Multilayer claw pole rotor and motor

Abstract

The invention provides a multilayer claw pole rotor and a motor. The multilayer claw pole rotor comprises at least two layers of claw pole rotor units. The claw pole rotor unit comprises a first rotor, a second rotor and a magnetic disk, the first rotor comprises a first rotor main body and a first claw, the second rotor comprises a second rotor main body and a second claw, and the first claw axially extends to the periphery of the second rotor main body towards the direction of the second rotor. The second claw also axially extends to the periphery of the first rotor main body towards the direction of the first rotor; in the projection plane of the axial end face of the first rotor, the circle center of each first claw does not coincide with the circle center of the first rotor, an eccentric distance e exists between the circle center of the peripheral face of each first claw and the circle center of the first rotor, the multiple first claws are provided with a first circumscribed circle, the radius between the circle center of the first rotor and the first circumscribed circle is R1, and the eccentric distance e meets the requirement that e is larger than 0.2 R1 and smaller than 0.7 R1. According to the invention, the problem of low utilization rate of a permanent magnet material of a permanent magnet motor in the prior art can be solved, and the problem of large torque pulsation is also solved.

Description

Technical Field

[0001] This invention relates to the field of motor technology, specifically to a multi-layer claw pole rotor and a motor. Background Technology

[0002] Permanent magnet motors are widely used in electrical appliances. In recent years, the price of copper wire has soared, leading to an increase in motor costs. Cost reduction has become an important task in the development of permanent magnet motors. Various methods are being sought to reduce the amount of copper wire used while ensuring the performance of the motor remains unchanged. The main methods include improving the utilization rate and amount of permanent magnet materials.

[0003] like Figure 1 It is a traditional embedded tangential rotor structure. Figure 2 Both are traditional surface-mounted rotor structures, and their permanent magnet materials are only magnetized on one side, resulting in low utilization. The amount of embedded tangential permanent magnet material used is limited by the rotor core and is therefore less.

[0004] Because existing permanent magnet motors cannot simultaneously solve technical problems such as low utilization of permanent magnet materials and large torque ripple, this invention studies and designs a multi-layer claw pole rotor and motor. Summary of the Invention

[0005] Therefore, the technical problem to be solved by the present invention is to overcome the shortcomings of the existing permanent magnet motors, which cannot simultaneously solve the problems of low utilization rate of permanent magnet materials and large torque ripple, thereby providing a multi-layer claw pole rotor and motor.

[0006] To address the above problems, the present invention provides a multi-layer claw pole rotor, comprising:

[0007] At least two layers of claw pole rotor units, and at least two layers of claw pole rotor units are spliced ​​together along the axial direction of the rotor;

[0008] The claw pole rotor unit includes a first rotor, a second rotor, and a disk. The first rotor, the disk, and the second rotor are arranged sequentially along the axial direction, such that the disk is located between the first rotor and the second rotor. The first rotor includes a first rotor body and a first claw. The second rotor includes a second rotor body and a second claw. The first rotor body has an annular structure. The first claw protrudes from the outer periphery of the first rotor body and extends axially toward the outer periphery of the second rotor body. The second rotor body has an annular structure. The second claw protrudes from the outer periphery of the second rotor body and extends axially toward the outer periphery of the first rotor body.

[0009] Within the projection plane of the axial end face of the first rotor, the outer peripheral surface of the first claw is an arc segment, the center of which does not coincide with the center of the first rotor, and there is an eccentricity e between the center of the outer peripheral surface of the first claw and the center of the first rotor. Multiple first claws have a first circumscribed circle, the radius between the center of the first rotor and the first circumscribed circle is R1, R1 is the maximum distance between the outer peripheral surface of the first claw and the center of the first rotor, and the eccentricity e satisfies 0.2R1 < e < 0.7R1.

[0010] In some implementations...

[0011] In the projection plane of the axial end face of the second rotor, the outer peripheral surface of the second claw is an arc segment, the center of which does not coincide with the center of the second rotor, and there is also an eccentricity e between the center of the outer peripheral surface of the second claw and the center of the second rotor. Multiple second claws have a second circumscribed circle, and the radius between the center of the second rotor and the second circumscribed circle is R1. R1 is the maximum distance between the outer peripheral surface of the second claw and the center of the second rotor, and the eccentricity e satisfies 0.2R1 < e < 0.7R1.

[0012] In some implementations...

[0013] There are multiple first claws and multiple second claws. Multiple first claws are spaced apart in the circumferential direction of the first rotor body, and multiple second claws are spaced apart in the circumferential direction of the second rotor body. The first claw is inserted between two adjacent second claws, and the second claw is inserted between two adjacent first claws, so that the first claws and the second claws are staggered in the circumferential direction.

[0014] The first claw extends axially to be flush with the bottom surface of the second rotor body, the bottom surface of the second rotor body being the end face facing away from the axial direction of the disk.

[0015] In some implementations...

[0016] The number of the first claws is p, where p is the pole pair number, and the number of the second claws is p.

[0017] In some implementations...

[0018] The circumferential distance between adjacent first claws and second claws is b1, and satisfies 0.1*πR1 / p<b1<0.4*πR1 / p, where p is the number of pole pairs of the claw pole rotor.

[0019] In some implementations...

[0020] The radial thickness of the first claw gradually decreases from its connection point with the first rotor body along the axial direction to its free end, and the minimum thickness of the first claw is its radial thickness at its free end, which is greater than or equal to 1 mm.

[0021] The radial thickness of the second claw gradually decreases from its connection point with the second rotor body along the axial direction to its free end, and the minimum thickness of the second claw is its radial thickness at its free end, which is greater than or equal to 1 mm.

[0022] In some implementations...

[0023] The claw pole rotor unit also includes a fixing member. The first rotor has a first central shaft hole, the second rotor also has a second central shaft hole, and the disk has a third central shaft hole. The first central shaft hole, the second central shaft hole, and the third central shaft hole are arranged opposite to each other in sequence. The fixing member passes through the first central shaft hole, the second central shaft hole, and the third central shaft hole simultaneously, so that the first rotor, the second rotor, the disk, and the fixing member can rotate as a whole.

[0024] In some implementations...

[0025] The outer peripheral surface of the fastener opposite to the third central shaft hole is cylindrical.

[0026] The outer peripheral surface of the fastener opposite to the first central shaft hole includes a first tangent structure. There are multiple first tangent structures, and the multiple first tangent structures are spaced apart in the circumferential direction of the fastener. The first central shaft hole is configured as an inner peripheral surface structure that mates with the multiple first tangent structures.

[0027] The outer peripheral surface of the fastener opposite to the second central shaft hole includes a second tangent structure. There are multiple second tangent structures, which are spaced apart in the circumferential direction of the fastener. The second central shaft hole is configured as an inner peripheral surface structure that mates with and engages with the multiple second tangent structures.

[0028] In some implementations...

[0029] The fastener includes a first extended cylindrical segment opposite to the first central shaft hole. The first extended cylindrical segment is connected to one axial end of the cylindrical structure, and the outer diameter of the first extended cylindrical segment is equal to that of the cylindrical structure. The first tangential structure is formed by cutting off a first preset length along the axial direction of the fastener based on the first extended cylindrical segment. The distance between the first tangential surface and the cylindrical surface of the cylindrical structure along its normal direction is the depth b2 of the first tangential structure, and b2 satisfies 1mm≤b2<R2-R2*cos(π / p); where R2 is the outer diameter of the cylindrical structure.

[0030] The fastener further includes a second extended cylindrical segment opposite to the second central shaft hole. The second extended cylindrical segment is connected to the other axial end of the cylindrical structure, and the outer diameter of the second extended cylindrical segment is equal to that of the cylindrical structure. The second tangent structure is formed by cutting off a second preset length along the axial direction of the fastener based on the second extended cylindrical segment. The distance between the second tangent surface and the cylindrical surface of the cylindrical structure along its normal direction is the depth b2 of the second tangent structure, and b2 satisfies 1mm≤b2<R2-R2*cos(π / p); where R2 is the outer diameter of the cylindrical structure.

[0031] In some implementations...

[0032] Within the projection plane of the axial end face of the fastener, there is an angular offset of 360° / 2p between the perpendicular line between the center of the fastener and the first tangent surface and the perpendicular line between the center of the fastener and the second tangent surface.

[0033] In some implementations...

[0034] The fixing member has a positioning post and a positioning hole on one end face of the axial direction, and a positioning post and a positioning hole are also provided on the other end face of the axial direction. Between two adjacent claw pole rotor units, the positioning post of the fixing member of one claw pole rotor unit can be inserted into the positioning hole of the fixing member of another claw pole rotor unit, and at the same time, the positioning hole of the fixing member of one claw pole rotor unit can accommodate the insertion of the positioning post of the fixing member of another claw pole rotor unit, so as to form the positioning and splicing of multiple claw pole rotor units along the axial direction.

[0035] The present invention also provides an electric motor comprising the aforementioned multi-layer claw pole rotor.

[0036] The multi-layer claw pole rotor and motor provided by this invention have the following beneficial effects:

[0037] 1. This invention improves the versatility of claw pole rotors by setting at least two layers of claw pole rotor units, which are spliced ​​together axially. Different numbers of claw pole rotor units can be used to form claw pole rotors with varying stack heights. Each claw pole rotor unit includes a first rotor and a second rotor structure, as well as a disk structure. The first and second rotors are arranged axially, with the disk located between them. This allows the first and second rotors to form magnetic conductors. Both the first and second rotors include a first claw and a second claw, respectively. The first claw extends towards the outer periphery of the second rotor body, and the second claw extends towards the outer periphery of the first rotor body. Because the claw pole rotor... By employing an axially magnetized disk, the amount of permanent magnet material used is not limited by the rotor core, and both polar surfaces of the disk participate in magnetization, effectively improving the utilization rate of permanent magnet material, enhancing rotor magnetic performance, and reducing the amount of copper wire used in the motor, thereby reducing motor costs. Furthermore, this invention features an eccentric design on the outer surface of each claw body, with the eccentricity e conforming to 0.2R1 < e < 0.7R1 (R1 being the maximum rotor radius). This creates an unequal air gap structure with a smaller air gap at the center and larger air gaps on both sides, making the air gap magnetic flux density distribution closer to a sine wave, reducing motor cogging torque and torque pulsation under load. This effectively solves the problem of low permanent magnet material utilization in existing permanent magnet motors, while also addressing the issue of large torque pulsation.

[0038] 2. The present invention further provides that both the first claw and the second claw are multiple, with multiple first claws spaced apart circumferentially on the first rotor body and multiple second claws spaced apart circumferentially on the second rotor body. The first claw is inserted between two adjacent second claws, and the second claw is inserted between two adjacent first claws, resulting in an alternating arrangement of the first and second claws in the circumferential direction. The number of first claws is p, where p is the number of pole pairs, and the number of second claws is p. This allows the claw-pole rotor of the present invention to have its upper and lower magnetic conductors respectively assigned N and S poles by the disk, with no contact between the two magnetic conductors of different polarities. Furthermore, the reasonable spacing design eliminates magnetic leakage. Traditional permanent magnet rotors have multiple permanent magnets with opposite polarities, which can easily lead to reversed magnet polarity during production, and the rotor production process involves many steps. In contrast, the claw-pole rotor of this application has only one disk, eliminating the need to consider the reverse polarity issue, simplifying assembly, and improving production efficiency.

[0039] 3. In addition, after the two magnetic conductors are assembled on the fixing component, the top surface of the claw of one magnetic conductor is flush with the bottom surface of the other magnetic conductor. There is no contact between each adjacent claw, and the distance b1 between them meets the condition 0.1*πR1 / p<b1<0.4*πR1 / p. This can effectively ensure that there is a sufficiently large gap between adjacent claws and avoid magnetic leakage. The root of the claw is designed with a slope that narrows towards the top. The slope must meet the requirement that the minimum thickness of the top is not less than 1mm. The slope design can ensure that there is a sufficiently large gap between the top of the claw and the base of the other magnetic conductor and avoid magnetic leakage. Attached Figure Description

[0040] Figure 1 This is a top view of a conventional embedded tangential rotor in the prior art;

[0041] Figure 2 This is a top view of a conventional surface-mounted rotor in the prior art;

[0042] Figure 3 This is a three-dimensional structural diagram of the claw pole rotor of the present invention;

[0043] Figure 4 This is a three-dimensional structural diagram of the double-layer claw pole rotor of the present invention;

[0044] Figure 5 This is a three-dimensional structural diagram of the three-layer claw pole rotor of the present invention;

[0045] Figure 6 yes Figure 3 A three-dimensional structural diagram of the second rotor in the image;

[0046] Figure 7 yes Figure 3 A three-dimensional structural diagram of the fasteners in the diagram;

[0047] Figure 8 This is a top view of the claw pole rotor of the present invention;

[0048] Figure 9 This is an exploded structural diagram of the claw pole rotor unit of the present invention;

[0049] Figure 10 This is a comparative structural diagram of the eccentric claw pole rotor of the present invention and the existing concentric claw pole rotor;

[0050] Figure 11 This is a comparison curve of the eccentric claw pole rotor of the present invention and the existing concentric claw pole rotor (the vertical axis of the graph is torque pulsation, and the horizontal axis is time).

[0051] The reference numerals in the attached figures are as follows:

[0052] 1. First rotor; 2. Second rotor; 3. Disk; 4. First rotor body; 5. First claw; 6. Second rotor body; 7. Second claw; 8. Fixing component; 9. First central shaft hole; 10. Second central shaft hole; 11. Third central shaft hole; 12. First tangential structure; 13. Second tangential structure; 14. Cylindrical structure; 15. First extended cylindrical section; 16. Second extended cylindrical section; 17. Stator inner circular surface; 18. Magnetic conductor; 19. Permanent magnet; 20. Rotor core; 21. Leakage magnetic circuit; 22. Positioning post; 23. Positioning hole. Detailed Implementation

[0053] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0054] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0055] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0056] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0057] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0058] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0059] like Figure 3-11 As shown, the present invention provides a multi-layer claw pole rotor, which includes:

[0060] At least two layers of claw pole rotor units, and at least two layers of claw pole rotor units are spliced ​​together along the axial direction of the rotor;

[0061] The claw pole rotor unit includes a first rotor 1, a second rotor 2, and a disk 3. The first rotor 1, the disk 3, and the second rotor 2 are arranged sequentially along the axial direction, such that the disk 3 is located between the first rotor 1 and the second rotor 2. The first rotor 1 includes a first rotor body 4 and a first claw 5. The second rotor 2 includes a second rotor body 6 and a second claw 7. The first rotor body 4 has an annular structure. The first claw 5 protrudes from the outer periphery of the first rotor body 4 and extends axially toward the second rotor 2 to the outer periphery of the second rotor body 6. The second rotor body 6 has an annular structure. The second claw 7 protrudes from the outer periphery of the second rotor body 6 and extends axially toward the first rotor 1 to the outer periphery of the first rotor body 4.

[0062] Within the projection plane of the axial end face of the first rotor 1, the outer peripheral surface of the first claw 5 is an arc segment, the center of which does not coincide with the center of the first rotor 1, and there is an eccentricity e between the center of the outer peripheral surface of the first claw 5 and the center of the first rotor 1. Multiple first claws 5 have a first circumscribed circle, and the radius between the center of the first rotor 1 and the first circumscribed circle is R1, where R1 is the maximum distance between the outer peripheral surface of the first claw 5 and the center of the first rotor 1, and the eccentricity e satisfies 0.2R1 < e < 0.7R1.

[0063] This invention improves the versatility of claw pole rotors by setting at least two layers of claw pole rotor units, which are spliced ​​together axially. Different numbers of claw pole rotor units can be used to form claw pole rotors with varying stack heights. Each claw pole rotor unit includes a first rotor and a second rotor structure, as well as a disk structure. The first and second rotors are arranged axially, with the disk located between them. This allows the first and second rotors to form magnetic conductors. Both the first and second rotors include a first claw and a second claw, respectively. The first claw extends towards the outer periphery of the second rotor body, and the second claw extends towards the outer periphery of the first rotor body. Because the claw pole rotor uses an axially magnetized disk, the amount of permanent magnet material is not limited by the rotor core, and both polar surfaces of the disk participate in magnetization, effectively improving the utilization rate of permanent magnet material, enhancing rotor magnetic performance, and reducing the amount of copper wire used in the motor, thereby reducing motor costs. This invention also features an eccentric design on the outer surface of the first claw of the first rotor. Figure 6 As shown, the eccentricity e conforms to 0.2R1 < e < 0.7R1 (R1 is the maximum radius of the rotor), forming an unequal air gap structure with a smaller air gap at the center of the claw body and a larger air gap on both sides. This makes the air gap magnetic flux density distribution closer to a sine wave, reducing the cogging torque of the motor and the torque pulsation under load. It effectively solves the problem of low utilization rate of permanent magnet materials in existing permanent magnet motors, and also solves the problem of large torque pulsation.

[0064] The multi-layer claw pole rotor of the present invention can be composed of multiple identical claw pole rotor units. According to different power requirements, different numbers of claw pole rotor units can be assembled into claw pole rotors with different stack heights. There is no need to add corresponding molds for rotors with different stack heights, thus reducing production cost investment. It can also solve the problem of increased investment due to the need to open new molds for rotors with different stack heights.

[0065] In some implementations...

[0066] In the projection plane of the axial end face of the second rotor 2, the outer peripheral surface of the second claw 7 is an arc segment, the center of which does not coincide with the center of the second rotor 2, and there is also an eccentricity e between the center of the outer peripheral surface of the second claw 7 and the center of the second rotor 2. Multiple second claws 7 have a second circumscribed circle, and the radius between the center of the second rotor 2 and the second circumscribed circle is R1. R1 is the maximum distance between the outer peripheral surface of the second claw 7 and the center of the second rotor 2, and the eccentricity e satisfies 0.2R1 < e < 0.7R1.

[0067] The present invention also features an eccentric design on the outer circular surface of the second claw body of the second rotor, with the eccentricity e conforming to 0.2R1 < e < 0.7R1 (R1 is the maximum radius of the rotor). This design further enables the formation of an unequal air gap structure at the second rotor, with a smaller air gap at the center of the claw body and a larger air gap on both sides. This makes the air gap magnetic flux density distribution closer to a sine wave, reducing the motor cogging torque and torque pulsation under load. This effectively solves the problem of low utilization rate of permanent magnet materials in existing permanent magnet motors, while also addressing the problem of large torque pulsation.

[0068] In some implementations...

[0069] There are multiple first claws 5 and multiple second claws 7. Multiple first claws 5 are spaced apart in the circumferential direction of the first rotor body 4, and multiple second claws 7 are spaced apart in the circumferential direction of the second rotor body 6. The first claw 5 is inserted between two adjacent second claws 7, and the second claw 7 is inserted between two adjacent first claws 5, so that the first claws 5 and the second claws 7 are staggered in the circumferential direction.

[0070] The first claw 5 extends axially to be flush with the bottom surface of the second rotor body 6, the bottom surface of the second rotor body 6 being the end face facing away from the axial direction of the disk 3. The second claw 7 extends axially to be flush with the bottom surface of the first rotor body 4, the bottom surface of the first rotor body 4 being the end face facing away from the axial direction of the disk 3.

[0071] The present invention further provides that both the first claw and the second claw are multiple, with multiple first claws spaced apart circumferentially on the first rotor body and multiple second claws spaced apart circumferentially on the second rotor body. The first claw is inserted between two adjacent second claws, and the second claw is inserted between two adjacent first claws, resulting in an alternating arrangement of the first and second claws in the circumferential direction. The number of first claws is p, where p is the number of pole pairs, and the number of second claws is p. This allows the claw-pole rotor of the present invention to have its upper and lower magnetic conductors respectively assigned N and S poles by the disk, with no contact between the two magnetic conductors of different polarities. Furthermore, the reasonable spacing design virtually eliminates magnetic leakage. Traditional permanent magnet rotors have multiple permanent magnets with opposite polarities, which can easily lead to reversed magnet polarity during production, and the rotor production process involves numerous steps. In contrast, the claw-pole rotor of this application has only one disk, eliminating the need to consider the reverse polarity issue, simplifying assembly, and improving production efficiency.

[0072] In some implementations...

[0073] The number of the first claw 5 is p, where p is the pole pair number, and the number of the second claw 7 is p.

[0074] The present invention uses the above structure to make the number of the first claw and the second claw equal to the number of pole pairs, so that the claw pole rotor of the present invention is given N and S poles by the upper and lower magnetic conductors by the disk, respectively. The two magnetic conductors with different polarities have no contact part, and the reasonable spacing is designed to eliminate almost no magnetic leakage.

[0075] In some implementations...

[0076] The circumferential distance between adjacent first claw 5 and second claw 7 is b1, and satisfies 0.1*πR1 / p<b1<0.4*πR1 / p, where p is the number of pole pairs of the claw pole rotor.

[0077] The present invention also features two magnetic conductors that, when assembled on a fixing component, have their top surfaces flush with the bottom surfaces of the claws of one magnetic conductor and the other magnetic conductor. There is no contact between each adjacent claw, and the distance b1 between them meets the condition 0.1*πR1 / p < b1 < 0.4*πR1 / p. This effectively ensures that there is a sufficiently large gap between adjacent claws and avoids magnetic leakage.

[0078] After the rotor of this invention is assembled, a sufficiently large gap is designed between two adjacent claw bodies and between the top of the claw body and the chassis of another magnetic conductor. Because the two magnetic conductors have opposite polarities, if the two magnetic conductors have contact parts or the gap is too small, a leakage magnetic circuit will be formed, resulting in large leakage magnetic flux and reducing rotor performance. Figure 6 As shown, the distance b1 between two adjacent claws satisfies 0.1*2πR1 / 2p < b1 < 0.4*2πR1 / 2p; Figure 4As shown, the claw body is designed with a slope that narrows towards the top from the root to the top. The slope angle must meet the requirement that the minimum thickness at the top is ≥1mm. The slope design ensures that there is a sufficiently large gap between the top of the claw body and the chassis of another magnetic conductor.

[0079] In some implementations...

[0080] The radial thickness of the first claw 5 gradually decreases from the position where it is connected to the first rotor body 4 along the axial direction to the free end of the first claw 5, and the minimum thickness of the first claw 5 is the radial thickness at its free end, and the minimum thickness is greater than or equal to 1 mm.

[0081] The radial thickness of the second claw 7 gradually decreases from its position where it is connected to the second rotor body 6 along the axial direction to the free end of the second claw 7, and the minimum thickness of the second claw 7 is the radial thickness at its free end, which is greater than or equal to 1 mm.

[0082] The present invention, through the design of the first and second claws in a further preferred structural form, makes the root of the claw body have a slope that narrows towards the top. The slope must meet the requirement that the minimum thickness at the top is not less than 1 mm. The slope design can ensure that there is a sufficiently large gap between the top of the claw body and the base of the other magnetic conductor, which can further effectively avoid magnetic leakage.

[0083] In some implementations...

[0084] The claw pole rotor unit also includes a fixing member 8. The first rotor 1 has a first central shaft hole 9, the second rotor 2 also has a second central shaft hole 10, and the disk 3 has a third central shaft hole 11. The first central shaft hole 9, the second central shaft hole 10, and the third central shaft hole 11 are arranged opposite to each other in sequence. The fixing member 8 passes through the first central shaft hole 9, the second central shaft hole 10, and the third central shaft hole 11, so that the first rotor 1, the second rotor 2, the disk 3, and the fixing member 8 can rotate as a whole.

[0085] The present invention, through the preferred structural form of the above-mentioned fastener, can connect the first and second rotors and the disk into one unit to form a rotating structure, and ensure that the first and second rotors are formed into a magnetic conductor structure.

[0086] To address the problems in the technical background, this invention proposes a claw-pole rotor motor with high permanent magnet material usage, high utilization rate, low torque ripple, and simple assembly, such as... Figure 3As shown, the claw-pole rotor of this invention consists of two magnetic conductors, a magnetic disk, and a fixing component. The magnetic conductors are made of magnetically conductive material, the magnetic disk is made of permanent magnet material, and the fixing component is made of non-magnetically conductive material. The two magnetic conductors have identical structures and are respectively assembled at both ends of the fixing component. The magnetic disk is fixed on the fixing component at the position between the two magnetic conductors. The magnetic disk is axially magnetized, giving the two magnetic conductors N and S poles, respectively.

[0087] In some implementations...

[0088] The outer peripheral surface of the fixing member 8 opposite to the third central shaft hole 11 is a cylindrical structure 14.

[0089] The outer peripheral surface of the fastener 8 opposite to the first central shaft hole 9 includes a first cutting edge structure 12. There are multiple first cutting edge structures 12, and the multiple first cutting edge structures 12 are spaced apart in the circumferential direction of the fastener 8. The first central shaft hole 9 is configured as an inner peripheral surface structure that mates with and engages with the multiple first cutting edge structures 12.

[0090] The outer peripheral surface of the fastener 8 opposite to the second central shaft hole 10 includes a second cutting edge structure 13. There are multiple second cutting edge structures 13, which are spaced apart in the circumferential direction of the fastener 8. The second central shaft hole 10 is configured as an inner peripheral surface structure that mates with and engages with the multiple second cutting edge structures 13.

[0091] The present invention, through the preferred structural form of the above-mentioned fastener, makes the shaft segment opposite to the disk disk cylindrical, and the shaft segment opposite to the first rotor includes multiple first tangential structures. The multiple first tangential structures can form a fit with the first central shaft hole of the first rotor to play a locking role, so that the first tangential structures can drive the first rotor to rotate as a whole. The shaft segment opposite to the second rotor includes multiple second tangential structures. The multiple second tangential structures can form a fit with the second central shaft hole of the second rotor to play a locking role, so that the second tangential structures can drive the second rotor to rotate as a whole.

[0092] The thickness of the chassis (i.e., the first and second rotor bodies) of the magnetic conductor (including the first and second rotors) of the present invention is preferably the same as the height of the cut edge of the fixing member, so that after the magnetic conductor is installed on the fixing member, the bottom surface of the magnetic conductor is flush with the end face of the fixing member; the total height of the fixing member is the thickness of the two chassis plus the thickness of the disk, and the total height of the magnetic conductor is the same as the total height of the fixing member, so that after the magnetic conductor is installed on the fixing member, the top surface of the magnetic conductor claw is flush with the other end face of the fixing member.

[0093] In some implementations...

[0094] The fixing member 8 includes a first extended cylindrical segment 15 opposite to the first central shaft hole 9. The first extended cylindrical segment 15 is connected to one axial end of the cylindrical structure 14, and the outer diameter of the first extended cylindrical segment 15 is equal to that of the cylindrical structure 14. The first cutting edge structure 12 is formed by cutting off a first preset length along the axial direction of the fixing member 8 based on the first extended cylindrical segment 15. The distance between the first cutting edge surface along its normal direction and the cylindrical surface of the cylindrical structure 14 is the depth b2 of the first cutting edge structure, and b2 satisfies 1mm≤b2<R2-R2*cos(π / p); where R2 is the outer diameter of the cylindrical structure 14.

[0095] The fixing member 8 further includes a second extended cylindrical section 16 opposite to the second central shaft hole 10. The second extended cylindrical section 16 is connected to the other axial end of the cylindrical structure 14, and the outer diameter of the second extended cylindrical section 16 is equal to that of the cylindrical structure 14. The second cutting edge structure 13 is a second cutting edge surface formed by cutting off a second preset length along the axial direction of the fixing member 8 based on the second extended cylindrical section 16. The distance between the second cutting edge surface and the cylindrical surface of the cylindrical structure 14 along its normal direction is the depth b2 of the second cutting edge structure, and b2 satisfies 1mm≤b2<R2-R2*cos(π / p); where R2 is the outer diameter of the cylindrical structure 14.

[0096] The present invention, through the above structure, makes the overall shape of the fixing member cylindrical, with a shaft hole at the center and p circumferentially distributed tangential edges at both ends. The tangential depth b2 satisfies 1mm≤b2<R2-R2*cos(π / p). The shape of the mounting hole of the magnetic conductor chassis is the same as the shape of the tangential edges at both ends of the fixing member. The magnetic conductor is fixed to the fixing member through the mounting hole with an interference fit. The tangential edges can prevent relative displacement between the magnetic conductor and the fixing member under large torque.

[0097] In some implementations...

[0098] Within the projection plane of the axial end face of the fastener 8, there is an angular offset of 360° / 2p between the perpendicular line between the center of the fastener 8 and the first tangent surface and the perpendicular line between the center of the fastener 8 and the second tangent surface.

[0099] Through the above-mentioned preferred structural form, the present invention achieves an angular offset of 360° / 2p between the cut edge of one end of the fixing member and the cut edge of the other end. After the magnetic conductors at both ends are installed, the claws of the two magnetic conductors are arranged in an interlocking manner, that is, the rotor forms N and S poles arranged in an interlocking manner in the circumferential direction, which generates armature reaction with the stator.

[0100] In some implementations...

[0101] The fixing member 8 has a positioning post 22 and a positioning hole 23 on one end face of the axial direction, and a positioning post 22 and a positioning hole 23 are also provided on the other end face of the axial direction. Between two adjacent claw pole rotor units, the positioning post 22 of the fixing member 8 of one claw pole rotor unit can be inserted into the positioning hole 23 of the fixing member 8 of another claw pole rotor unit. At the same time, the positioning hole 23 of the fixing member 8 of one claw pole rotor unit can accommodate the insertion of the positioning post 22 of the fixing member 8 of another claw pole rotor unit, so as to form the positioning and splicing of multiple claw pole rotor units along the axial direction.

[0102] This is the preferred structural form of the fastener of the present invention. Through the structure of positioning posts and positioning holes, the positioning of adjacent claw pole rotor units can be achieved by the interlocking of positioning posts and positioning holes, thereby realizing the positioning and assembly of adjacent claw pole rotor units, preventing misalignment, and enabling the assembly of claw pole rotor units with different layer heights as needed to adapt to motors with different power or operating conditions, thus improving their versatility.

[0103] The present invention also provides an electric motor comprising the aforementioned claw-pole rotor.

[0104] The outer diameter of the disk in this invention is preferably the same as or smaller than the outer diameter of the magnetic substrate chassis, so as to make full use of the magnetic properties of the disk. The disk is fixed to the fixing member by interference fit between the inner diameter surface and the outer diameter surface of the fixing member.

[0105] The optimal assembly sequence of the claw pole rotor of the present invention is as follows: first, press one magnetic conductor into the fixing component, then press the disk into the fixing component, and finally press the other magnetic conductor into the fixing component.

[0106] This invention solves the following technical problems:

[0107] 1. It solves the problem of high motor cost due to low utilization rate and small amount of permanent magnet materials in motors; it also solves the problem of large torque ripple in permanent magnet motors;

[0108] 2. This solved the problem of needing to open new molds for rotors with different stacking heights, thus increasing investment;

[0109] 3. Solved the problem of large magnetic leakage in permanent magnet motors;

[0110] 4. Solved the problem of low production efficiency caused by the easy reversal of the polarity of the rotor magnets in permanent magnet motors and the cumbersome assembly process;

[0111] The beneficial effects of this invention are:

[0112] 1. The claw pole rotor of the present invention uses an axially magnetized disk, the amount of permanent magnet material is not limited by the rotor core, and both polar surfaces of the disk participate in magnetization, which improves the utilization rate of permanent magnet material, improves the magnetic performance of the rotor, and reduces the amount of copper wire used in the motor, thereby reducing the cost of the motor; the claw pole rotor of the present invention has an eccentric outer circular surface of the claw body, forming an unequal air gap structure with a smaller air gap at the center of the claw body and a larger air gap on both sides, making the air gap magnetic flux density distribution closer to a sine wave, reducing the cogging torque of the motor and the torque pulsation under load;

[0113] 2. The multi-layer claw pole rotor of the present invention can be composed of multiple identical claw pole rotor units. According to different power requirements, different numbers of claw pole rotor units can be assembled into claw pole rotors with different stack heights. There is no need to add corresponding molds for rotors with different stack heights, thus reducing production cost investment.

[0114] 3. For example Figure 1 , 2 As shown, in traditional permanent magnet rotors, each permanent magnet is connected by an iron core, which inevitably leads to magnetic leakage circuits and reduces rotor performance. However, in the claw pole rotor of this invention, the upper and lower magnetic conductors are given N and S poles by a disk, respectively. The two magnetic conductors with different polarities have no contact parts and are reasonably spaced, so there is almost no magnetic leakage.

[0115] 4. Traditional permanent magnet rotors have multiple permanent magnets with opposite polarities, which can easily lead to reversed polarity during production. In addition, the rotor production process is complicated. However, the claw pole rotor of this invention has only one disk, eliminating the need to consider the problem of reverse polarity, simplifying assembly and improving production efficiency.

[0116] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention. The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the protection scope of the present invention.

Claims

1. A multi-layer claw pole rotor, characterized in that: include: At least two layers of claw pole rotor units, and at least two layers of claw pole rotor units are spliced ​​together along the axial direction of the rotor; The claw pole rotor unit includes a first rotor (1), a second rotor (2), and a disk (3). The first rotor (1), the disk (3), and the second rotor (2) are arranged sequentially along the axial direction, such that the disk (3) is located between the first rotor (1) and the second rotor (2). The first rotor (1) includes a first rotor body (4) and a first claw (5). The second rotor (2) includes a second rotor body (6) and a second claw (7). The first rotor body (4) is an annular structure. The first claw (5) protrudes from the outer periphery of the first rotor body (4). At the same time, the first claw (5) also extends axially toward the second rotor (2) to the outer periphery of the second rotor body (6). The second rotor body (6) is an annular structure. The second claw (7) protrudes from the outer periphery of the second rotor body (6). At the same time, the second claw (7) also extends axially toward the first rotor (1) to the outer periphery of the first rotor body (4). In the projection plane of the axial end face of the first rotor (1), the outer peripheral surface of the first claw (5) is an arc segment, the center of which does not coincide with the center of the first rotor (1), and there is an eccentricity e between the center of the outer peripheral surface of the first claw (5) and the center of the first rotor (1). Multiple first claws (5) have a first circumscribed circle, the radius between the center of the first rotor (1) and the first circumscribed circle is R1, R1 is the maximum distance between the outer peripheral surface of the first claw (5) and the center of the first rotor (1), and the eccentricity e satisfies 0.2R1 < e < 0.7R1.

2. The multi-layer claw pole rotor according to claim 1, characterized in that: In the projection plane of the axial end face of the second rotor (2), the outer peripheral surface of the second claw (7) is an arc segment, the center of which does not coincide with the center of the second rotor (2), and there is also an eccentricity e between the center of the outer peripheral surface of the second claw (7) and the center of the second rotor (2). Multiple second claws (7) have a second circumscribed circle, the radius between the center of the second rotor (2) and the second circumscribed circle is R1, R1 is the maximum distance between the outer peripheral surface of the second claw (7) and the center of the second rotor (2), and the eccentricity e conforms to 0.2R1<e<0.7R1.

3. The multi-layer claw pole rotor according to claim 1, characterized in that: There are multiple first claws (5) and multiple second claws (7). Multiple first claws (5) are spaced apart in the circumferential direction of the first rotor body (4), and multiple second claws (7) are spaced apart in the circumferential direction of the second rotor body (6). The first claw (5) is inserted between two adjacent second claws (7), and the second claw (7) is inserted between two adjacent first claws (5), so that the first claws (5) and the second claws (7) are staggered in the circumferential direction. The first claw (5) extends axially to be flush with the bottom surface of the second rotor body (6), the bottom surface of the second rotor body (6) being the end face of the side opposite to the axial direction of the disk (3), and the second claw (7) extends axially to be flush with the bottom surface of the first rotor body (4), the bottom surface of the first rotor body (4) being the end face of the side opposite to the axial direction of the disk (3).

4. The multi-layer claw pole rotor according to claim 3, characterized in that: The number of the first claw (5) is p, where p is the number of pole pairs, and the number of the second claw (7) is p.

5. The multi-layer claw pole rotor according to claim 1, characterized in that: The circumferential distance between the adjacent first claw (5) and the second claw (7) is b1, and satisfies 0.1*πR1 / p<b1<0.4*πR1 / p, where p is the number of pole pairs of the claw pole rotor.

6. The multi-layer claw pole rotor according to claim 1, characterized in that: The radial thickness of the first claw (5) gradually decreases from the position where it is connected to the first rotor body (4) along the axial direction to the free end of the first claw (5), and the minimum thickness of the first claw (5) is the radial thickness at its free end, and the minimum thickness is greater than or equal to 1 mm. The radial thickness of the second claw (7) gradually decreases from the position where it is connected to the second rotor body (6) along the axial direction to the free end of the second claw (7), and the minimum thickness of the second claw (7) is the radial thickness at its free end, which is greater than or equal to 1 mm.

7. The multi-layer claw pole rotor according to claim 1, characterized in that: The claw pole rotor unit also includes a fixing member (8). The first rotor (1) has a first central shaft hole (9), the second rotor (2) also has a second central shaft hole (10), and the disk (3) has a third central shaft hole (11). The first central shaft hole (9), the second central shaft hole (10), and the third central shaft hole (11) are arranged opposite to each other in sequence. The fixing member (8) passes through the first central shaft hole (9), the second central shaft hole (10), and the third central shaft hole (11) at the same time, so that the first rotor (1), the second rotor (2), the disk (3), and the fixing member (8) can rotate as a whole.

8. The multi-layer claw pole rotor according to claim 7, characterized in that: The outer peripheral surface of the fastener (8) opposite to the third central shaft hole (11) is a cylindrical structure (14). The outer peripheral surface of the fastener (8) opposite to the first central shaft hole (9) includes a first tangent structure (12). There are multiple first tangent structures (12), and the multiple first tangent structures (12) are spaced apart in the circumferential direction of the fastener (8). The first central shaft hole (9) is configured as an inner peripheral surface structure that mates with and connects with the multiple first tangent structures (12). The outer peripheral surface of the fastener (8) opposite to the second central shaft hole (10) includes a second tangent structure (13). There are multiple second tangent structures (13), which are spaced apart in the circumferential direction of the fastener (8). The second central shaft hole (10) is configured as an inner peripheral surface structure that mates with and engages with the multiple second tangent structures (13).

9. The multi-layer claw pole rotor according to claim 8, characterized in that: The fastener (8) includes a first extended cylindrical segment (15) opposite to the first central shaft hole (9). The first extended cylindrical segment (15) is connected to one axial end of the cylindrical structure (14), and the outer diameter of the first extended cylindrical segment (15) is equal to that of the cylindrical structure (14). The first tangent structure (12) is a first tangent surface formed by cutting off a first preset length along the axial direction of the fastener (8) based on the first extended cylindrical segment (15). The distance between the first tangent surface and the cylindrical surface of the cylindrical structure (14) along its normal direction is the depth b2 of the first tangent structure, and b2 satisfies 1mm≤b2<R2-R2*cos(π / p); where R2 is the outer diameter of the cylindrical structure (14). The fixing member (8) further includes a second extended cylindrical segment (16) opposite to the second central shaft hole (10). The second extended cylindrical segment (16) is connected to the other end of the cylindrical structure (14) along the axial direction. The outer diameter of the second extended cylindrical segment (16) is equal to that of the cylindrical structure (14). The second cutting edge structure (13) is a second cutting edge surface formed by cutting off a second preset length along the axial direction of the fixing member (8) based on the second extended cylindrical segment (16). The distance between the second cutting edge surface and the cylindrical surface of the cylindrical structure (14) along its normal direction is the depth b2 of the second cutting edge structure, and b2 satisfies 1mm≤b2<R2-R2*cos(π / p); where R2 is the outer diameter of the cylindrical structure (14).

10. The multi-layer claw pole rotor according to claim 9, characterized in that: In the projection plane of the axial end face of the fastener (8), there is an angular offset of 360° / 2p between the perpendicular line between the center of the fastener (8) and the first tangent surface and the perpendicular line between the center of the fastener (8) and the second tangent surface.

11. The multi-layer claw pole rotor according to claim 7, characterized in that: The fixing member (8) has a positioning post (22) and a positioning hole (23) on one end face of the axial direction, and a positioning post (22) and a positioning hole (23) are also provided on the other end face of the axial direction. Between two adjacent claw pole rotor units, the positioning post (22) of the fixing member (8) of one claw pole rotor unit can be inserted into the positioning hole (23) of the fixing member (8) of another claw pole rotor unit. At the same time, the positioning hole (23) of the fixing member (8) of one claw pole rotor unit can accommodate the insertion of the positioning post (22) of the fixing member (8) of another claw pole rotor unit, so as to form the positioning and splicing of multiple claw pole rotor units along the axial direction.

12. An electric motor, characterized in that: The multi-layer claw pole rotor includes any one of claims 1-11.

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