WO2023142239A1 - 转子、电机及转子的制造方法 - Google Patents

转子、电机及转子的制造方法 Download PDF

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Publication number
WO2023142239A1
WO2023142239A1 PCT/CN2022/080974 CN2022080974W WO2023142239A1 WO 2023142239 A1 WO2023142239 A1 WO 2023142239A1 CN 2022080974 W CN2022080974 W CN 2022080974W WO 2023142239 A1 WO2023142239 A1 WO 2023142239A1
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WO
WIPO (PCT)
Prior art keywords
rotor
sheets
several
sheet
cavity
Prior art date
Application number
PCT/CN2022/080974
Other languages
English (en)
French (fr)
Inventor
刘鹏
Original Assignee
淄博朗达复合材料有限公司
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 淄博朗达复合材料有限公司 filed Critical 淄博朗达复合材料有限公司
Priority to JP2024513551A priority Critical patent/JP2024518001A/ja
Priority to EP22923058.6A priority patent/EP4346072A1/en
Publication of WO2023142239A1 publication Critical patent/WO2023142239A1/zh

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    • 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
    • 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
    • H02K1/00—Details of the magnetic circuit
    • H02K1/02—Details of the magnetic circuit characterised by the magnetic material
    • 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
    • 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
    • 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
    • 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]
    • 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
    • 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
    • H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots
    • H02K15/026—Wound cores
    • 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
    • H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
    • 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

Definitions

  • the present application relates to the technical field of motors, in particular to a rotor, a motor and a rotor manufacturing method.
  • the rotor of the existing motor rotates by being supported on the shaft with bearings and the magnetic force of the stator coil of the induction motor.
  • the existing rotor includes a rotor body formed by laminating several silicon steel sheets, and a wire coil or coil wound on the rotor body. Permanent magnets attached to the rotor body. Since the shaft and the rotor body are made of metal materials, the density of the metal materials used exceeds 7g/cm 3 , so the mass density of the entire rotor is relatively large, and the mass density of the entire rotor is relatively large.
  • the wear is serious due to the large size of the rotor, especially when the rotor is running at high speed, which puts forward higher requirements for the wear resistance of the bearing;
  • the third aspect is that the centrifugal force caused by the density of the rotor at high speed rotation exceeds the tensile strength of the metal material, As a result, the rotor is deformed or damaged; fourthly, the high mass density of the rotor leads to slow response of the rotor, making it difficult to precisely control the rotor speed.
  • the purpose of this application is to provide a rotor, a motor, and a rotor manufacturing method to solve the problem that the rotor body of the motor rotor in the prior art is made of laminated silicon steel sheets, which leads to the high mass density of the entire rotor and the difficulty of instantaneous start and stop.
  • the control and shaft support parts have high inertial pressure and are easy to wear and tear. When the rotor is running at high speed, the rotor is easily deformed or damaged, and the technical problem that precise control of the speed cannot be realized.
  • a method for manufacturing a rotor provided by the present application includes:
  • the rotor is formed after shaping and curing steps.
  • the rotor is an inner rotor
  • the step of assembling several sheets, permanent magnet elements/rotor coils to form a rotor prefabricated body includes:
  • the shape of the several sheets used to manufacture the inner rotor satisfies that: after being aligned and stacked together, the several sheets can cooperate to form a rotor body having a shaft cavity and the installation cavity, and the shaft cavity is suitable for installing the rotor axis.
  • the shapes of the several sheets are consistent, and each includes a first central hole, and several first arc-shaped holes arranged around the first central hole. After the several sheets are aligned and stacked together, the first A central hole forms the rotating shaft cavity, and the first arc-shaped hole forms an installation cavity for installing permanent magnetic elements;
  • the shapes of the several sheets are inconsistent, and the sheets include several first sheets that are laminated to form both ends of the rotor body, and several second sheets that are laminated to form the middle part of the rotor body, and the first sheets Both the material and the second sheet have a second central hole, and the second sheet has a second arc-shaped hole surrounding the second central hole.
  • the rotor is an outer rotor, and the shape of the several sheets used to manufacture the outer rotor satisfies that: several sheets can be aligned and stacked together to form a rotor body with a central cavity and the installation cavity,
  • the central cavity includes a stator cavity suitable for installing a stator, and bearing cavities located at both ends of the stator cavity and suitable for installing bearings.
  • the shapes of the several sheets used to manufacture the outer rotor meet the following requirements: the shapes of the several sheets are inconsistent, the sheets include several third sheets that are stacked to form both ends of the rotor body, and several The fourth sheet is laminated to form the middle part of the rotor body, the third sheet has a third central hole, and after a plurality of the third sheets are assembled, the third central hole is aligned to form the bearing cavity; The four sheets have a fourth central hole. After several fourth sheets are laminated and assembled, the fourth central holes are aligned to form the stator cavity, and the diameter of the third central hole is larger than the outer diameter of the stator.
  • the third sheet and the fourth sheet are provided with a third arc-shaped hole, and after several sheets are aligned and stacked together, the third arc-shaped hole is aligned to form an installation for installing permanent magnetic elements.
  • Cavity
  • a fourth arc-shaped hole is provided on the fourth sheet, and after several fourth sheets are aligned and stacked together, the fourth arc-shaped hole is aligned to form an installation cavity for installing the rotor coil.
  • the setting step also includes wrapping the rotor prefabricated body along the circumferential direction with fiber filaments or belts bundled with pre-impregnated resin.
  • the sizing step includes wrapping a sizing tape on the surface of the rotor prefabricated body wound and bundled with pre-impregnated resin fibers or belts, or prefabricating the rotor with pre-impregnated resin fiber wires or belts. The body is put into the mold and pressurized for shaping.
  • the curing step includes putting the shaped rotor preform into a curing furnace for heating and curing to obtain a rotor.
  • the thickness of the sheet is 0.05-0.5mm
  • the volume proportion of the fiber fabric in the sheet is 67-70%, and the volume proportion of the resin is 30%-33%;
  • the sheet is obtained by cutting a fiber continuous fabric impregnated with resin
  • the fiber fabric is carbon fiber fabric, and the resin is thermosetting resin.
  • a rotor provided by the application includes:
  • the rotor body has an installation cavity, and the rotor body is formed by stacking and solidifying a plurality of sheets along the axial direction of the rotor body, wherein the sheets are formed of a sheet-shaped fiber fabric pre-impregnated with resin;
  • the permanent magnet element/rotor coil is arranged in the installation cavity.
  • the rotor is an inner rotor, and the rotor also includes a rotor shaft, and the rotor body also has a shaft cavity, and the shaft cavity is suitable for installing the rotor shaft.
  • the shapes of the several sheets are consistent, and each includes a first central hole, and several first arc-shaped holes arranged around the first central hole. After the several sheets are aligned and stacked together, the first A central hole forms the rotating shaft cavity, and the first arc-shaped hole forms an installation cavity for installing permanent magnetic elements;
  • the shapes of the several sheets are inconsistent, and the sheets include several first sheets that are laminated to form both ends of the rotor body, and several second sheets that are laminated to form the middle part of the rotor body, and the first sheets Both the material and the second sheet have a second central hole, and the second sheet has a second arc-shaped hole surrounding the second central hole.
  • the rotor is an outer rotor, and several of the sheets can be aligned and stacked together to form a rotor body with a central cavity and the installation cavity, the central cavity includes a stator cavity suitable for installing a stator, and a The two ends of the stator cavity are suitable for installing the bearing cavity of the bearing.
  • the shapes of the several sheets are inconsistent, and the sheets include several third sheets that are stacked to form the two ends of the rotor body, and several fourth sheets that are stacked to form the middle part of the rotor body.
  • the third sheet and the fourth sheet are provided with a third arc-shaped hole, and after several sheets are aligned and stacked together, the third arc-shaped hole is aligned to form an installation for installing permanent magnetic elements.
  • Cavity
  • the fourth sheet is provided with a fourth arc-shaped hole. After several fourth sheets are aligned and stacked together, the fourth arc-shaped hole is aligned to form an installation cavity for installing the rotor coil.
  • the reinforcement layer is formed by winding and bundling along the circumferential direction of the rotor body, and solidified with the rotor body into a pre-impregnated resin fiber filament or belt.
  • the sizing belt layer arranged outside the reinforcing layer, and the sizing belt layer is used for curing and setting of the rotor.
  • the thickness of the sheet is 0.05-0.5mm
  • the volume proportion of the fiber fabric in the sheet is 67-70%, and the volume proportion of the resin is 30%-33%;
  • the sheet is obtained by cutting a fiber continuous fabric impregnated with resin
  • the fiber fabric is carbon fiber fabric, and the resin is thermosetting resin.
  • the rotor shaft installation cavity is a spline hole, and a spline matching the spline hole is formed on the outer peripheral surface of the rotor shaft.
  • a motor provided by the present application has the above-mentioned rotor.
  • the density of the rotor body thus obtained is between 1.55g/cm 3 -3g/cm 3.
  • the density is much smaller, which in turn makes the mass density of the entire rotor smaller, and the mass density of the rotor becomes smaller, which has the following advantages: First, for the shaft support part that supports the rotor shaft If the inertial pressure of the bearing is reduced, the friction between the rotor shaft and the bearing will also be reduced accordingly, thereby prolonging the life of the bearing; secondly, the inertia of the rotor caused by the mass density is reduced, and the rotor starts from rest to rated speed The time is shortened, and the stop time from rated speed to standstill is shortened, so it is easier to control the instantaneous start and stop of the rotor.
  • the rotor body formed by solidifying several layers of sheets composed of composite materials uses resin as the matrix and multi-layer fiber fabric as the reinforcement, and the fiber fabric is uniform in the axial direction of the rotor body
  • the layered distribution makes the rotor body evenly reinforced everywhere, especially in the radial direction with good tensile strength, and the rotor body as a whole has high-strength mechanical functions.
  • the rotor is provided with a reinforcement layer formed by pre-impregnated resin fiber filaments or belts that are wound and bundled along the circumferential direction of the rotor body and solidified with the rotor body, which can make the rotor have good tensile strength in the circumferential direction to overcome the permanent
  • the centrifugal force of the magnetic element/rotor coil produces an outward extrusion force, and what overcomes the extrusion force is the pulling force of the outer layer of the circumferential pre-impregnated resin carbon fiber filament or belt.
  • the characteristic of carbon fiber is that it has high tensile strength and is more stable. , which is more in line with the principle, so that the rotor will not be deformed or damaged due to centrifugal force at high speed.
  • FIG. 1 is a schematic structural view of the sheet applied to the inner rotor in Example 1 provided by the present application;
  • Fig. 2 is a schematic structural view of the inner rotor of Example 1 provided by the present application (fiber filaments or bands of pre-impregnated resin are not drawn);
  • Fig. 3 is the sectional view of Fig. 2;
  • Fig. 4 is the structural representation of the permanent magnet element of the present application.
  • Fig. 5 is the structural representation of the axle sleeve of the present application.
  • Fig. 6 is the structural representation of the central axis of the present application.
  • Fig. 7 is a schematic structural diagram of a motor assembled with the outer rotor according to Embodiment 3 of the present application.
  • Icons 1-sheet; 11-first arc hole; 12-first central hole; 2-permanent magnetic element; 3-shaft sleeve; 4-central shaft; 5-coil; 6-metal core; 7-bearing ; 8 - stator; 9 - fiber filaments or strips pre-impregnated with resin.
  • Electric machines include electric motors and generators, and the rotor in this application is suitable as an inner rotor or an outer rotor of a motor, and is also suitable as an inner rotor or an outer rotor of a generator.
  • the rotor provided by Embodiment 1 of the present application is an inner rotor, which can be applied to a generator or a motor.
  • the specific rotor includes a rotor shaft, a rotor body, and a permanent magnet element 2.
  • the rotor body is installed on the rotor On the shaft, the rotor body has a mounting cavity and a shaft cavity, which are formed by stacking and solidifying a number of sheets 1 along the axial direction of the rotor body, wherein the sheet 1 is formed by a sheet-shaped fiber fabric pre-impregnated with resin; the permanent magnet
  • the element 2 is arranged in the installation cavity, and the rotor shaft is installed through the shaft cavity.
  • the shapes of the stacked sheets 1 can be set to be consistent or different, as long as the required shape of the rotor body can be formed after stacking.
  • all The shapes of the sheets 1 are consistent, and they are all disc-shaped.
  • Each sheet includes a first central hole 12, and several first arc-shaped holes 11 arranged around the first central hole 12. After several sheets 1 are aligned and stacked together, the first central hole 12 forms a shaft cavity, and the first arc-shaped The hole 11 forms an installation cavity for installing the permanent magnet element 2 .
  • the density of the rotor body formed by lamination of several sheets of fiber fabric pre-impregnated with resin after curing is 1.55g/cm 3 - 3g/ cm3 is also much smaller than the density of metal, so that the mass density of the entire rotor obtained in this way becomes smaller, and the mass density of the rotor becomes smaller, which has the following advantages: First, for the shaft supporting part supporting the rotor shaft, such as The inertial pressure of the bearing 7 decreases, and the friction between the rotor shaft and the bearing also decreases accordingly, thereby prolonging the life of the bearing 7; secondly, the inertia of the rotor caused by the mass density decreases, and the speed of the rotor from stationary to rated speed The start-up time is shortened, and the stop time from rated speed to standstill is shortened, so it is easier to control the instantaneous start and stop of the rotor.
  • the rotor body uses resin as the matrix and multi-layer fiber fabrics as reinforcements, and the fiber fabrics are uniform in the axial direction of the rotor body.
  • the layered distribution makes the rotor body evenly reinforced everywhere, especially in the radial direction with good tensile strength, and the rotor body as a whole has a high-strength mechanical function.
  • the permanent magnet element 2 is inserted into the installation cavity of the rotor body, which is not only simple and easy to assemble, but more importantly, it will not be thrown out during high-speed rotation, thereby prolonging the service life of the rotor.
  • the permanent magnet element 2 is arc-shaped permanent magnet steel.
  • the rotor also includes a reinforcement layer, the reinforcement layer is formed by winding and binding along the circumferential direction of the rotor body, and solidified with the rotor body into one pre-impregnated resin fiber filament or belt 9, preferably the pre-impregnated resin fiber filament or belt 9 is a pre-preg Resin-impregnated carbon fiber filaments or ribbons.
  • the fiber composite material is a fabric material, it has tensile resistance, stability and ease of construction in the mechanical direction of the fabric, and then the outer layer of the rotor body is reinforced with pre-impregnated resin carbon fiber filaments or belts, which can make the rotor in the circumference
  • the direction has a good tensile strength to overcome the outward extrusion force due to the centrifugal force of the permanent magnet element 2, and what overcomes the extrusion force is just the pulling force of the outer ring to the pre-impregnated resin carbon fiber wire or belt, the carbon fiber
  • the characteristic is that the tensile strength is high, more stable, and more in line with the principle, so that the rotor will not be deformed or damaged due to centrifugal force at high speed.
  • the rotor also includes a sizing belt layer arranged outside the reinforcing layer, and the sizing belt layer is used for solidifying and setting the rotor.
  • the shaping tape layer can preferably be a BOPP tape.
  • the BOPP tape is a biaxially oriented polypropylene film, and the BOPP tape is used to tightly wrap and pressurize the rotor body for shaping.
  • the rotor provided in the embodiment of the present application may not be provided with a shaping tape layer, but may be shaped directly through a mold during manufacture of the rotor.
  • the thickness of the sheet 1 is 0.05-0.5 mm; the volume proportion of the fiber fabric in the sheet 1 is 67-70%, and the volume proportion of the resin is 30%-33%.
  • the resin can be a thermosetting resin, wherein the thermosetting resin is an insoluble substance with a rigid three-dimensional network structure formed by cross-linking and curing through molecular polymerization.
  • the thermosetting resin can be epoxy resin, polyester resin, vinyl Base ester, bismaleimide, thermosetting polyimide, cyanate and other artificial polymer resins with strong fiber affinity and obvious reinforcement.
  • the resin can also be thermoplastic resin
  • thermoplastic resin is a large class of synthetic resin that can be softened by repeated heating and solidified by cooling
  • thermoplastic resin can be PPS polyphenylene sulfide, PEEK polyether ether ketone, PEKK polyether ketone ketone, PE- Polyethylene, PP-polypropylene, PVC-polyvinyl chloride, PS-polystyrene, PA-polyamide, POM-polyoxymethylene, PC-polycarbonate, polyphenylene ether, polysulfone, rubber, etc. have strong fiber affinity, Reinforced obvious synthetic resin.
  • Fiber fabrics are man-made long fibers or short fibers with a tensile strength greater than 1000Mpa. These fibers have a strong affinity for resins and can significantly increase tensile strength.
  • the types of fibers that can be applied to fiber fabrics are: carbon fiber, aramid fiber, quartz fiber, basalt fiber, glass fiber, etc., which have strong resin affinity and obvious reinforcement.
  • the tensile strength is greater than 1000Mpa artificial long fiber or short fiber.
  • the fiber fabric is carbon fiber
  • the resin is a thermosetting resin
  • the rotor formed in this way is made of a composite material with a mass density less than 1.6 g/cm 3 except for the rotor shaft and the permanent magnet element 2 Composition, compared with the traditional rotor, the mass density of the rotor of the present application is greatly reduced, and it is more suitable for occasions requiring high speed.
  • the rotor shaft installation cavity is a spline hole, and a spline matching the spline hole is formed on the outer peripheral surface of the rotor shaft; through the cooperation of the spline hole and the spline, on the one hand, the rotor shaft and the rotor body can be inserted After the connection, it can drive the rotor body to rotate synchronously.
  • the spline on the rotor shaft can position the sheet 1 when the sheet 1 is stacked and installed, so that after the stacked sheets 1 are installed on the rotor shaft, all sheets The first arc-shaped holes 11 on the material 1 can be aligned.
  • the rotor shaft can be integrally formed, or it can be formed by separate assembly of the central shaft 4 and the sleeve 3, and the interference fit between the central shaft 4 and the sleeve 3 is integrated.
  • the central shaft 4 is a steel shaft
  • the sleeve 3 is copper.
  • the spline is formed on the shaft sleeve 3.
  • a method of manufacturing the inner rotor of Embodiment 1 provided in the embodiment of the present application includes:
  • a plurality of sheets 1, permanent magnet elements 2, and rotor shafts are assembled together to form a rotor prefabricated body, wherein the sheet 1 is formed of a sheet-shaped fiber fabric pre-impregnated with resin, and the shape of several sheets 1 satisfies: several sheets 1 pair After being stacked together, they can cooperate to form a rotor body with a shaft cavity and an installation cavity, the shaft cavity is suitable for installing the rotor shaft; the installation cavity is suitable for installing the permanent magnet element 2;
  • the rotor is formed after shaping and curing steps.
  • the sheet material 1, the permanent magnet element 2 and the rotor shaft are assembled together to form a rotor prefabricated body, and then the rotor is formed after shaping and curing steps. In this way, the assembly is not only easy, but also the sheet 1 of the rotor formed after solidification, the permanent magnet element 2 and the rotor shaft are integrated, which can reduce the noise during the operation of the rotor.
  • the manufacturing method of the inner rotor in Example 1 can also be formed by assembling several sheets 1 and permanent magnet elements 2 together to form a rotor prefabricated body, and after shaping and curing steps to form a rotor, and finally Insert the rotor shaft into the shaft cavity of the rotor.
  • the shapes of the sheets used are the same, each including a first central hole 12, and several first arc-shaped holes 11 surrounding the first central hole 12, and several sheets 1 are aligned and stacked together.
  • the first central hole 12 forms a shaft cavity
  • the first arc-shaped hole 11 forms an installation cavity for installing the permanent magnet element 2 .
  • the rotor shaft and the permanent magnet element 2 can be pre-fixed by tools, and then the sheets 1 are passed through the rotor shaft and the permanent magnet element 2 one by one to form a rotor prefabricated body, or the rotor shaft can be fixed with the help of tools A number of sheets 1 are stacked together, and then inserted into the rotor shaft and the permanent magnet element 2. It is also possible to pass all the sheets 1 through the rotor shaft, and finally insert the permanent magnet element 2, etc.
  • the assembly method is not limited to this;
  • the shaping step also includes wrapping the rotor prefabricated body along the circumferential direction with pre-impregnated resin fiber filaments or strips 9, so that a reinforcement layer can be formed outside the rotor body, and solidified together with the rotor body to form an integral body.
  • the shaping step includes winding and binding the fiber filaments or bands 9 of pre-impregnated resin on the surface of the rotor prefabricated body with a shaping tape wrapped tightly and pressurized for shaping, and the shaping tape can preferably be a BOPP tape. film.
  • the shaping step can also be performed by directly putting the rotor prefabricated body wrapped with pre-impregnated resin fiber filaments or belts 9 into the mold for pressing and shaping.
  • the curing step includes putting the shaped rotor preform into a curing furnace for heating and curing to obtain a rotor.
  • the thickness of the sheet 1 is 0.05-0.5 mm; the volume proportion of the fiber fabric in the sheet 1 is 67-70%, and the volume proportion of the resin is 30%-33%.
  • the resin can be a thermosetting resin or a thermoplastic resin
  • Fiber fabrics are man-made long fibers or short fibers with a tensile strength greater than 1000Mpa.
  • the fiber fabric is carbon fiber fabric
  • the resin is thermosetting resin
  • Sheet 1 can be formed by injection molding, molding process, vacuum infusion TRM process, SMC molding process, pre-impregnated resin fiber resin fabric laminated process, and wet impregnated resin or hot-melt dry pre-impregnated resin winding reinforcement Molded reinforcement.
  • the inner rotor provided in Embodiment 2 of the present application differs from the rotor in Embodiment 1 in that: in Embodiment 2 of the present application, rotor coils are provided on the rotor body instead of permanent magnet elements 2, and the shape of the sheet The upper setting is also slightly different.
  • the sheet 1 includes several first sheets that are stacked to form the two ends of the rotor body, and several second sheets that are stacked to form the middle part of the rotor body. Both the first sheet and the second sheet have a second center hole, and the second sheet has a second arc-shaped hole surrounding the second center hole. After several sheets 1 are aligned and stacked together, the second center holes are aligned. A shaft cavity is formed, and the second arc-shaped hole is aligned to form an installation cavity for installing the rotor coil.
  • the rotor coil includes a metal core 6 and a coil 5 wound on the metal core 6 .
  • the manufacturing method of the inner rotor of the embodiment 2 provided in the embodiment of the present application is basically the same as the manufacturing method of the inner rotor of the embodiment 1, except that:
  • the specific steps of assembling several sheets 1, rotor coils, and rotor shafts together to form a rotor prefabricated body are different.
  • the rotor shafts can be sequentially passed through the second central holes on several first sheets, and the first holes on several second sheets. After inserting rotor coils into the second arc-shaped holes on the second center holes, several first sheets are installed on the rotor shaft.
  • the rotor body is formed by laminating several first sheets, several second sheets, and several first sheets, and there are many specific assembling methods, which are not limited to the above descriptions.
  • low temperature curing can be used, such as 60° curing temperature. You can also choose a coil with a high temperature resistant insulation layer.
  • an external rotor provided by Embodiment 3 of the present application is suitable for generators and motors.
  • the specific external rotor includes a rotor body and a rotor coil.
  • the rotor body is composed of several sheets 1 along the axial direction of the rotor body. Direction lamination and solidification to form an integral body, wherein the sheet 1 is formed by a sheet-like fiber fabric pre-impregnated with resin.
  • a plurality of sheets 1 can be aligned and stacked together to form a rotor body with a central cavity and a mounting cavity.
  • the central cavity includes a stator cavity suitable for installing the stator 8, and a bearing cavity suitable for installing the bearing 7 at both ends of the stator cavity. .
  • the shapes of the sheets constituting the rotor body are not exactly the same when they are specifically arranged.
  • the specific sheet 1 includes several third sheets that are stacked to form the two ends of the rotor body, and several fourth sheets that are stacked to form the middle part of the rotor body. material, the third sheet has a third center hole, and after several third sheets are assembled, the third center hole is aligned to form a bearing cavity; the fourth sheet has a fourth center hole, and after several fourth sheets are stacked and assembled, The fourth central holes are aligned to form a stator cavity, and the diameter of the third central hole is larger than the outer diameter of the stator, which facilitates the insertion of the stator 8 into the rotor for installation.
  • a fourth arc-shaped hole is provided on the fourth sheet, and after several fourth sheets are aligned and stacked together, the fourth arc-shaped holes are aligned to form an installation cavity for installing the rotor coil.
  • the rotor coil includes a metal core 6 and a coil 5 wound on the metal core 6 .
  • the outer rotor also includes a reinforcement layer and a shaping belt layer arranged outside the reinforcement layer.
  • a reinforcement layer and a shaping belt layer arranged outside the reinforcement layer.
  • the content of Embodiment 1 For the specific configuration, reference may be made to the content of Embodiment 1, which will not be repeated here.
  • the selection of the type of resin, fiber fabric, thickness of the sheet, etc. reference may be made to the content of Example 1.
  • the embodiment of the present application provides a manufacturing method for the outer rotor of Example 3, which is different from Example 1 in that the outer rotor of Example 3 only needs to assemble several sheets 1 and rotor coils together to form a rotor prefabricated body , during specific assembly, the rotor coils can be passed through the fourth arc-shaped holes on several fourth sheets, and then several third sheets are respectively stacked on both sides of several fourth sheets to form the rotor body, the specific assembly
  • the outer rotor of Example 3 only needs to assemble several sheets 1 and rotor coils together to form a rotor prefabricated body , during specific assembly, the rotor coils can be passed through the fourth arc-shaped holes on several fourth sheets, and then several third sheets are respectively stacked on both sides of several fourth sheets to form the rotor body, the specific assembly
  • the specific assembly There may be many ways, not limited to the above description.
  • low temperature curing can be used, such as a curing temperature of 60°. You can also choose a coil with an insulating layer that is resistant to high temperatures.
  • the outer rotor provided in Embodiment 4 of the present application differs from the external rotor in Embodiment 3 in that: in Embodiment 4 of the present application, permanent magnet elements 2 are installed on the rotor body instead of rotor coils. The settings are also slightly different in shape.
  • the third sheet and the fourth sheet are provided with a third arc-shaped hole. After several sheets 1 are aligned and stacked together, the third arc-shaped hole Align to form an installation cavity for installing the permanent magnet element 2.
  • the embodiment of the present application provides a manufacturing method for the outer rotor of Example 4, which differs from Example 1 in that the outer rotor of Example 4 only needs to assemble several sheets 1 and permanent magnet elements 2 together to form the rotor
  • the permanent magnet element 2 can be fixed by a tool, and the sheets 1 are stacked on the permanent magnet element 2 one by one.
  • install some third sheets, then install some fourth sheets, and finally install Some third sheets are installed; after some third sheets, some fourth sheets, and some third sheets can be stacked together, and then the permanent magnetic element 2 is inserted into the specific assembly mode, there are many ways, not limited to the above description .
  • a motor provided in an embodiment of the present application has the rotor as in the above embodiment.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
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  • Permanent Field Magnets Of Synchronous Machinery (AREA)
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Abstract

本申请提供了一种转子、电机及转子的制造方法，涉及电机的技术领域，制造方法包括，包括：将若干片片材、永磁元件/转子线圈一起组装形成转子预制体，其中所述片材由片状的预浸渍树脂的纤维织物形成，若干所述片材的形状满足：若干所述片材对准层叠一起后能够配合形成具有安装腔的转子体，所述安装腔适于安装所述永磁元件/转子线圈；经定型、固化步骤后形成转子，解决了矽钢片层叠形成的转子存在质量密度的技术问题，达到了转子质量密度小，转子高速旋转时的抗拉强度高的技术效果。

Description

转子、电机及转子的制造方法
相关申请的交叉引用
本申请要求于2022年01月28日提交中国国家知识产权局的申请号为2022101046897、名称为“转子、电机及转子的制造方法”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
本申请涉及电机技术领域，尤其是涉及一种转子、电机及转子制造方法。
背景技术
现有电动机的转子通过支撑在安装有轴承的轴上，感应电动机定子线圈的磁力而旋转，现有的转子包括由若干矽钢片层叠形成的转子体，以及缠绕在转子体上的导线线圈或贴附在转子体上的永磁磁钢。由于轴和转子体都是以金属材料制成，所使用的金属材料的密度都超过了7g/cm 3,因此，使得整个转子的质量密度比较大，而整个转子的质量密度比较大，在实际使用中会存在如下问题：第一方面，会导致电动机在瞬间启动，瞬间刹车时，由于转子自身惯量大的因素影响而无法得到有效控制；第二方面，会导致对支撑部如轴承的惯性压力大而出现磨损严重，尤其是转子高速运转时，对轴承的耐磨度提出了更高的要求；第三方面，转子在高速旋转时因密度引起的离心力，超过了金属材料的拉伸强度，从而导致转子变形或破坏；第四方面，转子质量密度大导致转子响应慢，难以实现对转子转速的精确控制。
发明内容
本申请的目的在于提供一种转子、电动机，以及转子制造方法，以解决现有技术中的电动机转子的转子体使用矽钢片层叠制成而导致整个转子的质量密度大而存在瞬间启停难以控制、轴支撑部惯性压力大，容易磨损，转子高速运转时，转子容易变形或破坏，无法实现转速精确控制的技术问题。
本申请提供的一种转子的制造方法，包括：
将若干片片材、永磁元件/转子线圈一起组装形成转子预制体，其中所述片材由片状的预浸渍树脂的纤维织物形成，若干所述片材的形状满足：若干所述片材对准层叠一起后能够配合形成具有安装腔的转子体，所述安装腔适于安装所述永磁元件/转子线圈；
经定型、固化步骤后形成转子。
进一步的，所述转子为内转子，所述将若干片片材、永磁元件/转子线圈组装一起形成转子预制体的步骤包括：
将若干片片材、转子轴、永磁元件/转子线圈一起组装形成转子预制体；
制造所述内转子的若干所述片材的形状满足：若干所述片材对准层叠一起后能够配合形成具有转轴腔和所述安装腔的转子体，所述转轴腔适于安装所述转子轴。
进一步的，若干所述片材的形状一致，均包括第一中心孔，以及环绕所述第一中心孔设置的若干第一弧形孔，若干所述片材对准层叠一起后，所述第一中心孔形成所述转轴腔，所述第一弧形孔形成安装永磁元件的安装腔；
或
若干所述片材的形状不一致，所述片材包括若干层叠构成转子体的两端端部的第一片材，以及若干层叠构成转子体的中间部的第二片材，所述第一片材和第二片材上均具有第二中心孔，所述第二片材上具有环绕所述第二中心孔的第二弧形孔，若干所述片材对准层叠一起后，所述第二中心孔对齐形成所述转轴腔，所述第二弧形孔对齐形成安装转子线圈的安装腔。
进一步的，所述转子为外转子，制造所述外转子的若干所述片材的形状满足：若干所述片材对准层叠一起后能够配合形成具有中心腔和所述安装腔的转子体，所述中心腔包括适于安装定子的定子腔，以及位于所述定子腔的两端，适于安装轴承的轴承腔。
进一步的，制造所述外转子的若干所述片材的形状满足：若干所述片材的形状不一致，所述片材包括若干层叠构成转子体的两端端部的第三片材，以及若干层叠构成转子体的中间部的第四片材，所述第三片材上具有第三中心孔，若干所述第三片材组装后，所述第三中心孔对齐形成所述轴承腔；第四片材上具有第四中心孔，若干第四片材层叠组装后，所述第四中心孔对齐形成所述定子腔，且所述第三中心孔的直径大于所述定子的外径。
进一步的，所述第三片材和第四片材上均设有第三弧形孔，若干所述片材对准层叠一起后，所述第三弧形孔对齐形成安装永磁元件的安装腔；
或
所述第四片材上设有第四弧形孔，若干所述第四片材对准层叠一起后，所述第四弧形孔对齐形成安装转子线圈的安装腔。
进一步的，在定型步骤前，还包括将转子预制体沿圆周方向缠绕捆扎预浸树脂的纤维丝或带。
进一步的，定型步骤包括在缠绕捆扎有预浸树脂的纤维丝或带的转子预制体的表面上用定型带缠紧加压定型，或将缠绕捆扎有预浸树脂的纤维丝或带的转子预制体放入模具中加压定型。
进一步的，所述固化步骤包括将定型后的转子预制体放入固化炉中加热固化获得转子。
进一步的，所述片材的厚度为0.05-0.5mm；
和/或
所述片材中所述纤维织物所占体积比例为67-70％，所述树脂所占体积比例为30％-33％；
和/或
所述片材由将预先浸渍树脂的纤维连续织物裁剪获得；
和/或
所述纤维织物为碳纤维织物，所述树脂为热固型树脂。
本申请提供的一种转子，包括：
转子体，具有安装腔，所述转子体由若干片片材沿所述转子体的轴向方向层叠并固化一体形成，其中所述片材由片状的预浸渍树脂的纤维织物形成；
永磁元件/转子线圈，设置在所述安装腔内。
进一步的，所述转子为内转子，所述转子还包括转子轴，所述转子体上还具有转轴腔，所述转轴腔适于安装所述转子轴。
进一步的，若干所述片材的形状一致，均包括第一中心孔，以及环绕所述第一中心孔设置的若干第一弧形孔，若干所述片材对准层叠一起后，所述第一中心孔形成所述转轴腔，所述第一弧形孔形成安装永磁元件的安装腔；
或
若干所述片材的形状不一致，所述片材包括若干层叠构成转子体的两端端部的第一片材，以及若干层叠构成转子体的中间部的第二片材，所述第一片材和第二片材上均具有第二中心孔，所述第二片材上具有环绕所述第二中心孔的第二弧形孔，若干所述片材对准层叠一起后，所述第二中心孔对齐形成所述转轴腔，所述第二弧形孔对齐形成安装转子线圈的安装腔。
进一步的，所述转子为外转子，若干所述片材对准层叠一起后能够配合形成具有中心腔和所述安装腔的转子体，所述中心腔包括适于安装定子的定子腔，以及位于所述定子腔的两端，适于安装轴承的轴承腔。
进一步的，若干所述片材的形状不一致，所述片材包括若干层叠构成转子体的两端端部的第三片材，以及若干层叠构成转子体的中间部的第四片材，所述第三片材上具有第三中心孔，若干所述第三片材组装后，所述第三中心孔对齐形成所述轴承腔；第四片材上具有第四中心孔，若干第四片材层叠组装后，所述第四中心孔对齐形成所述定子腔，且所述第三中心孔的直径大于所述定子的外径。
进一步的，所述第三片材和第四片材上均设有第三弧形孔，若干所述片材对准层叠一起后，所述第三弧形孔对齐形成安装永磁元件的安装腔；
或
所述第四片材上设有第四弧形孔，若干所述第四片材对准层叠一起后，所述第四弧形 孔对齐形成安装转子线圈的安装腔。
进一步的，还包括加强层，所述加强层由沿所述转子体的圆周方向缠绕捆扎，并与所述转子体固化一体的预浸树脂纤维丝或带形成。
进一步的，还包括设置在所述加强层外的定型带层，所述定型带层用于转子的固化定型。
进一步的，所述片材的厚度为0.05-0.5mm；
和/或
所述片材中所述纤维织物所占体积比例为67-70％，所述树脂所占体积比例为30％-33％；
所述片材由将预先浸渍树脂的纤维连续织物裁剪获得；
和/或
所述纤维织物为碳纤维织物，所述树脂为热固型树脂。
进一步的，所述转子轴安装腔为花键孔，所述转子轴的外圆周面上成型有与所述花键孔配合的花键。
本申请提供的一种电机，具有如上述的转子。
本申请提供的一种转子，由于转子体是由若干片预浸渍树脂的纤维织物的片材层叠后固化一体形成，因此，由此获得的转子体的密度在1.55g/cm 3-3g/cm 3，相对于金属材质制作的转子体的密度小的多，进而使得整个转子的质量密度变小，而转子的质量密度变小，具有如下优势：第一方面，对于支撑转子轴的轴支撑部如轴承的惯性压力变小，转子轴与轴承之间的摩擦力也相应变小，从而能够延长轴承的寿命；第二方面，转子因质量密度引起的惯量减小，转子从静止到额定转速的启动时间缩短，从额定转速到静止的停止时间缩短，因此，更容易控制转子的瞬间启停。第三方面，转子在高速旋转时因质量密度引起的离心力减小，离心力对转子材料拉伸力减小，更容易实现高速；第四方面，由于转子质量密度减小，转子变速的响应时间变小，更容易实现高速旋转过程中对转子转速的精确控制。更重要的是，由于若干层由复合材料构成的片材固化一体形成的转子体以树脂为基体，以多层片状的纤维织物为增强体，并且纤维织物在转子体的轴向方向上均匀分层分布，使得转子体各处都得到均匀的增强，特别是在径向方向具有良好的抗拉强度，转子体整体具有高强度的力学功能。
转子上设有由沿转子体的圆周方向缠绕捆扎，并与转子体固化一体的预浸树脂纤维丝或带形成的加强层，能够使转子在圆周方向具有良好的抗拉强度，以克服因永磁元件/转子线圈的离心力而产生向外的挤压力，而克服挤压力的正好是对外层环向预浸树脂碳纤维丝或带的拉力，碳纤维的特点正好是抗拉强度高，更稳定，更符合原理，从而转子在高速下不会因离心力而引起的转子变形或破坏。
附图说明
为了更清楚地说明本申请具体实施方式或现有技术中的技术方案，下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图是本申请的一些实施方式，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本申请提供的实施例1的运用于内转子上的片材的结构示意图；
图2为本申请提供的实施例1的内转子的结构示意图(未画出预浸树脂的纤维丝或带)；
图3为图2的剖视图；
图4为本申请的永磁元件的结构示意图；
图5为本申请的轴套的结构示意图；
图6为本申请的中心轴的结构示意图；
图7为本申请的实施例3的外转子所组装成电机的结构示意图。
图标：1-片材；11-第一弧形孔；12-第一中心孔；2-永磁元件；3-轴套；4-中心轴；5-线圈；6-金属芯；7-轴承；8-定子；9-预浸树脂的纤维丝或带。
具体实施方式
下面将结合实施例对本申请的技术方案进行清楚、完整地描述，显然，所描述的实施例是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
电机包括电动机和发电机，本申请中的转子适于作为电动机的内转子或外转子，也适于作为发电机的内转子或外转子。
实施例1
如图1-6所示，本申请实施例1提供的一种转子为内转子，可以适用于发电机或电动机上，具体转子包括转子轴、转子体、永磁元件2，转子体安装在转子轴上，转子体上具有安装腔和转轴腔，由若干片片材1沿转子体的轴向方向层叠并固化一体形成，其中片材1由片状的预浸渍树脂的纤维织物形成；永磁元件2设置在安装腔内，转子轴穿过转轴腔安装。根据转子体的形状的不同，层叠设置的片材1的形状可以设置一致，且可以设置不同，只要层叠后能够形成所需的转子体的形状即可，在本申请实施例1中，优选所有片材1的形状一致，都为圆片型。片材均包括第一中心孔12，以及环绕第一中心孔12设置的若干第一弧形孔11，若干片材1对准层叠一起后，第一中心孔12形成转轴腔，第一弧形孔11形成安装永磁元件2的安装腔。
由于纤维、树脂的密度均相对于金属的密度7g/cm 3小得多，因此，由若干片预浸渍树脂的纤维织物的片材层叠后固化一体形成的转子体的密度1.55g/cm 3-3g/cm 3也相对于金 属的密度小的多，这样获得的整个转子的质量密度变小，而转子的质量密度变小，具有如下优势：第一方面，对于支撑转子轴的轴支撑部如轴承7的惯性压力变小，转子轴与轴承之间的摩擦力也相应变小，从而能够延长轴承7的寿命；第二方面，转子因质量密度引起的惯量减小，转子从静止到额定转速的启动时间缩短，从额定转速到静止的停止时间缩短，因此，更容易控制转子的瞬间启停。第三方面，转子在高速旋转时因质量密度引起的离心力减小，离心力对转子材料拉伸力减小，更容易实现高速；第四方面，由于转子质量密度减小，转子变速的响应时间变小，更容易实现高速旋转过程中对转子转速的精确控制。
更重要的是，由于若干层由复合材料构成的片材固化一体形成的转子体以树脂为基体，以多层片状的纤维织物为增强体，并且纤维织物在转子体的轴向方向上均匀分层分布，使得转子体各处都得到均匀的增强，特别是在径向方向具有良好的抗拉强度，转子体整体具有高强度的力学功能。永磁元件2以插入的方式安装在转子体的安装腔内，不仅组装起来简单容易，更重要的是在高速旋转时，不会被甩出脱落，从而延长了转子的使用寿命。优选永磁元件2为弧形的永磁磁钢。
进一步的，转子上还包括加强层，加强层由沿转子体的圆周方向缠绕捆扎，并与转子体固化一体的预浸树脂纤维丝或带9形成，优选预浸树脂纤维丝或带9为预浸树脂碳纤维丝或带。由于纤维复合材料是织物材料，所以在织物力学方向上具有抗拉伸性，稳定性和易施工性，再在转子体的外层用预浸树脂碳纤维丝或带加强捆绑，能够使转子在圆周方向具有良好的抗拉强度，以克服因永磁元件2的离心力而产生向外的挤压力，而克服挤压力的正好是对外层环向预浸树脂碳纤维丝或带的拉力，碳纤维的特点正好是抗拉强度高，更稳定，更符合原理，从而转子在高速下不会因离心力而引起的转子变形或破坏。
进一步的，转子还包括设置在加强层外的定型带层，定型带层用于转子的固化定型。定型带层可以优选为BOPP带BOPP带为双向拉伸聚丙烯薄膜，BOPP带用于对转子体缠紧加压定型。当然，本申请实施例提供的转子也可以不设置定型带层，而是在转子制造时，直接通过模具定型。
优选片材1的厚度为0.05-0.5mm；片材1中纤维织物所占体积比例为67-70％，树脂所占体积比例为30％-33％。
树脂可以采用热固型树脂，其中热固型树脂为通过分子聚合交联固化形成不溶熔的，具有刚性的三维网状结构的物质，热固型树脂可以采用环氧树脂、聚酯树脂，乙烯基酯，双马来酰胺、热固性聚酰亚胺、氰酸酯等具有纤维亲和力强、增强明显的人工聚合树脂。
树脂也可以采用热塑型树脂，热塑性树脂为可反复加热软化、冷却固化的一大类合成树脂，热塑性树脂可以采用PPS聚苯硫醚、PEEK聚醚醚酮、PEKK聚醚酮酮、PE-聚乙烯、PP-聚丙烯、PVC-聚氯乙烯、PS-聚苯乙烯、PA-聚酰胺、POM-聚甲醛、PC-聚碳酸酯、聚 苯醚、聚砜、橡胶等具有纤维亲和力强、增强明显的人工合成树脂。
纤维织物为拉伸强度大于1000Mpa的人造长纤维或短纤维。这些纤维具有树脂亲和力强、能够明显增强拉伸强度的特性。纤维织物可以适用的纤维种类有：碳纤维、芳纶纤维石英纤维、玄武岩纤维、玻璃纤维等，具有树脂亲和力强、增强明显的拉伸强度大于1000Mpa人造长纤维或短纤维。
在本申请实施例中，优选纤维织物为碳纤维，树脂为热固型树脂，这样形成的转子除了转子轴和永磁元件2外，其他部分都是由质量密度小于1.6g/cm 3的复合材料构成，本申请的转子与传统的转子相比，质量密度大大降低，更适合需要高速的场合。
进一步的，转子轴安装腔为花键孔，转子轴的外圆周面上成型有与花键孔配合的花键；通过花键孔与花键的配合，一方面能够使转子轴与转子体插入连接后，能够带动转子体同步转动，另一方面，转子轴上的花键能够在片材1层叠安装时对片材1进行定位，保证层叠的片材1在转子轴上安装后，所有片材1上第一弧形孔11能够对齐。
转子轴可以一体成型，也可以由中心轴4和轴套3分体组装形成，中心轴4与轴套3之间过盈配合连接成一体，优选中心轴4为钢轴，轴套3为铜套，花键成型在轴套3上。
本申请实施例提供的一种制造实施例1的内转子的制造方法，包括：
将若干片片材1、永磁元件2、转子轴一起组装形成转子预制体，其中片材1由片状的预浸渍树脂的纤维织物形成，若干片材1的形状满足：若干片材1对准层叠一起后能够配合形成具有转轴腔和安装腔的转子体，转轴腔适于安装转子轴；安装腔适于安装永磁元件2；
经定型、固化步骤后形成转子。
片材1、永磁元件2、转子轴一起组装形成转子预制体，再经定型、固化步骤后形成转子。这样不仅组装容易，而且固化后所形成的转子的片材1、永磁元件2、转子轴是一体的，能够降低转子运转时的噪音。
作为可替换的实施方式，实施例1的内转子的制造方法，还可以以由若干片片材1、永磁元件2一起组装形成转子预制体，并经定型、固化步骤后形成转子，最后再往转子的转轴腔内插入转子轴。
在本实施例中，所使用的若干片材的形状一致，均包括第一中心孔12，以及环绕第一中心孔12设置的若干第一弧形孔11，若干片材1对准层叠一起后，第一中心孔12形成转轴腔，第一弧形孔11形成安装永磁元件2的安装腔。
关于转子预制体的具体组装，可以通过工具将转子轴、永磁元件2预先固定好，再将片材1逐片穿过转子轴、永磁元件2上形成转子预制体，也可以借助工具将若干片材1层叠一体，再插入转子轴、永磁元件2，还可以将所有片材1均穿过转子轴后，最后再插入 永磁元件2等，组装方式不限于此；
优选的，在定型步骤前，还包括将转子预制体沿圆周方向缠绕捆扎预浸树脂的纤维丝或带9，从而能够在转子体外形成加强层，并与转子体一同固化形成一体。
具体的，定型步骤包括在缠绕捆扎有预浸树脂的纤维丝或带9的转子预制体的表面上用定型带缠紧加压定型，定型带可以优选为BOPP带BOPP带为双向拉伸聚丙烯薄膜。
作为可选的方式，定型步骤还可以通过直接将缠绕捆扎有预浸树脂的纤维丝或带9的转子预制体放入模具中加压定型进行。
固化步骤包括将定型后的转子预制体放入固化炉中加热固化获得转子。
优选片材1的厚度为0.05-0.5mm；片材1中纤维织物所占体积比例为67-70％，树脂所占体积比例为30％-33％。
树脂可以为热固型树脂，也可以采用热塑型树脂；
纤维织物为拉伸强度大于1000Mpa的人造长纤维或短纤维。
在本实施例中，优选纤维织物为碳纤维织物，树脂为热固型树脂。
片材1可以通过注塑成型、模压工艺成型、真空灌注TRM工艺成型、SMC模压工艺成型、预浸树纤维脂织物叠层成型工艺、以及通过湿法浸润树脂或热熔干法预浸树脂缠绕增强成型加固。
实施例2
本申请实施例2提供的一种内转子，与实施例1的转子存在的不同在于：本申请实施例2在转子体上设置的是转子线圈，而不是永磁元件2，在片材的形状上设置也略有不同，在本申请实施例2中，片材1包括若干层叠构成转子体的两端端部的第一片材，以及若干层叠构成转子体的中间部的第二片材，第一片材和第二片材上均具有第二中心孔，第二片材上具有环绕第二中心孔的第二弧形孔，若干片材1对准层叠一起后，第二中心孔对齐形成转轴腔，第二弧形孔对齐形成安装转子线圈的安装腔。其中转子线圈包括金属芯6，以及绕制在金属芯6上的线圈5。
本申请实施例提供的一种制造实施例2的内转子的制造方法，与实施例1的内转子的制造方法大体一致，不同之处为：
将若干片片材1、转子线圈、转子轴一起组装形成转子预制体的具体步骤不同，可以将转子轴依次穿过若干第一片材上的第二中心孔、若干第二片材上的第二中心孔，再往若干第二片材上的第二弧形孔内插入转子线圈后，再往转子轴上安装若干第一片材。也可以将转子轴插入若干第二片材的第二中心孔，将转子线圈插入若干第二片材的第二弧形孔，再将若干第一片材分别从转子轴的两端穿设，使若干第一片材、若干第二片材、若干第一片材层叠形成转子体，具体组装的方式可以有多种，不限于以上记载。
安装转子线圈的转子在固化时，为了保护转子线圈上的导线的绝缘层，可以采用低温固化，如60°固化温度。也可以选择绝缘层耐高温的线圈。
实施例3
如图7所示，本申请实施例3提供的一种外转子，适用于发电机和电动机，具体外转子包括转子体、转子线圈，转子体上由若干片片材1沿转子体的轴向方向层叠并固化一体形成，其中片材1由片状的预浸渍树脂的纤维织物形成。若干片材1对准层叠一起后能够配合形成具有中心腔和安装腔的转子体，中心腔包括适于安装定子8的定子腔，以及位于定子腔的两端，适于安装轴承7的轴承腔。
构成转子体的片材在具体设置时形状设置不完全一致，具体片材1包括若干层叠构成转子体的两端端部的第三片材，以及若干层叠构成转子体的中间部的第四片材，第三片材上具有第三中心孔，若干第三片材组装后，第三中心孔对齐形成轴承腔；第四片材上具有第四中心孔，若干第四片材层叠组装后，第四中心孔对齐形成定子腔，且第三中心孔的直径大于定子的外径，这样便于定子8插入转子内进行安装。第四片材上设有第四弧形孔，若干第四片材对准层叠一起后，第四弧形孔对齐形成安装转子线圈的安装腔。其中转子线圈包括金属芯6，以及绕制在金属芯6上的线圈5。
同样，外转子上还包括加强层和设置在加强层外的定型带层，具体设置可以参考实施例1的内容，在此不再多叙。树脂、纤维织物的类型选择、片材的厚度等都可以参考实施例1的内容。
本申请实施例提供的一种制造实施例3的外转子的制造方法，与实施例1不同之处在于，实施3的外转子仅需将若干片片材1、转子线圈一起组装形成转子预制体，在具体组装时，可以将转子线圈穿过若干第四片材上的第四弧形孔，再将若干第三片材分别层叠于若干第四片材的两侧形成转子体，具体组装的方式可以有多种，不限于以上记载。
同样，由于外转子上安装的是转子线圈，因此，在固化时，为了保护转子线圈上的导线的绝缘层，可以采用低温固化，如60°的固化温度。也可以选择绝缘层耐高温的线圈。
实施例4
本申请实施例4提供的一种外转子，与实施例3的外转子存在的不同在于：本申请实施例4在转子体上设置的不是转子线圈，而是永磁元件2，在片材的形状上设置也略有不同，在本申请实施例4中，第三片材和第四片材上均设有第三弧形孔，若干片材1对准层叠一起后，第三弧形孔对齐形成安装永磁元件2的安装腔。
本申请实施例提供的一种制造实施例4的外转子的制造方法，与实施例1不同之处在于，实施4的外转子仅需将若干片片材1、永磁元件2一起组装形成转子预制体，在具体 组装时，可以通过工具将永磁元件2固定，逐片往永磁元件2上层叠安装片材1，先安装若干第三片材，再安装若干第四片材，最后再安装若干第三片材；也可以将若干第三片材、若干第四片材、若干第三片材层叠一体后，再插入永磁元件2具体组装的方式可以有多种，不限于以上记载。
本申请实施例提供的一种电机，具有如上述实施例的转子。
最后应说明的是：以上各实施例仅用以说明本申请的技术方案，而非对其限制；尽管参照前述各实施例对本申请进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本申请各实施例技术方案的范围。

Claims (21)

  1. 一种转子的制造方法，其特征在于，包括：
    将若干片片材(1)、永磁元件(2)/转子线圈一起组装形成转子预制体，其中所述片材(1)由片状的预浸渍树脂的纤维织物形成，若干所述片材(1)的形状满足：若干所述片材(1)对准层叠一起后能够配合形成具有安装腔的转子体，所述安装腔适于安装所述永磁元件(2)/转子线圈；
    经定型、固化步骤后形成转子。
  2. 根据权利要求1所述的制造方法，其特征在于，所述转子为内转子，所述将若干片片材(1)、永磁元件(2)/转子线圈组装一起形成转子预制体的步骤包括：
    将若干片片材(1)、转子轴、永磁元件(2)/转子线圈一起组装形成转子预制体；
    制造所述内转子的若干所述片材(1)的形状满足：若干所述片材(1)对准层叠一起后能够配合形成具有转轴腔和所述安装腔的转子体，所述转轴腔适于安装所述转子轴。
  3. 根据权利要求2所述的制造方法，其特征在于，若干所述片材的形状一致，均包括第一中心孔(12)，以及环绕所述第一中心孔(12)设置的若干第一弧形孔(11)，若干所述片材(1)对准层叠一起后，所述第一中心孔(12)形成所述转轴腔，所述第一弧形孔(11)形成安装永磁元件(2)的安装腔；
    或
    若干所述片材的形状不一致，所述片材(1)包括若干层叠构成转子体的两端端部的第一片材，以及若干层叠构成转子体的中间部的第二片材，所述第一片材和第二片材上均具有第二中心孔，所述第二片材上具有环绕所述第二中心孔的第二弧形孔，若干所述片材(1)对准层叠一起后，所述第二中心孔对齐形成所述转轴腔，所述第二弧形孔对齐形成安装转子线圈的安装腔。
  4. 根据权利要求1所述的制造方法，其特征在于，所述转子为外转子，制造所述外转子的若干所述片材(1)的形状满足：若干所述片材(1)对准层叠一起后能够配合形成具有中心腔和所述安装腔的转子体，所述中心腔包括适于安装定子(8)的定子腔，以及位于所述定子腔的两端，适于安装轴承的轴承腔。
  5. 根据权利要求4所述的制造方法，其特征在于，制造所述外转子的若干所述片材(1)的形状满足：若干所述片材的形状不一致，所述片材(1)包括若干层叠构成转子体的两端端部的第三片材，以及若干层叠构成转子体的中间部的第四片材，所述第三片材上具有第三中心孔，若干所述第三片材组装后，所述第三中心孔对齐形成所述轴承腔；第四片材上具有第四中心孔，若干第四片材层叠组装后，所述第四中心孔对齐形成所述定子腔，且所 述第三中心孔的直径大于所述定子(8)的外径。
  6. 根据权利要求5所述的制造方法，其特征在于，所述第三片材和第四片材上均设有第三弧形孔，若干所述片材(1)对准层叠一起后，所述第三弧形孔对齐形成安装永磁元件的安装腔；
    或
    所述第四片材上设有第四弧形孔，若干所述第四片材对准层叠一起后，所述第四弧形孔对齐形成安装转子线圈的安装腔。
  7. 根据权利要求1-6中任一项所述的制造方法，其特征在于，在定型步骤前，还包括将转子预制体沿圆周方向缠绕捆扎预浸树脂的纤维丝或带(9)。
  8. 根据权利要求7所述的制造方法，其特征在于，定型步骤包括在缠绕捆扎有预浸树脂的纤维丝或带(9)的转子预制体的表面上用定型带缠紧加压定型，或将缠绕捆扎有预浸树脂的纤维丝或带(9)的转子预制体放入模具中加压定型。
  9. 根据权利要求7所述的制造方法，其特征在于，
    所述固化步骤包括将定型后的转子预制体放入固化炉中加热固化获得转子。
  10. 根据权利要求1-6中任一项所述的制造方法，其特征在于，所述片材(1)的厚度为0.05-0.5mm；
    和/或
    所述片材(1)中所述纤维织物所占体积比例为67-70％，所述树脂所占体积比例为30％-33％；
    和/或
    所述片材(1)由将预先浸渍树脂的纤维连续织物裁剪获得；
    和/或
    所述纤维织物为碳纤维织物，所述树脂为热固型树脂。
  11. 一种转子，其特征在于，包括：
    转子体，具有安装腔，所述转子体由若干片片材(1)沿所述转子体的轴向方向层叠并固化一体形成，其中所述片材(1)由片状的预浸渍树脂的纤维织物形成；
    永磁元件(2)/转子线圈，设置在所述安装腔内。
  12. 根据权利要求11所述的转子，其特征在于，所述转子为内转子，所述转子还包括转子轴，所述转子体上还具有转轴腔，所述转轴腔适于安装所述转子轴。
  13. 根据权利要求12所述的转子，其特征在于，若干所述片材的形状一致，均包括第一中心孔(12)，以及环绕所述第一中心孔(12)设置的若干第一弧形孔(11)，若干所述片材(1)对准层叠一起后，所述第一中心孔(12)形成所述转轴腔，所述第一弧形孔(11) 形成安装永磁元件(2)的安装腔；
    或
    若干所述片材的形状不一致，所述片材(1)包括若干层叠构成转子体的两端端部的第一片材，以及若干层叠构成转子体的中间部的第二片材，所述第一片材和第二片材上均具有第二中心孔，所述第二片材上具有环绕所述第二中心孔的第二弧形孔，若干所述片材(1)对准层叠一起后，所述第二中心孔对齐形成所述转轴腔，所述第二弧形孔对齐形成安装转子线圈的安装腔。
  14. 根据权利要求11所述的转子，其特征在于，所述转子为外转子，若干所述片材(1)对准层叠一起后能够配合形成具有中心腔和所述安装腔的转子体，所述中心腔包括适于安装定子(8)的定子腔，以及位于所述定子腔的两端，适于安装轴承的轴承腔。
  15. 根据权利要求14所述的转子，其特征在于，若干所述片材的形状不一致，所述片材(1)包括若干层叠构成转子体的两端端部的第三片材，以及若干层叠构成转子体的中间部的第四片材，所述第三片材上具有第三中心孔，若干所述第三片材组装后，所述第三中心孔对齐形成所述轴承腔；第四片材上具有第四中心孔，若干第四片材层叠组装后，所述第四中心孔对齐形成所述定子腔，且所述第三中心孔的直径大于所述定子(8)的外径。
  16. 根据权利要求15所述的转子，其特征在于，所述第三片材和第四片材上均设有第三弧形孔，若干所述片材(1)对准层叠一起后，所述第三弧形孔对齐形成安装永磁元件的安装腔；
    或
    所述第四片材上设有第四弧形孔，若干所述第四片材对准层叠一起后，所述第四弧形孔对齐形成安装转子线圈的安装腔。
  17. 根据权利要求11-16中任一项所述的转子，其特征在于，还包括加强层，所述加强层由沿所述转子体的圆周方向缠绕捆扎，并与所述转子体固化一体的预浸树脂纤维丝或带(9)形成。
  18. 根据权利要求17所述的转子，其特征在于，还包括设置在所述加强层外的定型带层，所述定型带层用于转子的固化定型。
  19. 根据权利要求11-16中任一项所述的转子，其特征在于，所述片材(1)的厚度为0.05-0.5mm；
    和/或
    所述片材(1)中所述纤维织物所占体积比例为67-70％，所述树脂所占体积比例为30％-33％；
    所述片材(1)由将预先浸渍树脂的纤维连续织物裁剪获得；
    和/或
    所述纤维织物为碳纤维织物，所述树脂为热固型树脂。
  20. 根据权利要求12或13所述的转子，其特征在于，所述转子轴安装腔为花键孔，所述转子轴的外圆周面上成型有与所述花键孔配合的花键。
  21. 一种电机，其特征在于，具有如权利要求11-19中任一项所述的转子。
PCT/CN2022/080974 2022-01-28 2022-03-15 转子、电机及转子的制造方法 WO2023142239A1 (zh)

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