Rotor and manufacturing method thereof

Abstract

The invention relates to the field of motors, provides a rotor and a manufacturing method thereof, is applied to an asynchronous induction motor, and comprises a rotor core, guide bars and end rings. A plurality of tooth grooves are formed in the circumferential direction of the rotor iron core, and the two ends of each tooth groove penetrate through the two end faces of the rotor iron core in the axial direction respectively; the conducting bars are independently processed and formed, the conducting bars are inserted into the tooth grooves, and the two ends of each conducting bar protrude out of the two end faces of the rotor iron core in the axial direction respectively; the two end rings are respectively arranged at two ends of the rotor core in the axial direction, and the two end rings are respectively connected with two ends of each conducting bar into a whole. The guide bars forming the mouse cage are manufactured independently and are connected into a whole through the end rings at the two ends to form a complete mouse cage structure. A traditional casting process often causes pores in a casting. The porosity can be effectively controlled by separately casting the conducting bars and the end rings.

Description

Technical Field

[0001] The present invention relates to the field of motors, and in particular to a rotor and a manufacturing method thereof. Background Art

[0002] Asynchronous induction motor, also known as asynchronous motor, is a widely used AC motor. The rotor of asynchronous induction motor consists of iron core and winding. The rotor core contains bars for induction current, forming a squirrel cage or winding structure. The rotor winding is usually cast with aluminum or copper bars in the iron core, forming a squirrel cage structure (squirrel cage rotor).

[0003] In the prior art, a casting process is usually used to cast aluminum bars and end rings coupled to the aluminum bars in the slots in the iron core to form a structure similar to a squirrel cage. However, the porosity of high-pressure castings is greatly affected by the product structure. The squirrel cage structure of the cast aluminum rotor makes it easy for the aluminum liquid to produce flocculent and reflux during injection, which easily produces larger pores and shrinkage holes, and has poor consistency. Centrifugal casting can solve the problem of high porosity, but the production cycle of centrifugal casting is long, the process is complicated, and the overall cost is high. Summary of the invention

[0004] In view of the above-mentioned shortcomings of the prior art, an object of the present invention is to provide a rotor and a manufacturing method thereof, so as to reduce the difficulty of manufacturing the rotor of an asynchronous induction motor.

[0005] To achieve the above and other related purposes, the present invention provides a rotor for an asynchronous induction motor, comprising:

[0006] A rotor core, wherein a plurality of tooth slots are arranged in the circumferential direction of the rotor core, and two ends of the tooth slots are respectively arranged through two end surfaces of the rotor core in the axial direction;

[0007] Guide bars, the guide bars are individually processed and formed, the guide bars are inserted into the tooth slots, and the ends of the guide bars protrude from at least one end surface of the rotor core in the axial direction;

[0008] End rings, the two end rings are respectively arranged at the two ends of the rotor core in the axial direction, and the two end rings are respectively connected to the two ends of each guide bar as a whole.

[0009] In a specific embodiment of the present invention, two ends of each of the conductive bars protrude from two ends of the rotor core in the axial direction.

[0010] In a specific embodiment of the present invention, the end ring is formed at the end of each of the guide bars by an insert casting process.

[0011] In a specific embodiment of the present invention, the guide bar includes a main body and a clamping structure arranged at both ends of the main body, and the clamping structure has a portion for the casting material to be embedded and clamped during the casting of the end ring.

[0012] In a specific embodiment of the present invention, the clamping structure includes through holes or grooves arranged at both ends of the conductive bar.

[0013] In a specific embodiment of the present invention, a projection of the clamping structure on the end surface of the body is located inside the end surface of the body.

[0014] In a specific embodiment of the present invention, the connection between the clamping structure and the body is a connecting surface, and the projection of the clamping structure on the end surface of the body protrudes from the connecting surface.

[0015] In a specific embodiment of the present invention, a projection of the clamping structure on the end surface of the body covers the connecting surface.

[0016] In a specific embodiment of the present invention, an end surface of the body is flush with an axial end surface of the rotor core.

[0017] In a specific embodiment of the present invention, the side of the guide bar away from the axis is spaced apart from the outer circumference of the rotor core in the radial direction, and the side of the guide bar away from the axis is located on the side of the outer circumference of the rotor core close to the axis.

[0018] In a specific embodiment of the present invention, chamfers are provided at both ends of the guide bar, and the chamfers are located on a side of the guide bar away from the axis.

[0019] The present invention also includes a rotor manufacturing method for manufacturing the rotor as described above, comprising the following steps:

[0020] Inserting the guide bars into the tooth slots of the rotor core;

[0021] The end rings are respectively cast at both ends of the axis of the rotor core.

[0022] The present invention proposes a rotor and a manufacturing method thereof, wherein the conductive bars constituting the squirrel cage are manufactured separately and then connected as a whole through end rings at both ends to form a complete squirrel cage structure. Traditional casting processes often result in pores inside the casting. Separately casting the conductive bars and end rings can effectively control the porosity. The separate casting and processing processes are easier to monitor and control, and can ensure that each component achieves higher dimensional accuracy and better surface finish. At the same time, the conductive bars and end rings have a balanced conductivity distribution and good consistency after casting. The conductive bars and end rings with balanced conductivity distribution and good consistency ensure that the rotor produces a uniform current distribution during operation, thereby forming a stable rotating magnetic field. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for describing the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0024] Figure 1 It is a schematic diagram of the rotor structure of an asynchronous induction motor in the prior art;

[0025] Figure 2 It is an exploded diagram of the rotor structure of an asynchronous induction motor in the prior art;

[0026] Figure 3 It is a schematic diagram of the end face of the rotor core in a specific embodiment of the present invention;

[0027] Figure 4 It is a three-dimensional schematic diagram of a rotor core in a specific embodiment of the present invention;

[0028] Figure 5 It is a three-dimensional schematic diagram of a guide bar in a specific embodiment of the present invention;

[0029] Figure 6 A three-dimensional schematic diagram of a guide bar from another perspective in a specific embodiment of the present invention;

[0030] Figure 7 It is a schematic diagram of the assembly of the rotor core and the guide bars in a specific embodiment of the present invention;

[0031] Figure 8 It is a schematic diagram of the assembly of the rotor core, the guide bars and the end rings in a specific embodiment of the present invention;

[0032] Fig. 9 It is a structural schematic diagram of the clamping structure on the guide bar in a specific embodiment of the present invention;

[0033] Fig.10 It is a three-dimensional schematic diagram of the clamping structure on the guide bar in a specific embodiment of the present invention;

[0034] Fig.11 It is a schematic diagram of various styles of clamping structures on a guide bar in a specific embodiment of the present invention;

[0035] Fig.12 It is a schematic diagram of the spacing arrangement of the conductor bars and the outer peripheral surface of the rotor core in a specific embodiment of the present invention;

[0036] Fig.13 A schematic diagram of an elliptical tooth groove in a specific embodiment of the present invention;

[0037] Fig.14FIG. 1 is a schematic diagram of a trapezoidal tooth groove in a specific embodiment of the present invention.

[0038] Explanation of the reference numerals: 1. rotor shaft; 2. squirrel cage; 10. rotor core; 11. tooth slot; 20. guide bar; 21. body; 22. clamping structure; 23. chamfer; 30. end ring. DETAILED DESCRIPTION

[0039] The following describes the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict.

[0040] It should be noted that the illustrations provided in the following embodiments are only used to illustrate the basic concept of the present invention in a schematic manner, and thus the illustrations only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0041] The asynchronous induction motor works based on the Faraday electromagnetic induction principle. When the three-phase AC current passes through the stator winding, a rotating magnetic field is generated. This magnetic field acts on the rotor bars 20 through magnetic induction to form an induced current. The induced current is acted upon by the Lorentz force in the magnetic field, thereby generating a torque that drives the rotor to rotate. Due to its simple structure, low cost, and easy maintenance, the asynchronous induction motor is widely used in various industrial and household appliances, such as water pumps, fans, compressors, elevators, etc.

[0042] The rotor structure of an asynchronous induction motor is as follows Figure 1 , 2 As shown, it comprises a rotor shaft 1, a rotor core 10 and a cage 2, and the cage 2 is generally formed by casting.

[0043] The rotor shaft 1 is the backbone of the motor rotor. It provides the necessary mechanical support to ensure the stable rotation of the rotor and withstands various stresses generated during the operation of the rotor. The rotor shaft 1 also transmits the torque generated by the motor to the load, such as water pumps, fans and other equipment, and is a key component for converting electrical energy into mechanical energy. The rotor shaft 1 is usually made of high-strength and high-toughness alloy steel to ensure that it will not be fatigued and damaged during long-term operation. The selection of materials is directly related to the reliability and service life of the motor.

[0044] The rotor core 10 is a main component of the motor magnetic circuit, plays a magnetic conduction role, reduces the leakage of magnetic flux, and improves the efficiency of the motor. The rotor core 10 is usually made of stacked silicon steel sheets, which have the characteristics of high magnetic permeability and low eddy current loss. By optimizing the coating and stacking method of the silicon steel sheets, the iron loss can be further reduced and the motor performance can be improved.

[0045] The squirrel cage2 is a unique structure of asynchronous induction motors and is usually formed by casting aluminum or copper bars. The casting process needs to be precisely controlled to avoid the formation of porosity and shrinkage. Aluminum is widely used because of its light weight and good electrical conductivity. However, for more demanding motors, copper becomes a better choice due to its better electrical and thermal conductivity.

[0046] In the prior art, the rotor is manufactured by high-pressure casting, where aluminum or copper bars 20 are cast into the rotor core 10 to form a squirrel cage 2 structure. Although this method is fast and suitable for large-scale production, it has some inherent defects. During the high-pressure casting process, due to the physical properties of the aluminum liquid when it is injected, large pores and shrinkage holes are easily formed inside the casting. These problems will affect the performance and reliability of the motor. Specifically, they are:

[0047] Porosity problem: The porosity of high pressure castings is greatly affected by the product structure. Especially in cast aluminum rotors with complex structures, aluminum liquid is prone to flocculent flow and reflux during injection, leading to the formation of pores and shrinkage holes.

[0048] Consistency issues: Due to uncontrollable factors in the casting process, the cast rotor has poor consistency in conductivity and mechanical strength, which directly affects the overall performance and reliability of the motor.

[0049] In order to solve the problem of high pressure casting, centrifugal casting was proposed as an alternative. Centrifugal casting improves metal distribution and reduces porosity by using centrifugal force. Although centrifugal casting can significantly improve the problem of high porosity, it has a long production cycle, a complex process and a high overall cost. This not only limits its application in large-scale production, but also increases the production cost of the motor.

[0050] like Figure 3-14 As shown, the present invention provides a rotor, which is applied to an asynchronous induction motor, and includes a rotor core 10 , a conductive bar 20 , an end ring 30 and a rotor shaft 1 .

[0051] The rotor core 10 is provided with a plurality of tooth slots 11 in the circumferential direction, and the two ends of the tooth slots 11 are respectively provided through the two end surfaces of the rotor core 10 in the axial direction. The plurality of tooth slots 11 provided on the rotor core 10 can effectively concentrate the magnetic flux and increase the magnetic flux density, thereby improving the electromagnetic torque and efficiency of the motor. The design of the tooth slots 11 makes the magnetic field more evenly distributed in the rotor and reduces the leakage of the magnetic flux. The structure of the tooth slots 11 not only helps to improve the utilization efficiency of the magnetic field, but also increases the heat dissipation area of ​​the rotor surface, further improves the cooling efficiency of the motor, and prolongs the service life of the motor.

[0052] The guide bars 20 are individually processed and formed. Figure 7 As shown, the guide bar 20 is inserted into the tooth slot 11, and the end of each guide bar 20 protrudes from at least one end face of the rotor core 10 in the axial direction. Both ends of each guide bar 20 protrude from both ends of the rotor core 10 in the axial direction. The separate processing of the guide bar 20 allows the use of higher precision equipment and technology to ensure the consistency of the size and shape of the guide bar 20, thereby improving the overall manufacturing accuracy of the squirrel cage 2. At the same time, separate processing can be more flexible in the selection of materials for the guide bar 20, such as selecting materials with high electrical conductivity to reduce resistance losses and improve motor performance. The cross-section of the tooth slot 11 and the guide bar 20 can be pear-shaped, such as Fig.12 , 13 As shown, it can also be an elliptical, trapezoidal or other designs.

[0053] Among them, the tooth slot 11 and the guide bar 20 use clearance fit. The clearance fit allows the guide bar 20 to be easily inserted into the tooth slot 11 without forced assembly, which simplifies the assembly process and improves production efficiency. The operator does not need to perform precise alignment or use external force to press the guide bar 20 into the tooth slot 11, thereby reducing assembly time and cost. In large-scale production, there may be slight differences in the size of each part. The clearance fit provides a certain amount of tolerance so that small deviations of parts in certain dimensions will not affect the overall assembly. This helps to reduce the extreme requirements for dimensional accuracy during the manufacturing process, thereby reducing production costs. Compared with the traditional interference fit, the clearance fit avoids stress concentration caused by forcibly pressing the guide bar 20. Stress concentration may cause micro cracks or early fatigue failure of the parts, affecting the service life and reliability of the motor. The clearance fit ensures that no additional stress is introduced during the assembly process. Since the clearance fit does not require excessive force to be applied to the guide bar 20, the guide bar 20 and the tooth slot 11 are not easily deformed during the assembly process. Maintaining the structural and shape integrity of the parts helps the motor maintain stable performance during operation. The motor generates heat during operation, causing thermal expansion of the rotor components. The clearance fit provides enough space for the bars 20 and the tooth slots 11 to accommodate thermal expansion, preventing internal stress from being generated by interference fit caused by thermal expansion. Under different ambient temperatures, the parts of the motor will have certain dimensional changes. The clearance fit can adapt to the dimensional fluctuations caused by temperature changes, ensuring that the motor can maintain stable operation under different environmental conditions.

[0054] like Figure 8 As shown, the two end rings 30 are respectively arranged at the two ends of the rotor core 10 in the axial direction, and the two end rings 30 are respectively connected to the two ends of each of the conductive bars 20 as a whole. The design of the end ring 30 not only connects the two ends of the conductive bar 20 into a whole to form a closed circuit, but also enhances the mechanical strength of the entire cage 2 through a reasonable structural design. The end ring 30 is usually made of the same high-conductivity material as the conductive bar 20 to ensure efficient and reliable transmission of current in the rotor.

[0055] When the scheme in the present application is actually applied, the porosity of a single manufactured conductor bar 20 is less than 1%, which means that there are very few defects inside the conductor bar 20, which directly improves the mechanical strength of the conductor bar 20. Because pores are a kind of defect inside the material, they are prone to become areas of stress concentration, causing the material to break when subjected to force. Conductive bars 20 with low porosity can better withstand the electromagnetic force and mechanical stress generated during the operation of the motor, reducing the risk of broken bars. Conductive bars 20 with low porosity have better electrical conductivity because pores block the flow path of current and increase resistance. Conductive bars 20 are a key part of the motor rotor, and their electrical conductivity is directly related to the efficiency of the motor. The improvement of electrical conductivity also helps to reduce energy consumption and temperature rise during motor operation. Due to the low porosity, the conductor bar 20 has stronger fatigue resistance during long-term operation, is not prone to cracks and fractures, and thus extends the overall service life of the motor. This is particularly important for equipment that needs to run continuously for a long time, such as industrial machine tools, air-conditioning compressors, etc.

[0056] In actual application, the porosity of the end rings 30 on both sides is less than 4%, and there are no large pores or shrinkage holes. The function of the end rings 30 is to short-circuit the rotor bars 20 to form a closed conductive loop, so its connection reliability is crucial. The porosity of the end rings 30 is less than 4% and there are no large pores or shrinkage holes, which ensures that the connection between the end rings 30 and the bars 20 is firm and reliable, avoiding the increase in resistance and local overheating caused by poor connection. The breakage of the end rings 30 is one of the common faults of asynchronous induction motors, usually caused by casting defects or stress concentration. The end rings 30 with low porosity and no large pores or shrinkage holes greatly reduce the risk of breakage and improve the reliability and stability of the motor. Due to the enhanced reliability of the end rings 30, the motor rarely fails during use, thereby reducing the frequency and cost of maintenance and replacement. This not only saves maintenance costs, but also reduces the downtime of equipment and improves overall production efficiency.

[0057] In addition, the conductivity distribution of the conductive bars 20 and the end rings 30 is balanced and consistent after casting. The conductive bars 20 and the end rings 30 with balanced and consistent conductivity distribution ensure that the rotor produces a uniform current distribution during operation, thereby forming a stable rotating magnetic field. This is crucial to improving the electromagnetic performance of the motor, and can effectively reduce electromagnetic noise and vibration, and improve the operating efficiency of the motor. Components with good conductivity consistency will not generate hot spots during current conduction, avoiding local overheating and the resulting degradation of material properties. This is crucial to improving the long-term stability and safety of the motor. The balanced and consistent distribution of conductivity reflects the high quality control in the manufacturing process. This not only improves the yield rate of the product, but also provides a reliable guarantee for subsequent assembly and use.

[0058] In a specific embodiment of the present invention, the end ring 30 is formed at the end of each of the guide bars 20 by an insert casting process. Insert casting (also known as embedded casting or embedded casting) is a casting process used to produce complex castings. This process is usually used to embed metal parts into castings to improve the strength, wear resistance or achieve other special functions of the castings. The following are the main steps of the insert casting process:

[0059] During the casting process, a pattern or mold is usually used to form the outer shape of the casting. The pattern can be a wax, resin or metal mold, and the mold is used to form the final shape of the casting.

[0060] The prefabricated guide bars 20 are placed in the appropriate position of the mold. The positioning of the guide bars 20 must be very accurate to ensure that they do not move or deform during the casting process.

[0061] The mold is placed into a shell, which is usually made of sand, ceramic or other high temperature resistant material. The shell forms the outer shell of the casting and ensures that the cast metal can flow into the mold.

[0062] Molten metal is poured into the mold, flowing into the space around the shell and insert. The metal solidifies after cooling and firmly embeds the guide bar 20 in the end ring 30.

[0063] After the end ring 30 is cooled, the shell is removed and the end ring 30 is taken out. Usually, some post-processing steps are required, such as removing excess metal, grinding the surface, inspecting the quality, etc., to ensure that the casting reaches the required specifications and performance.

[0064] like Figure 9-11 As shown, the guide bar 20 includes a body 21 and a clamping structure 22 arranged at both ends of the body 21, and the clamping structure 22 has a portion for the casting material to be embedded and clamped when the end ring 30 is cast. The clamping structure 22 is a portion embedded in the end ring 30 in the insert casting process. After the end ring 30 is cast, the clamping structure 22 locks the position of the end ring 30 like a buckle. The clamping structure 22 is embedded in the casting material to form a stable buckle connection, which effectively prevents the guide bar 20 from being displaced due to vibration or temperature changes during the operation of the motor. The clamping structure 22 not only fixes the guide bar 20, but also enhances the overall structural strength of the rotor through a close connection with the end ring 30, so that the motor can withstand greater mechanical loads and thermal stresses. The clamping structure 22 ensures a stable connection between the guide bar 20 and the end ring 30, optimizes the conduction path of the current in the rotor, reduces power loss, and improves the efficiency and output power of the motor. The stable clamping structure 22 reduces the free current and mechanical vibration inside the motor, thereby reducing the operating noise and improving the quietness and operating stability of the motor.

[0065] like Fig.11As shown, the snap-fit ​​structure 22 includes through holes or grooves arranged at both ends of the guide bar 20. In this way, when the end ring 30 is cast, the injection material can enter the through hole or groove to further form a snap-fit. The through hole or groove provides a precise space so that the injection material can fill these positions during the casting process to form a structure similar to a lock buckle, thereby achieving stable locking of the end ring 30. The snap-fit ​​structure 22 can effectively prevent the end ring 30 from loosening or falling off during use by filling the fixed points formed by the through hole or groove. The lock buckle filled with injection material increases the contact area, improves the friction and tightening force of the contact surface, and further enhances the stability of the connection. During the casting process, the snap-fit ​​structure 22 formed during the casting process can maintain a high degree of consistency and repeatability, ensuring that the assembly of each end ring 30 meets the design requirements. Injection material filling the through hole or groove can directly form a complete lock buckle without the need for subsequent additional processing or installation steps. The snap-fit ​​structure 22 provides stronger mechanical fixation, increasing the impact resistance and durability of the overall structure. The clamping structure 22 improves the durability of the end ring 30 and the guide bar 20 and reduces wear and fatigue by evenly applying force and enhancing fixation.

[0066] like Fig.11 As shown, the projection of the snap-in structure 22 on the end face of the body 21 is located within the end face of the body 21. The body 21 is used to be inserted into the tooth groove 11, that is, the shape of the body 21 is basically the same as the tooth groove 11. If the snap-in structure 22 is larger, the snap-in structure 22 will interfere with the tooth groove 11 when inserting the guide bar 20. The meaning of being located within the end face includes line overlap. The circumferential surface of the snap-in structure 22 remains within the end face of the body 21, which ensures that when the body 21 is inserted into the tooth groove 11, the snap-in structure 22 will not interfere with the tooth groove 11, thereby completing the insertion process smoothly. Assembly problems or component damage caused by interference are avoided, ensuring the smoothness and reliability of assembly. Since there is no interference problem, the adjustment and correction time during the assembly process is greatly reduced, which improves the assembly efficiency. The projection of the snap-in structure 22 is strictly controlled within the end face of the body 21 (including line overlap) to ensure the accuracy and consistency of the design.

[0067] like Fig.11As shown, the connection between the snap-in structure 22 and the main body 21 is a connection surface, and the projection of the snap-in structure 22 on the end surface of the main body 21 protrudes from the connection surface. That is, the snap-in structure 22 is a structure with a large head and a small bottom, the head of the snap-in structure 22 is a part away from the main body 21, and the bottom of the snap-in structure 22 is a connection surface. The snap-in structure 22 can specifically be in the shape of an inverted trapezoid, a spindle, a sphere, etc. The purpose is to cooperate with the end ring 30 after casting to form a structure similar to a mortise and tenon. The design of the snap-in structure 22 with a larger head and a smaller bottom can form a stronger locking effect when connected. The large head design can be firmly embedded in the end ring 30, because the size of the head enables it to better cooperate with the inner surface of the end ring 30, thereby forming a stable connection. The large head is equivalent to a "lock buckle", which can more effectively prevent the loosening of the connection part.

[0068] like Fig.11 As shown, the projection of the clamping structure 22 on the end surface of the body 21 covers the connection surface. By making the projection of the clamping structure 22 cover the connection surface, a stronger locking effect can be ensured in the circumferential direction. This design enhances the stability of the structure, reduces the looseness of the clamping part, and thus improves the overall connection strength and reliability.

[0069] like Fig.11 As shown, the end face of the body 21 is flush with the axial end face of the rotor core 10. This reduces assembly errors caused by axial misalignment, ensures uniform force on the connection parts, and reduces the risk of vibration or loosening. The flush design helps to improve the running balance of the equipment and reduce wear and noise.

[0070] In a specific embodiment of the present invention, the side of the guide bar 20 away from the axis is spaced apart from the outer peripheral surface of the rotor core 10 in the radial direction, and the side of the guide bar 20 away from the axis is located on the side of the outer peripheral surface of the rotor core 10 close to the axis. In this way, a pole shoe structure of the teeth of the rotor core 10 can be formed. The pole shoe refers to the part of the rotor core 10 located in the magnetic pole area. The pole shoe design reduces the electromagnetic noise during motor operation by optimizing the tooth structure of the rotor core 10. This design reduces sound radiation by improving the magnetic field distribution, making the motor run quieter. A reasonable pole shoe structure can effectively balance the magnetic pull and reduce vibration during motor operation. This not only improves the stability of the motor, but also extends the service life of the motor and related equipment.

[0071] The gap between the guide bar 20 and the outer peripheral surface of the rotor core 10 can be used as a cooling channel, so that the coolant or gas can effectively remove the heat generated during the operation of the rotor to prevent overheating. The cooling system between the rotor core 10 and the guide bar 20 helps to achieve more uniform heat dissipation and avoid local overheating, thereby improving the overall temperature control of the equipment. Good cooling can keep the equipment within the optimal operating temperature range, thereby maintaining the performance stability of the equipment. An effective cooling system helps to control the temperature rise of the equipment and prevent performance degradation or damage due to overheating.

[0072] like Figure 6 As shown, both ends of the guide bar 20 are provided with chamfers 23, and the chamfers 23 are located on the side of the guide bar 20 away from the axis. Among them, the angle between the surface where the chamfer 23 is located and the axis is greater than 2°. The chamfer 23 provides a slope that is convenient for part alignment and insertion, so that the guide bar 20 can be more easily installed in the tooth groove 11. This design greatly simplifies the assembly process, reduces the adjustment time required due to assembly difficulties, and improves assembly efficiency. The operator only needs to place the guide bar 20 in the specified position, and the chamfer 23 will automatically guide the guide bar 20 to be assembled correctly, without worrying about assembly errors, which significantly reduces the requirements for operating skills.

[0073] Since the end ring 30 needs to be arranged relative to the two ends of the guide bar 20, a draft surface can be set at the position of the end ring 30 corresponding to the chamfer 23 to facilitate demolding of the end ring 30. The draft surface design can reduce the bite force between the mold and the casting, making it easier to remove the casting from the mold. This can reduce the friction during demolding and reduce damage to the casting. It helps to prevent stress concentration or deformation of the casting during the demolding process, ensuring that the casting maintains its designed shape and size. Simplifying the demolding process can improve the efficiency of the production line and reduce the problem of mold jamming during the production process, thereby improving production speed and product consistency.

[0074] The present invention also includes a rotor manufacturing method for manufacturing the rotor as described above, comprising the following steps:

[0075] S10 , inserting the conductive bars 20 into the tooth slots 11 of the rotor core 10 .

[0076] S20 , casting the end rings 30 at both ends of the axis of the rotor core 10 .

[0077] In the above scheme, since the end ring 30 is directly cast at both ends of the rotor core 10, the molten aluminum does not need to pass through the complex guide bar 20 groove, which simplifies the casting process. The situation of molten aluminum flowing through complex channels is reduced, thereby reducing the flocculent flow (uneven flow in the molten metal) and reflux phenomenon (molten metal flowing back from the mold) during the casting process, making the casting process smoother. The exhaust design of the casting process can be more optimized. An effective exhaust design can reduce the bubbles or pores generated by the gas during the casting process, thereby improving the quality of the casting. The improvement of exhaust helps to reduce the porosity of the molten aluminum and ensure that the end ring 30 after casting is stronger and more consistent. Due to the improvement of the casting process and the optimization of the exhaust design, the end ring 30 after casting has a lower porosity. This means that there are fewer bubbles or internal defects in the casting, which improves the compactness and strength of the end ring 30. The low porosity and improved casting process enable the end ring 30 to show better physical consistency and mechanical strength during the manufacturing process. The rotor end ring 30 produced in this way not only has higher strength, but also has more consistency in quality, and can show more reliable performance in practical applications.

[0078] In summary, the present invention proposes a rotor and a method for manufacturing the same, wherein the conductive bars 20 constituting the squirrel cage 2 are manufactured separately and then connected as a whole through the end rings 30 at both ends to form a complete squirrel cage 2 structure. Traditional casting processes often result in pores inside the casting. Separately casting the conductive bars 20 and the end rings 30 can effectively control the porosity. The separate casting and processing processes are easier to monitor and control, and can ensure that each component achieves higher dimensional accuracy and better surface finish. At the same time, the conductive bars 20 and the end rings 30 have a balanced conductivity distribution and good consistency after casting. The conductive bars 20 and the end rings 30 with balanced conductivity distribution and good consistency ensure that the rotor generates a uniform current distribution during operation, thereby forming a stable rotating magnetic field.

[0079] The above embodiments are only illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with this technology may modify or change the above embodiments without violating the spirit and scope of the present invention. Therefore, all equivalent modifications or changes made by those with ordinary knowledge in the relevant technical field without departing from the spirit and technical ideas disclosed by the present invention should still be covered by the claims of the present invention. Efficiently realize the connection between the high voltage of the motor and the high voltage of the controller, small size, oil-resistant sealing design, reliable sealing of the controller cavity and the motor cavity, rotor oil cooling design, effectively reduce the temperature, achieve greater flow and increase product life.

[0080] In the description herein, many specific details, such as examples of components and / or methods, are provided to provide a complete understanding of embodiments of the present invention. However, those skilled in the art will recognize that embodiments of the present invention may be practiced without one or more of the specific details or with other devices, systems, components, methods, components, materials, parts, etc. In other cases, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.

[0081] References throughout this specification to "one embodiment," "an embodiment," or "a specific embodiment" mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention, and not necessarily in all embodiments. Thus, various appearances of the phrases "in one embodiment," "in an embodiment," or "in a specific embodiment" in different places throughout this specification do not necessarily refer to the same embodiment. In addition, the particular features, structures, or characteristics of any specific embodiment of the invention may be combined with one or more other embodiments in any suitable manner. It should be understood that other variations and modifications of the embodiments of the invention described and illustrated herein may be possible in light of the teachings herein and are to be considered part of the spirit and scope of the invention.

[0082] It should also be understood that one or more of the elements shown in the figures may also be implemented in a more separate or more integrated manner, or even removed because they are inoperable in certain circumstances or provided because they may be useful depending on the application.

[0083] In addition, unless otherwise explicitly indicated, any marking arrows in the drawings should be regarded as exemplary only and not limiting. In addition, unless otherwise indicated, the term "or" used herein is generally intended to mean "and / or". In the case where the term is not clear because it is anticipated that the ability to separate or combine is provided, the combination of components or steps will also be regarded as indicated.

[0084] As used in the description herein and throughout the claims that follow, "a", "an", and "the" include plural references unless otherwise indicated. Likewise, as used in the description herein and throughout the claims that follow, the meaning of "in" includes "in" and "on" unless otherwise indicated.

[0085] The above description of the illustrated embodiments of the present invention (including the contents described in the Abstract) is not intended to be an exhaustive list or to limit the present invention to the precise form disclosed herein. Although specific embodiments of the present invention and examples of the present invention are described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the present invention as will be recognized and appreciated by those skilled in the art. As noted, these modifications may be made to the present invention in accordance with the above description of the embodiments described in the present invention, and these modifications will be within the spirit and scope of the present invention.

[0086] Systems and methods have been generally described herein as details that aid in understanding the present invention. In addition, various specific details have been given to provide an overall understanding of embodiments of the present invention. However, those skilled in the relevant art will recognize that embodiments of the present invention may be practiced without one or more of the specific details, or may be practiced using other devices, systems, accessories, methods, components, materials, parts, etc. In other cases, well-known structures, materials, and / or operations are not specifically shown or described in detail to avoid confusion with various aspects of embodiments of the present invention.

[0087] Thus, although the invention has been described herein with reference to specific embodiments thereof, freedom of modification, various changes and substitutions are also within the foregoing disclosure, and it should be understood that in some cases, some features of the invention will be employed without the corresponding use of other features without departing from the scope and spirit of the proposed invention. Thus, many modifications may be made to adapt a particular environment or material to the essential scope and spirit of the invention. The invention is not intended to be limited to the specific terms used in the claims below and / or the specific embodiments disclosed as the best mode contemplated for carrying out the invention, but the invention will include any and all embodiments and equivalents falling within the scope of the appended claims. Thus, the scope of the invention will be determined solely by the appended claims.

Claims

1. A rotor, applied to an asynchronous induction motor, characterized in that: include: A rotor core, wherein a plurality of tooth slots are arranged in the circumferential direction of the rotor core, and two ends of the tooth slots are respectively arranged through two end surfaces of the rotor core in the axial direction; Guide bars, the guide bars are individually processed and formed, the guide bars are inserted into the tooth slots, and the ends of the guide bars protrude from at least one end surface of the rotor core in the axial direction; End rings, the two end rings are respectively arranged at the two ends of the rotor core in the axial direction, and the two end rings are respectively connected to the two ends of each guide bar as a whole.

2. The rotor according to claim 1, characterized in that Both ends of each of the conductive bars protrude from both ends of the rotor core in the axial direction.

3. The rotor according to claim 2, characterized in that The end ring is formed at the end of each guide bar by an insert casting process.

4. The rotor according to claim 3, characterized in that The guide bar comprises a main body and a clamping structure arranged at both ends of the main body, and the clamping structure has a portion for the casting material to be embedded and clamped when the end ring is cast.

5. The rotor according to claim 4, characterized in that The clamping structure includes through holes or grooves arranged at two ends of the guide bar.

6. The rotor according to claim 4, characterized in that The projection of the clamping structure on the end surface of the body is located inside the end surface of the body.

7. The rotor according to claim 6, characterized in that The connection between the clamping structure and the body is a connecting surface, and the projection of the clamping structure on the end surface of the body protrudes from the connecting surface.

8. The rotor according to claim 7, characterized in that The projection of the clamping structure on the end surface of the body covers the connecting surface.

9. The rotor according to claim 4, characterized in that The end surface of the body is flush with the axial end surface of the rotor core.

10. The rotor according to claim 1, characterized in that The side of the guide bar away from the axis is spaced apart from the outer peripheral surface of the rotor core in the radial direction, and the side of the guide bar away from the axis is located on the side of the outer peripheral surface of the rotor core close to the axis.

11. The rotor according to claim 3, characterized in that Both ends of the guide bar are provided with chamfers, and the chamfers are located on a side of the guide bar away from the axis.

12. A method for manufacturing a rotor, for manufacturing a rotor as claimed in any one of claims 1 to 11, characterized in that: The steps include: Inserting the guide bars into the tooth slots of the rotor core; The end rings are respectively cast at both ends of the axis of the rotor core.

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