WO2024104600A1 - Rotor pour une machine électrique et machine électrique - Google Patents

Rotor pour une machine électrique et machine électrique Download PDF

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Publication number
WO2024104600A1
WO2024104600A1 PCT/EP2022/082477 EP2022082477W WO2024104600A1 WO 2024104600 A1 WO2024104600 A1 WO 2024104600A1 EP 2022082477 W EP2022082477 W EP 2022082477W WO 2024104600 A1 WO2024104600 A1 WO 2024104600A1
Authority
WO
WIPO (PCT)
Prior art keywords
rotor
main body
segments
permanent magnets
magnetic members
Prior art date
Application number
PCT/EP2022/082477
Other languages
English (en)
Inventor
Alberto PEÑA RODRIGUEZ
Iago MARTINEZ OCAÑA
Covadonga GÓMEZ BARREALES
Marta Diez
Jon GARCÍA URBIETA
Original Assignee
Gkn Automotive Limited
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 Gkn Automotive Limited filed Critical Gkn Automotive Limited
Priority to PCT/EP2022/082477 priority Critical patent/WO2024104600A1/fr
Publication of WO2024104600A1 publication Critical patent/WO2024104600A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—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

Definitions

  • the application refers to a rotor for an electric machine comprising a rotational axis, a rotor core including a central rotor main body and at least two rotor segments, which are circumferentially distributed around the rotor main body, a plurality of permanent magnets being arranged between the rotor main body and the rotor segments, as well as to an electric machine.
  • a rotor for an electric machine includes a plurality of permanent magnets and a rotor core that defines pockets, between a hub portion and a pole portion, for receiving pairs of magnets.
  • Lateral bridges of the rotor core extend between the outer surface and the radially outward ends of the magnet pockets.
  • Central bridges of the rotor core extend between adjacent magnet openings for receiving the pairs of magnets.
  • Central and lateral bridges provide structural integrity of the rotor and magnet retention. They are the result of hollowing the rotor lamination to create pockets where the magnets are allocated.
  • the central and lateral bridges form the main electromagnetic flux leakage path. Further, the central and lateral bridges experience high mechanical stresses due to their reduced cross-sectional area.
  • US 1 1 152 825 B2 discloses a rotor for an electric machine including pairs of magnets with a bridge region therebetween. Laminations that comprise the rotor define openings in the bridge region between the magnets of each of the pairs. A first projection extends from the pole portion and a second projection extends from the hub portion into the opening in the bridge region. A clip is installed in the openings and a bonding material fills the remainder of the bridge region. The clip cooperates with the first projection, the second projection, and the bonding material to provide a structural connection between the hub portion and pole portion.
  • DE 10 2017 205 858 A1 discloses a rotor for a permanent-magnet synchronous machine, the rotor comprising a rotor body in which at least one recess extends substantially in an axial direction at least partially through the rotor body, and at least two permanent magnets, the recess having at least two elongate first regions and at least one second region which extends in a radial direction and which extends radially between the two first regions, a permanent magnet being received in each case in a first region and a connecting element being received in the second region and having a geometric widening at its respective ends in accordance with the contour of the second region of the recess.
  • GB 2 562 704 A discloses a rotor comprising one or more slots located between adjacent pairs of magnetic poles, and one or more windings located in the one or more slots.
  • a two part retainer assembly is provided in between the poles to retain the windings in place.
  • the retainer comprises a root portion, preferably attached to the core using a fir tree root type connection, and a cover portion for attachment to the root portion to retain the windings in place on the core.
  • GB 2 546 298 A discloses a rotor assembly having a rotor support hub which includes a plurality of first fir tree connection parts arranged about a periphery the rotor support hub.
  • the rotor assembly further has a plurality of rotor segments each having a second connection part.
  • Each of the second connection parts are cooperable with at least one of the plurality of first connection parts to connect each of the rotor segments about the periphery the rotor support hub.
  • a plurality of fixing parts in the form of roll pins are each configured to be received between cooperating first and second connection parts and to form an inference fit there between so as to secure the rotor segments to the rotor support hub.
  • the rotor segments and support hub may comprise a plurality of laminations with the rotor hub being non-magnetic material.
  • the objective is accomplished by a rotor for an electric machine according to claim 1 .
  • the rotor for an electric machine comprises a rotational axis, a rotor core including a central rotor main body and at least two rotor segments, which are circumferentially distributed around the rotor main body, a plurality of permanent magnets arranged between the rotor main body and the rotor segments, wherein the rotor main body and the rotor segments are separated and wherein a plurality of non-magnetic members form joining links between the rotor main body and the rotor segments.
  • Removing both the central and the lateral bridges of the rotor advantageously increases a performance of an electric machine, allowing higher torque, higher power and being able to drive the motor at higher speeds.
  • the central bridges are substituted by the non-magnetic members forming the joining links.
  • the rotor core is separated into the rotor main body and the rotor segments, which means the rotor core is not a one-piece part, but assembled from multiple parts, and the rotor main body and the rotor segments have to be connected by the non-magnetic members.
  • the non-magnetic members are connected with positive locking to the rotor main body and to the respective rotor segments.
  • the non-magnetic members are dovetailed to the rotor main body and/or to the respective rotor segments.
  • the non-magnetic members can be connected to the rotor main body and/or the respective rotor segments by a fir tree joint.
  • Fir tree joints are known to provide multiple areas of contact over which advantageously large thermal and centrifugal stresses can be transmitted. It provides increased contact surface in the available space.
  • a fir tree joint comprises an arrangement of plural pairs of opposing teeth or lobes extending from a stem, which arrangement is also referred to as a fir tree root.
  • the teeth or lobes at a distal end of the stem basis have a lesser degree of lateral projection than the teeth or lobes located nearer the stem basis.
  • the commonly used term originates from the form of the tapering of the teeth or lobes, having an appearance of a fir tree.
  • the fir tree joint is advantageous to establish the connection between the rotor segments and the non-magnetic members, because that connection is positioned at the narrowest point between the two permanent magnets of a magnet pair arranged in a V-form, where low space is available for a positive locking.
  • a male fir tree joint member at the rotor segment has a low circumferential extension and thus fits into the narrow space between the permanent magnets.
  • the non-mag- netic member accordingly comprises a complementary female fir tree joint retaining recess with low circumferential extension at its narrowest end.
  • the connection between the non-metal member and the rotor main body can advantageously be a simpler dovetail connection as there is more space for that connection between the permanent magnets.
  • the dovetail connection can be wider in circumferential direction, in particular with the male connector at the non-metal member and the complementary female dovetail retaining recess at the rotor main body.
  • a further advantage of the dovetail joint is its lower radial extension compared to the fir tree joint.
  • the non-metal member extends radially less far into the rotor main body, thus minimizing its influence on the magnetic flux in the rotor main body.
  • the permanent magnets are arranged in magnet pairs between the rotor main body and one of the respective rotor segments, so that the respective non-magnetic members extending in a radial direction between the respective two permanent magnets forming one of the magnet pairs.
  • the region between the two permanent magnets forming a magnet pair is also referred to as the central bridge region.
  • the central bridge region As the rotor main body is separate from the rotor segments, there is no rotor core material in the central bridge regions. Instead, the non-magnetic members extending in the central bridge region.
  • the regions between radially outer ends of the two permanent magnets forming one of the magnet pairs are referred to as lateral bridge regions, and there is no rotor core material in the lateral bridge regions, either.
  • the lateral and central bridge regions form a space between the rotor main body and the respective rotor segments, which is partly occupied by the permanent magnets and the non-magnetic member.
  • the rest of the space can be filled with air.
  • the space can at least partly be filled with an epoxy or plastic compound filler.
  • each rotor segment is wedge-formed, an axially extending outer surface of the rotor segment forming a section of a circumferential surface of the rotor core.
  • Two axially extending inner surfaces of the rotor segment abut against the respective magnet pair, the inner surfaces enclosing an obtuse angle, spanning particularly between 100° and 140°.
  • the rotor main body can have radially extending portions forming intermediate sections of the circumferential surface of the rotor core between respective two adjacent rotor segments.
  • the rotor main body and the rotor segments of the rotor core are comprised of a plurality of axially stacked laminations.
  • the non-magnetic members may be extrusion profiles extending along an axial length of the rotor core or at least a part of the axial length.
  • the non-magnetic members can be made of aluminium, a metal matrix composite, non-magnetic metal, in particular non-magnetic steel or carbon fibre.
  • the permanent magnets can be bonded to the rotor main body and to the rotor segments by an adhesive.
  • the rotor main body has a framework structure comprising axially extending openings, wherein beams supporting the permanent magnets are connected to a circumferentially extending continuous hub ring.
  • the number of rotor segments may be between six and ten.
  • the electric machine comprises a rotor as described above and a stator, the rotor being rotatable relative to the stator about the rotational axis.
  • Figure 1 shows an embodiment of a rotor in a perspective view
  • Figure 2 shows an enlarged detail of Figure 1 ;
  • Figure 3 shows the further enlarged detail in a plan view
  • Figure 4 shows an enlarged detail of a further embodiment of the rotor in a perspective view
  • Figure 5 shows an embodiment of an electric machine in a perspective exploded view
  • Figure 6 shows the electric machine of Figure 5 in a cross-sectional view
  • Figure 7 shows an enlarged detail of Figure 6.
  • a rotor 1 for an electric machine is shown.
  • the rotor 1 has a rotor shaft 18 and is rotatable about a rotational axis L.
  • a rotor core 6 comprises a central rotor main body 2 and eight circumferentially distributed rotor segments 3.
  • the rotor main body 2 and the rotor segments 3 are separate parts, which are held together by non-magnetic members 4 forming joining links between the rotor main body 2 and the rotor segments 3.
  • Permanent magnets 5 are arranged between the rotor main body 2 and the rotor segments 3.
  • the permanent magnets 5 are arranged in eight magnet pairs 7, each positioned between the rotor main body 2 and one of the eight rotor segments 3.
  • the rotor main body 2 and the rotor segments 3 of the rotor core 6 are comprised of a plurality of axially stacked laminations 14.
  • the non-magnetic members 4 are extrusion profiles, for example made of aluminium, extending along an axial length of the rotor core 6.
  • FIG 2 an enlarged detail of Figure 1 is depicted illustrating that the rotor main body 2 has radially extending portions 12 forming intermediate sections of the circumferential surface of the rotor core 6 between respective two adjacent rotor segments 3.
  • the rotor main body 2 further has a framework structure comprising axially extending openings 17, wherein beams 15 supporting the permanent magnets 5 are connected to a circumferentially extending continuous hub ring 16.
  • FIG 3 the further enlarged detail is shown in a plan view with the rotational axis L being oriented orthogonal with respect to the plane of projection.
  • the non-magnetic member 4 extends in a central bridge region, i.e. in a radial direction between the two magnets 5 forming one of the permanent magnet pairs 7.
  • the material of the rotor core 6 has been removed or omitted from the central bridge region to reduce the flux leakage.
  • a space between the magnets 5 is filled with the non-magnetic member 4 and an epoxy or plastic compound filler 9.
  • the non-magnetic member 4 is connected with positive locking to the rotor main body 2 and to the rotor segment 3.
  • the non-magnetic member 4 is connected to the rotor main body 2 by a dovetail joint 22 and to the rotor segment 3 by a fir tree joint 23.
  • a male fir tree structure at the rotor segment 3 extends radially between the permanent magnets 5 and is locked to a corresponding female fir tree structure at the non-magnetic member 4.
  • the material of the rotor core 6 has been removed or omitted from the lateral bridge regions between the radially outward ends of the magnets and the outer surface 10 of the rotor core 6, which also advantageously reduces the flux leakage.
  • the space between the rotor main body 2 and the rotor segment 3, which is unoccupied by the permanent magnets 5 and the non-magnetic member 4, is filled with the epoxy or plastic compound filler 9.
  • the permanent magnets 5 can be bonded to the rotor main body 2 and to the rotor segments 3 by an adhesive, in order to reduce a radial deformation of the rotor segment 3 under centripetal force, in particular at its peripheral ends remote from the non-magnetic member 4.
  • the rotor segment 3 is wedge-formed and the axially extending outer surface 10 of the rotor segment 3 forms a section of a circumferential surface of the rotor core 6.
  • Two axially extending inner surfaces 11 of the rotor segment 3 abut against the magnet pair 7, the inner surfaces 1 1 enclosing an obtuse angle of about 120°.
  • FIG. 4 A further embodiment of the rotor 1 is illustrated in Figure 4, showing an enlarged detail in a perspective view. Again, the material of the rotor core 6 has been removed or omitted from the central bridge region and the lateral bridge regions to reduce the flux leakage.
  • the space between the rotor main body 2 and the rotor segment 3, which is unoccupied by the permanent magnets 5 and the non-magnetic member 4, is partly filled with the epoxy or plastic compound filler 9 and partly with air 8.
  • the epoxy or plastic compound filler 9 can comprise reinforced plastics, hybrid reinforcements and pre-impregnated materials for bonding and higher mechanical stiffness.
  • the non-magnetic member 4 is connected to the rotor main body 2 by the dovetail joint 22 and to the rotor segment 3 by the fir tree joint 23.
  • FIG 5 an embodiment of an electric machine is depicted in a perspective exploded view.
  • Figure 6 shows the electric machine of Figure 5 in a cross-sectional view
  • Figure 7 shows an enlarged detail of Figure 6.
  • the electric machine comprises the rotor 1 and a stator 19, the rotor 1 being rotatable relative to the stator 19 about the rotational axis L.
  • the stator 19 comprises windings 20, which are not depicted in Figure 5, received in slots 21 formed in the stator 19 in axial direction.
  • the rotor main body 2 and the rotor segments 3 are separate parts, which are held together by the non-magnetic members 4 forming the joining links between the rotor main body 2 and the rotor segments 3.
  • the permanent magnets 5 are arranged between the rotor main body 2 and the rotor segments 3.
  • the space between the rotor main body 2 and the rotor segment 3, which is unoccupied by the permanent magnets 5 and the non-magnetic members 4, including the lateral bridge regions, is filled with the epoxy or plastic compound filler 9.
  • the rotational axis L defines the axial direction with regard to the rotor 1 and the electric machine.
  • the radial and circumferential directions are defined relative to the rotational axis L.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

L'invention concerne un rotor pour une machine électrique comprenant un axe de rotation, un noyau de rotor comprenant un corps principal de rotor central et au moins deux segments de rotor, qui sont répartis de manière circonférentielle autour du corps principal de rotor, une pluralité d'aimants permanents étant agencée entre le corps principal de rotor et les segments de rotor. L'invention concerne également une machine électrique.
PCT/EP2022/082477 2022-11-18 2022-11-18 Rotor pour une machine électrique et machine électrique WO2024104600A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/EP2022/082477 WO2024104600A1 (fr) 2022-11-18 2022-11-18 Rotor pour une machine électrique et machine électrique

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2022/082477 WO2024104600A1 (fr) 2022-11-18 2022-11-18 Rotor pour une machine électrique et machine électrique

Publications (1)

Publication Number Publication Date
WO2024104600A1 true WO2024104600A1 (fr) 2024-05-23

Family

ID=84421497

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2022/082477 WO2024104600A1 (fr) 2022-11-18 2022-11-18 Rotor pour une machine électrique et machine électrique

Country Status (1)

Country Link
WO (1) WO2024104600A1 (fr)

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4506181A (en) * 1984-03-02 1985-03-19 General Electric Company Permanent magnet rotor with complete amortisseur
US20130026872A1 (en) * 2010-03-30 2013-01-31 Volvo Technology Corporation Rotor of an electric machine with embedded permanent magnets and electric machine
CN103683603A (zh) * 2013-12-26 2014-03-26 安徽江淮汽车股份有限公司 一种转子硅钢片结构
GB2546298A (en) 2016-01-14 2017-07-19 Univ Newcastle Rotor assembly
DE102017205858A1 (de) 2017-04-06 2018-04-19 Magna powertrain gmbh & co kg Rotor für eine permanenterregte Synchronmaschine und Verfahren zur Herstellung eines solchen Rotors
GB2562704A (en) 2017-03-20 2018-11-28 Safran Electrical & Power A rotor for an electrical machine
EP3522336A1 (fr) * 2018-02-01 2019-08-07 Baumüller Nürnberg GmbH Rotor
US11152825B2 (en) 2019-06-13 2021-10-19 Ford Global Technologies, Llc Electrical machine rotor with eliminated iron bridge
CN217692845U (zh) * 2022-03-31 2022-10-28 北京车和家汽车科技有限公司 转子铁芯组件、电机转子结构以及电机

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4506181A (en) * 1984-03-02 1985-03-19 General Electric Company Permanent magnet rotor with complete amortisseur
US20130026872A1 (en) * 2010-03-30 2013-01-31 Volvo Technology Corporation Rotor of an electric machine with embedded permanent magnets and electric machine
CN103683603A (zh) * 2013-12-26 2014-03-26 安徽江淮汽车股份有限公司 一种转子硅钢片结构
GB2546298A (en) 2016-01-14 2017-07-19 Univ Newcastle Rotor assembly
GB2562704A (en) 2017-03-20 2018-11-28 Safran Electrical & Power A rotor for an electrical machine
DE102017205858A1 (de) 2017-04-06 2018-04-19 Magna powertrain gmbh & co kg Rotor für eine permanenterregte Synchronmaschine und Verfahren zur Herstellung eines solchen Rotors
EP3522336A1 (fr) * 2018-02-01 2019-08-07 Baumüller Nürnberg GmbH Rotor
US11152825B2 (en) 2019-06-13 2021-10-19 Ford Global Technologies, Llc Electrical machine rotor with eliminated iron bridge
CN217692845U (zh) * 2022-03-31 2022-10-28 北京车和家汽车科技有限公司 转子铁芯组件、电机转子结构以及电机

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