WO2021063014A1 - 转子铁芯片、转子铁芯、转子、永磁同步电机及相关产品 - Google Patents

转子铁芯片、转子铁芯、转子、永磁同步电机及相关产品 Download PDF

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Publication number
WO2021063014A1
WO2021063014A1 PCT/CN2020/094225 CN2020094225W WO2021063014A1 WO 2021063014 A1 WO2021063014 A1 WO 2021063014A1 CN 2020094225 W CN2020094225 W CN 2020094225W WO 2021063014 A1 WO2021063014 A1 WO 2021063014A1
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WIPO (PCT)
Prior art keywords
rotor core
opening
magnetic
permanent magnet
arc
Prior art date
Application number
PCT/CN2020/094225
Other languages
English (en)
French (fr)
Inventor
李义
巴亚尔 额尔和木
李孟德
Original Assignee
华为技术有限公司
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 华为技术有限公司 filed Critical 华为技术有限公司
Priority to EP20870925.3A priority Critical patent/EP3989403B1/en
Priority to JP2022508571A priority patent/JP2022544250A/ja
Publication of WO2021063014A1 publication Critical patent/WO2021063014A1/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
    • 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
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H02K1/2766—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
    • H02K1/2773—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect consisting of tangentially magnetized radial 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
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H02K1/2766—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/14—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2201/00—Specific aspects not provided for in the other groups of this subclass relating to the magnetic circuits
    • H02K2201/03—Machines characterised by aspects of the air-gap between rotor and stator
    • 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
    • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
    • 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

  • This application relates to the technical field of electric vehicles, in particular to a rotor core, a rotor core, a rotor, a permanent magnet synchronous motor, a powertrain, and an electric vehicle.
  • the rotor of the built-in permanent magnet synchronous motor includes a rotor iron core and a permanent magnet.
  • the rotor iron core is provided with a magnetic slot, and the permanent magnet is installed in the magnetic slot.
  • the motor torque of a permanent magnet synchronous motor is equal to the sum of permanent magnet torque and reluctance torque.
  • the traditional built-in permanent magnet synchronous motor has a limited salient pole ratio, which makes the motor's utilization rate of reluctance torque low.
  • it is necessary to increase the proportion of the permanent magnet torque which leads to a large amount of permanent magnets and increases the cost.
  • the present application provides a rotor core, a rotor core, a rotor, a permanent magnet synchronous motor, a powertrain, and an electric vehicle, which can reduce the amount of permanent magnets and reduce costs.
  • the present application provides a rotor core sheet.
  • the rotor core sheet has an axial surface, and the axial surface is provided with a first inner magnetic slot, a second inner magnetic slot, a first outer magnetic slot, and a second outer magnetic slot. ;
  • the first inner magnetic slot forms a first inner opening on the axial surface, and the second inner magnetic slot forms a second inner opening on the axial surface.
  • the first inner opening and the second inner opening enclose an inner magnetic pole angle
  • the included angle of the magnetic poles opens toward the outside of the rotor core, and the included angle of the inner magnetic poles is an obtuse angle;
  • the first outer magnetic slot forms a first outer opening on the axial plane, and the second outer magnetic slot forms a second outer opening on the axial plane.
  • the first outer opening and the second outer opening are both located in the area of the inner magnetic pole included angle, the first outer opening and the second outer opening enclose the outer magnetic pole included angle, the outer magnetic pole included angle opens toward the outside of the rotor core, the outer The magnetic pole included angle is an obtuse angle greater than or equal to the inner magnetic pole included angle, and the difference between the outer magnetic pole included angle and the inner magnetic pole included angle is [0°,50°], the first inner opening and the second inner opening are both the same as the first outer The opening and the second outer opening are spaced apart, and the width of the first inner opening is 1.5-2 times the width of the first outer opening.
  • the rotor core is a unit constituting the rotor core.
  • the rotor core is cylindrical, and its axial surface is provided with a number of first outer magnetic slots, a number of second outer magnetic slots, a number of first inner magnetic slots, and a number of second inner magnetic slots.
  • the axis penetrates the opposite ends of the rotor core.
  • a first outer magnetic slot, a second outer magnetic slot, a first inner magnetic slot and a second inner magnetic slot constitute a magnetic slot unit.
  • the first outer magnetic slot, the second outer magnetic slot, the first inner magnetic slot, and the second inner magnetic slot are separated from each other, and all four are spaced apart from the boundary of the axial plane.
  • the first outer magnetic slot and the second outer magnetic slot enclose a V shape
  • the first inner magnetic slot and the second inner magnetic slot also enclose a V shape
  • the two V-shaped openings are both facing the outer side of the rotor core
  • the first The V shape enclosed by the inner magnetic groove and the second inner magnetic groove surrounds the outer periphery of the V shape enclosed by the first outer magnetic groove and the second outer magnetic groove.
  • the first outer magnetic slot and the second outer magnetic slot are symmetrical with respect to a radius of the rotor core
  • the first inner magnetic slot and the second inner magnetic slot are also symmetrical with respect to the radius
  • the four have the same symmetry axis.
  • a number of such magnetic slot units are distributed in an interval array around the axis of the rotor core.
  • the opening formed on the axial surface of the magnetic slot can reflect the cross-sectional structure of the magnetic slot.
  • the angle of the inner magnetic pole enclosed by the first inner opening and the second inner opening is the V-shaped opening angle enclosed by the first inner magnetic slot and the second inner magnetic slot.
  • the first outer opening and the second outer opening surround The angle between the outer magnetic poles is the V-shaped opening angle enclosed by the first outer magnetic slot and the second outer magnetic slot; the first inner opening, the second inner opening, the first outer opening and the second outer opening can all be striped
  • the shape can define its width, where the first inner opening and the second inner opening have the same width, and the first outer opening and the second outer opening have the same width.
  • the value of the width of the first outer opening and the width of the first inner opening has a greater impact on the reluctance of the direct-axis magnetic circuit of the motor, that is, it has a greater impact on the inductance of the direct-axis magnetic circuit.
  • the value of the angle between the outer magnetic pole and the inner magnetic pole has a greater impact on the reluctance of the quadrature axis magnetic circuit of the motor, that is, the greater the impact on the inductance of the quadrature axis magnetic circuit (the smaller the magnetic resistance, the greater the inductance; on the contrary, the magnetic The greater the resistance, the smaller the inductance).
  • the salient pole ratio of the motor is the ratio of the quadrature axis inductance to the direct axis inductance
  • the motor torque is the reluctance torque (the electromagnetic torque component produced by the difference between the alternating and direct axis inductance of the permanent magnet synchronous motor) plus the permanent magnet torque (The electromagnetic torque component produced by the permanent magnet of the permanent magnet synchronous motor).
  • the ratio of the quadrature axis inductance to the direct axis inductance of the motor can be increased.
  • improve the salient pole ratio After the salient pole ratio is increased, the utilization rate of the reluctance torque of the motor is also improved.
  • the permanent magnet torque can be smaller, which can reduce the amount of permanent magnets, thereby reducing the cost.
  • the outer pole arc angle and the inner pole arc angle can be defined on the axial plane of the rotor core, where the outer pole arc angle is the pole arc angle corresponding to the first outer opening and the second outer opening,
  • the inner pole arc angle is the pole arc angle corresponding to the first inner opening and the second inner opening.
  • the arc angle of the inner pole is 2-2.5 times the arc angle of the outer pole.
  • the resultant magnetic potential of a magnetic pole unit is the magnetic potential generated by the permanent magnets in the first outer magnetic slot and the second outer magnetic slot (hereinafter referred to as the outer magnetic potential), and the first inner magnetic slot and the second inner magnetic slot
  • the magnetic potential generated by the permanent magnets (hereinafter referred to as the inner magnetic potential) is superimposed.
  • the resultant magnetic potential is not only affected by the outer magnetic potential or the inner magnetic potential alone, but also by the superposition of the two.
  • the waveforms of the composite magnetic potential, the outer magnetic potential and the inner magnetic potential all include fundamental waves and harmonics.
  • the fundamental wave and harmonics in the outer magnetic potential are all related to the outer magnetic pole angle and outer pole arc angle
  • the fundamental wave and harmonics in the inner magnetic potential are all related to the inner magnetic pole angle and inner pole arc angle.
  • the waveform of the synthesized magnetic potential can be optimized, and the harmonics in the waveform of the synthesized magnetic potential can be effectively suppressed.
  • the wave component improves the sine of the air gap magnetic field waveform, thereby reducing the cogging torque and torque ripple of the permanent magnet synchronous motor, and reducing the vibration and noise of the motor.
  • the outer magnetic pole included angle and the inner magnetic pole included angle can produce more combinations when the values are matched, so that the waveform of the synthesized magnetic potential can be more flexibly optimized to meet the requirements. product demand.
  • the end of the first inner opening close to and/or far from the second inner opening includes at least two arcs, the at least two arcs are sequentially tangent, and the chords of every two adjacent arcs form an obtuse angle . Therefore, the two arcs not only transition smoothly, but also do not form sharp corners. Since the width of the first inner opening is relatively large, and the end of the first inner opening away from the second inner opening is farther from the center of the axial surface, when the rotor iron core rotates at a high speed, the end will have greater stress due to centrifugal force.
  • This arc transition structure can effectively reduce the curvature change of the end, so that the stress distribution at the end is more uniform, and the stress concentration coefficient is low, so as to avoid stress concentration at the end, which is beneficial to ensure the peak speed of the motor and improve the power density of the motor .
  • the end of the first inner opening close to the second inner opening includes a first arc segment, a second arc segment, a straight line segment, a third arc segment, and a fourth arc segment that are sequentially connected.
  • the two arc segments are tangent to the straight line segment, and the straight line segment is tangent to the third arc segment.
  • the straight section can ensure the structural strength of the rotor core.
  • the second arc segment and the third arc segment are respectively tangent to opposite ends of the straight line segment.
  • the first arc segment and the second arc segment form the aforementioned smooth transition connection, that is, the first arc segment is tangent to the second arc segment, and the chord of the first arc segment and the chord of the second arc segment form an obtuse angle .
  • the third arc line segment and the fourth arc line segment also form the aforementioned smooth transition connection, that is, the third arc line segment is tangent to the fourth arc line segment, and the chord of the first arc line segment is connected to the second arc line segment.
  • the string forms an obtuse angle.
  • the smooth transition of multiple arcs is beneficial to further reduce the curvature change of the end of the first inner opening close to the second inner opening, so that the stress distribution is more uniform, and the stress concentration is avoided.
  • the shape and location dimensions of the first arc segment, the second arc segment, the straight line segment, the third arc segment, and the fourth arc segment can be reasonably designed according to product requirements.
  • the end of the first inner opening close to the second inner opening may have an "pinna-shaped" structure.
  • the "pinna-shaped" structure is not only conducive to optimizing the stress distribution, but also can be well adapted to the main structure of the rotor core, which improves the mass production of the rotor core.
  • the radii of at least two arcs are different, which can refine the gradient of the curvature change, make the stress distribution smoother, and further reduce the stress concentration factor.
  • the rotor core has a circumferential surface, a partial area of the circumferential surface is concave to form a depression, the depression has two opposite sides parallel to the axial direction, and the opposite ends of the depression in the axial direction both penetrate the axial surface.
  • the arrangement of the recesses changes the shape of the circumferential surface of the rotor core, which in turn changes the air gap between the rotor and the stator.
  • the permeance waveform of the air gap is related to the width of the air gap. In this implementation manner, the width of the air gap can be locally increased by setting the recess, thereby optimizing the permeance waveform of the air gap, and suppressing the harmonic components in the permeance waveform of the air gap.
  • the suppression of the harmonic components improves the sine of the waveform of the magnetic field strength of the air gap.
  • a local area of the circumferential surface is convex to form a protrusion, and the opposite ends of the protrusion in the axial direction extend to the axial surface.
  • the protrusion has two opposite sides parallel to the axial direction, and the recesses are distributed symmetrically. On opposite sides of the protrusion, the recess is spaced from the protrusion.
  • the arrangement of the protrusions also changes the shape of the rotor core and the circumferential surface of the rotor core, thereby locally reducing the air gap, thereby optimizing the permeance waveform of the air gap and suppressing the harmonic components in the permeance waveform of the air gap.
  • a magnetic isolation bridge is formed between the two adjacent ends of the first outer opening and the second outer opening.
  • the provision of a magnetic isolation bridge can reduce magnetic leakage, and the arrangement can increase the mechanical strength of the rotor core, and prevent the rotor core from being damaged due to internal stress during high-speed rotation.
  • the mechanical strength of the rotor iron chip is improved, so that the peak speed of the motor is no longer limited, thereby ensuring the power density of the motor.
  • the present application provides a rotor core, which includes several rotor core cores. All rotor core cores are stacked in the axial direction. The circumferential contours of all rotor cores are completely overlapped. This stacked assembly design can reduce rotor cores. Eddy current loss of the core.
  • the rotor core of the present application can increase the salient pole ratio of the permanent magnet synchronous motor, reduce the amount of permanent magnets, and reduce the cost.
  • the present application provides a rotor, including a rotating shaft, a permanent magnet, and a rotor core.
  • the first outer magnetic slot, the second outer magnetic slot, the first inner magnetic slot, and the second inner magnetic slot of each rotor core Permanent magnets are installed in the slots, and the rotating shaft passes through the rotor core along the axial direction of the rotor core and is fixedly connected to the rotor core.
  • the first outer magnetic slot, the second outer magnetic slot, and the first inner magnetic slot of each rotor core The magnetic slots and the second inner magnetic slots are both distributed on the outer circumference of the rotating shaft.
  • the rotor of the present application can increase the salient pole ratio of the permanent magnet synchronous motor, reduce the amount of permanent magnets, and reduce the cost.
  • the present application provides a permanent magnet synchronous motor, which includes a stator and a rotor.
  • the stator is sleeved on the outer circumference of the rotor core and has an air gap with the rotor core, and the rotating shaft extends out of the stator.
  • the permanent magnet synchronous motor of the present application has a large salient pole ratio, a small amount of permanent magnets, and low cost.
  • the present application provides a power assembly including a motor controller and a permanent magnet synchronous motor, and the motor controller is electrically connected to the permanent magnet synchronous motor to control the permanent magnet synchronous motor.
  • the power assembly of the present application has good performance and low cost.
  • the present application provides an electric vehicle, including a frame and a power assembly, and the power assembly is installed on the frame.
  • the electric vehicle of the application has good performance and low cost.
  • Fig. 1 is a schematic structural diagram of an electric vehicle according to an embodiment of the present application.
  • Figure 2 is a structural block diagram of the powertrain of the electric vehicle in Figure 1;
  • Fig. 3 is a schematic structural diagram of a permanent magnet synchronous motor in the powertrain in Fig. 2;
  • FIG. 4 is a schematic diagram of the cross-sectional structure of the permanent magnet synchronous motor in FIG. 3;
  • FIG. 5 is a schematic diagram of the structure of the rotor of the permanent magnet synchronous motor in FIG. 4;
  • FIG. 6 is a schematic diagram showing the assembly structure of the rotor core and permanent magnets of the rotor in FIG. 5;
  • FIG. 7 is a schematic diagram showing an assembly structure of a rotor iron chip and a permanent magnet of the rotor in FIG. 5;
  • Fig. 8 is a schematic front view of the structure of the rotor core in Fig. 7;
  • Fig. 9 is a partial structural diagram of the rotor core sheet in Fig. 8.
  • Fig. 10 is another partial structural schematic diagram of the rotor core in Fig. 8;
  • FIG. 11 is another partial structural diagram of the rotor core in FIG. 8;
  • Fig. 12 is a partial enlarged schematic diagram of the structure at B1 in Fig. 10;
  • FIG. 13 is a schematic diagram of a partial enlarged structure at B2 in FIG. 10;
  • FIG. 14 is a schematic diagram of another structure of a rotor core sheet according to an embodiment of the present application.
  • FIG. 1 illustrates an electric SUV (Sport Utility Vehicle) 10.
  • the electric vehicle 10 may include a frame and a powertrain mounted on the frame.
  • the frame is used as the structural skeleton of the electric vehicle 10 to support, fix and connect various assemblies, and bear the load from the interior of the automobile system and from the external environment.
  • a powertrain is a system composed of a series of components that is used to generate power and transmit power to the road.
  • the powertrain 11 may include a motor controller 12 and a permanent magnet synchronous motor 13.
  • the motor controller 12 is electrically connected to the permanent magnet synchronous motor 13 for controlling the operation of the permanent magnet synchronous motor 13.
  • the permanent magnet synchronous motor 13 includes a stator 14 and a rotor 15.
  • the stator 14 may have a cylindrical inner cavity.
  • the rotor 15 includes a rotor core 18, permanent magnets 19 and a rotating shaft 17.
  • the rotor core 18 may have a cylindrical shape, which has an axial surface (a surface with a normal line along the axial direction of the rotor core 18) and a circumferential surface. A number of magnetic slots are opened on the axial surface, and the magnetic slots can penetrate the rotor core 18 in the axial direction.
  • each magnetic slot does not extend to the axis (that is, all are spaced from the axis), and a number of magnetic slots are distributed in an array around the axis at intervals.
  • a permanent magnet 19 for providing a magnetic field is installed in each magnetic slot.
  • the rotor core 18 is installed in the inner cavity of the stator 14, and an air gap is left between the circumferential surface of the rotor core 18 and the cavity wall of the inner cavity.
  • the rotor core 18 is provided with a shaft hole extending in the axial direction.
  • the rotating shaft 17 passes through the shaft hole and is fixedly connected with the rotor core 18 to follow the rotor core 18 to rotate.
  • the magnetic slots and permanent magnets 19 are distributed on the outer circumference of the rotating shaft 17 .
  • the rotating shaft 17 extends outside the inner cavity of the stator 14 to facilitate the output of torque.
  • end caps 16 can be provided at both axial ends of the rotor core 18, and the rotating shaft 17 penetrates through the end caps 16.
  • the rotor core 18 may include a plurality of rotor core cores 181.
  • the rotor core core 181 has a cylindrical shape. All the rotor core cores 181 are stacked in sequence along the axial direction, and the circumferential contours of all the rotor cores 18 are completely overlapped. This stacked assembly design can reduce the eddy current loss of the rotor core 18.
  • the rotor core 181 is provided with a number of magnetic slots. According to product requirements, the magnetic slots of the rotor core 181 at the same position can form a set positional relationship.
  • all the magnetic slots of the rotor core 181 at the same position are completely overlapped, or the same All the magnetic slots in the position can be misaligned in sequence.
  • a single rotor iron chip 181 will be taken as an example to describe the solution of the embodiment of the present application in detail.
  • the cylindrical rotor core core 181 has an axial surface A (there are two axial surfaces A) and a circumferential surface C.
  • a number of first outer magnetic slots 1812, a number of second outer magnetic slots 1813, a number of first inner magnetic slots 1811, and a number of second inner magnetic slots 1814 are opened on the rotor iron chip 181, all of which are along the axis of the rotor iron chip 181
  • all the magnetic slots are spaced apart from each other and are kept spaced apart from the boundary of the axial surface A (that is, the magnetic slots do not penetrate the circumferential surface C).
  • an adjacent first outer magnetic slot 1812 and a second outer magnetic slot 1813 enclose a V-shape, and the V-shaped opening faces the outer side of the rotor core core 181.
  • An adjacent first inner magnetic slot 1811 and a second inner magnetic slot 1814 also enclose a V shape, and the V-shaped opening also faces the outer side of the rotor core core 181.
  • a first outer magnetic slot 1812 and a second outer magnetic slot 1813 enclosing a V shape, and a first inner magnetic slot 1811 and a second inner magnetic slot 1814 enclosing a V shape constitute a magnetic slot unit.
  • the first inner magnetic slot 1811 and the second inner magnetic slot 1814 surround the outer peripheries of the first outer magnetic slot 1812 and the second outer magnetic slot 1813.
  • the first outer magnetic slot 1812 and the second outer magnetic slot 1813 have the same shape, and the first inner magnetic slot 1811 and the second inner magnetic slot 1814 have the same shape.
  • a number of such magnetic slot units may be distributed in an array around the axis of the rotor core 181 at intervals.
  • a permanent magnet 19 is installed in each magnetic slot.
  • a magnetic slot unit and the permanent magnet 19 installed therein can be called a magnetic pole unit together.
  • the rotor core 181 can also be provided with a number of weight reduction holes 1815, which penetrate the opposite ends of the rotor core 181 along the axial direction of the rotor core 181, and the weight reduction holes 1815 are spaced apart from the magnetic slot.
  • the weight-reducing hole 1815 is used to reduce the weight of the rotor core 181 so as to increase the rotation speed of the rotor core 181.
  • the first outer magnetic slot 1812 and the second outer magnetic slot 1813 form an obtuse angle, and the obtuse angle opens toward the outside of the rotor iron core 181, that is, the first outer magnetic slot 1812
  • the two ends with a smaller distance from the second outer magnetic slot 1813 are located on the inner circumference of the rotor core 181, and the two ends with a larger distance between the first outer magnetic slot 1812 and the second outer magnetic slot 1813 are located on the outer circumference of the rotor core 181.
  • first inner magnetic slot 1811 and the second inner magnetic slot 1814 also enclose an obtuse angle, and the obtuse angle opens toward the outside of the rotor iron core 181, that is, the distance between the first inner magnetic slot 1811 and the second inner magnetic slot 1814
  • the smaller two ends are located on the inner circumference of the rotor core 181, and the two ends with a larger distance between the first inner magnetic slot 1811 and the second inner magnetic slot 1814 are located on the outer circumference of the rotor core 181.
  • the first outer magnetic slot 1812 and the second outer magnetic slot 1813 are located in the area of the obtuse angle enclosed by the first inner magnetic slot 1811 and the second inner magnetic slot 1814, that is, the first inner magnetic
  • the slot 1811 and the second inner magnetic slot 1814 surround the outer peripheries of the first outer magnetic slot 1812 and the second outer magnetic slot 1813.
  • the obtuse angle enclosed by the first outer magnetic slot 1812 and the second outer magnetic slot 1813 is greater than or equal to the obtuse angle enclosed by the first inner magnetic slot 1811 and the second inner magnetic slot 1814.
  • the first outer magnetic slot 1812 and the second outer magnetic slot 1813 are symmetrical with respect to a radius of the rotor core 181, and the first inner magnetic slot 1811 and the second inner magnetic slot 1814 are also symmetrical with respect to the radius, that is, the first outer magnetic slot 1812,
  • the symmetry axis of the second outer magnetic slot 1813 is the same as the symmetry axis of the first inner magnetic slot 1811 and the second inner magnetic slot 1814.
  • the symmetry axes of the inner and outer magnetic slots in a single magnetic slot unit can be different, or at least one pair of the inner magnetic slot and the outer magnetic slot can be arranged asymmetrically.
  • the first inner magnetic slot 1811 and the second inner magnetic slot 1814, and/or the first outer magnetic slot 1812 and the second outer magnetic slot 1813 may communicate with each other.
  • the magnetic slot extends along the axis of the rotor core core 181 and penetrates the rotor core core 181.
  • the opening formed by the magnetic slot on the axial plane A is the cross-sectional profile of the magnetic slot.
  • the first inner magnetic slot 1811 forms a first inner opening 1811m on the axial plane A
  • the second inner magnetic slot 1814 forms a second inner opening on the axial plane A
  • the ends of the first inner opening 1811m and the second inner opening 1814m close to the center of the axial plane A are spaced apart from the center of the circle.
  • the first inner opening 1811m may include two parallel opposite straight sides L1 and L2.
  • the second inner opening 1814m may also include two parallel opposite straight sides L3 and L4.
  • One straight side L2 of the first inner opening 1811m and the second A straight side L3 of the inner opening 1814m forms an obtuse angle, which can be called the inner magnetic pole included angle ⁇ 1, that is, the first inner opening 1811m and the second inner opening 1814m enclose the inner magnetic pole included angle ⁇ 1, and the inner magnetic pole included angle ⁇ 1 is the above
  • the range of the inner magnetic pole included angle ⁇ 1 may be [110°, 140°], for example.
  • the first inner opening 1811m and the second inner opening 1814m are both elongated, and the distance between the two parallel opposite straight sides L1 and L2 of the first inner opening 1811m is called the width W1 of the first inner opening 1811m.
  • the width W1 of the first inner opening 1811m may be, for example, 2mm-6mm (including endpoint values).
  • the distance between the two parallel opposite straight sides L3 and L4 of the second inner opening 1814m is called the width of the second inner opening 1814m, and the width of the second inner opening 1814m is equal to the width W1 of the first inner opening 1811m.
  • the space between the two straight sides L1 and L2 of the first inner opening 1811m and the space between the two straight sides L3 and L4 of the second inner opening 1814m are both used to install the permanent magnet 19.
  • the opposite ends of a straight side of the first inner opening 1811m (for example, the lower straight side L1 in FIG. 9) can form protrusions T1 and T2, and the two protrusions T1 and T2 at both ends are used to hold the permanent magnet 19.
  • the opposite ends of a straight side of the second inner opening 1814m (for example, the straight side L4 at the bottom of FIG. 9) can form protrusions T3 and T4, and the two protrusions T3 and T4 at both ends are used to hold the permanent magnet. 19.
  • the raised portion T1 and the raised portion T2 may be located on the straight side L1 and the straight side L2, respectively, that is, the raised portion T1 and the raised portion T2 are distributed diagonally;
  • the protrusion T3 and the protrusion T4 may also be located on the straight side L3 and the straight side L4, respectively, that is, the protrusions T3 and the protrusions T4 are distributed diagonally.
  • the inner magnetic pole included angle ⁇ 1 and/or the width W1 of the first inner opening 1811m can be selected as required, and is not limited to the above.
  • the first outer magnetic slot 1812 forms a first outer opening 1812m on the axial plane A
  • the second outer magnetic slot 1813 forms a second outer opening 1813m on the axial plane A.
  • the first outer opening 1812m and the second outer opening 1813m are both located in the area of the inner magnetic pole included angle ⁇ 1.
  • the first outer opening 1812m may include two parallel and opposite straight sides S1 and S2, and the second outer opening 1813m may also include two parallel and opposite straight sides S3 and S4.
  • a straight side S2 of the first outer opening 1812m and a straight side S3 of the second outer opening 1813m form an obtuse angle.
  • This obtuse angle can be called the outer magnetic pole included angle ⁇ 2, that is, the first outer opening 1812m and the second outer opening 1813m enclose
  • the outer magnetic pole included angle ⁇ 2 is the obtuse angle enclosed by the first outer magnetic slot 1812 and the second outer magnetic slot 1813.
  • the range of the outer magnetic pole included angle ⁇ 2 may be, for example, [110°, 160°]. Both the first outer opening 1812m and the second outer opening 1813m are elongated.
  • the distance between the two parallel opposite straight sides S1 and S2 of the first outer opening 1812m is called the width W2 of the first outer opening 1812m, and the width W2 of the first outer opening 1812m may be, for example, 1mm-3mm (including endpoint values).
  • the distance between the two parallel opposite straight sides S3 and S4 of the second outer opening 1813m is called the width of the second outer opening 1813m, and the width of the second outer opening 1813m is equal to the width W2 of the first outer opening 1812m.
  • the space between the two straight sides S1 and S2 of the first outer opening 1812m and the space between the two straight sides S3 and S4 of the second outer opening 1813m are both used to install the permanent magnet 19.
  • the opposite ends of a straight side S1 of the first outer opening 1812m and the opposite ends of a straight side S4 of the second outer opening 1813m are also Any protrusion can be formed, and the protrusion is used to hold the permanent magnet 19.
  • the two protrusions can also be located on the two straight sides S1 and S2, or S3 and S4 respectively, that is, the two protrusions are diagonal distributed.
  • the outer magnetic pole included angle ⁇ 2 and/or the width W2 of the first outer opening 1812m can be selected as required, and is not limited to the above.
  • the outer magnetic pole included angle ⁇ 2 may be greater than or equal to the inner magnetic pole included angle ⁇ 1, and the range of the difference between the two may be [0°, 50°].
  • the width W1 of the first inner opening 1811m may be, for example, 1.5-2 times (including the end point value) of the width W2 of the first outer opening 1812m.
  • the values of the width W2 of the first outer opening 1812m and the width W1 of the first inner opening 1811m have a greater influence on the reluctance of the direct-axis magnetic circuit of the motor, that is, the inductance of the direct-axis magnetic circuit Greater impact.
  • the value of the angle between the outer magnetic pole ⁇ 2 and the inner magnetic pole angle ⁇ 1 has a greater impact on the reluctance of the quadrature axis magnetic circuit of the motor, that is, the greater the impact on the inductance of the quadrature axis magnetic circuit (the smaller the magnetic resistance, the greater the inductance; vice versa) , The greater the magnetic resistance, the smaller the inductance).
  • the salient pole ratio of the motor is the ratio of the quadrature axis inductance to the direct axis inductance
  • the motor torque is the reluctance torque (the electromagnetic torque component produced by the difference between the alternating and direct axis inductance of the permanent magnet synchronous motor 13) plus the permanent magnet rotation Moment (the electromagnetic torque component generated by the permanent magnet 19 of the permanent magnet synchronous motor 13).
  • the quadrature axis inductance of the motor can be increased.
  • the ratio of the inductance to the direct axis increases the salient pole ratio.
  • the utilization rate of the reluctance torque of the motor is also improved.
  • the permanent magnet torque can be smaller, which can reduce the amount of permanent magnet 19 (for example, it can reduce 20% dosage), thereby reducing costs.
  • the included angle ⁇ 2 of the outer magnetic pole and the included angle ⁇ 1 of the inner magnetic pole are not equal (that is, the inner and outer magnetic grooves are not nested in parallel)
  • the width W2 of the first outer opening 1812m and the width W1 of the first inner opening 1811m are different, so that the outer The magnetic pole included angle ⁇ 2 and the inner magnetic pole included angle ⁇ 1 can produce more combinations when the values match, so that the width W2 of the first outer opening 1812m and the width W1 of the first inner opening 1811m can also produce more combinations when the values match. This can optimize the salient pole ratio more flexibly to meet product requirements.
  • the quadrature axis inductance and the direct axis inductance can be made larger, thereby increasing the motor inductance, so as to control the work of the motor and improve the performance of the motor.
  • making the direct-axis inductance larger also improves the motor's field weakening and speed expansion capability.
  • the first outer opening 1812m and the second outer opening 1813m are spaced apart, and a magnetic isolation bridge 1818 is formed between the two adjacent ends.
  • the first outer opening 1812m is opposite to the axial direction.
  • a magnetic isolation bridge 1817 is formed between the boundary of the surface A, and a magnetic isolation bridge 1820 is formed between the second outer opening 1813m and the boundary of the axial surface A.
  • the area defined by the outer magnetic pole included angle ⁇ 2 may be referred to as the rotor pole piece core 1819.
  • first inner opening 1811m and the second inner opening 1814m are spaced apart, a magnetic isolation bridge 1824 is formed between the two adjacent ends, and a space is formed between the first inner opening 1811m and the boundary of the axial plane A.
  • a magnetic isolation bridge 1822 is formed between the boundary between the second inner opening 1814m and the axial plane A.
  • the area defined by the inner magnetic pole included angle ⁇ 1 and the outer magnetic pole included angle ⁇ 2 can be referred to as an iron core branch 1821, and the rotor pole piece iron core 1819 is connected to the iron core branch 1821 through a magnetic isolation bridge 1818.
  • the area connected by the end of the magnetic isolation bridge 1824 away from the iron core branch 1821 may be referred to as the rotor yoke 1825, and the rotor yoke 1825 is the axis area of the rotor iron core 181.
  • the magnetic field lines of the permanent magnet 19 pass through the rotor yoke 1825, the iron core branch 1821 and the rotor pole shoe iron core 1819 in turn to reach the air gap, that is, the rotor yoke 1825, the iron core branch 1821 and the rotor pole shoe iron core 1819 are all magnetic field lines. Delivery path.
  • the area between adjacent magnetic slot units is called a magnetic rib 1823, and the magnetic rib 1823 is located between the first inner opening 1811m of one magnetic slot unit and the second inner opening 1814m of another adjacent magnetic slot unit.
  • the magnetic flux passing through the magnetic isolation bridge is limited, and the magnetic saturation state can be reached at the magnetic isolation bridge and a magnetic blocking phenomenon occurs, so that the remaining magnetic lines of force will not be able to pass through the magnetic isolation bridge.
  • It can only reach the air gap through the transmission path and be transmitted to the stator 14 to realize electromagnetic induction. Therefore, by providing the above-mentioned magnetic isolation bridge, it is possible to ensure that most of the magnetic lines of force pass through the transmission path, thereby reducing magnetic flux leakage.
  • a magnetic isolation bridge can also increase the mechanical strength of the rotor core core 181, especially the magnetic isolation bridge 1818 formed between the two ends close to the first outer opening 1812m and the second outer opening 1813m can be connected to the first outer opening.
  • the 1812m and the second outer opening 1813m bear the stress together with the magnetic isolation bridge 1817 and the magnetic isolation bridge 1820 between the boundary of the axial plane A, respectively, to prevent the rotor iron core 181 from being damaged due to internal stress during high-speed rotation.
  • the mechanical strength of the rotor core 181 is improved, so that the peak speed of the motor is no longer limited (for example, the peak speed can be increased by 20%), thereby ensuring the power density of the motor.
  • the outer pole arc angle ⁇ 2 and the inner pole arc angle ⁇ 1 can be defined on the axial plane A of the rotor core 181, and the vertices of the outer pole arc angle ⁇ 2 and the inner pole arc angle ⁇ 1 are both on the axial plane A.
  • Center O Specifically, as shown in FIG. 11, the first outer opening 1812m has a first outer periphery L6 facing the boundary of the axial plane A, the first outer periphery L6 is a straight line, and the first outer periphery L6 is also the boundary of the magnetic isolation bridge 1817. .
  • the line connecting the end of the first outer periphery L6 close to the second outer opening 1813m and the circle center O serves as one side of the outer pole arc angle ⁇ 2.
  • the second outer opening 1813m has a second outer periphery L7 facing the boundary of the axial plane A, the second outer periphery L7 is a straight line, and the second outer periphery L7 is also the boundary of the magnetic isolation bridge 1820.
  • the line connecting the end of the second outer periphery L7 close to the first outer opening 1812m and the circle center O serves as the other side of the outer pole arc angle ⁇ 2.
  • the other side of the outer pole arc angle ⁇ 2 passes through the end point of the second outer periphery L7 instead of passing through the rounded arc Point.
  • the first inner opening 1811m has a first inner periphery L5 facing the boundary of the axial plane A, the first inner periphery L5 is a straight line, and the first inner periphery L5 is also the boundary of the magnetic isolation bridge 1816.
  • the line connecting the end of the first inner periphery L5 close to the second inner opening 1814m and the circle center O serves as one side of the inner pole arc angle ⁇ 1.
  • the second inner opening 1814m has a second inner periphery L8 facing the boundary of the axial plane A, the second inner periphery L8 is a straight line, and the second inner periphery L8 is also the boundary of the magnetic isolation bridge 1822.
  • the line connecting the end of the second inner periphery L8 close to the first inner opening 1811m and the circle center O serves as the other side of the inner pole arc angle ⁇ 1.
  • the other side of the inner pole arc angle ⁇ 1 passes through the end point of the second inner periphery L8 instead of passing on the rounded arc Point.
  • the inner pole arc angle ⁇ 1 is greater than the outer pole arc angle ⁇ 2, and the inner pole arc angle ⁇ 1 may be 2-2.5 (including the endpoint value) of the outer pole arc angle ⁇ 2.
  • the inner pole arc angle ⁇ 1 may be 40°-56.67° (inclusive of endpoint values)
  • the outer pole arc angle ⁇ 2 may be 18.33°-26.67° (inclusive of endpoint values).
  • the inner pole arc angle ⁇ 1 and/or the outer pole arc angle ⁇ 2 can take values as needed, and are not limited to the above.
  • the resultant magnetic potential of a magnetic pole unit is the magnetic potential generated by the permanent magnets 19 in the first outer magnetic slot 1812 and the second outer magnetic slot 1813 (hereinafter referred to as the outer magnetic potential), which is the same as the first inner magnetic slot 1811 and the first inner magnetic slot 1811 and the second outer magnetic slot 1813.
  • the magnetic potential generated by the permanent magnet 19 in the two inner magnetic slots 1814 (hereinafter referred to as the inner magnetic potential) is superimposed.
  • the resultant magnetic potential is affected by the outer magnetic potential or the inner magnetic potential alone, and of course it is also affected by the two Superimpose the effect of the result.
  • the waveforms of the composite magnetic potential, the outer magnetic potential and the inner magnetic potential all include fundamental waves and harmonics.
  • the fundamental wave and harmonics in the outer magnetic potential are all related to the outer magnetic pole angle ⁇ 2 and the outer pole arc angle ⁇ 2.
  • the fundamental wave and harmonics in the inner magnetic potential are all related to the inner magnetic pole angle ⁇ 1 and the inner pole arc angle ⁇ 1. related.
  • the waveform of the synthesized magnetic potential can be optimized. , Effectively suppress the harmonic components in the waveform of the synthesized magnetic potential, improve the sine of the air gap magnetic field waveform, thereby reduce the cogging torque and torque ripple of the permanent magnet synchronous motor 13, and reduce the vibration and noise of the motor.
  • the outer magnetic pole included angle ⁇ 2 and the included angle of the inner magnetic pole ⁇ 1 are not equal, the outer magnetic pole included angle ⁇ 2 and the inner magnetic pole included angle ⁇ 1 can produce more combinations when the values are matched, which can optimize the composite magnetic potential more flexibly. Waveform to meet product demand. In other embodiments, this design is not necessary.
  • an arc transition design can also be given to the opening of the magnetic slot to optimize the stress distribution and avoid stress concentration.
  • the end of the first inner opening 1811m away from the second inner opening 1814m may include two arcs R1 and R2 (referring to circular arcs), the arc R1 and the arc R2 phase Tangential connection, the arc R1 and the arc R2 both have a chord (chord refers to the line segment connecting the two end points of the arc), and the chord of the arc R1 and the arc R2 forms an obtuse angle. Therefore, the two arcs R1 and R2 not only transition smoothly, but also do not form sharp corners.
  • the two arcs R1 and R2 can be specifically arranged at the connection between the magnetic isolation bridge 1816 and the magnetic rib 1823, and/or at the connection between the magnetic isolation bridge 1816 and the iron core branch 1821.
  • the width W1 of the first inner opening 1811m is relatively large, and the end of the first inner opening 1811m away from the second inner opening 1814m is farther from the center of the axial plane A.
  • This end will be affected by centrifugal force. Larger stress occurs.
  • This arc transition structure can effectively reduce the curvature change of the end, so that the stress distribution at the end is more uniform, and the stress concentration coefficient is low, thereby avoiding stress concentration at the end.
  • the smooth transition arc can be three or more segments.
  • the end of the second inner opening 1814m away from the first inner opening 1811m may also have the arc transition structure, and the arc transition structure at this end is symmetrical to the arc transition structure at the end of the first inner opening 1811m away from the second inner opening 1814m.
  • Both ends of the first outer opening 1812m and the second outer opening 1813m that are close to each other may have the arc transition structure, and the arc transition structures are symmetrical at the two locations.
  • the opposite ends of the first outer opening 1812m and the second outer opening 1813m may also have the arc transition structure, and the arc transition structure is symmetrical at the two locations.
  • the arc transition structure in the embodiment of the present application is not necessary.
  • the opening of the magnetic slot may only include straight segments.
  • the end of the first inner opening 1811m close to the second inner opening 1814m is close to the rotor yoke 1825, the structure space is relatively large, and the arc transition structure at this end may be more complicated.
  • the end of the first inner opening 1811m close to the second inner opening 1814m may include a first arc segment R3, a second arc segment R4, a straight line segment L9, and a third arc line
  • the segment R5 and the fourth arc segment R6, the first arc segment R3, the second arc segment R4, the straight line segment L9, the third arc segment R5, and the fourth arc segment R6 are connected in sequence.
  • the straight line segment L9 can be used as a width boundary of the magnetic isolation bridge, and its linear shape can ensure the structural strength of the magnetic isolation bridge.
  • the second arc segment R4 and the third arc segment R5 are respectively tangent to opposite ends of the straight line segment L9.
  • the first arc segment R3 and the second arc segment R4 form the aforementioned smooth transition connection, that is, the first arc segment R3 is tangent to the second arc segment R4, and the chord of the first arc segment R3 is connected to the second arc.
  • the chord of segment R4 forms an obtuse angle.
  • the third arc segment R5 and the fourth arc segment R6 also form the aforementioned smooth transition connection, that is, the third arc segment R5 is tangent to the fourth arc segment R6, and the chord of the first arc segment R3 is The chord of the second arc segment R4 forms an obtuse angle.
  • the smooth transition of multiple arcs is beneficial to further reduce the curvature change of the end of the first inner opening 1811m close to the second inner opening 1814m, so as to make the stress distribution more uniform and avoid stress concentration.
  • the end of the second inner opening 1814m close to the first inner opening 1811m may also have the arc transition structure, and the arc transition structure at this end is symmetrical to the arc transition structure at the end of the first inner opening 1811m close to the second inner opening 1814m.
  • the shape and location dimensions of the first arc segment R3, the second arc segment R4, the straight line segment L9, the third arc segment R5, and the fourth arc segment R6 can be reasonably designed according to product requirements.
  • the first arc segment R3 can be connected to a straight side L2 of the first inner opening 1811m, and the fourth arc segment R6 is far away from the end of the third arc segment R5.
  • the end of the first inner opening 1811m close to the second inner opening 1814m can present a "pinna-shaped" structure.
  • pinna-shaped structure is not only beneficial for optimizing the stress distribution, but also can be well adapted to the protruding portion T2 and the main body of the first inner opening 1811m, which improves the mass production of the rotor core 181.
  • the "pinna-shaped” structure is only an example, and is not essential.
  • the radius of each arc may be different.
  • This design can refine the gradient of curvature change, make the stress distribution smoother, and further reduce the stress concentration factor.
  • this design is not necessary, for example, the radius of all arcs can be the same.
  • a partial area of the circumferential surface C of the rotor core core 181 may be recessed to form a depression.
  • the depression may be strip-shaped and have two opposite sides parallel to the axial direction of the rotor core core 181. .
  • the recess extends along the axial direction of the rotor core core 181, and opposite ends pass through the axial surface A of the rotor core core 181.
  • the recess can form an arc-shaped opening on the axial surface A, and the depth of the recess can be small to avoid major changes to the shape of the circumferential surface C.
  • the number of the recesses may be several.
  • a recess C1, a recess C2, a recess C4, and a recess C5 may be provided near each magnetic slot unit, and the plurality of recesses are distributed on the circumferential surface C at intervals.
  • the arrangement of the recesses changes the shape of the rotor core 181 and the circumferential surface C of the rotor core 18, which in turn causes the air gap between the rotor 15 and the stator 14 to change.
  • the permeance waveform of the air gap is related to the width of the air gap.
  • the width of the air gap can be locally increased by providing recesses, thereby optimizing the permeance waveform of the air gap, and suppressing the harmonic components in the permeance waveform of the air gap.
  • the suppression of the intensity of the harmonic components improves the sine of the waveform of the magnetic field intensity of the air gap.
  • the specific structure and number of the recesses are not limited to the above, or the recesses can also be eliminated.
  • a local area of the circumferential surface C may also be convexly formed with a protrusion C3.
  • the protrusion C3 may be in a strip shape with two opposite sides parallel to the axial direction of the rotor core 181 .
  • the protrusion C3 can extend along the axial direction of the rotor core core 181, and its opposite ends in the axial direction extend to the axial plane A.
  • the depressions are symmetrically distributed on opposite sides of the protrusion C3, and the depressions are spaced from the protrusion C3.
  • one side of the protrusion C3 can be provided with a recess C1 and a recess C2, the other side can be provided with a recess C4 and a recess C5, the recess C1 and the recess C5 are symmetrical, and the recess C2 and the recess C4 are symmetrical.
  • the arrangement of the protrusion C3 also changes the shape of the rotor core 181 and the circumferential surface C of the rotor core 18, thereby locally reducing the air gap, thereby optimizing the permeability waveform of the air gap and suppressing the change in the permeability waveform of the air gap.
  • the harmonic component can also suppress the harmonic component of the magnetic field intensity of the air gap, and improve the sine of the waveform of the magnetic field intensity of the air gap.
  • the simultaneous provision of the protrusions C3 and the recesses can finely adjust the permeability waveform of the air gap and the magnetic field intensity waveform of the air gap.
  • the specific structure and number of the protrusions C3 are not limited to the above, and the protrusions C3 may be symmetrically arranged on opposite sides of the depression, or only the protrusions C3 may be provided without the depressions, or only the depressions may be provided. There is no bump C3.

Abstract

本申请提供了一种应用于电动车的永磁同步电机的转子结构，该转子结构采用内置双层V形磁极结构，其中内层V形磁极结构的磁极夹角大于外层V形磁极结构的磁极夹角，且二者差值在[0°,50°]，内层磁极结构的永磁体槽的宽度是外层磁极结构的永磁体槽宽度的1.5-2倍。本申请还提供了一种包括该转子结构的永磁同步电机、包括该永磁同步电机的动力总成，以及包括该动力总成的电动车。本申请的方案通过对内、外磁极结构的磁极夹角以及永磁体槽的宽度做合理数值匹配，能提升永磁同步电机的凸极比，减少永磁体用量，降低成本。

Description

转子铁芯片、转子铁芯、转子、永磁同步电机及相关产品
本申请要求于2019年09月30日提交中国专利局、申请号为201910945828.7、申请名称为“转子铁芯片、转子铁芯、转子、永磁同步电机及相关产品”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及电动汽车技术领域，尤其涉及一种转子铁芯片、转子铁芯、转子、永磁同步电机、动力总成及电动车。
背景技术
内置式永磁同步电机被广泛应用于电动汽车动力总成系统中。内置式永磁同步电机的转子包括转子铁芯和永磁体，转子铁芯中开设有磁槽，永磁体安装在磁槽内。
永磁同步电机的电机转矩等于永磁转矩与磁阻转矩之和。传统的内置式永磁同步电机的凸极比有限，使得电机对磁阻转矩的利用率较低。为了能输出设定的电机转矩以满足需求，需要提升永磁转矩的占比，这导致永磁体用量较大，增加了成本。
发明内容
本申请提供了一种转子铁芯片、转子铁芯、转子、永磁同步电机、动力总成及电动车，能够减少永磁体用量，降低成本。
第一方面，本申请提供了一种转子铁芯片，转子铁芯片具有轴向面，轴向面开设有第一内磁槽、第二内磁槽、第一外磁槽及第二外磁槽；第一内磁槽在轴向面上形成第一内开口，第二内磁槽在轴向面上形成第二内开口，第一内开口与第二内开口围成内磁极夹角，内磁极夹角朝转子铁芯片的外侧张开，内磁极夹角为钝角；第一外磁槽在轴向面上形成第一外开口，第二外磁槽在轴向面上形成第二外开口，第一外开口与第二外开口均位于内磁极夹角的区域内，第一外开口与第二外开口围成外磁极夹角，外磁极夹角朝转子铁芯片的外侧张开，外磁极夹角为大于或等于内磁极夹角的钝角，且外磁极夹角与内磁极夹角的差值在[0°,50°]，第一内开口及第二内开口均与第一外开口及第二外开口相间隔，第一内开口的宽度为第一外开口的宽度的1.5-2倍。
本申请的方案中，转子铁芯片是构成转子铁芯的单元。转子铁芯片呈圆柱状，其轴向面开设有若干第一外磁槽、若干第二外磁槽、若干第一内磁槽及若干第二内磁槽，所有磁槽均沿转子铁芯片的轴线贯通转子铁芯片的相对两端。一个第一外磁槽、一个第二外磁槽、一个第一内磁槽及一个第二内磁槽构成一个磁槽单元。一个磁槽单元中，第一外磁槽、第二外磁槽、第一内磁槽及第二内磁槽相互隔开，且四者均与轴向面的边界相间隔。第一外磁槽与第二外磁槽围成V形，第一内磁槽与第二内磁槽也围成V形，两个V形的开口均朝转子铁芯片的外侧，且第一内磁槽与第二内磁槽围成的V形包围在第一外磁槽与第二外磁槽围成的V形的外周。第一外磁槽与第二外磁槽关于转子铁芯片的一条半径对称，第一内磁槽与第二内磁槽同样关于该半径对称，四者具有同一对称轴。若干个这样的磁槽单元环绕转子铁芯片的轴线间隔阵列分布。
本申请的方案中，磁槽在轴向面上形成的开口可反映磁槽的横截面结构。具体的，第一 内开口与第二内开口围成的内磁极夹角即第一内磁槽与第二内磁槽围成的V形的张角，第一外开口与第二外开口围成的外磁极夹角即第一外磁槽与第二外磁槽围成的V形的张角；第一内开口、第二内开口、第一外开口及第二外开口均可呈条形，可定义其宽度，其中第一内开口与第二内开口等宽度，第一外开口与第二外开口等宽度。
在永磁同步电机中，第一外开口的宽度与第一内开口的宽度的取值对电机的直轴磁路的磁阻影响较大，即对直轴磁路的电感影响较大。外磁极夹角与内磁极夹角的取值对电机的交轴磁路的磁阻影响较大，即对交轴磁路的电感影响较大(磁阻越小，电感越大；反之，磁阻越大，电感越小)。电机的凸极比为交轴电感与直轴电感的比值，电机转矩为磁阻转矩(永磁同步电机的交、直轴电感差异所产生的电磁转矩分量)加上永磁转矩(由永磁同步电机的永磁体所产生的电磁转矩分量)。永磁体用量与永磁转矩之间为正相关的数值关系。本方案中，通过对第一外开口的宽度与第一内开口的宽度，以及外磁极夹角与内磁极夹角做上述数值匹配，能够增大电机的交轴电感与直轴电感的比值，提升凸极比。凸极比提升后，电机对磁阻转矩的利用率也得到提升，在输出同样大小的电机转矩时，永磁转矩可以较小，由此可以减少永磁体用量，从而降低成本。
在一种实现方式中，可以在转子铁芯片的轴向面上定义出外极弧角和内极弧角，其中外极弧角为第一外开口及第二外开口所对应的极弧角，内极弧角为第一内开口及第二内开口所对应的极弧角。内极弧角为外极弧角的2-2.5倍。
一个磁极单元的合成磁势是由第一外磁槽及第二外磁槽中的永磁体产生的磁势(以下简称为外层磁势)，与第一内磁槽及第二内磁槽中的永磁体产生的磁势(以下简称为内层磁势)叠加得到，合成磁势既受外层磁势或内层磁势的单独影响，当然也受二者的叠加结果影响。合成磁势、外层磁势及内层磁势的波形均包括基波与谐波。外层磁势中的基波与谐波均与外磁极夹角、外极弧角有关，内层磁势中的基波与谐波均与内磁极夹角、内极弧角有关。本实现方式中，通过同时对内磁极夹角、外磁极夹角、内极弧角、外极弧角做如上数值匹配，能够优化合成磁势的波形，有效抑制合成磁势的波形中的谐波分量，提高气隙磁场波形的正弦性，从而降低永磁同步电机的齿槽转矩和转矩波动，减小电机的振动噪声。并且，由于外磁极夹角与内磁极夹角不等，使得外磁极夹角与内磁极夹角在数值匹配时可产生更多组合，由此能更加灵活地优化合成磁势的波形，以满足产品需求。
在一种实现方式中，第一内开口靠近和/或远离第二内开口的一端包括至少两段弧线，至少两段弧线依次相切，且每相邻两段弧线的弦形成钝角。由此，该两段弧线不仅平滑过渡，且不会形成尖锐的转角。由于第一内开口的宽度较大，且第一内开口远离第二内开口的一端距离轴向面的圆心较远，在转子铁芯片高速转动时，该端由于离心力作用会出现较大应力。此种弧线过渡结构能够有效减小该端的曲率变化，使得该端的应力分布较为均匀，应力集中系数较低，从而避免该端出现应力集中，有利于保证电机的峰值转速，提升电机的功率密度。
在一种实现方式中，第一内开口靠近第二内开口的一端包括依次相连的第一弧线段、第二弧线段、直线段、第三弧线段及第四弧线段，第二弧线段直线段相切，直线段与第三弧线段相切。其中，直线段能够保证转子铁芯片的结构强度。第二弧线段与第三弧线段分别与直线段的相对两端相切。第一弧线段与第二弧线段形成上述的平滑过渡连接，即第一弧线段与第二弧线段相切，第一弧线段的弦与第二弧线段的弦形成钝角。同样的，第三弧线段及第四弧线段也形成上述的平滑过渡连接，即第三弧线段与第四弧线段相切，第一弧线段的弦与第二弧线段的弦形成钝角。多段弧线平滑过渡，有利于进一步减小第一内开口靠近第二内开口的一端的曲率变化，使应力分布更为均匀，避免应力集中。
本实现方式中，根据产品需要可以合理设计第一弧线段、第二弧线段、直线段、第三弧线段及第四弧线段的形状尺寸和位置尺寸。例如，可以使第一内开口靠近第二内开口的一端呈现“耳廓形”结构。该“耳廓形”结构不仅有利于优化应力分布，而且能与转子铁芯片的主体结构很好地适应，提升了转子铁芯片的量产性。
在一种实现方式中，至少两段弧线的半径均不同，这能够细化曲率变化的梯度，使应力分布更加平滑，从而进一步减小应力集中系数。
在一种实现方式中，转子铁芯片具有圆周面，圆周面的局部区域内凹形成凹陷，凹陷具有与轴向平行的相对的两边，凹陷在轴向上的相对两端均贯通轴向面。凹陷的设置使得转子铁芯片的圆周面的形状发生改变，进而使转子与定子之间的气隙发生变化。永磁同步电机中，气隙的磁导波形与气隙的宽度有关。本实现方式中，通过设置凹陷可以局部增大气隙的宽度，进而优化气隙的磁导波形，抑制气隙的磁导波形中的谐波分量。另外，由转子的磁场强度＝磁势*磁导可知，基于上述优化合成磁势的波形的方案，配合本实施方式中对气隙的磁导波形的优化，能够进一步实现对气隙的磁场强度的谐波分量的抑制，提高气隙的磁场强度的波形的正弦性。
在一种实现方式中，圆周面的局部区域外凸形成凸起，凸起在轴向上的相对两端均延伸至轴向面，凸起具有与轴向平行的相对的两边，凹陷对称分布在凸起的相对两侧，凹陷与凸起相间隔。凸起的设置同样使得转子铁芯片及转子铁芯的圆周面的形状发生改变，进而局部减小气隙，从而优化气隙的磁导波形，抑制气隙的磁导波形中的谐波分量，还可以对气隙的磁场强度的谐波分量进行抑制，提高气隙的磁场强度的波形的正弦性。并且，同时设置凸起与凹陷能够对气隙的磁导波形及气隙的磁场强度波形进行更加精细的调整。
在一种实现方式中，第一外开口与第二外开口相靠近的两端之间形成隔磁桥。设置隔磁桥能够减少漏磁，并且设置能增加转子铁芯片的机械强度，避免转子铁芯片在高速旋转时由于内部应力导致转子铁芯片损坏。转子铁芯片的机械强度得到提升，能够使电机的峰值转速不再受限，从而能够保证电机的功率密度。
第二方面，本申请提供了一种转子铁芯,包括若干个转子铁芯片，所有转子铁芯片沿轴向层叠，所有转子铁芯的圆周向轮廓完全重叠，此种层叠组装设计能降低转子铁芯的涡流损耗。本申请的转子铁芯能够提升永磁同步电机的凸极比，减少永磁体用量，降低成本。
第三方面，本申请提供了一种转子，包括转轴、永磁体及转子铁芯，每个转子铁芯片的第一外磁槽、第二外磁槽、第一内磁槽及第二内磁槽内均安装有永磁体，转轴沿转子铁芯的轴向穿过转子铁芯并与转子铁芯固定连接，每个转子铁芯片的第一外磁槽、第二外磁槽、第一内磁槽及第二内磁槽均分布在转轴的外周。本申请的转子能够提升永磁同步电机的凸极比，减少永磁体用量，降低成本。
第四方面，本申请提供了一种永磁同步电机，包括定子和转子，定子套设在转子铁芯的外周并与转子铁芯之间留有气隙，转轴伸出定子。本申请的永磁同步电机具有较大凸极比，永磁体用量小，成本低廉。
第五方面，本申请提供了一种动力总成，包括电机控制器和永磁同步电机，电机控制器与永磁同步电机电连接以控制永磁同步电机。本申请的动力总成性能良好，成本低廉。
第六方面，本申请提供了一种电动车，包括车架和动力总成，动力总成安装于车架上。本申请的电动车性能良好，成本低廉。
附图说明
为了说明本申请实施例或背景技术中的技术方案，下面将对本申请实施例或背景技术中所需要使用的附图进行说明。
图1是本申请实施例的电动车的结构示意图；
图2是图1中的电动车的动力总成的结构框图；
图3是图2中的动力总成中的永磁同步电机的结构示意图；
图4是图3中的永磁同步电机的横截面结构示意图；
图5是图4中的永磁同步电机的转子的结构示意图；
图6是表示图5中的转子的转子铁芯与永磁体的组装结构示意图；
图7是表示图5中的转子的一个转子铁芯片与永磁体的组装结构示意图；
图8是图7中的转子铁芯片的正视结构示意图；
图9是图8中的转子铁芯片的一个局部结构示意图；
图10是图8中的转子铁芯片的另一个局部结构示意图；
图11是图8中的转子铁芯片的另一个局部结构示意图；
图12是图10中B1处的局部放大结构示意图；
图13是图10中B2处的局部放大结构示意图；
图14是本申请实施例的转子铁芯片的另一种结构示意图。
具体实施方式
本申请实施例提供了一种电动车，包括但不限于电动小汽车、电动巴士、电动摩托等，例如图1示意出了一种电动SUV(Sport Utility Vehicle，运动型实用汽车)10。电动车10可以包括车架和安装在车架上的动力总成。其中，车架作为电动车10的结构骨架，用于支撑、固定和连接各个总成，承受汽车系统内部和来自外部环境的载荷。动力总成是由一系列部件构成的、用于产生动力并将动力传递到路面的系统。如图2所示，动力总成11可以包括电机控制器12和永磁同步电机13。电机控制器12与永磁同步电机13电连接，用于控制永磁同步电机13工作。
如图3、图4、图5和图6所示，永磁同步电机13包括定子14和转子15。定子14可以具有圆筒状内腔。转子15包括转子铁芯18、永磁体19及转轴17。转子铁芯18可以呈圆柱状，其具有轴向面(法线沿转子铁芯18的轴向的表面)和圆周面。该轴向面上开设有若干磁槽，该磁槽可以沿轴向贯通转子铁芯18。在该轴向面上，每个磁槽均未延伸至轴心(即均与轴心保持间隔)，若干磁槽环绕轴心间隔阵列分布。每个磁槽内均安装有用于提供磁场的永磁体19。转子铁芯18安装在定子14的内腔中，转子铁芯18的圆周面与该内腔的腔壁之间留有气隙。转子铁芯18内设有沿轴向延伸的轴孔，转轴17穿过该轴孔与转子铁芯18固定连接以跟随转子铁芯18转动，磁槽及永磁体19均分布在转轴17的外周。转轴17伸到定子14的内腔外，便于输出转矩。为对安装有永磁体19的转子铁芯18进行限位和防护，在转子铁芯18的轴向两端均可以设置端盖16，转轴17贯穿该端盖16。
如图6所示，本申请实施例中，转子铁芯18可包括若干个转子铁芯片181。转子铁芯片181呈圆柱状，所有转子铁芯片181沿轴向依次层叠，所有转子铁芯18的圆周向轮廓完全重叠，此种层叠组装设计能降低转子铁芯18的涡流损耗。转子铁芯片181上开设有若干磁槽，根据产品需要，各个转子铁芯片181同一位置的磁槽可以形成设定的位置关系，例如各个转子铁芯片181同一位置的所有磁槽完全重叠，或者同一位置的所有磁槽可以依次错位。以下将以单个转子铁芯片181为例，详细描述本申请实施例的方案。
如图7所示，一种实施方式中，圆柱状的转子铁芯片181具有轴向面A(轴向面A有两个)和圆周面C。转子铁芯片181上开设有若干第一外磁槽1812、若干第二外磁槽1813、若干第一内磁槽1811及若干第二内磁槽1814，所有磁槽均沿转子铁芯片181的轴向贯穿转子铁芯片181的相对两端，所有磁槽相互间隔，并均与该轴向面A的边界保持间隔(即磁槽未贯穿该圆周面C)。其中，相邻的一个第一外磁槽1812与一个第二外磁槽1813围成V形，该V形的开口朝转子铁芯片181的外侧。相邻的一个第一内磁槽1811与一个第二内磁槽1814也围成V形，该V形的开口也朝转子铁芯片181的外侧。围成V形的一个第一外磁槽1812与一个第二外磁槽1813，以及围成V形的一个第一内磁槽1811与一个第二内磁槽1814构成一个磁槽单元。该磁槽单元中，第一内磁槽1811与第二内磁槽1814包围在第一外磁槽1812与第二外磁槽1813的外周。每个磁槽单元中，第一外磁槽1812与第二外磁槽1813形状相同，第一内磁槽1811与第二内磁槽1814形状相同。若干这样的磁槽单元可绕转子铁芯片181的轴线间隔阵列分布。每个磁槽中均安装有永磁体19。一个磁槽单元及其中安装的永磁体19合起来可称为一个磁极单元。转子铁芯片181上还可以开设若干减重孔1815，减重孔1815沿转子铁芯片181的轴向贯穿转子铁芯片181的相对两端，减重孔1815与磁槽间隔布置。减重孔1815用于减小转子铁芯片181的重量，便于提升转子铁芯片181的转速。
如图7所示，单个磁槽单元中，第一外磁槽1812与第二外磁槽1813围成钝角，且该钝角朝转子铁芯片181的外侧张开，也即第一外磁槽1812与第二外磁槽1813间距较小的两端位于转子铁芯片181的内周，第一外磁槽1812与第二外磁槽1813间距较大的两端位于转子铁芯片181的外周。同样的，第一内磁槽1811与第二内磁槽1814也围成钝角，并且该钝角朝转子铁芯片181的外侧张开，也即第一内磁槽1811与第二内磁槽1814间距较小的两端位于转子铁芯片181的内周，第一内磁槽1811与第二内磁槽1814间距较大的两端位于转子铁芯片181的外周。从转子铁芯片181的轴向看，第一外磁槽1812与第二外磁槽1813位于第一内磁槽1811与第二内磁槽1814所围的钝角的区域内，即第一内磁槽1811与第二内磁槽1814包围在第一外磁槽1812与第二外磁槽1813的外周。单个磁槽单元中，第一外磁槽1812与第二外磁槽1813围成的钝角，大于或等于第一内磁槽1811与第二内磁槽1814围成的钝角。第一外磁槽1812与第二外磁槽1813关于转子铁芯片181的一条半径对称，第一内磁槽1811与第二内磁槽1814也关于该半径对称，即第一外磁槽1812、第二外磁槽1813的对称轴与第一内磁槽1811、第二内磁槽1814的对称轴相同。在其他实施方式中，根据产品需要，单个磁槽单元中内外磁槽的对称轴可以不同，或者内磁槽与外磁槽中的至少一对可以呈非对称排布。另外，第一内磁槽1811与第二内磁槽1814之间，和/或第一外磁槽1812与第二外磁槽1813之间可以连通。
磁槽沿转子铁芯片181的轴线延伸并贯通转子铁芯片181，磁槽在该轴向面A上形成的开口即为磁槽的横截面轮廓，以下将针对单个磁槽单元，以该开口为描述对象，继续说明本申请实施例的磁槽设计。
如图7、图8和图9所示，第一内磁槽1811在该轴向面A上形成第一内开口1811m，第二内磁槽1814在该轴向面A上形成第二内开口1814m，第一内开口1811m与第二内开口1814m近该轴向面A的圆心的一端均与该圆心保持间隔。第一内开口1811m可以包括平行相对的两条直边L1与L2，第二内开口1814m也可以包括平行相对的两条直边L3与L4，第一内开口1811m的一条直边L2与第二内开口1814m的一条直边L3形成钝角，该钝角可称为内磁极夹角θ1，也即第一内开口1811m与第二内开口1814m围成内磁极夹角θ1，内磁极夹角θ1即上述第一内磁槽1811与第二内磁槽1814所围成的钝角。内磁极夹角θ1的范围例如可以是 [110°,140°]。第一内开口1811m与第二内开口1814m均呈长条状，第一内开口1811m的两条平行相对直边L1与L2的间距称为第一内开口1811m的宽度W1。第一内开口1811m的宽度W1例如可以是2mm-6mm(含端点值)。同样，第二内开口1814m的两条平行相对直边L3与L4的间距称为第二内开口1814m的宽度，第二内开口1814m的宽度等于第一内开口1811m的宽度W1。第一内开口1811m的两条直边L1与L2之间的空间，以及第二内开口1814m的两条直边L3与L4之间的空间，均用于安装永磁体19。第一内开口1811m的一条直边(例如图9中下方的直边L1)的相对两端可以形成凸起部T1与T2，两端的两个凸起部T1与T2用于卡持永磁体19。同样，第二内开口1814m的一条直边(例如图9中下方的直边L4)的相对两端可以形成凸起部T3与T4，两端的两个凸起部T3与T4用于卡持永磁体19。当然，对于第一内开口1811m而言，凸起部T1与凸起部T2可以分别位于直边L1与直边L2上，即凸起部T1与凸起部T2呈对角线分布；对于第二内开口1814m而言，凸起部T3与凸起部T4也可以分别位于直边L3与直边L4上，即凸起部T3与凸起部T4呈对角线分布。在其他实施方式中，内磁极夹角θ1和/或第一内开口1811m的宽度W1可以根据需要取值，不限于为上文。
如图7-图9所示，第一外磁槽1812在该轴向面A上形成第一外开口1812m，第二外磁槽1813在该轴向面A上形成第二外开口1813m。第一外开口1812m与第二外开口1813m均位于内磁极夹角θ1的区域内。第一外开口1812m可以包括平行相对的两条直边S1与S2，第二外开口1813m也可以包括平行相对的两条直边S3与S4。第一外开口1812m的一条直边S2与第二外开口1813m的一条直边S3形成钝角，该钝角可称为外磁极夹角θ2，也即第一外开口1812m与第二外开口1813m围成外磁极夹角θ2，外磁极夹角θ2即上述第一外磁槽1812与第二外磁槽1813所围成的钝角。外磁极夹角θ2的范围例如可以是[110°,160°]。第一外开口1812m与第二外开口1813m均呈长条状。第一外开口1812m的两条平行相对直边S1与S2的间距称为第一外开口1812m的宽度W2，第一外开口1812m的宽度W2例如可以是1mm-3mm(含端点值)。同样，第二外开口1813m的两条平行相对直边S3与S4的间距称为第二外开口1813m的宽度，第二外开口1813m的宽度等于第一外开口1812m的宽度W2。第一外开口1812m的两条直边S1与S2之间的空间，以及第二外开口1813m的两条直边S3与S4之间的空间，均用于安装永磁体19。与第一内开口1811m和第二内开口1814m包括凸起部的设计相同，第一外开口1812m的一条直边S1的相对两端、第二外开口1813m的一条直边S4的相对两端也可以形成凸起部均可以形成凸起部，凸起部用于卡持永磁体19。当然，对于第一外开口1812m或第二外开口1813m而言，两个凸起部也可以分别位于两条直边S1与S2，或者S3与S4上，即两个凸起部呈对角线分布。在其他实施方式中，外磁极夹角θ2和/或第一外开口1812m的宽度W2可以根据需要取值，不限于为上文。
本实施方式中，外磁极夹角θ2可以大于或等于内磁极夹角θ1，二者差值的范围可以是[0°,50°]。第一内开口1811m的宽度W1例如可以是第一外开口1812m的宽度W2的1.5-2倍(含端点值)。
在永磁同步电机13中，第一外开口1812m的宽度W2与第一内开口1811m的宽度W1的取值对电机的直轴磁路的磁阻影响较大，即对直轴磁路的电感影响较大。外磁极夹角θ2与内磁极夹角θ1的取值对电机的交轴磁路的磁阻影响较大，即对交轴磁路的电感影响较大(磁阻越小，电感越大；反之，磁阻越大，电感越小)。电机的凸极比为交轴电感与直轴电感的比值，电机转矩为磁阻转矩(永磁同步电机13的交、直轴电感差异所产生的电磁转矩分量)加上永磁转矩(由永磁同步电机13的永磁体19所产生的电磁转矩分量)。永磁体19的用量与永磁转矩之间为正相关的数值关系。
本实施方式中，通过对第一外开口1812m的宽度W2与第一内开口1811m的宽度W1，以及外磁极夹角θ2与内磁极夹角θ1做如上数值匹配，能够增大电机的交轴电感与直轴电感的比值，提升凸极比。凸极比提升后，电机对磁阻转矩的利用率也得到提升，在输出同样大小的电机转矩时，永磁转矩可以较小，由此可以减少永磁体19的用量(例如可以减少20％的用量)，从而降低成本。并且，由于外磁极夹角θ2与内磁极夹角θ1不等(即内外磁槽并非平行嵌套)，第一外开口1812m的宽度W2与第一内开口1811m的宽度W1也不等，使得外磁极夹角θ2与内磁极夹角θ1在数值匹配时可产生更多组合，使第一外开口1812m的宽度W2与第一内开口1811m的宽度W1在数值匹配时也可产生更多组合，由此能更加灵活地优化凸极比，以满足产品需求。另外，还可以使交轴电感与直轴电感均较大，从而增大电机电感，以便于对电机进行工作控制，提升电机性能。同时，使得直轴电感较大也提高了电机的弱磁扩速能力。
如图10所示，本实施方式中，第一外开口1812m与第二外开口1813m相间隔，二者之中相靠近的两端之间形成隔磁桥1818，第一外开口1812m与轴向面A的边界之间形成隔磁桥1817，第二外开口1813m与轴向面A的边界之间形成隔磁桥1820。外磁极夹角θ2所限定的区域可称为转子极靴铁芯1819。相应的，第一内开口1811m与第二内开口1814m相间隔，二者之中相靠近的两端之间形成隔磁桥1824，第一内开口1811m与轴向面A的边界之间形成隔磁桥1816，第二内开口1814m与轴向面A的边界之间形成隔磁桥1822。内磁极夹角θ1与外磁极夹角θ2共同限定的区域可称为铁芯支路1821，转子极靴铁芯1819通过隔磁桥1818与铁芯支路1821连接。隔磁桥1824背离铁芯支路1821的一端所连接的区域可称为转子轭部1825，转子轭部1825为转子铁芯片181的轴心区域。永磁体19的磁力线依次经转子轭部1825、铁芯支路1821及转子极靴铁芯1819到达气隙，即转子轭部1825、铁芯支路1821及转子极靴铁芯1819均为磁力线的传递路径。相邻的磁槽单元之间的区域称为磁肋1823，磁肋1823位于一个磁槽单元的第一内开口1811m与另一相邻磁槽单元的第二内开口1814m之间。
本实施方式中，由于隔磁桥的结构及尺寸限制，穿过隔磁桥的磁通量受限，隔磁桥处能达到磁饱和状态而出现磁堵塞现象，使得其余的磁力线将无法通过隔磁桥，只能经过该传递路径到达气隙并传递到定子14，实现电磁感应。因此，通过设置上述隔磁桥，能够确保大部分磁力线均通过该传递路径，减少漏磁。另外，设置隔磁桥也能增加转子铁芯片181的机械强度，尤其是第一外开口1812m与第二外开口1813m相靠近的两端之间形成的隔磁桥1818，能与第一外开口1812m及第二外开口1813m分别与轴向面A边界之间的隔磁桥1817和隔磁桥1820共同承受应力，避免转子铁芯片181在高速旋转时由于内部应力导致转子铁芯片181损坏。转子铁芯片181的机械强度得到提升，能够使电机的峰值转速不再受限(例如峰值转速可提升20％)，从而能够保证电机的功率密度。
本实施方式中，可以在转子铁芯片181的轴向面A上定义出外极弧角α2和内极弧角α1，外极弧角α2和内极弧角α1的顶点均为轴向面A的圆心O。具体的，如图11所示，第一外开口1812m具有朝向轴向面A的边界的第一外周边L6，第一外周边L6为直线，第一外周边L6也为隔磁桥1817的边界。第一外周边L6靠近第二外开口1813m的一端与该圆心O的连线作为外极弧角α2的一边。当第一外周边L6靠近第二外开口1813m的一端与倒圆角圆弧连接时，外极弧角α2的一边经过第一外周边L6的端点，而非经过该倒圆角圆弧上的点。同样的，第二外开口1813m具有朝向轴向面A的边界的第二外周边L7，第二外周边L7为直线，第二外周边L7也为隔磁桥1820的边界。第二外周边L7靠近第一外开口1812m的一端与该圆心O的连线作为外极弧角α2的另一边。当第二外周边L7靠近第一外开口1812m的一端与倒圆角 圆弧连接时，外极弧角α2的另一边经过第二外周边L7的端点，而非经过该倒圆角圆弧上的点。同样的，第一内开口1811m具有朝向轴向面A的边界的第一内周边L5，第一内周边L5为直线，第一内周边L5也为隔磁桥1816的边界。第一内周边L5靠近第二内开口1814m的一端与该圆心O的连线作为内极弧角α1的一边。当第一内周边L5靠近第二内开口1814m的一端与倒圆角圆弧连接时，内极弧角α1的一边经过第一内周边L5的端点，而非经过该倒圆角圆弧上的点。同样的，第二内开口1814m具有朝向轴向面A的边界的第二内周边L8，第二内周边L8为直线，第二内周边L8也为隔磁桥1822的边界。第二内周边L8靠近第一内开口1811m的一端与该圆心O的连线作为内极弧角α1的另一边。当第二内周边L8靠近第一内开口1811m的一端与倒圆角圆弧连接时，内极弧角α1的另一边经过第二内周边L8的端点，而非经过该倒圆角圆弧上的点。
本实施方式中，内极弧角α1大于外极弧角α2，并且内极弧角α1可以为外极弧角α2的2-2.5(含端点值)。例如，内极弧角α1可以是40°-56.67°(含端点值)，外极弧角α2可以是18.33°-26.67°(含端点值)。在其他实施方式中，内极弧角α1和/或外极弧角α2可以根据需要取值，不限于为上文。
一个磁极单元的合成磁势是由第一外磁槽1812及第二外磁槽1813中的永磁体19产生的磁势(以下简称为外层磁势)，与第一内磁槽1811及第二内磁槽1814中的永磁体19产生的磁势(以下简称为内层磁势)叠加得到，合成磁势既受外层磁势或内层磁势的单独影响，当然也受二者的叠加结果影响。合成磁势、外层磁势及内层磁势的波形均包括基波与谐波。外层磁势中的基波与谐波均与外磁极夹角θ2、外极弧角α2有关，内层磁势中的基波与谐波均与内磁极夹角θ1、内极弧角α1有关。
结合图9与图11，本实施方式中，通过同时对内磁极夹角θ1、外磁极夹角θ2、内极弧角α1、外极弧角α2做如上数值匹配，能够优化合成磁势的波形，有效抑制合成磁势的波形中的谐波分量，提高气隙磁场波形的正弦性，从而降低永磁同步电机13的齿槽转矩和转矩波动，减小电机的振动噪声。并且，由于外磁极夹角θ2与内磁极夹角θ1不等，使得外磁极夹角θ2与内磁极夹角θ1在数值匹配时可产生更多组合，由此能更加灵活地优化合成磁势的波形，以满足产品需求。在其他实施方式中，该设计并非是必需的。
本实施方式中，还可以通过对磁槽的开口赋予弧线过渡设计，以优化应力分布，避免应力集中。
具体结合图9、图10和图12所示，第一内开口1811m远离第二内开口1814m的一端可以包括两段弧线R1和R2(指圆弧线)，弧线R1和弧线R2相切连接，弧线R1与弧线R2均具有弦(弦指连接弧线的两个端点的线段)，弧线R1与弧线R2的弦形成钝角。由此，该两段弧线R1和R2不仅平滑过渡，且不会形成尖锐的转角。该两段弧线R1和R2具体可以设在隔磁桥1816与磁肋1823的连接处，和/或设在隔磁桥1816与铁芯支路1821连接处。第一内开口1811m的宽度W1较大，且第一内开口1811m远离第二内开口1814m的一端距离轴向面A的圆心较远，在转子铁芯片181高速转动时，该端由于离心力作用会出现较大应力。此种弧线过渡结构能够有效减小该端的曲率变化，使得该端的应力分布较为均匀，应力集中系数较低，从而避免该端出现应力集中。当然，根据产品需要，平滑过渡的弧线可以是三段或更多。第二内开口1814m远离第一内开口1811m的一端也可以具有该弧线过渡结构，该端的弧线过渡结构与第一内开口1811m远离第二内开口1814m的一端的弧线过渡结构对称。第一外开口1812m与第二外开口1813m相靠近的两端可以均具有该弧线过渡结构，两处该弧线过渡结构对称。第一外开口1812m与第二外开口1813m相背离的两端也可以具有该弧线过渡结构，两 处该弧线过渡结构对称。当然，本申请实施例中该弧线过渡结构并非是必需的，例如磁槽的开口可以只包括直线段。
特别的，鉴于第一内开口1811m靠近第二内开口1814m的一端靠近转子轭部1825，结构空间较大，该端的弧线过渡结构可以更为复杂。具体结合图9、图10和图13所示，第一内开口1811m靠近第二内开口1814m的一端可以包括第一弧线段R3、第二弧线段R4、直线段L9、第三弧线段R5及第四弧线段R6，第一弧线段R3、第二弧线段R4、直线段L9、第三弧线段R5及第四弧线段R6依次相连。其中，直线段L9可以作为隔磁桥的一条宽度边界，其直线形状能够保证隔磁桥的结构强度。第二弧线段R4与第三弧线段R5分别与直线段L9的相对两端相切。第一弧线段R3与第二弧线段R4形成上述的平滑过渡连接，即第一弧线段R3与第二弧线段R4相切，第一弧线段R3的弦与第二弧线段R4的弦形成钝角。同样的，第三弧线段R5及第四弧线段R6也形成上述的平滑过渡连接，即第三弧线段R5与第四弧线段R6相切，第一弧线段R3的弦与第二弧线段R4的弦形成钝角。多段弧线平滑过渡，有利于进一步减小第一内开口1811m靠近第二内开口1814m的一端的曲率变化，使应力分布更为均匀，避免应力集中。第二内开口1814m靠近第一内开口1811m的一端也可以具有该弧线过渡结构，该端的弧线过渡结构与第一内开口1811m靠近第二内开口1814m的一端的弧线过渡结构对称。
本实施方式中，根据产品需要，可以合理设计第一弧线段R3、第二弧线段R4、直线段L9、第三弧线段R5及第四弧线段R6的形状尺寸和位置尺寸。例如，结合图9、图10和图13所示，第一弧线段R3可与第一内开口1811m的一条直边L2相连，第四弧线段R6远离第三弧线段R5的一端可与该凸起部T2相连，使第一内开口1811m靠近第二内开口1814m的一端可以呈现“耳廓形”结构。该“耳廓形”结构不仅有利于优化应力分布，而且能与凸起部T2及第一内开口1811m的主体部分很好地适应，提升了转子铁芯片181的量产性。当然，该“耳廓形”结构仅仅是一种举例，并非是必需的。
本实施方式中，上述弧线过渡结构中，各条弧线的半径可以均不相同，该设计能够细化曲率变化的梯度，使应力分布更加平滑，从而进一步减小应力集中系数。当然此种设计并非是必需的，例如所有弧线的半径均可以相同。
如图14所示，一种实施方式中，转子铁芯片181的圆周面C的局部区域可以内凹形成凹陷，该凹陷可以呈条形，其具有与转子铁芯片181的轴向平行的相对两边。该凹陷沿转子铁芯片181的轴向延伸，且相对两端均贯通转子铁芯片181的轴向面A。该凹陷在该轴向面A上可以形成圆弧形开口，凹陷的深度可以较小以避免对圆周面C的形状造成较大改变。该凹陷可以是若干个，例如每个磁槽单元附近可以均设置凹陷C1、凹陷C2、凹陷C4及凹陷C5，若干个凹陷间隔分布在该圆周面C上。凹陷的设置使得转子铁芯片181及转子铁芯18的圆周面C的形状发生改变，进而使转子15与定子14之间的气隙发生变化。永磁同步电机13中，气隙的磁导波形与气隙的宽度有关。本实施方式中，通过设置凹陷可以局部增大气隙的宽度，进而优化气隙的磁导波形，抑制气隙的磁导波形中的谐波分量。另外，由转子15的磁场强度＝磁势*磁导可知，基于上述优化合成磁势的波形的方案，配合本实施方式中对气隙的磁导波形的优化，能够进一步实现对气隙的磁场强度的谐波分量的抑制，提高气隙的磁场强度的波形的正弦性。在其他实施方式中，凹陷的具体结构及数量不限于上文，或者凹陷也可以取消。
如图14所示，一种实施方式中，圆周面C的局部区域还可以外凸形成凸起C3，该凸起C3可以呈条形，其具有与转子铁芯片181的轴向平行的相对两边。该凸起C3可沿转子铁芯片181的轴向延伸，其在轴向上的相对两端均延伸至轴向面A。凹陷则对称分布在凸起C3的相对两侧，凹陷与凸起C3相间隔。例如，凸起C3的一侧可以设凹陷C1与凹陷C2，另一侧 可以设凹陷C4与凹陷C5，凹陷C1与凹陷C5对称，凹陷C2与凹陷C4对称。凸起C3的设置同样使得转子铁芯片181及转子铁芯18的圆周面C的形状发生改变，进而局部减小气隙，从而优化气隙的磁导波形，抑制气隙的磁导波形中的谐波分量，还可以对气隙的磁场强度的谐波分量进行抑制，提高气隙的磁场强度的波形的正弦性。并且，同时设置凸起C3与凹陷能够对气隙的磁导波形及气隙的磁场强度波形进行更加精细的调整。在其他实施方式中，凸起C3的具体结构及数量不限于上文，也可以是凸起C3对称设在凹陷的相对两侧，还可以仅设置凸起C3而没有凹陷，或者仅有凹陷而没有凸起C3。
以上所述，仅为本申请的具体实施方式，但本申请的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本申请揭露的技术范围内，可轻易想到变化或替换，都应涵盖在本申请的保护范围之内。因此，本申请的保护范围应以所述权利要求的保护范围为准。

Claims (13)

  1. 一种转子铁芯片，其特征在于，
    所述转子铁芯片具有轴向面，所述轴向面开设有第一内磁槽、第二内磁槽、第一外磁槽及第二外磁槽；所述第一内磁槽在所述轴向面上形成第一内开口，所述第二内磁槽在所述轴向面上形成第二内开口，所述第一内开口与所述第二内开口围成内磁极夹角，所述内磁极夹角朝所述转子铁芯片的外侧张开，所述内磁极夹角为钝角；所述第一外磁槽在所述轴向面上形成第一外开口，所述第二外磁槽在所述轴向面上形成第二外开口，所述第一外开口与所述第二外开口均位于所述内磁极夹角的区域内，所述第一外开口与所述第二外开口围成外磁极夹角，所述外磁极夹角朝所述转子铁芯片的外侧张开，所述外磁极夹角为大于或等于所述内磁极夹角的钝角，且所述外磁极夹角与所述内磁极夹角的差值在[0°,50°]，所述第一内开口及所述第二内开口均与所述第一外开口及所述第二外开口相间隔，所述第一内开口的宽度为所述第一外开口的宽度的1.5-2倍。
  2. 根据权利要求1所述的转子铁芯片，其特征在于，
    所述转子铁芯片具有外极弧角和内极弧角，所述外极弧角的一条边经过第一外开口与所述轴向面的边界之间的区域靠近所述第二外开口的一端，所述外极弧角的另一条边经过第二外开口与所述轴向面的边界之间的区域中靠近所述第一外开口的一端，所述内极弧角的一条边经过第一内开口与所述轴向面的边界之间的区域中靠近所述第二内开口的一端，所述内极弧角的另一条边经过第二内开口与所述轴向面的边界之间的区域中靠近所述第二内开口的一端，所述内极弧角为所述外极弧角的2-2.5倍。
  3. 根据权利要求1或2所述的转子铁芯片，其特征在于，
    所述第一内开口靠近和/或远离所述第二内开口的一端包括至少两段弧线，所述至少两段弧线依次相切，且每相邻两段弧线的弦形成钝角。
  4. 根据权利要求3所述的转子铁芯片，其特征在于，
    所述第一内开口靠近所述第二内开口的一端包括依次相连的第一弧线段、第二弧线段、直线段、第三弧线段及第四弧线段，所述第二弧线段所述直线段相切，所述直线段与所述第三弧线段相切。
  5. 根据权利要求3所述的转子铁芯片，其特征在于，
    所述至少两段弧线的半径均不同。
  6. 根据权利要求1或2所述的转子铁芯片，其特征在于，
    所述转子铁芯片具有圆周面，所述圆周面的局部区域内凹形成凹陷，所述凹陷具有与所述轴向平行的相对的两边，所述凹陷在所述轴向上的相对两端均贯通所述轴向面。
  7. 根据权利要求6所述的转子铁芯片，其特征在于，
    所述圆周面的局部区域外凸形成凸起，所述凸起在所述轴向上的相对两端均延伸至所述轴向面，所述凸起具有与所述轴向平行的相对的两边，所述凹陷对称分布在所述凸起的相对两侧，所述凹陷与所述凸起相间隔。
  8. 根据权利要求1或2所述的转子铁芯片，其特征在于，
    所述第一外开口与所述第二外开口相靠近的两端之间形成隔磁桥。
  9. 一种转子铁芯，其特征在于，
    包括若干个权利要求1-8任一项所述的转子铁芯片，所有所述转子铁芯片沿轴向层叠。
  10. 一种转子，其特征在于，
    包括转轴、永磁体及权利要求9所述的转子铁芯，每个所述转子铁芯片的所述第一外磁槽、所述第二外磁槽、所述第一内磁槽及所述第二内磁槽内均安装有所述永磁体，所述转轴沿所述转子铁芯的轴向穿过所述转子铁芯并与所述转子铁芯固定连接，每个所述转子铁芯片的所述第一外磁槽、所述第二外磁槽、所述第一内磁槽及所述第二内磁槽均分布在所述转轴的外周。
  11. 一种永磁同步电机，其特征在于，
    包括定子和权利要求10所述的转子，所述定子套设在所述转子铁芯的外周并与所述转子铁芯之间留有气隙，所述转轴伸出所述定子。
  12. 一种动力总成，其特征在于，
    包括电机控制器和权利要求11所述的永磁同步电机，所述电机控制器与所述永磁同步电机电连接。
  13. 一种电动车，其特征在于，
    包括车架和权利要求12所述的动力总成，所述动力总成安装于所述车架上。
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