孔145和转子磁轭150上的螺纹孔，从而使磁极模块100机械地固定到转子磁轭150。
如图9中所示，多个磁极模块100可沿着平行于电机转子1000的中心旋转轴线的轴向方向(即，轴向)成列地设置在转子磁轭150上，成列的磁极模块100中的每个磁极模块100在平行于电机转子1000的中心旋转轴线的轴向方向(即，轴向)上彼此对齐，并且每个磁极模块100中的第一磁极单元120和第二磁极单元130分别在轴向上彼此对齐。不同磁极模块中的轴向相邻的磁极单元的极性相同，即，相同极性的磁极单元沿着轴向对齐。如图9中所示，成列的磁极模块100整体上竖直地沿着轴向布置，磁极模块100彼此不偏移或不倾斜。
此外，多个磁极模块100可沿着转子磁轭150的圆周方向(即，周向)成排地设置在转子磁轭150上，成排的磁极模块100中的每个磁极模块100在转子磁轭150的圆周方向(即，周向)上彼此对齐，并且每个磁极模块100中的第一磁极单元120与相邻的磁极模块100中的第二磁极单元130相邻。相同磁极模块中或不同磁极模块中的周向相邻的磁极单元的极性相反，即，在圆周方向极性不同的磁极单元交替设置。例如，一个磁极模块100中的第一磁极单元120和第二磁极单元130的极性可相反，如上所述，当一个磁极模块100中的第一磁极单元120的极性为N，第二磁极单元130的极性为S时，则成排的磁极模块100中的所述一个磁极模块100中的第二磁极单元130(极性为S)与相邻的另一个磁极模块100的第一磁极单元120(极性为N)相邻，也就是说，在转子磁轭150的圆周方向上形成N-S-N-S极性交替形式的磁极单元布置。
当将磁极模块100设置在转子磁轭150上时，每个磁极模块100内的一对磁极单元120、130沿着转子磁轭150的圆周方向彼此间隔开第一距离d 1。此外，多个磁极模块100还被设置为使得周向相邻的不同磁极模块100中的相邻的磁极单元沿着转子磁轭150的圆周方向彼此间隔开第二距离d 2，如图 9所示。
返回参照图4，第一磁极单元120的第一侧表面122a可以与基板110的第一侧表面112a间隔开第三距离d 3。第二磁极单元130的第二侧面132b可以与基板110的第二侧表面112b间隔开第四距离d 4。此外，如图9所示，在装配磁极模块100时，可以使两个相邻的磁极模块100之间间隔开第五距离d 5。在这种情况下，第二距离d 2可大致等于第三距离d 3、第四距离d 4和第五距离d 5之和(考虑罩壳140与基板110以及磁极单元120、130之间的各个间隙)。
因此，一个磁极模块100中的两列磁极单元(第一磁极单元120和第二磁极单元130)之间分隔开的距离为第一距离d 1，而两个相邻的磁极模块100中的相邻的两列磁极单元之间分隔开的距离为第二距离d 2，并且d 1不等于d 2。在该实施例中，d 1<d 2。
因此，在根据本公开的实施例的电机转子的磁极分布中，转子磁轭上的所有磁极单元不是等距分布的，而是每对磁极单元(即，在一个磁极模块中的一对磁极单元)之间的间距相等，而每个磁极单元与相邻磁极单元的距离是不相等的。采用这种磁极偏移结构型式，能够降低永磁直驱发电机的齿槽转矩和转矩脉动。
在将多个磁极模块100全部装配完成后，可以对所有磁极模块100整体进行一次树脂真空灌注，以实现对磁极模块100与转子磁轭150之间的间隙、紧固件170、垫片160以及基板通孔115、罩壳通孔145、转子磁轭150上的螺纹孔中的各个间隙进行有效填胶和密封。
电机转子还可包括其它部件(例如，转子支架等结构件)，在本实施例中，出于说明性目的，仅示出并描述了转子磁轭150和转子磁轭150上布置和固定的磁极模块100。
对于根据本公开的实施例的磁极偏移结构型式，每个磁极模块100均分别制造，并且每个磁极模块100包括成对的磁极单元(极性相反的第一磁极单元120和第二磁极单元130)，这相比于传统的“每个磁极模块包括一个基板、一列磁极、一个罩壳”而言，工时大幅减小。
此外，通过采用这样的磁极模块100以及磁极偏移结构型式，可以有效地实现磁极偏移从而降低齿槽转矩和转矩脉动，并且通过粘结剂结合和真空灌封树脂的方式，每个磁极模块100中的磁极单元120、130与基板110之间、 磁极单元120、130与罩壳140之间、基板110与罩壳140之间均充分地被粘接，从而实现对磁极模块100中各个间隙的100％填胶，实现对磁极的可靠密封。
此外，通过在基板110、罩壳140以及转子磁轭150上开孔并利用紧固件170(可加设垫片160)，实现对磁极模块100与磁极单元120、130的可靠的机械固定。
综上，通过采用上述的磁极模块100以及电机转子1000，不仅可以实现磁极偏移结构型式，能够有效地降低永磁直驱发电机的齿槽转矩和转矩脉动，还可以对磁极(磁极单元)进行有效地密封并将其牢固地机械固定在转子磁轭150上，从而实现磁极的有效密封和磁极模块100的安全可靠固定，从而保证了磁极在发电机全生命周期内高温度和高湿度工况下的使用可靠性。因此，本公开提供的磁极模块100和包括该磁极模块100的具有磁极偏移结构特征的电机转子1000兼顾了发电机性能(齿槽转矩、转矩脉动)、磁极防护和磁极机械固定。
以下将结合图3至图9描述制造根据本公开的第一实施例的磁极模块100和电机转子1000的方法。
首先，如图3所示，制造开设有多个基板通孔115的基板110。然后，在基板110的中部(优选地，在对称中心线处)设置突起部114，可通过粘结剂将突起部114粘贴在基板110的正表面111a上。在此，也可以使开设有多个基板通孔115的基板110与突起部114一体地形成。
然后，如图4所示，将一对极性相反的磁极单元(第一磁极单元120(N极)和第二磁极单元130(S极))并列设置在基板110上，并使这对磁极单元间隔开第一距离d 1。可使第一磁极单元120和第二磁极单元130紧贴着突起部114设置在突起部114的两侧，并可通过粘结剂将第一磁极单元120的背表面121b和第二磁极单元130的背表面131b粘贴在基板110的正表面111a上。第一磁极单元120和第二磁极单元130可通过突起部114隔离开，且对称地分布在突起部114的两侧。
然后，如图5至图6所示，可将罩壳140扣装在基板110、第一磁极单元120和第二磁极单元130上，并在罩壳140和基板110之间形成密封空间。
具体地，在扣装罩壳140之前，可在第一磁极单元120的正表面121a和第二磁极单元130的正表面131a上涂覆粘结剂(例如，点涂或通过打胶线 涂覆粘结剂)，用于使正表面121a和正表面131a粘接到罩壳140上。
将罩壳140扣装在基板110、第一磁极单元120和第二磁极单元130上，使得罩壳140的第一部分141a覆盖第一磁极单元120和第二磁极单元130，并使罩壳140的第二部分141b和第三部分141c覆盖基板110的位于磁极单元120和130两侧的部分。
在将罩壳140扣装在基板110、第一磁极单元120和第二磁极单元130上之后，可压紧罩壳140与第一磁极单元120、第二磁极单元130，以使罩壳140的第一部分141a与第一磁极单元120的正表面121a、第二磁极单元130的正表面131a之间的粘结剂完全且均匀地铺开，从而填充罩壳140与第一磁极单元120、第二磁极单元130之间的间隙，并加热固化粘结剂。
在将罩壳140覆盖在第一磁极单元120和第二磁极单元130以及基板110上之后，第一磁极单元120、第二磁极单元130整体被密封在罩壳140中，并且基板110的侧表面、端表面也被覆盖，仅露出基板110的背表面。
之后，可利用密封剂对罩壳140和基板110之间的外部接缝进行密封，然后固化密封剂，由此罩壳140和基板110形成了用于容纳磁极单元120、130的密封空间。
罩壳140还可包括分别设置在罩壳140的两个端表面上的抽真空嘴148和注胶嘴149。
如图7所示，将图6所示的磁极模块100立式放置，将抽真空嘴148连接到抽真空管路，以将磁极模块100的内部抽真空。从罩壳140轴向底部的注胶嘴149连接到注胶管路，并向由罩壳140与基板110形成的密封空间的内部真空灌注树脂，以使树脂完全填充在罩壳140与基板110之间、罩壳140与磁极单元120、130之间的各个间隙，真空灌注树脂完成后，加热固化树脂。
在本实施例中，采用了真空灌注树脂的方式对由罩壳140与基板110形成的密封空间进行密封和填充，在罩壳140较薄时，该方式可以保证罩壳140与磁极单元120、130伏贴。然而，也可采用其它注胶方式，例如，如果罩壳140较厚，刚度较大，则可使用正压注胶方式。
如图8所示，在完成真空灌注树脂之后，可以将罩壳140上的抽真空嘴148和注胶嘴149去除或切除，然后将罩壳140的两个端表面打磨平整，去除毛刺，并对去除注胶嘴149和抽真空嘴148后的位置涂覆密封剂以进行密封，例如，使用密封剂封堵裸露的注胶口和抽真空口。加热固化密封剂，完 成对磁极模块100的密封，由此完成单个磁极模块100的制造。
如图9所示，将多个磁极模块100装配到开设有螺纹孔(图中不可见)的转子磁轭150上。通过工装或机械臂将磁极模块100定位，以将磁极模块100的基板通孔115、罩壳通孔145与转子磁轭150上的螺纹孔一一对应。通过使多个紧固件170(可加设垫片160)分别穿过多个基板通孔115、多个罩壳通孔145和转子磁轭150上的多个螺纹孔而将多个磁极模块100机械地固定到转子磁轭150上，实现对磁极模块100的机械固定。机械固定后，可以使用密封剂对裸露的紧固件170、垫片160、基板通孔115、罩壳通孔145以及转子磁轭150上的螺纹孔进行刮涂覆盖并加热固化，实现对该处的密封。也可以在磁极模块100全部装配完成后，对所有磁极模块100整体进行一次树脂真空灌注，实现对磁极模块100与转子磁轭150之间、紧固件170、垫片160以及基板通孔115、罩壳通孔145、转子磁轭150上的螺纹孔中的各个间隙进行有效填胶和密封。
如图9所示，在装配磁极模块100时，可使周向相邻的不同磁极模块100中的相邻的磁极单元沿着转子磁轭150的圆周方向彼此间隔开第二距离d 2。
此外，如图9所示，可使周向相邻的磁极模块100沿着转子磁轭150的圆周方向彼此间隔开一定距离(例如，如上文所述的第五距离d 5)。同时，装配时需确保不同磁极模块中的周向相邻的磁极单元的极性相反，不同磁极模块中的轴向相邻的磁极单元的极性相同。
以下将结合图10至图13说明书根据本公开的第二实施例的可替代的磁极模块200和电机转子2000以及制造磁极模块200和电机转子2000的方法。根据第二实施例的磁极模块200与根据第一实施例的磁极模块100的不同之处在于，磁极模块200的基板210和罩壳240上没有设置通孔，除此之外，其它部分结构特征可相同。电机转子2000与根据第一实施例的电机转子1000的不同之处在于，电机转子2000还包括压条280，并且磁极模块200通过压条280被机械固定到转子磁轭250上。因此，在下面的描述中，将对这些不同之处进行详细描述，而与第一实施例相同或类似的部分将简要描述或省略，本领域技术人员应理解，第一实施例和第二实施例可以结合使用。
如图10所示，磁极模块200可主要包括基板210、一对磁极单元(第一磁极单元220和第二磁极单元230)和罩壳240。一对磁极单元220、230设置在基板210上，并相互间隔预定距离(如上所述的第一距离d 1)，罩壳240 覆盖在一对磁极单元220、230上，密封一对磁极单元220、230。罩壳240的两个端表面上分别设置有注胶嘴249和抽真空嘴248(在真空灌注树脂之后被去除)。
磁极模块200没有开设通孔。如图13所示，多个磁极模块200可通过压条280和紧固件270被机械地固定到转子磁轭250上。
如图11所示，压条280可包括突出部分281和位于突出部分281两侧的第一边缘部分282和第二边缘部分283。突出部分281的厚度可以比第一边缘部分282和第二边缘部分283的厚度大，以此来匹配磁极模块200的形状。压条280还可包括沿着长度方向设置的多个通孔284。优选地，多个通孔284可沿着压条280的轴向中心线设置。
此外，如图12所示，转子磁轭250上可设置有多个螺纹孔251，螺纹孔251沿着转子磁轭250的圆周方向彼此间隔开的距离可大于磁极模块200的宽度。磁极模块200可布置在轴向列的螺纹孔251的两侧。此外，转子磁轭250上的各个螺纹孔251沿轴向的间距与图11中所示的压条280上的通孔284之间的间距相等。
如图12和图13所示，可通过工装或机械壁将多个磁极模块200定位在转子磁轭250上，可以使周向相邻的两个磁极模块200之间间隔开预定距离(如上文所述的第五距离d 5)，该预定距离可等于或略大于压条280的突出部分281的宽度。
在利用工装或机械臂将磁极模块200定位之后，如图13所示，可以将压条280设置在两列磁极模块200之间，使压条280的突出部分281设置在周向相邻的两列磁极模块200之间的间隙中，并使压条280的第一边缘部分282和第二边缘部分283分别压在相邻的磁极模块200上，同时使压条280上的多个通孔284与转子磁轭250上的多个螺纹孔251一一对齐，将紧固件270(可加设垫片260)穿过通孔284和螺纹孔251，以将磁极模块200机械地固定到转子磁轭250上。
如图13所示，图中所示的压条280的长度可对应于两个磁极模块200的长度。然而，本公开并不限于此，压条280可具有能够同时保持多个磁极模块200的长度，其可以通过实际应用进行调整。此外，压条280上的通孔284的数量也可以根据实际应用来调整，只要与转子磁轭250上设置的螺纹孔251对应即可。
通过设置压条280，可以高效地将密封好的磁极模块200机械地固定在转子磁轭250上。
与根据第一实施例的电机转子1000中的磁极模块100的排布类似，一个磁极模块200中的两列磁极单元(第一磁极单元220和第二磁极单元230)之间分隔开的距离为第一距离d 1，而两个相邻的磁极模块200中的相邻的两列磁极单元之间分隔开的距离为第二距离d 2，并且d 1不等于d 2。在该实施例中，d 1<d 2。
下面将参照图10至图13描述制造根据本公开的第二实施例的磁极模块200和电机转子2000的方法。
磁极模块200与根据第一实施例的磁极模块100的制造方法类似，除了基板210和罩壳240上不开设通孔之外。因此，在此将不再详细描述磁极模块200的制造方法(例如，基板210、磁极单元220和230以及罩壳240的结构特征、组装或空间关系)。第一实施例和第二实施例可以相互结合，从而产生未详细描述的实施例。
下面，将详细描述制造根据本公开的第二实施例的电机转子2000的方法。
在利用与上述制造磁极模块100类似的方法制得磁极模块200之后，通过工装或机械臂将多个磁极模块200定位在转子磁轭250上，转子磁轭250上开设有多个螺纹孔251。可以将磁极模块200布置在轴向列的螺纹孔251的两侧，如图12所示。
之后，可以将压条280设置在两列磁极模块200之间，使压条280的突出部分281设置在周向相邻的两列磁极模块200之间的间隙中，并使压条280的第一边缘部分282和第二边缘部分283分别压在相邻的磁极模块200上，同时使压条280上的多个通孔284与转子磁轭250上的多个螺纹孔251一一对齐，将紧固件270(可加设垫片260)穿过通孔284和螺纹孔251，以将磁极模块200机械地固定到转子磁轭250上。
在磁极模块200装配完成之后，一个磁极模块200中的两列磁极单元(第一磁极单元220和第二磁极单元230)之间分隔开的距离为第一距离d 1，而两个相邻的磁极模块200中的相邻的两列磁极单元之间分隔开的距离为第二距离d 2，并且d 1不等于d 2。在该实施例中，d 1<d 2。
在将多个磁极模块200全部装配完成后，可以对所有磁极模块200整体进行一次树脂真空灌注，以实现对磁极模块200与转子磁轭250之间的间隙、 紧固件270、垫片260以及压条280上的通孔284、转子磁轭250上的螺纹孔251中的各个间隙进行有效填胶和密封。
根据第二实施例的电机转子2000通过利用“压条+紧固件固定”的方式，可以更高效地将可靠密封的磁极模块200机械地固定到转子磁轭250上，以上描述了通过在磁极模块100上开设通孔或利用压条280将磁极模块100或200机械地固定到转子磁轭上，但本公开不限于此，在不脱离本公开的技术构思和范围的情况下，可以考虑其它机械固定方式，使得根据本公开的电机转子能够兼顾发电机性能(齿槽转矩、转矩脉动)、磁极防护和磁极机械固定。
上面对本公开的具体实施方式进行了详细描述，虽然已示出和描述了一些实施例，但本领域技术人员应该理解，在不脱离由权利要求限定其范围的本公开的原理和精神的情况下，可以对这些实施例进行组合、修改和完善(例如，可以对本公开的不同技术特征进行组合以得到新的技术方案)。这些组合、修改和完善也应在本公开的保护范围内。

Claims (20)

  1. 一种电机转子，其特征在于，所述电机转子包括转子磁轭(150)和设置在所述转子磁轭(150)上的多个磁极模块(100)，每个磁极模块(100)包括基板(110)、罩壳(140)和容纳在由所述基板(110)和所述罩壳(140)形成的容纳空间中的极性相反的一对磁极单元(120、130)，其中，每个磁极模块(100)内的一对磁极单元(120、130)沿着所述转子磁轭(150)的圆周方向彼此间隔开第一距离。
  2. 根据权利要求1所述的电机转子，其特征在于，周向相邻的不同磁极模块(100)中的相邻的磁极单元沿着所述转子磁轭(150)的圆周方向彼此间隔开第二距离，其中，所述第一距离与所述第二距离不同。
  3. 根据权利要求1所述的电机转子，其特征在于，周向相邻的不同磁极模块(100)沿着所述转子磁轭(150)的圆周方向彼此间隔开预定距离。
  4. 根据权利要求1所述的电机转子，其特征在于，所述基板(110)上设置有突起部(114)，所述突起部(114)沿着轴向设置在所述基板(110)的正表面(111a)上，所述一对磁极单元(120、130)中的每个磁极单元(120、130)分别紧贴着所述突起部(114)设置在所述突起部(114)的两侧，每个磁极单元包括在轴向上对齐的多个磁极，每个磁极单元中的多个磁极具有相同的极性。
  5. 根据权利要求1至4中任一项所述的电机转子，其特征在于，每个磁极单元(120、130)的正表面通过粘结剂被粘接在所述罩壳(140)的内表面上。
  6. 根据权利要求1至4中任一项所述的电机转子，其特征在于，所述罩壳(140)、所述基板(110)和所述一对磁极单元(120、130)之间的各个间隙被树脂填充。
  7. 根据权利要求1所述的电机转子，其特征在于，所述基板(110)上设置有多个基板通孔(115)，所述罩壳(140)上设置有与所述多个基板通孔(115)对应的多个罩壳通孔(145)，所述转子磁轭(150)上设置有螺纹孔，所述多个基板通孔(115)、所述多个罩壳通孔(145)、所述螺纹孔彼此对齐，通过使紧固件(170)穿过所述多个基板通孔(115)、所述多个罩壳通孔(145)和所述螺纹孔而将所述磁极模块(100)机械固定在所述转子磁轭(150)上。
  8. 根据权利要求1所述的电机转子，其特征在于，多个磁极模块(100)沿着所述转子磁轭(150)的圆周方向成排地设置在所述转子磁轭(150)上，成排的磁极模块(100)中的每个磁极模块(100)在所述转子磁轭(150)的圆周方向上彼此对齐，并且，多个磁极模块(100)沿着平行于所述电机转子的中心旋转轴线的轴向方向成列地设置在所述转子磁轭(150)上，成列的磁极模块(100)中的每个磁极模块(100)在平行于所述电机转子的中心旋转轴线的轴向方向上彼此对齐。
  9. 根据权利要求1所述的电机转子，其特征在于，不同磁极模块中的周向相邻的磁极单元的极性相反，不同磁极模块中的轴向相邻的磁极单元的极性相同。
  10. 一种磁极模块，其特征在于，所述磁极模块包括：
    基板(110)；
    第一磁极单元(120)和第二磁极单元(130)，设置在所述基板(110)的正表面(111a)上，所述第一磁极单元(120)和所述第二磁极单元(130)的极性相反并彼此间隔开第一距离；
    罩壳(140)，扣装在所述第一磁极单元(120)、所述第二磁极单元(130)和所述基板(110)上。
  11. 根据权利要求10所述的磁极模块，其特征在于，所述磁极模块还包括突起部(114)，所述突起部(114)设置在所述基板(110)的正表面(111a)上，并位于所述第一磁极单元(120)和所述第二磁极单元(130)之间。
  12. 根据权利要求10或11所述的磁极模块，其特征在于，所述第一磁极单元(120)和所述第二磁极单元(130)与所述罩壳(140)的内表面之间通过粘结剂粘接在一起。
  13. 根据权利要求10所述的磁极模块，其特征在于，所述基板(110)包括设置在所述基板(110)的两侧上的多个基板通孔(115)，所述罩壳(140)包括设置在所述罩壳(140)的两侧上的多个罩壳通孔(145)，其中，所述多个基板通孔(115)与所述多个罩壳通孔(145)对齐。
  14. 根据权利要求11所述的磁极模块，其特征在于，所述罩壳(140)、所述基板(110)、所述第一磁极单元(120)和所述第二磁极单元(130)之间的各个间隙被树脂填充。
  15. 根据权利要求10所述的磁极模块，其特征在于，所述第一磁极单元 (120)和所述第二磁极单元(130)在宽度方向上彼此间隔开，每个磁极单元包括在长度方向上对齐的多个磁极，每个磁极单元中的多个磁极具有相同的极性。
  16. 一种制造电机转子的方法，其特征在于，所述方法包括：
    将极性相反的一对磁极单元(120、130)并列设置在基板(110)上，并使所述一对磁极单元(120、130)间隔开第一距离；
    将罩壳(140)扣装在所述一对磁极单元(120、130)和所述基板(110)上并在所述罩壳(140)与所述基板(110)之间形成密封空间；
    对由所述罩壳(140)和所述基板(110)形成的密封空间灌注树脂，从而形成磁极模块(100)；
    将多个磁极模块(100)设置在转子磁轭(150)上，以使周向相邻的不同磁极模块(100)中的相邻的磁极单元沿着所述转子磁轭(150)的圆周方向彼此间隔开第二距离，所述第一距离与所述第二距离不同。
  17. 根据权利要求16所述的方法，其特征在于，还包括：
    在将所述一对磁极单元(120、130)设置在所述基板(110)上之前，在所述基板(110)的中部设置突起部(114)，并将所述一对磁极单元(120、130)设置在所述突起部(114)的两侧。
  18. 根据权利要求16所述的方法，其特征在于，在扣装所述罩壳(140)之前，在所述一对磁极单元(120、130)的每个磁极单元(120、130)的正表面上涂覆粘结剂，用于使所述正表面粘接到所述罩壳(140)上；
    在将所述罩壳(140)扣装在所述一对磁极单元(120、130)之后，压紧所述罩壳(140)和所述一对磁极单元(120、130)的正表面，以使所述罩壳(140)和所述一对磁极单元(120、130)的正表面之间的粘结剂完全铺开；
    对所述罩壳(140)与所述基板(110)之间的外部接缝进行密封，以使所述罩壳(140)和所述基板(110)形成密封空间。
  19. 根据权利要求16所述的方法，其特征在于，所述罩壳(140)还包括分别设置在所述罩壳(140)的两个端表面上的抽真空嘴(148)和注胶嘴(149)，所述方法还包括如下步骤：
    通过所述抽真空嘴(148)和所述注胶嘴(149)对由所述罩壳(140)与所述基板(110)形成的密封空间的内部灌注树脂，以使所述罩壳(140)、所述基板(110)和所述一对磁极单元(120、130)之间的各个间隙被树脂填充， 在灌注树脂完成后，去除所述抽真空嘴(148)和所述注胶嘴(149)，并对去除所述注胶嘴(149)和所述抽真空嘴(148)后的位置涂覆密封剂以进行密封。
  20. 根据权利要求16所述的方法，其特征在于，在所述基板(110)上开设多个基板通孔(115)、在所述罩壳(140)上开设多个罩壳通孔(145)并在所述转子磁轭(150)上开设多个螺纹孔，所述方法还包括如下步骤：
    通过使多个紧固件(170)分别穿过所述多个基板通孔(115)、所述多个罩壳通孔(145)和所述多个螺纹孔而将多个磁极模块(100)机械地固定到所述转子磁轭(150)上，并使不同磁极模块中的周向相邻的磁极单元的极性相反，不同磁极模块中的轴向相邻的磁极单元的极性相同。
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CN108777521B (zh) 2019-09-06
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US20210067019A1 (en) 2021-03-04

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