Rotor core, method of manufacturing the same, rotor structure, electric machine, and electric appliance

Abstract

The application provides a rotor core, a manufacturing method thereof, a rotor structure, a motor and an electrical appliance. The rotor core comprises at least two first punching sheets, the at least two first punching sheets are distributed along an axial direction of the rotor core, adjacent two first punching sheets are connected, any first punching sheet comprises at least two punching sheet units, the at least two punching sheet units are distributed along a circumferential direction of the rotor core at intervals, adjacent two punching sheet units have a first interval therebetween, any punching sheet unit comprises at least two first magnetic conductive parts, the at least two first magnetic conductive parts are distributed along the circumferential direction of the rotor core at intervals, adjacent two first magnetic conductive parts have a second interval therebetween, and a first connecting part is arranged to connect adjacent two first magnetic conductive parts. In the axial direction of the rotor core, in adjacent two first punching sheets, the first interval of one first punching sheet is communicated with the second interval of the other first punching sheet, and opposite two first magnetic conductive parts are connected.

Description

Technical Field

[0001] This invention relates to the field of motor rotor technology, and more specifically, to a rotor core and its manufacturing method, rotor structure, motor, and electrical equipment. Background Technology

[0002] In related technologies, a portion of the rotor core is integrally stamped, resulting in low utilization of core material and waste.

[0003] In related technologies, some rotor cores are made in a modular form, but the resulting additional air gap and insufficient rotor rigidity lead to a deterioration in the electromagnetic performance and vibration noise of the motor. Summary of the Invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art.

[0005] Therefore, the first aspect of the present invention provides a rotor core.

[0006] A second aspect of the present invention provides a rotor structure.

[0007] A third aspect of the present invention provides an electric motor.

[0008] The fourth aspect of the present invention provides an electrical device.

[0009] The fifth aspect of this invention provides a method for manufacturing a rotor core.

[0010] A first aspect of the present invention provides a rotor core comprising: at least two first laminations distributed along the axial direction of the rotor core, adjacent first laminations being connected, each first lamination comprising at least two lamination units distributed circumferentially along the rotor core, adjacent lamination units having a first gap, each lamination unit comprising: at least two first magnetic conductive portions distributed circumferentially along the rotor core, adjacent first magnetic conductive portions having a second gap; and a first connecting portion connecting adjacent first magnetic conductive portions; wherein, along the axial direction of the rotor core, in adjacent first laminations, the first gap of one first lamination is connected to the second gap of the other first lamination, and opposing first magnetic conductive portions are connected.

[0011] The rotor core proposed in this invention includes at least two first laminations. These at least two first laminations are distributed along the axial direction of the rotor core, and adjacent first laminations are connected. Furthermore, each first lamination includes at least two lamination units. These at least two lamination units are distributed at intervals along the circumferential direction of the rotor core, and adjacent lamination units have a first interval in the circumferential direction of the rotor core.

[0012] Furthermore, each lamination unit includes at least two first magnetically conductive parts and a first connecting part. The at least two first magnetically conductive parts are circumferentially spaced on the rotor core and form a ring structure; a second gap exists between adjacent first magnetically conductive parts in the circumferential direction of the rotor core. In addition, a first connecting part is provided between adjacent first magnetically conductive parts, the first connecting part being located within the second gap and connected to the adjacent two first magnetically conductive parts.

[0013] Furthermore, along the axial direction of the rotor core, in two adjacent first laminations, the first gap of one first lamination is connected to the second gap of the other first lamination, and the two opposing first magnetic conductive parts of the two first laminations are connected. That is, the two adjacent first laminations are staggered in the circumferential direction of the rotor core, so that one first lamination rotates at a certain angle relative to the other first lamination, thereby allowing two connected lamination units in one first lamination to be connected through lamination units in the other first lamination.

[0014] Specifically, in the rotor core proposed in this invention, the first and second intervals are staggered along the axial direction of the rotor core. This ensures, on the one hand, that adjacent lamination units on the same first lamination are connected, and on the other hand, that the motor using this rotor core has lower leakage flux and higher torque density. Therefore, with the same motor volume, the motor using the rotor core proposed in this invention can have higher torque and power.

[0015] Furthermore, in the rotor core proposed in this invention, the first lamination includes at least two lamination units. Compared with the complete laminations used in related technologies, the lamination units have lower requirements for material size, which can improve the utilization rate of raw materials of the lamination units (e.g., improve the utilization rate of silicon steel) and thus reduce the cost of the rotor core.

[0016] Furthermore, two connected lamination units in one first lamination are connected through a lamination unit in another first lamination, ensuring that at least two first laminations are axially connected as a single unit in the rotor core. This guarantees multiple connection points between adjacent first laminations, which helps improve the overall rigidity of the rotor core and results in better roundness (i.e., a more regular circle). Thus, when a rotor structure with this rotor core is applied to a motor, the air gap between the rotor and stator structures is more uniform, improving motor vibration and noise, and enabling smooth and efficient motor operation.

[0017] In some possible designs, a first connecting part connects two adjacent first magnetic conductive parts.

[0018] In this design, a first connecting part can be connected between two adjacent first magnetic conductive parts; after the rotor core is fully assembled, one first connecting part is located on the outer circumference of the rotor core. This simplifies the overall structure of the rotor core while ensuring a stable connection between adjacent first magnetic conductive parts. Furthermore, the connection between adjacent first magnetic conductive parts creates an open magnet slot between them, facilitating the placement of permanent magnets into the slot.

[0019] In some possible designs, there are at least two first connecting parts connecting two adjacent first magnetic conductive parts.

[0020] In this design, at least two first connecting parts can connect two adjacent first magnetic conductive parts; after the rotor core is fully assembled, at least two first connecting parts are located at least on the outer and inner circumferences of the rotor core. Thus, by designing at least two first connecting parts, the connection strength between the two first magnetic conductive parts can be further improved, preventing the first connecting parts from breaking during the use of the rotor core.

[0021] In some possible designs, the rotor core also includes at least one second lamination, which is connected to the ends of at least two first laminations along the axial direction of the rotor core.

[0022] In this design, the rotor core also includes at least one second lamination. Specifically, along the axial direction of the rotor core, at least one second lamination is connected to the end of at least two first laminations.

[0023] When the rotor core also includes at least two second laminations, the at least two second laminations are respectively connected to the two ends of the at least two first laminations. That is, in the axial direction of the rotor core, second laminations, first laminations and second laminations are respectively provided.

[0024] In some possible designs, the second lamination includes: at least two second magnetically conductive parts, each connected to at least two first magnetically conductive parts; and a second connecting part, connecting two adjacent second magnetically conductive parts.

[0025] In this design, the second lamination includes at least two second magnetically conductive parts and a second connecting part. Specifically, in the circumferential direction of the rotor core, there is a third interval between two adjacent first magnetically conductive parts, and the second connecting part is located within the third interval and connected to the two adjacent second magnetically conductive parts.

[0026] Furthermore, after the rotor core is assembled, the third interval of the second lamination is connected to the first interval and the second interval of the first lamination, and the second magnetic part of the second lamination is connected to the first magnetic part of the first lamination.

[0027] In some possible designs, at least two second magnetic conductive parts and the second connecting part are integrated into one structure.

[0028] In this design, at least two second magnetic conductive parts and the second connecting part are integral structures. That is, in the rotor core proposed in this invention, the second lamination is an integral lamination. Specifically, the rotor core proposed in this invention can use a spliced ​​first lamination in conjunction with an integral second lamination, with the spliced ​​first lamination positioned inside the integral second lamination. Thus, the use of the spliced ​​first lamination results in motors using this rotor core exhibiting lower leakage flux, higher torque density, and reduced rotor core cost; the use of the integral second lamination significantly improves the overall structural rigidity and hardness of the rotor core, thereby extending its service life.

[0029] In some possible designs, the rotor core also includes: magnet slots, located between two adjacent first magnetic sections, for accommodating permanent magnets.

[0030] In this design, the rotor core also includes magnet slots. These magnet slots are located between two adjacent first magnetic conductive sections and can hold permanent magnets of the rotor structure during use, thus enabling the rotor structure to work in conjunction with the stator structure.

[0031] Specifically, in the case where the rotor core includes a first lamination, the magnet slots along the axial direction of the rotor core include a first spacer and a second spacer that are connected.

[0032] Specifically, in the case where the rotor core includes a first lamination and a second lamination, the magnet slots along the axial direction of the rotor core include a first spacer, a second spacer, and a third spacer that are connected to each other.

[0033] A second aspect of the present invention provides a rotor structure comprising: a rotor core as described in the first aspect of the present invention.

[0034] A second aspect of the present invention provides a rotor structure including a rotor core as described in the first aspect of the present invention. Therefore, all the beneficial effects of the aforementioned rotor core will not be discussed in detail here.

[0035] In some possible designs, the rotor structure also includes permanent magnets, which are disposed in magnet slots in the rotor core, with the polarities of two adjacent permanent magnets opposite.

[0036] In this design, the rotor structure also includes permanent magnets. These permanent magnets are positioned in the magnet slots of the rotor core, between two adjacent first magnetically conductive sections. Furthermore, the polarities of adjacent permanent magnets are opposite, creating a magnetic focusing effect.

[0037] In this design, the permanent magnets can be configured as either a built-in spoke-type magnet arrangement or a built-in V-shaped magnet arrangement.

[0038] In some possible designs, the rotor core may also include a first limiting part, disposed at the end of the first magnetically conductive part, and used to limit the permanent magnet.

[0039] In this design, the rotor core also includes a first limiting part. This first limiting part is disposed on the first and second magnetically conductive parts and located at the opening end of the magnet slot; furthermore, the first limiting part protrudes from the sidewalls of the first and second magnetically conductive parts. Thus, during the use of the rotor structure, the permanent magnets located within the magnet slots can be confined by the first limiting part, thereby ensuring that the temperature of the permanent magnets remains within the magnet slots and reducing the possibility of the permanent magnets falling out of the magnet slots.

[0040] In this design, the first limiting part is further defined as a protruding structure. That is, the present invention provides a protruding structure on the sidewalls of the first and second magnetically conductive parts to limit the permanent magnet at the opening end of the magnet slot.

[0041] In this design, the first limiting part and the first magnetic guiding part are further integrated into one structure. This simplifies the assembly process of the rotor core and ensures the connection strength between the first limiting part and the first magnetic guiding part.

[0042] In this design, the first limiting part and the second magnetic guiding part are further integrated into a single structure. This simplifies the assembly process of the rotor core while ensuring the connection strength between the first limiting part and the second magnetic guiding part.

[0043] In some possible designs, the rotor core is a ring structure; the rotor structure also includes a shaft that passes through and is connected to the rotor core.

[0044] In this design, the rotor core is a ring structure; the rotor structure also includes a shaft. The shaft passes through and connects to the rotor core. Thus, when the motor using this rotor structure is running, the rotor structure can drive the shaft to rotate to output torque.

[0045] In some possible designs, the rotating shaft includes a second limiting part that protrudes radially from the rotating shaft; the inner wall of the magnet slot is provided with a third limiting part, at least a portion of which extends into the magnet slot and is connected to the second limiting part.

[0046] In this design, the shaft includes a second limiting part, and a third limiting part is provided on the inner wall of the magnet slot. Furthermore, the second limiting part protrudes radially from the shaft, and at least a portion of the second limiting part extends into the magnet slot and connects with the third limiting part. Thus, the cooperation of the second and third limiting parts further enhances the connection strength between the shaft and the rotor core, ensuring a secure connection between them.

[0047] In some possible designs, the third limiting part is a limiting groove, and the second limiting part includes: an extension that protrudes radially from the rotating shaft and the end of the extension extends into the magnet groove; and a limiting protrusion that is disposed at the end of the extension and connected to the limiting groove.

[0048] In this design, the second limiting part is a limiting groove, which is recessed into the side wall of the magnetically conductive part. Furthermore, the second limiting part includes an extension and a limiting protrusion; the first end of the extension is located radially on the rotating shaft, and the second end of the extension extends into the magnet slot; the limiting protrusion is located at the second end of the extension and protrudes beyond the extension. Moreover, the structure of the limiting protrusion is adapted to the limiting groove so that the limiting protrusion and the limiting groove connect, thereby ensuring a firm connection between the rotating shaft and the rotor core through the cooperation of the limiting protrusion and the limiting groove.

[0049] A third aspect of the present invention provides an electric motor, comprising: a stator structure; and a rotor structure as described in the second aspect of the present invention.

[0050] The motor proposed in this invention includes the rotor structure as described in the second aspect of this invention. Therefore, all the beneficial effects of the aforementioned rotor structure will not be discussed in detail here.

[0051] In addition, the motor also includes a stator structure, which works in conjunction with the rotor structure to output torque.

[0052] In some possible designs, the stator structure includes: stator teeth with stator slots between adjacent stator teeth; windings wound around the stator teeth and located within the stator slots; wherein the number of magnet slots Nr of the rotor structure, the number of stator slots Ns, and the number of pole pairs Pa of the windings satisfy: Pa=│Nr / 2±Ns│.

[0053] In this design, the stator structure includes a stator core, which includes stator teeth and stator slots located between two adjacent stator teeth; the stator structure also includes a winding, which is wound around the stator teeth and located in the stator slots.

[0054] In this design, the number of magnet slots Nr in the rotor structure, the number of stator slots Ns, and the number of pole pairs Pa in the windings satisfy: Pa=│Nr / 2±Ns│. This allows the new harmonic components appearing in the air gap magnetic flux density to serve as the motor's operating harmonics, providing output torque and effectively improving the motor's torque density, thus further enhancing its efficiency. Specifically, the number of magnet slots is equal to the number of permanent magnets.

[0055] In this design, the windings are further concentrated, which facilitates winding and further improves the production efficiency of the motor.

[0056] A fourth aspect of the present invention provides an electrical device comprising: a motor as described in the third aspect of the present invention.

[0057] The electrical device proposed in this invention includes the motor as described in the third aspect above. Therefore, it possesses all the beneficial effects of the aforementioned motor, which will not be discussed in detail here.

[0058] Specifically, the electrical equipment proposed in this invention can be products such as refrigerators, washing machines, and air conditioners.

[0059] The fifth aspect of the present invention provides a method for manufacturing a rotor core, for manufacturing a rotor core as described in the first aspect of the present invention. The method for manufacturing the rotor core includes: performing stamping processes on at least two first laminations in succession, wherein, during two adjacent stamping processes, the second interval of the first laminations stamped in the second stamping is connected to the first interval of the first laminations stamped in the first stamping.

[0060] The present invention provides a method for manufacturing a rotor core, which is used for a rotor core as described in the first aspect of the present invention. Specifically, in the process of manufacturing the rotor core, the present invention performs stamping processing on at least two first laminations in multiple stages.

[0061] Specifically, during the stamping process of at least two first laminations in multiple stages, in the process of two adjacent stamping processes, the first lamination of the second stamping is rotated at a certain angle relative to the other first lamination, so that the second gap of the first lamination of the second stamping is connected to the first gap of the first lamination of the first stamping, thereby connecting two lamination units connected in one first lamination through one lamination unit of the other first lamination.

[0062] In this way, the first and second intervals are staggered along the axial direction of the rotor core. This ensures that adjacent lamination units on the same first lamination are connected, and also ensures that the motor using this rotor core has lower leakage flux and higher torque density. Therefore, with the same motor volume, the motor using the rotor core proposed in this invention can have higher torque and power.

[0063] Furthermore, in two adjacent first laminations, two connected lamination units in one first lamination are connected through a lamination unit in the other first lamination, ensuring that at least two first laminations are axially connected as a single unit in the rotor core. This arrangement guarantees multiple connection points between adjacent first laminations, which helps improve the overall rigidity of the rotor core and results in better roundness (i.e., a more regular circle). Thus, when a rotor structure with this rotor core is applied to a motor, the air gap between the rotor and stator structures is more uniform, improving motor vibration and noise, and enabling smooth and efficient motor operation.

[0064] In some possible designs, during the stamping process of at least two first laminations in stages, the first lamination of the second stamping is rotated by a preset angle relative to the first lamination of the first stamping.

[0065] In this design, during the stamping process of at least two first laminations in stages, before the second stamping, the first lamination for the second stamping needs to be rotated by a certain angle so that the first lamination for the second stamping is rotated by a preset angle relative to the first lamination for the first stamping. At this time, the second gap of the first lamination for the second stamping is connected to the first gap of the first lamination for the first stamping, ensuring that the first magnetic part of the first lamination for the second stamping is positioned opposite to the first magnetic part of the first lamination for the first stamping.

[0066] In some possible designs, the preset angle is (2×k-1)×360 / Npm, where k is an integer and Npm is the number of poles of the rotor core.

[0067] In this design, during the stamping process of at least two first laminations in stages, before the second stamping, the first lamination for the second stamping needs to be rotated by a preset angle, which is (2×k-1)×360 / Npm, where k is an integer and Npm is the number of poles of the rotor core. This ensures that the second gap of the first lamination for the second stamping is connected to the first gap of the first lamination for the first stamping, and that the first magnetic part of the first lamination for the second stamping is positioned relative to the first magnetic part of the first lamination for the first stamping.

[0068] In some possible designs, during the stamping process of the first lamination, one or at least two lamination units are stamped at a time.

[0069] In this design, the first lamination includes at least two lamination units. During the stamping process of the first lamination, the present invention can stamp one lamination unit at a time, thereby reducing the stamping difficulty and improving the stamping accuracy. In addition, during the stamping process of the first lamination, the present invention can also stamp at least two lamination units at a time to improve stamping efficiency, thereby improving the manufacturing efficiency of the rotor core.

[0070] In some possible designs, the method of manufacturing the rotor core further includes: stamping a portion of the second laminations before stamping at least two first laminations in stages; and stamping a portion of the second laminations after stamping at least two first laminations in stages.

[0071] In this design, the rotor core also includes at least two second laminations; and along the axial direction of the rotor core, the at least two second laminations are respectively connected to both ends of the at least two first laminations. Therefore, before the at least two first laminations are stamped in stages, the present invention first stamps a portion of the second laminations; and after the at least two first laminations are stamped in stages, a portion of the second laminations are stamped.

[0072] Specifically, the second lamination is a one-piece lamination. That is, the rotor core proposed in this invention can be used in conjunction with a spliced ​​first lamination and a one-piece second lamination, with the spliced ​​first lamination positioned inside the one-piece second lamination. In this way, the use of the spliced ​​first lamination results in motors using this rotor core exhibiting lower leakage flux, higher torque density, and reduced rotor core cost; while the use of the one-piece second lamination significantly improves the overall structural rigidity and hardness of the rotor core, thereby extending its service life.

[0073] Additional aspects and advantages of the invention will become apparent in the following description or may be learned by practice of the invention. Attached Figure Description

[0074] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0075] Figure 1 This is one of the structural schematic diagrams of the first lamination in the rotor core according to an embodiment of the present invention;

[0076] Figure 2 yes Figure 1 A schematic diagram of the structure of the middle lamination unit of the first lamination shown;

[0077] Figure 3 This is a second schematic diagram of the structure of the first lamination in the rotor core according to an embodiment of the present invention;

[0078] Figure 4 yes Figure 3 A schematic diagram of the structure of the middle lamination unit of the first lamination shown;

[0079] Figure 5 This is a schematic diagram of the structure of the first lamination in the rotor core of another embodiment of the present invention;

[0080] Figure 6 This is a schematic diagram of the structure of the first lamination in the rotor core of another embodiment of the present invention;

[0081] Figure 7 This is a schematic diagram of the structure of the second lamination in the rotor core according to an embodiment of the present invention;

[0082] Figure 8 This is a schematic diagram of the rotor structure according to an embodiment of the present invention;

[0083] Figure 9 yes Figure 8 A schematic diagram of the rotating shaft of the rotor structure shown;

[0084] Figure 10 This is a flowchart of a method for manufacturing a rotor core according to an embodiment of the present invention;

[0085] Figure 11 This is a flowchart of a method for manufacturing a rotor core according to another embodiment of the present invention;

[0086] Figure 12 This is a schematic diagram of the stamping position of the first lamination during the first stamping in a rotor core manufacturing method according to an embodiment of the present invention.

[0087] Figure 13 This is a schematic diagram of the stamping position of the first lamination in the second stamping of a rotor core manufacturing method according to an embodiment of the present invention.

[0088] Figure 14 This is a schematic diagram of the stamping position of the first lamination in the Nth stamping of a rotor core manufacturing method according to an embodiment of the present invention.

[0089] Figure 15 This is a schematic diagram of the stamping position of the second lamination during the first stamping in a rotor core manufacturing method according to an embodiment of the present invention.

[0090] Figure 16 This is a schematic diagram of the stamping position of the first lamination in the second stamping of a rotor core manufacturing method according to an embodiment of the present invention.

[0091] Figure 17 This is a schematic diagram of the stamping position of the first lamination in the Nth stamping of a rotor core manufacturing method according to an embodiment of the present invention.

[0092] Figure 18 This is a schematic diagram of the stamping position of the second lamination during the first stamping in a rotor core manufacturing method according to an embodiment of the present invention.

[0093] Figure 19 This is a schematic diagram of the stamping position of a lamination unit of the first lamination in the second stamping of a rotor core manufacturing method according to an embodiment of the present invention.

[0094] Figure 20 This is a schematic diagram of the stamping position of a lamination unit of the first lamination in the third stamping of a rotor core manufacturing method according to an embodiment of the present invention.

[0095] Figure 21This is a schematic diagram of the stamping position of a lamination unit of the first lamination in the fourth stamping of a rotor core manufacturing method according to an embodiment of the present invention.

[0096] in, Figures 1 to 9 ,as well as Figures 12 to 21 The correspondence between the reference numerals and component names in the attached drawings is as follows:

[0097] 100 Rotor core, 102 First lamination, 104 Lamination unit, 106 First spacer, 108 First magnetic conductive part, 110 Second spacer, 112 First connecting part, 114 Second lamination, 116 Second magnetic conductive part, 118 Second connecting part, 120 Third spacer, 122 First limiting part, 124 Third limiting part, 126 Fastening point, 130 Second limiting part, 132 Extension part, 134 Limiting protrusion, 136 Permanent magnet, 138 Rotating shaft. Detailed Implementation

[0098] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0099] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0100] The following reference Figures 1 to 21 This describes a rotor core 100 and its manufacturing method, rotor structure, motor, and electrical equipment provided according to some embodiments of the present invention. Figures 12 to 14 A schematic diagram of the manufacturing process of a rotor core 100 according to one embodiment; Figures 15 to 17 A schematic diagram of the manufacturing process of a rotor core 100 according to one embodiment; Figures 18 to 21 This is a schematic diagram of the manufacturing process of a rotor core 100 according to one embodiment.

[0101] like Figure 1 and Figure 3 As shown, the first embodiment of the present invention proposes a rotor core 100, which includes at least two first laminations 102.

[0102] Among them, such as Figure 1 , Figure 2 , Figure 3 and Figure 4As shown, at least two first laminations 102 are distributed along the axial direction of the rotor core 100, and adjacent first laminations 102 are connected. Furthermore, each first lamination 102 includes at least two lamination units 104. These at least two lamination units 104 are spaced apart circumferentially along the rotor core 100, and a first interval 106 exists between adjacent lamination units 104 in the circumferential direction of the rotor core 100.

[0103] Furthermore, such as Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, any lamination unit 104 includes at least two first magnetically conductive portions 108 and a first connecting portion 112. The at least two first magnetically conductive portions 108 are circumferentially spaced around the rotor core 100, forming a ring structure. A second interval 110 is provided between adjacent first magnetically conductive portions 108 in the circumferential direction of the rotor core 100. Furthermore, a first connecting portion 112 is provided between adjacent first magnetically conductive portions 108, located within the second interval 110 and connected to the adjacent first magnetically conductive portions 108.

[0104] Furthermore, such as Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, in the axial direction of the rotor core 100, in two adjacent first laminations 102, the first gap 106 of one first lamination 102 is connected to the second gap 110 of the other first lamination 102, and the two opposing first magnetic conductive parts 108 in the two first laminations 102 are connected. That is, the two adjacent first laminations 102 are staggered in the circumferential direction of the rotor core 100, so that one first lamination 102 is rotated at a certain angle relative to the other first lamination 102, thereby allowing two lamination units 104 connected in one first lamination 102 to be connected through one first lamination unit 104 in the other first lamination 102.

[0105] Specifically, in the rotor core 100 proposed in this invention, the first interval 106 and the second interval 110 are staggered along the axial direction of the rotor core 100. This ensures, on the one hand, that adjacent lamination units 104 on the same first lamination 102 are connected, and on the other hand, that the motor using this rotor core 100 has lower leakage flux and higher torque density. Therefore, with the same motor volume, the motor using the rotor core 100 proposed in this invention can have higher torque and power.

[0106] Furthermore, in the rotor core 100 proposed in this invention, the first lamination 102 includes at least two lamination units 104. Compared with the complete laminations used in related technologies, the lamination unit 104 has lower requirements for material size, which can improve the utilization rate of raw materials of the lamination unit 104 (e.g., improve the utilization rate of silicon steel), thereby reducing the cost of the rotor core 100.

[0107] Furthermore, two lamination units 104 connected in one first lamination 102 are connected through one first lamination unit 104 in another first lamination 102, so that at least two first laminations 102 are connected as one unit in the axial direction of the rotor core 100, and ensure that two adjacent first laminations 102 have multiple connection positions, which is beneficial to improving the overall rigidity of the rotor core 100 and making the roundness of the rotor core 100 better (i.e., the roundness of the rotor core 100 is more regular).

[0108] In this way, when the rotor structure with the rotor core 100 is applied to the motor, the air gap between the rotor structure and the stator structure is more uniform, which can improve the vibration and noise of the motor, so as to make the motor run smoothly and efficiently.

[0109] The second embodiment of the present invention proposes a rotor core 100, which, based on the first embodiment, further includes:

[0110] like Figure 1 and Figure 2 As shown, a first connecting part 112 can be connected between two adjacent first magnetic conductive parts 108; after the rotor core 100 is fully assembled, a first connecting part 112 is located on the outer circle of the rotor core 100.

[0111] In this way, while ensuring a stable connection between two adjacent first magnetic conductive parts 108, the overall structure of the rotor core 100 can be simplified. In addition, a first connecting part 112 is connected between two adjacent first magnetic conductive parts 108, so that the magnet slot between the two adjacent first magnetic conductive parts 108 is open, which facilitates the placement of the permanent magnet 136 into the magnet slot.

[0112] Furthermore, the rotor core 100 proposed in this embodiment has all the beneficial effects of the rotor core 100 in the first embodiment. It can ensure that the motor using the rotor core 100 has lower leakage flux and higher torque density, and improves the utilization rate of raw materials of the lamination unit 104, thereby reducing the cost of the rotor core 100. In addition, it helps to improve the overall rigidity of the rotor core 100, making the rotor core 100 more round, thereby making the air gap between the rotor structure and the stator structure more uniform, improving the vibration and noise of the motor, so as to make the motor run smoothly and efficiently. This will not be discussed in detail here.

[0113] The third embodiment of the present invention proposes a rotor core 100, which, based on the first embodiment, further includes:

[0114] like Figure 3 and Figure 4 As shown, at least two first connecting parts 112 can be connected between two adjacent first magnetic conductive parts 108; after the rotor core 100 is fully assembled, at least two first connecting parts 112 are located at least on the outer circle and inner circle of the rotor core 100.

[0115] In this way, by designing at least two first connecting parts 112, the connection strength of the two first magnetic conductive parts 108 can be further improved, and the breakage of the first connecting parts 112 during the use of the rotor core 100 can be avoided.

[0116] Furthermore, the rotor core 100 proposed in this embodiment has all the beneficial effects of the rotor core 100 in the first embodiment. It can ensure that the motor using the rotor core 100 has lower leakage flux and higher torque density, and improves the utilization rate of raw materials of the lamination unit 104, thereby reducing the cost of the rotor core 100. In addition, it helps to improve the overall rigidity of the rotor core 100, making the rotor core 100 more round, thereby making the air gap between the rotor structure and the stator structure more uniform, improving the vibration and noise of the motor, so as to make the motor run smoothly and efficiently. This will not be discussed in detail here.

[0117] The fourth embodiment of the present invention provides a rotor core 100, which, based on the first, second, and third embodiments, further includes:

[0118] The rotor core 100 further includes at least one second lamination 114, which is connected to the ends of at least two first laminations 102 along the axial direction of the rotor core 100.

[0119] In this embodiment, the rotor core 100 further includes at least one second lamination 114. Along the axial direction of the rotor core 100, at least one second lamination 114 is connected to the end of at least two first laminations 102.

[0120] Furthermore, such as Figure 7 As shown, the rotor core 100 also includes at least two second laminations 114. Along the axial direction of the rotor core 100, at least two second laminations 114 are respectively connected to both ends of at least two first laminations 102. That is, in the axial direction of the rotor core 100, second laminations 114, first laminations 102, and second laminations 114 are respectively provided.

[0121] In this embodiment, further, as Figure 7As shown, the second lamination 114 includes at least two second magnetically conductive portions 116 and a second connecting portion 118. In the circumferential direction of the rotor core 100, a third interval 120 is provided between two adjacent first magnetically conductive portions 108, and the second connecting portion 118 is located within the third interval 120 and connected to two adjacent second magnetically conductive portions 116.

[0122] Furthermore, after the rotor core 100 is assembled, the third interval 120 of the second lamination 114 is connected to the first interval 106 and the second interval 110 of the first lamination 102, and the second magnetic part 116 of the second lamination 114 is connected to the first magnetic part 108 of the first lamination 102.

[0123] In this embodiment, further, as Figure 7 As shown, at least two second magnetically conductive parts 116 and the second connecting part 118 are integral structures. That is, in the rotor core 100 proposed in this invention, the second lamination 114 is an integral lamination. In other words, the rotor core 100 proposed in this invention can be used in conjunction with a spliced ​​first lamination 102 and an integral second lamination 114, with the spliced ​​first lamination 102 disposed on the inner side of the integral second lamination 114.

[0124] Thus, by using the spliced ​​first lamination 102, the present invention enables the motor using the rotor core 100 to have lower leakage flux, higher torque density, and lower cost of the rotor core 100; by using the integral second lamination 114, the overall structural rigidity and hardness of the rotor core 100 are significantly improved, thereby increasing the service life of the rotor core 100.

[0125] Furthermore, the rotor core 100 proposed in this embodiment has all the beneficial effects of the rotor core 100 in the first embodiment. It can ensure that the motor using the rotor core 100 has lower leakage flux and higher torque density, and improves the utilization rate of raw materials of the lamination unit 104, thereby reducing the cost of the rotor core 100. In addition, it helps to improve the overall rigidity of the rotor core 100, making the rotor core 100 more round, thereby making the air gap between the rotor structure and the stator structure more uniform, improving the vibration and noise of the motor, so as to make the motor run smoothly and efficiently. This will not be discussed in detail here.

[0126] The fifth embodiment of the present invention proposes a rotor core 100, which, based on the first, second, third, and fourth embodiments, further includes:

[0127] like Figure 1 , Figure 3 and Figure 8As shown, the rotor core 100 also includes a magnet slot. The magnet slot is located between two adjacent first magnetic conductive parts 108 and can hold the permanent magnet 136 of the rotor structure during use, thereby enabling the rotor structure to be used in conjunction with the stator structure.

[0128] Specifically, when the rotor core 100 includes a first lamination 102, along the axial direction of the rotor core 100, the magnet slot includes a first spacer 106 and a second spacer 110 that are connected.

[0129] Specifically, when the rotor core 100 includes a first lamination 102 and a second lamination 114, along the axial direction of the rotor core 100, the magnet slot includes a first spacer 106, a second spacer 110 and a third spacer 120 that are connected.

[0130] Based on the first to fifth embodiments, the first magnetic conductive part 108 of the first lamination 102 is provided with a fastening point 126, and the two opposing first magnetic conductive parts 108 are connected by the fastening point 126 in the axial direction of the rotor core 100.

[0131] Furthermore, the rotor core 100 proposed in this embodiment has all the beneficial effects of the rotor core 100 in the first embodiment. It can ensure that the motor using the rotor core 100 has lower leakage flux and higher torque density, and improves the utilization rate of raw materials of the lamination unit 104, thereby reducing the cost of the rotor core 100. In addition, it helps to improve the overall rigidity of the rotor core 100, making the rotor core 100 more round, thereby making the air gap between the rotor structure and the stator structure more uniform, improving the vibration and noise of the motor, so as to make the motor run smoothly and efficiently. This will not be discussed in detail here.

[0132] Based on the first to fifth embodiments, further, as follows: Figure 2 , Figure 4 , Figure 5 and Figure 6 As shown, the first magnetic conductive part 108 of the first lamination 102 is provided with a fastening point 126. On the axial direction of the rotor core 100, two opposing first magnetic conductive parts 108 are connected by the fastening point 126.

[0133] Based on the first to fifth embodiments, further, as follows: Figure 7 As shown, the second magnetic part 116 of the second lamination 114 is provided with a fastening point 126. On the axial direction of the rotor core 100, the opposite first magnetic part 108 and second magnetic part 116 are connected by the fastening point 126.

[0134] like Figure 8As shown, the sixth embodiment of the present invention provides a rotor core 100, including the rotor core 100 as described in any of the above embodiments.

[0135] The rotor core 100 proposed in this embodiment of the invention includes the rotor core 100 as described in any of the above embodiments. Therefore, all the beneficial effects of the rotor core 100 described above can ensure that the motor using the rotor core 100 has lower leakage flux and higher torque density; and improve the utilization rate of raw materials of the lamination unit 104, thereby reducing the cost of the rotor core 100; and it is beneficial to improve the overall rigidity of the rotor core 100, making the rotor core 100 more round, thereby making the air gap between the rotor structure and the stator structure more uniform, improving the vibration and noise of the motor, so as to enable the motor to operate smoothly and efficiently, which will not be discussed in detail here.

[0136] The seventh embodiment of the present invention proposes a rotor core 100, which, based on the sixth embodiment, further includes:

[0137] like Figure 8 As shown, the rotor structure also includes permanent magnets 136. These permanent magnets 136 are disposed in the magnet slots of the rotor core 100, located between two adjacent first magnetically conductive sections 108. Furthermore, the polarities of two adjacent permanent magnets 136 are opposite, creating a magnetic focusing effect.

[0138] In this embodiment, the permanent magnet 136 can be configured as a built-in spoke-type magnet arrangement or a built-in V-shaped magnet arrangement.

[0139] In this embodiment, further, as Figure 5 As shown, the rotor core 100 also includes a first limiting part 122. The first limiting part 122 is disposed on the first magnetically conductive part 108 and the second magnetically conductive part 116, and is located at the opening end of the magnet slot; furthermore, the first limiting part 122 protrudes from the sidewalls of the first magnetically conductive part 108 and the second magnetically conductive part 116. Thus, during the use of the rotor structure, the permanent magnet 136 located in the magnet slot can be limited by the first limiting part 122, thereby ensuring that the temperature of the permanent magnet 136 remains within the magnet slot and reducing the possibility of the permanent magnet 136 falling out of the magnet slot.

[0140] In this embodiment, further, as Figure 5 As shown, the first limiting part 122 is a protruding structure. That is, the present invention provides a protruding structure on the sidewall of the first magnetic conductive part 108 and the second magnetic conductive part 116 to limit the permanent magnet 136 at the opening end of the magnet slot through the protruding structure.

[0141] In this embodiment, further, as Figure 5As shown, the first limiting part 122 and the first magnetic conductive part 108 are integrally formed. This simplifies the assembly process of the rotor core 100 and ensures the connection strength between the first limiting part 122 and the first magnetic conductive part 108.

[0142] In this embodiment, the first limiting part 122 and the second magnetic conductive part 116 are further integrated into one structure. This simplifies the assembly process of the rotor core 100 and ensures the connection strength between the first limiting part 122 and the second magnetic conductive part 116.

[0143] Furthermore, the rotor structure proposed in this embodiment has all the beneficial effects of the rotor core 100 of the first embodiment. It can ensure that the motor using the rotor core 100 has lower leakage flux and higher torque density, and improves the utilization rate of raw materials of the lamination unit 104, thereby reducing the cost of the rotor core 100. In addition, it helps to improve the overall rigidity of the rotor core 100, making the rotor core 100 more round, thereby making the air gap between the rotor structure and the stator structure more uniform, improving the vibration and noise of the motor, so as to make the motor run smoothly and efficiently. This will not be discussed in detail here.

[0144] The eighth embodiment of the present invention proposes a rotor structure, which, based on the sixth and seventh embodiments, further includes:

[0145] like Figure 8 and Figure 9 As shown, the rotor core 100 has a ring structure; the rotor structure also includes a rotating shaft 138. The rotating shaft 138 passes through and is connected to the rotor core 100. Thus, when the motor using this rotor structure is running, the rotor structure can drive the rotating shaft 138 to rotate and output torque.

[0146] In this embodiment, further, as Figure 5 and Figure 9 As shown, the rotating shaft 138 includes a second limiting portion 130, and a third limiting portion 124 is provided on the inner wall of the magnet slot. Furthermore, the second limiting portion 130 protrudes radially from the rotating shaft 138, and at least a portion of the second limiting portion 130 extends into the magnet slot and connects with the third limiting portion 124. Thus, through the cooperation of the second limiting portion 130 and the third limiting portion 124, the connection strength between the rotating shaft 138 and the rotor core 100 can be further enhanced, ensuring the secure connection between the rotating shaft 138 and the rotor core 100.

[0147] In this embodiment, further, as Figure 5 As shown, the second limiting part 130 is a limiting groove, which is recessed into the side wall of the magnetically conductive part. Furthermore, as... Figure 9As shown, the second limiting portion 130 includes an extension portion 132 and a limiting protrusion 134; wherein, the first end of the extension portion 132 is disposed radially on the rotating shaft 138, and the second end of the extension portion 132 extends into the magnet slot; the limiting protrusion 134 is disposed at the second end of the extension portion 132 and protrudes from the extension portion 132. Furthermore, the structure of the limiting protrusion 134 is adapted to the limiting groove so that the limiting protrusion 134 and the limiting groove are connected, thereby ensuring the firmness of the connection between the rotating shaft 138 and the rotor core 100 through the cooperation of the limiting protrusion 134 and the limiting groove.

[0148] Furthermore, the rotor structure proposed in this embodiment has all the beneficial effects of the rotor core 100 of the first embodiment. It can ensure that the motor using the rotor core 100 has lower leakage flux and higher torque density, and improves the utilization rate of raw materials of the lamination unit 104, thereby reducing the cost of the rotor core 100. In addition, it helps to improve the overall rigidity of the rotor core 100, making the rotor core 100 more round, thereby making the air gap between the rotor structure and the stator structure more uniform, improving the vibration and noise of the motor, so as to make the motor run smoothly and efficiently. This will not be discussed in detail here.

[0149] The ninth embodiment of the present invention provides an electric motor, including a stator structure and a rotor structure as described in any of the above embodiments.

[0150] The motor proposed in this embodiment includes the rotor structure as described in the second aspect of the present invention. Therefore, it possesses all the beneficial effects of the aforementioned rotor structure, ensuring that the motor using this rotor core 100 has lower leakage flux, higher torque density, and improved utilization of raw materials in the lamination unit 104, thereby reducing the cost of the rotor core 100. Furthermore, it helps to improve the overall rigidity of the rotor core 100, resulting in better roundness and a more uniform air gap between the rotor and stator structures, thus improving motor vibration and noise, and enabling the motor to operate smoothly and efficiently. Further details will not be elaborated here.

[0151] In addition, the motor also includes a stator structure, which works in conjunction with the rotor structure to output torque.

[0152] The tenth embodiment of the present invention proposes a motor, which, based on the ninth embodiment, further includes:

[0153] The stator structure includes a rotor core 100, which includes stator teeth and stator slots located between two adjacent stator teeth; the stator structure also includes a winding wound around the stator teeth and located in the stator slots.

[0154] In this embodiment, the number of magnet slots Nr, the number of stator slots Ns, and the number of pole pairs Pa of the windings further satisfy: Pa = |Nr / 2±Ns|. Thus, the new harmonic components appearing in the air gap magnetic flux density can serve as the motor's operating harmonics, providing output torque and effectively improving the motor's torque density, thereby further enhancing the motor's efficiency. Specifically, the number of magnet slots is equal to the number of permanent magnets 136.

[0155] In this embodiment, the winding is further a centralized winding, which facilitates winding and further improves the production efficiency of the motor.

[0156] Building upon the ninth and tenth embodiments, the present invention further proposes a dual-air-gap permanent magnet motor. The motor proposed in this invention exhibits lower leakage flux and higher torque density. Therefore, within the same motor volume, this invention can improve the motor's torque and power.

[0157] The eleventh embodiment of the present invention provides an electrical device including a motor as described in any of the above embodiments.

[0158] The electrical device proposed in this invention includes a motor as described in any of the above embodiments. Therefore, it possesses all the beneficial effects of the motor described above, which will not be discussed in detail here.

[0159] Specifically, the electrical equipment proposed in this invention can be products such as refrigerators, washing machines, and air conditioners.

[0160] The twelfth embodiment of the present invention provides a method for manufacturing a rotor core, used to manufacture a rotor core 100 as described in any of the above embodiments. Figure 10 As shown, the manufacturing method of the rotor core includes:

[0161] Step 1002: At least two first stamping pieces are stamped in multiple stages, wherein during two adjacent stamping processes, the second gap of the first stamping piece in the second stamping is connected to the first gap of the first stamping piece in the first stamping.

[0162] The present invention provides a method for manufacturing a rotor core 100, which is used for a rotor core 100 as described in the first aspect of the present invention. Specifically, in the process of manufacturing the rotor core 100, the present invention performs stamping processing on at least two first laminations 102 in several stages.

[0163] Specifically, during the stamping process of at least two first stamping pieces 102 in multiple stages, in the process of two adjacent stamping processes, the first stamping piece 102 of the second stamping is rotated at a certain angle relative to the other first stamping piece 102, so that the second interval 110 of the first stamping piece 102 of the second stamping is connected to the first interval 106 of the first stamping piece 102 of the first stamping, thereby connecting two stamping units 104 connected in one first stamping piece 102 through one stamping unit 104 of the other first stamping piece 102.

[0164] Thus, in the axial direction of the rotor core 100, the first interval 106 and the second interval 110 are staggered. This ensures, on the one hand, that adjacent lamination units 104 on the same first lamination 102 are connected, and on the other hand, that the motor using this rotor core 100 has lower leakage flux and higher torque density. Therefore, with the same motor volume, the motor using the rotor core 100 proposed in this invention can have higher torque and power.

[0165] Furthermore, in two adjacent first laminations 102, two connected lamination units 104 in one first lamination 102 are connected through one lamination unit 104 in the other first lamination 102, so that at least two first laminations 102 are connected as a whole in the axial direction of the rotor core 100, and multiple connection positions are ensured for two adjacent first laminations 102. This is beneficial to improving the overall rigidity of the rotor core 100 and making the roundness of the rotor core 100 better (i.e., the roundness of the rotor core 100 is more regular). In this way, when the rotor structure with this rotor core 100 is applied to a motor, the air gap between the rotor structure and the stator structure is more uniform, which can improve the vibration and noise of the motor, so as to enable the motor to operate smoothly and efficiently.

[0166] The thirteenth embodiment of the present invention proposes a method for manufacturing a rotor core 100, which further improves upon the method described in embodiment twelve:

[0167] like Figure 12 , Figure 13 and Figure 14 As shown, during the stamping process of at least two first laminations 102 in multiple stages, before the second stamping, the first laminations 102 for the second stamping need to be rotated by a certain angle so that the first laminations 102 for the second stamping are rotated by a preset angle relative to the first laminations 102 for the first stamping. At this time, the second gap 110 of the first laminations 102 for the second stamping is connected to the first gap 106 of the first laminations 102 for the first stamping, and ensures that the first magnetic part 108 of the first laminations 102 for the second stamping is positioned opposite to the first magnetic part 108 of the first laminations 102 for the first stamping.

[0168] In this embodiment, further, as Figure 12 , Figure 13 and Figure 14 As shown, during the stamping process of at least two first laminations 102 in multiple passes, before the second stamping, the first lamination 102 for the second stamping needs to be rotated by a preset angle; and the preset angle is (2×k-1)×360 / Npm, where k is an integer and Npm is the number of poles of the rotor core 100. In this way, it can be ensured that the second interval 110 of the first lamination 102 for the second stamping is connected to the first interval 106 of the first lamination 102 for the first stamping, and that the first magnetic part 108 of the first lamination 102 for the second stamping is positioned opposite to the first magnetic part 108 of the first lamination 102 for the first stamping.

[0169] Building upon the twelfth and thirteenth embodiments, the first lamination 102 further includes at least two lamination units 104. For example... Figure 19 , Figure 20 and Figure 21 As shown, during the stamping process of the first lamination 102, the present invention can stamp one lamination unit 104 at a time, thereby reducing the stamping difficulty and improving the stamping accuracy. In addition, during the stamping process of the first lamination 102, the present invention can also stamp at least two lamination units 104 at a time to improve the stamping efficiency and thus improve the manufacturing efficiency of the rotor core 100.

[0170] The fourteenth embodiment of the present invention provides a method for manufacturing a rotor core, used to manufacture a rotor core 100 as described in any of the above embodiments. Figure 11 As shown, the manufacturing method of the rotor core includes:

[0171] Step 1102: Stamping process is performed on a portion of the second laminations;

[0172] Step 1104: At least two first stamping pieces are stamped in multiple stages, wherein during two adjacent stamping processes, the second gap of the first stamping piece in the second stamping is connected to the first gap of the first stamping piece in the first stamping.

[0173] Step 1106: Stamping process is performed on a portion of the second laminations.

[0174] In this design, the rotor core 100 also includes at least two second laminations 114; and, along the axial direction of the rotor core 100, the at least two second laminations 114 are respectively connected to both ends of at least two first laminations 102. Furthermore, as... Figure 15 , Figure 16 and Figure 17 ,as well as Figure 18 , Figure 19 , Figure 20 and Figure 21As shown, compared to the twelfth embodiment, in this embodiment, before stamping at least two first stamping pieces 102 in multiple stages, a portion of the second stamping pieces 114 are first stamped; after stamping at least two first stamping pieces 102 in multiple stages, a portion of the second stamping pieces 114 are stamped.

[0175] Specifically, the second lamination 114 is an integral lamination. That is, the rotor core 100 proposed in this invention can be used in conjunction with the spliced ​​first lamination 102 and the integral second lamination 114, with the spliced ​​first lamination 102 disposed on the inner side of the integral second lamination 114. In this way, by using the spliced ​​first lamination 102, the motor using this rotor core 100 has lower leakage flux, higher torque density, and reduced cost of the rotor core 100; by using the integral second lamination 114, the overall structural rigidity and hardness of the rotor core 100 are significantly improved, thereby increasing the service life of the rotor core 100.

[0176] Therefore, the present invention proposes a rotor core 100, a rotor structure, a motor, electrical equipment, and a manufacturing method for the rotor core 100, which has the advantages of high efficiency in large-scale production and low vibration and noise.

[0177] The rotor structure includes a rotor core 100, magnet slots, and permanent magnets 136. The rotor core 100 is formed by stamping rotor laminations.

[0178] Specifically, the rotor laminations include at least two first laminations 102, which are distributed along the axial direction of the rotor core 100, with adjacent first laminations 102 connected together. Each first lamination 102 includes at least two lamination units 104, with a first gap 106 between adjacent lamination units 104. Each lamination unit 104 includes a first magnetically conductive portion 108 and a first connecting portion 112. At least two first magnetically conductive portions 108 are circumferentially spaced in the rotor core 100, with a second gap 110 between adjacent first magnetically conductive portions 108, and the first connecting portion 112 connects adjacent first magnetically conductive portions 108. Axially, in adjacent first laminations 102, the first gap 106 of one first lamination 102 communicates with the second gap 110 of the other first lamination 102, and opposite first magnetically conductive portions 108 are connected together.

[0179] Furthermore, the number of magnet slots Nr in the rotor structure, the number of stator slots Ns, and the number of pole pairs Pa in the winding satisfy: Pa=│Nr / 2±Ns│

[0180] Furthermore, the rotor laminations also include at least two second laminations 114, which are used in the first or later stamping processes. Each second lamination 114 includes at least two second magnetically conductive portions 116 and a second connecting portion 118. A third gap 120 exists between adjacent second magnetically conductive portions 116, and the second connecting portion 118 connects adjacent second magnetically conductive portions 116. During the manufacturing of the rotor core 100, the second lamination 114 is stamped first, and is stamped at least once. Subsequently, when stamping two adjacent first laminations 102, the first lamination 102 stamped in the second stamping is rotated by a preset angle of (2×k-1)×360 / Npm compared to the first lamination 102 stamped in the first stamping, where k is an integer and Npm is the number of poles of the rotor core 100.

[0181] Specifically, such as Figure 1 As shown, the rotor structure has 20 magnet slots. It is applied to a motor with 12 stator slots and 2 pole pairs formed by the windings. In this case, when stamping the first lamination 102, the first lamination 102 stamped for the second time is rotated by 18° compared to the first lamination 102 stamped for the first time.

[0182] Furthermore, during the stamping process of the first lamination 102, one or at least two lamination units 104 are stamped at a time.

[0183] Furthermore, a first connecting part 112 may be connected between two adjacent first magnetic conductive parts 108, or at least two first connecting parts 112 may be connected.

[0184] Furthermore, a magnet slot is provided between the two first magnetic conductive parts 108, and a permanent magnet 136 is placed in the magnet slot; and the polarities of two adjacent permanent magnets 136 under the same pole are opposite, forming a magnetic focusing effect. In addition, the permanent magnets 136 can be configured as a built-in spoke-type magnet arrangement or a built-in V-shaped magnet arrangement.

[0185] Furthermore, a first limiting part 122 can be provided on the magnetic conductive part; after being assembled into a rotor structure, the first limiting part 122 can prevent the permanent magnet 136 from sliding out of the magnet slot.

[0186] Furthermore, a third limiting part 124 may be provided on the magnetic conductive part; after being assembled into a rotor structure, the third limiting part 124 is connected to the second limiting part 130 of the rotating shaft 138.

[0187] Furthermore, compared to the integral stamped iron core used in related technologies, the present invention can improve the utilization rate of silicon steel.

[0188] Furthermore, compared to existing modular iron cores, the present invention can improve the overall rigidity of the rotor iron core 100, the uniformity of the air gap between the rotor structure and the stator structure, and can improve the vibration and noise of the motor.

[0189] Therefore, as Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, any lamination unit 104 includes at least two first magnetically conductive portions 108 and a first connecting portion 112. The at least two first magnetically conductive portions 108 are circumferentially spaced around the rotor core 100, forming a ring structure. A second interval 110 is provided between adjacent first magnetically conductive portions 108 in the circumferential direction of the rotor core 100. Furthermore, a first connecting portion 112 is provided between adjacent first magnetically conductive portions 108, located within the second interval 110 and connected to the adjacent first magnetically conductive portions 108.

[0190] And, as Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, in the axial direction of the rotor core 100, in two adjacent first laminations 102, the first gap 106 of one first lamination 102 is connected to the second gap 110 of the other first lamination 102, and the two opposing first magnetic conductive parts 108 in the two first laminations 102 are connected. That is, the two adjacent first laminations 102 are staggered in the circumferential direction of the rotor core 100, so that one first lamination 102 is rotated at a certain angle relative to the other first lamination 102, thereby allowing two lamination units 104 connected in one first lamination 102 to be connected through one first lamination unit 104 in the other first lamination 102.

[0191] Specifically, in the rotor core 100 proposed in this invention, the first interval 106 and the second interval 110 are staggered along the axial direction of the rotor core 100. This ensures, on the one hand, that adjacent lamination units 104 on the same first lamination 102 are connected, and on the other hand, that the motor using this rotor core 100 has lower leakage flux and higher torque density. Therefore, with the same motor volume, the motor using the rotor core 100 proposed in this invention can have higher torque and power.

[0192] Furthermore, in the rotor core 100 proposed in this invention, the first lamination 102 includes at least two lamination units 104. Compared with the complete laminations used in related technologies, the lamination unit 104 has lower requirements for material size, which can improve the utilization rate of raw materials of the lamination unit 104 (e.g., improve the utilization rate of silicon steel), thereby reducing the cost of the rotor core 100.

[0193] Furthermore, two lamination units 104 connected in one first lamination 102 are connected through one first lamination unit 104 in another first lamination 102, so that at least two first laminations 102 are connected as one unit in the axial direction of the rotor core 100, and ensure that two adjacent first laminations 102 have multiple connection positions, which is beneficial to improving the overall rigidity of the rotor core 100 and making the roundness of the rotor core 100 better (i.e., the roundness of the rotor core 100 is more regular).

[0194] In this way, when the rotor structure with the rotor core 100 is applied to the motor, the air gap between the rotor structure and the stator structure is more uniform, which can improve the vibration and noise of the motor, so as to make the motor run smoothly and efficiently.

[0195] The motor proposed in this invention is a dual-air-gap permanent magnet motor. This motor exhibits lower leakage flux and higher torque density. Therefore, within the same motor volume, this invention can improve both the torque and power of the motor.

[0196] In the description of this invention, the term "a plurality of" refers to two or more. Unless otherwise explicitly defined, the terms "upper," "lower," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and 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 of the invention. The terms "connection," "installation," "fixing," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection or an indirect connection through an intermediate medium. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0197] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0198] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A rotor core, characterized in that, include: At least two first laminations are distributed along the axial direction of the rotor core, with adjacent first laminations connected together. Each first lamination includes at least two lamination units, which are distributed circumferentially along the rotor core, with a first gap between adjacent lamination units. Each lamination unit includes: At least two first magnetic conductive parts are distributed circumferentially in the rotor core, and there is a second interval between two adjacent first magnetic conductive parts. The first connecting part connects two adjacent first magnetic conductive parts; In the axial direction of the rotor core, in two adjacent first laminations, the first interval of one first lamination is connected to the second interval of the other first lamination, and the two opposing first magnetic conductive parts are connected. The rotor core also includes: At least one second lamination is connected to the end of the at least two first laminations along the axial direction of the rotor core. The second lamination includes: At least two second magnetic conductive parts are respectively connected to the at least two first magnetic conductive parts, and a third interval is provided between two adjacent second magnetic conductive parts in the circumferential direction of the rotor core; The second connecting part connects two adjacent second magnetic conductive parts; The third interval of the second lamination is connected to the first interval and the second interval of the first lamination, respectively; The rotor core also includes: A magnet slot, located between two adjacent first magnetic conductive parts, is used to accommodate a permanent magnet. The magnet slot includes a first spacer, a second spacer, and a third spacer that are connected.

2. The rotor core according to claim 1, characterized in that, A first connecting part connects two adjacent first magnetic conductive parts; or At least two first connecting parts are connected between two adjacent first magnetic conductive parts.

3. The rotor core according to claim 1, characterized in that, The at least two second magnetic conductive parts and the second connecting part are an integral structure.

4. A rotor structure, characterized in that, include: The rotor core as described in any one of claims 1 to 3.

5. The rotor structure according to claim 4, characterized in that, Also includes: Permanent magnets are disposed in the magnet slots of the rotor core, with the polarities of two adjacent permanent magnets being opposite.

6. The rotor structure according to claim 5, characterized in that, The rotor core also includes: The first limiting part is disposed at the end of the first magnetic conductive part and is used to limit the permanent magnet.

7. The rotor structure according to any one of claims 4 to 6, characterized in that, The rotor core has a ring structure; The rotor structure also includes a rotating shaft, which passes through the rotor core and is connected to the rotor core.

8. The rotor structure according to claim 7, characterized in that, The rotating shaft includes a second limiting part, which protrudes radially from the rotating shaft; The inner wall of the magnet slot of the rotor core is provided with a third limiting part, and at least a portion of the second limiting part extends into the magnet slot and is connected to the second limiting part.

9. The rotor structure according to claim 8, characterized in that, The third limiting part is a limiting groove, and the second limiting part includes: An extension portion is provided radially protruding from the rotating shaft, and the end of the extension portion extends into the magnet groove; A limiting protrusion is provided at the end of the extension and is connected to the limiting groove.

10. An electric motor, characterized in that, include: Stator structure; The rotor structure as described in any one of claims 4 to 9.

11. The motor according to claim 10, characterized in that, The stator structure includes: Stator teeth, with stator slots between two adjacent stator teeth; The winding is wound around the stator teeth and located in the stator slot; The number of magnet slots Nr in the rotor structure, the number of stator slots Ns, and the number of pole pairs Pa in the winding satisfy: Pa = |Nr / 2±Ns|.

12. An electrical appliance, characterized in that, include: The motor as described in claim 10 or 11.

13. A method for manufacturing a rotor core, used to manufacture a rotor core as described in any one of claims 1 to 3, characterized in that, The method for manufacturing the rotor core includes: At least two first laminations are stamped in stages, wherein during two adjacent stamping processes, the second gap of the first lamination stamped in the second stage is connected to the first gap of the first lamination stamped in the first stage.

14. The method for manufacturing the rotor core according to claim 13, characterized in that, During the stamping process of at least two first laminations in multiple stages, the first lamination stamped in the second stage is rotated by a preset angle relative to the first lamination stamped in the first stage.

15. The method for manufacturing a rotor core according to claim 14, characterized in that, The preset angle is (2×k-1)×360 / Npm, where k is an integer and Npm is the number of poles of the rotor core.

16. The method for manufacturing a rotor core according to any one of claims 13 to 15, characterized in that, During the stamping process of the first lamination, one or at least two lamination units are stamped at a time.

17. A method for manufacturing a rotor core according to any one of claims 13 to 15, characterized in that, Also includes: Before stamping at least two of the first laminations in multiple passes, a portion of the second laminations are stamped. as well as After stamping at least two of the first laminations in stages, a portion of the second laminations are stamped.

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