WO2025129571A1 - 转子总成和电机 - Google Patents

转子总成和电机 Download PDF

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Publication number
WO2025129571A1
WO2025129571A1 PCT/CN2023/140665 CN2023140665W WO2025129571A1 WO 2025129571 A1 WO2025129571 A1 WO 2025129571A1 CN 2023140665 W CN2023140665 W CN 2023140665W WO 2025129571 A1 WO2025129571 A1 WO 2025129571A1
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WO
WIPO (PCT)
Prior art keywords
rotor
component
rotor assembly
assembly according
lamination stack
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Pending
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PCT/CN2023/140665
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English (en)
French (fr)
Inventor
殷庆振
迈尔·马塞尔菲利普
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Schaeffler Technologies AG and Co KG
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Schaeffler Technologies AG and Co KG
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.)
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Application filed by Schaeffler Technologies AG and Co KG filed Critical Schaeffler Technologies AG and Co KG
Priority to PCT/CN2023/140665 priority Critical patent/WO2025129571A1/zh
Priority to CN202380103896.3A priority patent/CN122249974A/zh
Publication of WO2025129571A1 publication Critical patent/WO2025129571A1/zh
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures

Definitions

  • CN 115917927 A discloses an electric motor, comprising a stator and a rotor, wherein the stator is configured to generate a magnetic field and accommodate the rotor in a central opening, and the size of the rotor is designed to fit into the central opening, wherein the rotor comprises a plurality of magnets and a fiber sleeve is wound around the outer circumference of the rotor, and the fiber sleeve holds the magnet in the rotor under tension.
  • the magnet will be subjected to very high stress during the carbon fiber winding process and high-speed rotation.
  • the magnet itself is a brittle material and is easily broken under the action of external forces. In particular, when the magnet is not completely fixed in the rotor lamination, the magnet will also collide with the groove accommodating it, making the magnet easy to break.
  • the technical problem to be solved by the present invention is to provide an improved rotor assembly which can adapt to ultra-high-speed rotation and significantly improve the service life of magnets and rotor laminations.
  • the technical problem is solved by a rotor assembly for an electric motor.
  • the rotor assembly includes a rotor shaft, a rotor lamination group, and a tensioned fiber sleeve wound around the outer circumference of the rotor lamination group.
  • a groove is provided on the rotor lamination group, and a bonding member is filled in the groove to fix the magnet in the groove.
  • the outer layer of the rotor lamination group is wrapped with carbon fiber, and the carbon fiber is wound into a sleeve around the rotor.
  • the high-strength carbon fiber sleeve provides protection for the rotor laminations and magnets, and is filled into the magnetic slots with adhesives, which not only acts as an adhesive filler to fix the magnets, but also combines the rotor laminations and magnets into a whole.
  • the magnets are fixed in the grooves immovably by adhesives, which can reduce the stress on the magnets when the motor runs at high speeds, creating a sturdy design with better performance.
  • the bonding member is formed by injection molding in the groove.
  • This injection molding method makes the bonding member and the groove more firmly bonded, which helps to improve the durability and reliability of the rotor assembly, and the injection molding process is low in cost and easy to implement.
  • the bonding member covers the axial end face of the rotor lamination stack, that is, the bonding member fills the groove and covers the groove in the axial direction. This covering method ensures the close combination of the magnet and the rotor, reduces possible loosening or falling off, and thus improves the performance and stability of the motor.
  • the bonding member cannot cover the entire axial end face to avoid stress concentration.
  • the bonding agent is a polymer material.
  • the polymer material has excellent adhesion and durability, and can effectively bond the magnet and the rotor lamination stack, thereby providing a reliable fixing effect.
  • the rotor lamination group is evenly divided into a plurality of magnet placement areas in the circumferential direction, and three magnets are arranged in a triangular shape and spaced apart from each other in each magnet placement area.
  • the magnets are arranged in a triangular shape to form a stable structure, and the magnets are spaced apart from each other to leave space for the injection molding adhesive, so that the magnets can be better fixed.
  • the rotor lamination group is composed of a first component and a second component, wherein the first component is torsionally connected to the rotor shaft, and the second component is used for magnetic conduction. This design helps to optimize the structure of the rotor and improve the efficiency and performance of the motor.
  • a groove is formed between the first component and the second component, which simplifies the processing and assembly processes of the groove. It is further preferred that the first component limits the movement of the second component toward the radial outside. This limitation helps to maintain the stable position of the second component, thereby ensuring the accurate installation of the magnet and the normal operation of the rotor.
  • This limitation can be achieved by shape matching, for example, the second component is designed as a triangle, and the first component is designed as a corresponding structure to accommodate the triangle. When rotating at high speed, the first component can limit the second component from moving radially outward due to centrifugal force, thereby forming a more stable structure.
  • the second component is inserted into the first component in contact with the rotor shaft, and at high speed During rotation, the force caused by the weight of the second component is not directly transmitted to the outer fiber sleeve, which not only reduces the stress of the carbon fiber sleeve, but also reduces the risk of deformation of the rotor. More preferably, there is a gap on the outer edge of the rotor lamination stack, and the bonding member can evenly fill the gap, so that the bonding member as an injection-molded polymer material replaces the traditional ferromagnetic bridge between the magnets, thereby reducing magnetic flux leakage.
  • the thickness of the fiber sleeve is 0.5 to 3 mm, especially 0.5 to 1 mm. Since the bonding member is used to fix the magnet, the stress of the rotor laminations and the magnet on the fiber sleeve is reduced, so the thickness of the fiber sleeve can be reduced, which helps to reduce the size and weight of the rotor assembly while maintaining sufficient strength to meet the performance requirements of the motor.
  • the present invention provides a rotor assembly for a motor, whose optimized design and structure help improve the performance, efficiency and reliability of the motor.
  • the bonding member is used to provide additional holding force for the magnet, so that the rotor lamination forms a self-locking structure that can withstand the centrifugal force at ultra-high speed.
  • FIG1 shows a perspective view and an exploded view of a rotor assembly designed according to the present invention
  • FIG2 shows a cross-sectional view of a rotor assembly and its components designed according to the present invention
  • FIG. 3 shows a structural diagram of a rotor assembly designed according to the present invention.
  • the “axial direction”, “radial direction” and circumferential direction mentioned in the present invention are all relative to the rotor axis.
  • the rotor assembly has a rotor shaft 1 and a rotor lamination stack 2, on the outer periphery of the rotor lamination stack 2 is wound a fiber sleeve 5, preferably carbon fiber, to limit the deformation of the rotor laminations at high speed.
  • the fiber sleeve 5 is pre-tensioned and wound around the outside of the rotor lamination stack 2.
  • the thickness of the fiber sleeve 5 can be between 0.5 mm and 3 mm, depending on the calculation of the centrifugal force.
  • the fiber sleeve 5 can be wound around the rotor lamination stack under pre-tensioning and low temperature (-20 degrees).
  • FIG. 2 is a cross-sectional view of the components shown in FIG. 1 .
  • the rotor lamination stack 2 has a central hole in the middle for placing the rotor shaft 1.
  • a plurality of weight-reducing holes 24 are arranged on the periphery of the central hole for reducing the overall weight of the rotor lamination stack 2.
  • the outer periphery of the weight-reducing hole 24 and the annular region to the edge are evenly divided into a plurality of magnet placement regions 25.
  • a plurality of grooves 23 are arranged in each magnet security region 25.
  • the grooves in each magnet placement region 25 are arranged in a triangular shape, and a magnet 3 is arranged on each of the three sides, and the three magnets 3 are spaced apart from each other and do not contact each other.
  • the grooves are injection molded to fill the gaps left by the magnets 3 and thereby fix the magnets 3 in the grooves.
  • the injection molding material may be PPS, PA or other polymer materials, and the present invention is not strictly limited as long as the same function is achieved. During the injection molding process, all the grooves 23 are filled with these polymer materials to ensure that there are no gaps or pores.
  • injection molding materials not only act as adhesives, but also can combine the rotor laminations and magnets into a whole, thereby improving the stability of the rotor lamination group 2, especially when the motor rotates at ultra-high speeds, these features create a more robust design with better performance.
  • the adhesive material after injection molding will cover the axial end surface of the groove 23, but will not cover the entire axial end surface to avoid stress concentration. This covering shape can be formed by demolding.
  • FIG3 shows a specific embodiment of the rotor lamination.
  • the rotor lamination 2 is not a whole, but is divided into two parts: a first component 21 and a second component 22.
  • the first component 21 assumes the main rotor support function and is connected to the rotor shaft 1.
  • the second component 2 serves as the key path for the magnetic flux from the rotor to the stator.
  • the second component 22 is generally triangular in shape. After being assembled on the first component 21, the second component 22 is radially outward.
  • the movement of the second component 22 is restricted by the first component 21, so when rotating at high speed, the force generated by the second component 22 will not be directly transmitted to the external fiber sleeve 5, which not only reduces the stress of the fiber sleeve 5, but also reduces the risk of deformation of the rotor.
  • the magnet 3 is combined with the first component 21 and the second component 22 into a whole, so that the rotor lamination forms a self-locking structure that can withstand centrifugal force at high speed.
  • the outer circumference of the rotor lamination is not completely closed, but the traditional ferromagnetic bridge is replaced by the injection molding polymer material 4. Since the polymer material does not conduct magnetic flux, there is no magnetic flux leakage in the rotor lamination.

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

Abstract

本发明涉及一种用于电机的转子总成，具有转子轴(1)、转子叠片组(2)和缠绕在所述转子叠片组(2)外周的、被张紧的纤维套(5)，所述转子叠片组(2)具有用于安置磁体(3)的凹槽(23)，其中，在所述凹槽(23)内还设有粘结件(4)，用于将所述磁体(3)固定在所述凹槽(23)内。此外，本发明还涉及具有这种转子总成的电机。

Description

转子总成和电机 技术领域
本发明涉及车辆技术领域，更具体地，本发明尤其涉及用于新能源车辆的电机和转子总成，电机尤其是永磁同步电动机(PMSM)。
背景技术
随着电动汽车的发展，电动机设计变得越来越重要。电动机设计的趋势是适应高速旋转，从而可以用在加速更快的汽车上。但是随着速度的提高，转子叠片会承受非常高的离心力，导致变形和损坏。传统的永磁同步电动机设计中，通常需要使转子的磁桥更厚，以抵抗高速下的非常高离心力。当转子速度提高到20000转/分钟以上时，为考虑高速下转子的变形，磁桥将被设计得非常坚固和厚实。然而，更厚的磁桥会导致漏磁，降低转子磁体利用率和整个电动机效率。
为了解决这个问题，由CN 115917927 A已知一种电动机，包括定子和转子，定子被配置为生成磁场并且将转子容纳到中央开口中，转子的尺寸被设计为适配在所述中央开口内，其中，转子包括多个磁体并且在转子的外周上缠绕有纤维套筒，该纤维套筒在张力下将磁体保持在转子中。但是，磁体在碳纤维绕制过程和高速旋转过程中将承受非常高的应力，磁体本身是一种脆性材料，在外力作用下容易破裂，尤其当磁体在转子叠片内不被完全固定的情况下，磁体也会与容纳他的凹槽进行磕碰，从而使得磁体容易碎裂。
发明内容
本发明所要解决的技术问题是提供一种改进的转子总成，其能够适应超高速旋转，且磁体和转子叠片的使用寿命会被显著提高。
所述技术问题通过一种用于电机的转子总成所解决。该转子总成包括转子轴、转子叠片组和缠绕在转子叠片组外周的、被张紧的纤维套。在转子叠片组上具有凹槽，凹槽内填充粘结件，粘结件用于将磁体固定在凹槽 内。根据本发明的设计方案，在转子叠片组外层包裹着碳纤维，将碳纤维缠绕成一个套管围绕转子，高强度碳纤维套管为转子叠片和磁体提供了保护，采用粘结件将其充满到磁槽中，既起到粘合填充剂的作用固定磁体，又将转子叠片和磁体结合为一个整体。通过粘结件将磁体不可移动地固定在凹槽中，能够在电机高速运转时减少了磁体受到的应力，其创造了一个具有更好性能的坚固设计。
根据本发明的优选实施方案，粘结件通过在凹槽内注塑形成。这种注塑的方法使得粘结件与凹槽之间的结合更加牢固，有助于提高转子总成的耐用性和可靠性，且注塑工艺成本较低容易施行。进一步优选的是，粘结件覆盖在转子叠片组的轴向端面上，即粘结件填满凹槽且在轴向上覆盖凹槽。这种覆盖方式确保了磁体与转子的紧密结合，减少了可能的松动或脱落，从而提高了电机的性能和稳定性。此外，粘结件也不能铺满整个轴向端面，以避免应力集中。这种在轴向端面上的铺设可以简单地通过脱模形成。进一步优选的是，粘结剂是聚合物材料。聚合物材料具有优良的粘附性和耐用性，能够有效地粘合磁体和转子叠片组，从而提供了可靠的固定效果。
根据本发明的优选实施方案，转子叠片组在圆周方向上被均匀地划分为多个磁体安放区域，在每个磁体安放区域内设置三个呈三角形且相互间隔布置的所述磁体。磁体呈三角形布置可以形成稳定的结构，磁体相互间间隔开以给注塑粘结件留有空间，从而能够更好地固定磁体。进一步优选的是，转子叠片组由第一组件和第二组件构成，其中第一组件与转子轴抗扭连接，第二组件用于导磁。这种设计有助于优化转子的结构，提高了电机的效率和性能。在第一组件和第二组件之间形成凹槽，简化了凹槽的加工工艺和装配工艺。进一步优选的是，第一组件限制第二组件朝向径向外侧移动。这种限制有助于保持第二组件的稳定位置，从而确保了磁体的准确安装和转子的正常运转。这种限制可以通过形状配合实现，例如第二组件设计为三角形，第一组件设计为相应的容纳三角形的结构，在高速旋转时第一组件能够限制第二组件因为离心力而沿着径向向外运动，从而形成了更加稳固的结构。第二组件插入到与转子轴接触的第一组件中，在高速 旋转时，第二组件的重量所引起的力没有直接传递到外部纤维套上，这不仅减少了碳纤维套管的应力，还减小了转子的变形风险。更优选的是，在转子叠片组的外边缘上存在间隙，粘结件能够均匀地填充该间隙，因此作为注塑聚合物材料的粘结件取代了传统的磁体之间的铁磁桥，从而减少了磁通泄漏。
根据本发明的优选实施方案，纤维套的厚度为0.5至3毫米，尤其是0.5至1毫米。由于使用了粘结件用于固定磁体，减轻了转子叠片和磁体对纤维套的应力作用，可以因此降低纤维套的厚度，有助于减少转子总成的尺寸和重量，同时保持了足够的强度，以满足电机的性能要求。
综上所述，本发明提供了一种用于电机的转子总成，其优化的设计和结构有助于提高电机的性能、效率和可靠性。通过改进磁体的固定方式，利用粘结件为磁体提供额外的固持力，从而使得转子叠片形成了自锁结构，能够承受超高速时的离心力。
此外，本发明所要解决的技术问题还可以被一种电机所解决，该电机具有包括上述特征的转子总成。
附图说明
下面通过附图进一步阐述本发明的优选实施方式。附图为：
图1示出根据本发明设计的转子总成的立体图以及其分解图；
图2示出根据本发明设计的转子总成以及其部件的截面图；
图3示出根据本发明设计的转子总成的结构组成图。
除了单独说明以外，本发明所述的“轴向”、“径向”以及圆周方向皆是相对于转子轴而言。
具体实施方式
下文中，参照附图描述本发明的实施例。下面的详细描述和附图用于示例性地说明本发明的原理，本发明不限于所描述的优选实施例，本发明的范围由权利要求书限定。现参考示例性的实施方式详细描述本发明，一些实施例图示在附图中。以下描述参考附图进行，除非另有表示，否则在 不同附图中的相同附图标记代表相同或类似的元件。以下示例性实施方式中描述的方案不代表本发明的所有方案。相反，这些方案仅是所附权利要求中涉及的本发明的各个方面的系统和方法的示例。
如图1所示，转子总成具有转子轴1和转子叠片组2，在转子叠片组2的外周上缠绕有一层纤维套5，优选是碳纤维，以限制高速下转子叠片的变形。在绕制过程中，纤维套5被预拉紧绕绕在转子叠片组2外部。纤维套5的厚度可以在0.5毫米至3毫米之间，具体取决于离心力的计算。为了减小纤维套5的厚度，可以在预拉紧和低温(-20度)下将纤维套5绕在转子叠片组上。
图2是图1所示部件的截面图。从图中可见，转子叠片组2中间具有中心孔，用于安置转子轴1。在中心孔的外周布置有多个减重孔24，用于减轻转子叠片组2的整体重量。在减重孔24的外周直到边缘的圆环区域内，平均分成若干个磁体安放区域25。在每个磁体安防区域25内设有多个凹槽23。根据本实施例，在每个磁体安放区域25内的凹槽呈现三角形布置，在三条边上分别布置一个磁体3，三个磁体3相互间隔，不接触。根据本发明的设计方案，对凹槽进行注塑，以填满磁体3留下的空隙并且由此将磁体3固定在凹槽内。注塑材料可以是PPS、PA或其他聚合物材料，本发明并不做严格限制，只要实现相同的功能即可。在注塑过程中，所有的凹槽23都被这些聚合物材料充填，以确保没有空隙或孔隙。这些注塑材料既起到粘合剂的作用，又能够将转子叠片和磁体结合成一个整体，从而提高了转子叠片组2的稳定性，尤其在电机超高速旋转时，这些特点创造了一个更坚固的设计，具有更好的性能。如图1左侧附图所示，注塑后的粘结件材料会覆盖凹槽23的轴向端面，但是也不会铺满整个轴向端面以避免应力集中，这个覆盖形状可以通过脱模形成。
图3示出转子叠片的一个具体实施例。在该实施例中，转子叠片2不是一个整体，而是分为两种部分：第一组件21和第二组件22。除了磁感应外，第一组件21承担主要的转子支撑功能，并与转子轴1连接。第二组件2作为磁通从转子到定子的关键路径。如图所示，第二组件22大体上成三角形，在被装配到第一组件21上后，在径向向外的方向上第二组 件22被第一组件21限制移动，因此在高速旋转时，第二组件22产生的力不会直接传递给外部的纤维套5，这不仅减少了纤维套5的应力，还降低了转子的变形风险。在通过将注塑材料填充到凹槽23中，使得磁体3与第一组件21和第二组件22结合成一个整体，因此转子叠片形成了自锁结构，能够承受高速下的离心力。此外，如图所示，第一组件21和第二组件22装配完成后并没有完全封闭转子叠片的外圆周，而是用注塑聚合物材料4取代了传统的铁磁体桥梁。由于聚合物材料不传导磁通，所以转子叠片内没有磁通泄漏。
尽管已经参考示例性实施例描述了本发明，但是应理解，本发明并不限于上述实施例的构造和方法。相反，本发明意在覆盖各种修改例和等同配置。另外，尽管在各种示例性结合体和构造中示出了所公开发明的各种元件和方法步骤，但是包括更多、更少的元件或方法的其它组合也落在本发明的范围之内。
附图标记列表
1     转子轴
2     转子叠片组
21    第一组件
22    第二组件
23    凹槽
24    减重孔
25    磁体安放区域
3     磁体
4     粘结件
5     纤维套

Claims (10)

  1. 一种用于电机的转子总成，具有转子轴(1)、转子叠片组(2)和缠绕在所述转子叠片组(2)外周的、被张紧的纤维套(5)，所述转子叠片组(2)具有用于安置磁体(3)的凹槽(23)，其中，在所述凹槽(23)内还设有粘结件(4)，用于将所述磁体(3)固定在所述凹槽(23)内。
  2. 根据权利要求1所述的转子总成，其特征在于，通过在所述凹槽(23)内注塑形成所述粘结件(4)。
  3. 根据权利要求2所述的转子总成，其特征在于，所述粘结件(4)在所述转子叠片组(2)的轴向端面上封盖所述凹槽(23)。
  4. 根据权利要求2所述的转子总成，其特征在于，所述粘结件(4)由聚合物材料构成。
  5. 根据权利要求1至4中任一项所述的转子总成，其特征在于，所述转子叠片组(2)在圆周方向上被均匀地划分为多个磁体安放区域(25)，在每个所述磁体安放区域(25)内设置三个呈三角形且相互间隔布置的所述磁体(3)。
  6. 根据权利要求5所述的转子总成，其特征在于，所述转子叠片组(2)具有第一组件(21)和第二组件(22)，所述第一组件(21)与所述第二组件(22)之间的间隙形成所述凹槽(23)，其中，所述第一组件(21)与所述转子轴(1)抗扭连接，所述第二组件(22)用于导磁。
  7. 根据权利要求6所述的转子总成，其特征在于，所述第一组件(21)限制所述第二组件(22)朝向径向外侧移动。
  8. 根据权利要求7所述的转子总成，其特征在于，在所述转子叠片组(2)的外边缘上、在所述第一组件(21)和所述第二组件(22)之间存在间隙。
  9. 根据权利要求1至4中任一项所述的转子总成，其特征在于，所述纤维套(5)的厚度为0.5至3毫米。
  10. 一种电机，其特征在于，所述电机具有根据权利要求1至9中任一项所述的转子总成。
PCT/CN2023/140665 2023-12-21 2023-12-21 转子总成和电机 Pending WO2025129571A1 (zh)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN203734403U (zh) * 2014-01-17 2014-07-23 汉宁电气工厂有限责任两合公司 电动机
CN207968109U (zh) * 2017-01-19 2018-10-12 西门子公司 永磁激励的旋转电机的转子
DE102019117691A1 (de) * 2019-07-01 2021-01-07 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Verfahren zum Herstellen eines Rotors einer elektrischen Maschine und Rotor einer elektrischen Maschine
CN115917927A (zh) * 2020-05-04 2023-04-04 特斯拉公司 具有绕组的永磁电机
CN116896239A (zh) * 2022-04-01 2023-10-17 保时捷股份公司 转子装置和用于制造电机的转子装置的方法

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN203734403U (zh) * 2014-01-17 2014-07-23 汉宁电气工厂有限责任两合公司 电动机
CN207968109U (zh) * 2017-01-19 2018-10-12 西门子公司 永磁激励的旋转电机的转子
DE102019117691A1 (de) * 2019-07-01 2021-01-07 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Verfahren zum Herstellen eines Rotors einer elektrischen Maschine und Rotor einer elektrischen Maschine
CN115917927A (zh) * 2020-05-04 2023-04-04 特斯拉公司 具有绕组的永磁电机
CN116896239A (zh) * 2022-04-01 2023-10-17 保时捷股份公司 转子装置和用于制造电机的转子装置的方法

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