Rotor, disc motor, motor drive system, and vehicle

Abstract

The application provides a rotor, a disc motor, a motor driving system and a vehicle. The rotor comprises a fixing sleeve and a magnetic concentration structure. The fixing sleeve comprises 2P accommodation grooves arranged along the circumference of the fixing sleeve, wherein P is an integer greater than or equal to 1. The magnetic concentration structure comprises 2P composite magnetic concentration components, each of which is fixedly accommodated in a corresponding accommodation groove. Each composite magnetic concentration component comprises a permanent magnet structure and a soft magnetic structure which are embedded in each other. The magnetic concentration structure is formed by 2P composite magnetic concentration components along the circumference of the fixing sleeve instead of being formed by a whole structure wound, so that the outer wall of each composite magnetic concentration component can be well connected with the inner wall of the accommodation groove, the connection stability between the magnetic concentration structure and the fixing sleeve (or other rotor structural members, such as a rotating shaft) is improved, and the strength of the rotor is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of driving, in particular to a rotor, a disc motor, a motor driving system and a vehicle. BACKGROUND

[0002] The disc motor is also called an axial flux permanent magnet machine (AFPMM). The disc motor has the advantages of compact structure, high torque density, high efficiency, large power density, etc. The disc motor can be applied to electric vehicles, renewable energy systems, energy storage systems and industrial equipment, etc.

[0003] For the structure of a conventional surface-mounted disc motor, as the operating frequency of the rotor increases, the eddy current loss of the conventional surface-mounted permanent magnet rotor structure increases significantly, which can cause the performance of the motor to decrease, and the rotor reluctance torque component is small, and the power decreases rapidly at high speed.

[0004] For the structure of an existing built-in disc motor, when manufacturing the disc motor, silicon steel sheets are wound to form a whole annular rotor core, and then a magnetic steel is embedded in the rotor core. However, when the silicon steel sheets are wound to form a whole annular rotor core, the inner ring wall and the outer ring wall of the rotor core are both Archimedes spirals instead of circles, which makes it difficult for the inner ring wall and the outer ring wall of the rotor core to effectively cooperate with other motor rotor structural components, and makes the connection between the inner ring wall of the magnetic steel and the motor shaft unreliable, thereby affecting the structural strength of the disc motor. SUMMARY

[0005] The embodiments of the present application provide a rotor, a disc motor, a motor driving system and a vehicle capable of improving the structural strength.

[0006] In a first aspect, the embodiments of the present application provide a rotor applied to a disc motor, comprising: a fixing sleeve comprising 2P receiving grooves arranged along the circumference of the fixing sleeve, wherein P is an integer greater than or equal to 1; and a magnetic concentrating structure comprising 2P composite magnetic concentrating components, each composite magnetic concentrating component being fixedly received in a corresponding receiving groove, and the composite magnetic concentrating component comprising a mutually embedded permanent magnet structure and a soft magnetic structure.

[0007] The composite magnetic concentrating component comprises the mutually embedded permanent magnet structure and the soft magnetic structure, and the soft magnetic structure can effectively guide the magnetic field. The magnetic concentrating structure can effectively reduce the eddy current loss, which is conducive to increasing the output torque of the rotor, reducing the torque fluctuation, and improving the performance of the rotor.

[0008] The poly-magnetic structure is formed by 2P poly-magnetic components along the circumference of the fixing sleeve, rather than being formed by winding, so that the outer wall of each poly-magnetic component can be well connected with the inner wall of the accommodating groove, the connection stability between the poly-magnetic structure and the fixing sleeve (or other rotor structure, such as the rotating shaft) is improved, and the strength of the rotor is improved.

[0009] The poly-magnetic component can be regarded as a part of the whole annular structure, and when the poly-magnetic structure is prepared, the silicon steel sheet does not need to be wound into a whole annular structure, and the inner ring wall and the outer ring wall of the rotor do not need to be finished to ensure the coaxiality of the rotor, so that the preparation difficulty and assembly difficulty of the poly-magnetic structure are reduced.

[0010] The fixing sleeve is made of non-magnetic and non-conductive material. The poly-magnetic structure is fixed on the fixing sleeve, and the fixing sleeve can reduce the magnetic leakage of the rotor, thereby improving the output torque of the rotor.

[0011] According to the first aspect, in a possible implementation, the permanent magnet structure includes a middle axial permanent magnet unit and side permanent magnet units distributed on one side or both sides of the middle axial permanent magnet unit along the axial direction of the rotor. The middle axial permanent magnet unit and each side permanent magnet unit jointly form a first accommodating space, and the soft magnetic structure is embedded in the first accommodating space.

[0012] By the poly-magnetic permanent magnet arrangement, cooperating with the special rotor core structure, the built-in structure of the permanent magnet is realized. Compared with the surface-mounted permanent magnet rotor, the saliency effect of the motor is obvious, has the advantage of large reluctance torque, and improves the output torque of the rotor. Each pair of magnetic poles is composed of multiple soft magnetic materials and permanent magnets, and the process is simple; different shapes and magnetizing methods of permanent magnets are combined to form a composite poly-magnetic structure, and a large saliency ratio is set. The magnetic circuit forms a complete magnetic circuit through the soft magnetic material, the permanent magnet and the stator, increases the main magnetic flux, reduces the magnetic leakage, achieves the purpose of poly-magnetism, improves the air gap flux density; and the permanent magnet realizes the built-in structure, the motor has obvious saliency effect, good flux weakening performance, large reluctance torque.

[0013] In a possible implementation manner according to the first aspect, the side permanent magnet unit includes an inner side permanent magnet and two outer side permanent magnets. In the circumferential direction of the rotor, the intermediate axial permanent magnet unit and the inner side permanent magnet are both located between the two outer side permanent magnets. In the axial direction of the rotor, the inner side permanent magnet is spaced apart from the intermediate axial permanent magnet unit. The intermediate axial permanent magnet unit, the inner side permanent magnet and the two outer side permanent magnets jointly enclose the first receiving space. The soft magnetic structure includes a first soft magnet embedded in the first receiving space. In a possible implementation manner according to the first aspect, the inner side permanent magnet includes a side axial permanent magnet and two inner side permanent magnets. In the circumferential direction of the rotor, the side axial permanent magnet is connected between the two inner side permanent magnets. The side of the side axial permanent magnet, which is away from the intermediate axial permanent magnet unit, and the two inner side permanent magnets jointly enclose a second receiving space. The soft magnetic structure further includes a second soft magnet embedded in the second receiving space.

[0014] In a possible implementation manner according to the first aspect, the receiving groove is a through groove penetrating the fixed sleeve in the axial direction of the rotor. The number of the side permanent magnet units is two. In the axial direction of the rotor, the two side permanent magnet units are respectively located on the two sides of the intermediate axial permanent magnet unit.

[0015] In a possible implementation manner according to the first aspect, in the axial direction of the rotor, the two side permanent magnet units located on the two sides of the intermediate axial permanent magnet unit are symmetrical about the intermediate axial permanent magnet unit, which is beneficial to improving the stability of the rotor output torque.

[0016] In a possible implementation manner according to the first aspect, the fixed sleeve further includes 2P number of partitions. Each partition is located in the receiving groove and is used to divide the receiving groove into a first receiving sub-groove and a second receiving sub-groove in the axial direction of the rotor. Each composite magnet concentration component includes a first magnetic member and a second magnetic member. The first magnetic member is fixedly received in the first receiving sub-groove, and the second magnetic member is fixedly received in the second receiving sub-groove. The first magnetic member and the second magnetic member both include a permanent magnet structure and a soft magnetic structure embedded with each other. In the axial direction of the rotor, the partition is located between the intermediate axial permanent magnet unit of the first magnetic member and the intermediate axial permanent magnet unit of the second magnetic member. The side permanent magnet unit of the first magnetic member is located on the side, which is away from the partition, of the intermediate axial permanent magnet unit of the first magnetic member. The side permanent magnet unit of the second magnetic member is located on the side, which is away from the partition, of the intermediate axial permanent magnet unit of the second magnetic member. The partition is beneficial to enhancing the overall strength of the fixed sleeve and improving the reliability of the rotor and the disc motor.

[0017] According to the first aspect, in a possible implementation manner, structures of the first magnetic component and the second magnetic component are symmetrical about the partition layer in an axial direction of the rotor, which facilitates improving stability of a rotor output torque.

[0018] According to the first aspect, in a possible implementation manner, the fixing sleeve comprises an inner ring, an outer ring and 2P ribs, the outer ring is sleeved outside the inner ring, 2P ribs are fixedly connected between the inner ring and the outer ring, and the 2P ribs are arranged at intervals in a circumferential direction of the fixing sleeve, and each adjacent two ribs, the inner ring and the outer ring jointly enclose the accommodation groove.

[0019] The fixing sleeve comprises the inner ring, the outer ring and the 2P ribs, so that the structure of the fixing sleeve is simple and the manufacturing of the fixing sleeve is facilitated. According to the first aspect, in a possible implementation manner, each rib comprises a positioning column and a limiting rib protruding from a side of the positioning column facing the accommodation groove, and the limiting rib is used for limiting the composite magnetic component.

[0020] The positioning column is used for positioning when the composite magnetic component is assembled into the corresponding accommodation groove, which improves the assembly convenience of the composite magnetic component assembled on the fixing sleeve, and improves the assembly efficiency and assembly precision of the rotor. The limiting rib is used for limiting the movement of the composite magnetic component in the axial direction of the rotor, which improves the position stability between the composite magnetic component and the fixing sleeve, thereby improving the stability and reliability of the rotor.

[0021] According to the first aspect, in a possible implementation manner, each composite magnetic component is provided with a limiting groove, and the limiting rib is accommodated in the limiting groove. The accommodation groove is a through groove penetrating through the fixing sleeve, so as to facilitate the manufacturing of the fixing sleeve.

[0022] According to the first aspect, in a possible implementation manner, the fixing sleeve is further provided with a cooling channel for flowing a cooling medium.

[0023] Since the fixing sleeve can flow the cooling medium, the heat dissipation performance of the rotor is improved, and thus the reliability of the rotor is improved.

[0024] The second aspect, the embodiments of the present application also provide a disc type motor, comprising two stators, a rotor according to the first aspect, a rotating shaft and a shell, the rotor is located between the two stators in an axial direction of the disc type motor, the rotating shaft is arranged through the two stators and the rotor, the rotating shaft is connected with the rotor to be able to rotate with the rotor, and the shell is sleeved outside the two stators, the rotor and the rotating shaft.

[0025] The rotor's magnetic focusing structure is assembled from 2P composite magnetic focusing components along the circumference of the fixed sleeve, rather than being a single structure formed by winding. In this way, the outer walls of each composite magnetic focusing component can fit well with the inner wall of the receiving groove, improving the connection stability between the magnetic focusing structure and the fixed sleeve (or other rotor structural components, such as the shaft), thereby enhancing the rotor's strength and improving the structural strength and stability of the disc motor.

[0026] Thirdly, embodiments of this application also provide a motor drive system, including the disc motor, controller, and battery described in the second aspect, wherein the controller is electrically connected to the disc motor, and the battery is electrically connected to the disc motor.

[0027] Fourthly, embodiments of this application also provide a vehicle, including the motor drive system and frame described in the third aspect, wherein the motor drive system is mounted on the frame. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of an application scenario for a vehicle provided in an embodiment of this application;

[0029] Figure 2a A perspective view of a disc motor provided for an embodiment of this application;

[0030] Figure 2b for Figure 2a The diagram shown is a three-dimensional exploded view of a disc motor.

[0031] Figure 2c This is a three-dimensional assembly diagram of the rotor and stator of a disc motor.

[0032] Figure 3a A three-dimensional schematic diagram of a partial structure of a distributed winding disc motor provided in an embodiment of this application;

[0033] Figure 3b for Figure 3a The side view of the disc motor shown;

[0034] Figure 4 A three-dimensional assembly diagram of a rotor provided in an embodiment of this application;

[0035] Figure 5a for Figure 4 A three-dimensional schematic diagram of the rotor's retaining sleeve;

[0036] Figure 5b for Figure 5a A magnified schematic diagram of a partial area of ​​the fixing sleeve shown;

[0037] Figure 6 This is a three-dimensional schematic diagram of a magnetic field-concentrating structure provided in an embodiment of this application;

[0038] Figure 7 A perspective view of a composite magnetic assembly according to an embodiment of the present application;

[0039] Figure 8 A perspective view of a permanent magnet structure according to an embodiment of the present application;

[0040] Figure 9 A perspective view of a soft magnetic structure according to an embodiment of the present application;

[0041] Figure 10 A perspective view of a middle axial permanent magnet unit and a side axial permanent magnet according to an embodiment of the present application;

[0042] Figure 11 A perspective view of two composite magnetic assemblies;

[0043] Figure 12 A side view of a composite magnetic assembly;

[0044] Figure 13 A magnetizing direction magnetic circuit diagram of a permanent magnet structure under the same pair of magnetic poles;

[0045] Figure 14a An air gap flux density waveform diagram of a disc motor using a surface-mounted type;

[0046] Figure 14b An air gap flux density waveform diagram of a disc motor according to an embodiment of the present application;

[0047] Figure 15a A magnetizing direction magnetic circuit diagram of a permanent magnet structure under the same pair of magnetic poles according to a possible implementation of the present application;

[0048] Figure 15b A magnetizing direction magnetic circuit diagram of a permanent magnet structure under the same pair of magnetic poles according to a possible implementation of the present application;

[0049] Figure 15c A magnetizing direction magnetic circuit diagram of a permanent magnet structure under the same pair of magnetic poles according to a possible implementation of the present application;

[0050] Figure 15d A magnetizing direction magnetic circuit diagram of a permanent magnet structure under the same pair of magnetic poles according to a possible implementation of the present application;

[0051] Figure 15e A magnetizing direction magnetic circuit diagram of a permanent magnet structure under the same pair of magnetic poles according to a possible implementation of the present application;

[0052] Figure 16 A perspective view of a fixing sleeve according to an embodiment of the present application;

[0053] Figure 17 This is a schematic diagram of the permanent magnet structure of a composite magnetic component provided in an embodiment of this application. Detailed Implementation

[0054] Please see Figure 1 , Figure 1 This is a schematic diagram illustrating an application scenario of a vehicle 1000 provided in an embodiment of this application. The vehicle 1000 can be one of the following: electric vehicle (EV), pure electric vehicle (PEV / BEV), hybrid electric vehicle (HEV), range-extended electric vehicle (REEV), plug-in hybrid electric vehicle (PHEV), or new energy vehicle.

[0055] The vehicle 1000 includes a frame 1001 and a motor drive system 1003. The motor drive system 1003 is mounted on the frame 1001. The frame 1001 serves as the structural skeleton of the vehicle 1000, supporting, fixing, and connecting the various systems, and bearing the loads inside the vehicle 1000 and from the external environment.

[0056] The electric motor drive system 1003 is a system consisting of a series of components used to generate power and transmit that power to the road surface, wherein, see [link to relevant documentation]. Figure 1 As shown, the motor drive system 1003 may include a disc motor 100, a controller 200, and a battery 400. The controller 200 is electrically connected to the disc motor 100 and is used to control the operation of the disc motor 100. The battery 400 is electrically connected to the disc motor 100 and is used to provide electrical energy to the disc motor 100. The motor drive system 1003 may also include a speed reducer 500, which is connected to the disc motor 100 to adjust the speed of the vehicle 1000.

[0057] The vehicle 1000 further comprises wheels 1005 arranged on the vehicle frame 1001. The rotating shaft of the disc motor 100 is connected to the wheels 1005 through transmission components, so that the rotating shaft of the disc motor 100 outputs power, and the transmission components transmit the power to the wheels 1005 to drive the wheels 1005 to rotate. The wheels 1005 comprise front wheels and rear wheels. In the embodiments of the present application, the disc motor 100 included in the motor drive system 1003 can be one or two. When the disc motor 100 is one, the disc motor 100 is connected to two front wheels or two rear wheels through transmission components. When the disc motor 100 is two, one of the disc motors is connected to two front wheels through transmission components, and the other disc motor is connected to two rear wheels through another transmission component.

[0058] Please refer to Figure 2a , Figure 2b and Figure 2c , an embodiment of the present application provides a disc motor 100, comprising a stator 10, a rotor 30, a rotating shaft 50 and a housing 70. The stator 10 and the rotor 30 are arranged along the axial direction of the disc motor 100. The rotating shaft 50 penetrates the stator 10 and the rotor 30. The rotating shaft 50 is connected to the rotor 30 so as to be able to rotate with the rotor 30. The housing 70 is sleeved on the stator 10, the rotor 30 and the rotating shaft 50, and is used for protecting the stator 10 and the rotor 30. The rotating shaft 50 is rotatably arranged in the housing 70 and connected to the wheels through transmission components.

[0059] In some embodiments of the present application, the number of stators 10 is two, and the number of rotors 30 is one, i.e., the disc motor 100 is a double-stator single-rotor structure. Since the disc motor 100 is a double-stator single-rotor structure, compared with a single-stator single-rotor structure, the electromagnetic torque acting on the rotor 30 is increased, thereby improving the overall torque density and power density of the disc motor 100. Along the axial direction of the disc motor 100, the rotor 30 is located between the two stators 10. The stator 10 comprises a stator main body 11 and a winding 13 arranged on the stator main body 11. The winding 13 generates a rotating magnetic field acting on the rotor 30 after being energized, thereby driving the rotor 30 to rotate relative to the stator 10. The winding 13 can be a concentrated winding (also known as a concentrated winding).

[0060] The housing 70 comprises a first housing 71, a second housing 72 and a third housing 73. The first housing 71 is sleeved on the stator 10 and the rotor 30. Along the axial direction of the disc motor 100, the second housing 72 is fixedly connected to the first end of the first housing 71, the third housing 73 is fixedly connected to the second end of the first housing 71, and the second housing 72 and the third housing 73 are arranged opposite to each other.

[0061] The first housing 71, the second housing 72 and the third housing 73 jointly form a receiving space for receiving the stators 10 and the rotor 30. One of the two stators 10 close to the second housing 72 is fixed to the second housing 72, and the other of the two stators 10 close to the third housing 73 is fixed to the third housing 73. Since the rotor 30 of the disc motor 100 is located between the two stators 10, the stators 10 can be directly fixed to the second housing 72 or the third housing 73, which facilitates the assembly and disassembly of the rotor 30.

[0062] In some embodiments of the present application, the stator 10 can be fixed to the second housing 72 or the third housing 73 by clamping. It can be understood that the present application does not limit the fixing mode between the second housing 72 or the third housing 73 and the stator 10.

[0063] Since the first housing 71, the second housing 72 and the third housing 73 are separately arranged, the assembly and maintenance of the disc motor 100 are facilitated. The second housing 72 is provided with a first through hole 722, and one end of the rotating shaft 50 is arranged in the first through hole 722. The third housing 73 is provided with a second through hole 732, and the rotating shaft 50 is arranged in the second through hole 732.

[0064] The disc motor 100 further comprises a connecting piece 62, a first bearing 64, a second bearing 66 and a position detector 68. The connecting piece 62 is arranged on the second housing 72 and located on the side of the second housing 72 facing the third housing 73. The first bearing 64 is mounted on the connecting piece 62, and one end of the rotating shaft 50 is arranged in the first bearing 64, so that the rotating shaft 50 is rotationally connected with the second housing 72. The second bearing 66 is mounted on the third housing 73, and one end of the rotating shaft 50 is arranged in the second bearing 66, so that the rotating shaft 50 is rotationally connected with the third housing 73. The position detector 68 is fixed to the second housing 72, and the rotating shaft 50 is rotationally arranged in the position detector 68. The position detector 68 is used for detecting the position of the rotor 30.

[0065] In other embodiments of the present application, as shown in Figure 3a With Figure 3b It is shown that the stator 10 comprises a stator body 11 and a winding 13 arranged on the stator body 11, and the winding 13 can also be a distributed winding (also known as a distributed winding).

[0066] In some embodiments of the present application, the rotor 30 is a magnetized permanent magnet built-in rotor. Please refer to Figure 4 、 Figure 5a and Figure 6The rotor 30 comprises a fixing sleeve 31 and a magnetic concentration structure 33 fixed on the fixing sleeve 31. The fixing sleeve 31 comprises 2P accommodating grooves 310 arranged along the circumference of the fixing sleeve 31, wherein P is an integer greater than or equal to 1. The magnetic concentration structure 33 comprises 2P composite magnetic concentration components 330. Each composite magnetic concentration component 330 is fixedly accommodated in a corresponding accommodating groove 310. Each composite magnetic concentration component 330 comprises a permanent magnetic structure 332 and a soft magnetic structure 334 embedded with each other. The soft magnetic structure 334 is made of a soft magnetic composite (SMC) material, and the soft magnetic structure 334 can also be made of other magnetic conductive materials. In the embodiments of the present application, the soft magnetic structure 334 is made of an SMC material, and the permanent magnetic structure 332 is made of a magnetic steel material. Adjacent composite magnetic concentration components 330 have different polarities.

[0067] The accommodating groove 310 is substantially a fan-shaped space. In some embodiments of the present application, the accommodating groove 310 is a through groove penetrating the fixing sleeve 31 along the axial direction of the rotor 30, so as to facilitate the manufacturing of the fixing sleeve 31.

[0068] The composite magnetic concentration component 330 is substantially a fan-shaped structure, and the composite magnetic concentration component 330 is adapted to the accommodating groove 310. Each composite magnetic concentration component 330 further comprises an inner wall 3301 and an outer wall 3303 arranged opposite along the radial direction of the rotor 30. In a cross section perpendicular to the axial direction of the rotor 30, the profile of the inner wall 3301 is a circular arc, and the profile of the outer wall 3303 is a circular arc. The 2P composite magnetic concentration components 330 are arranged in a ring-shaped magnetic concentration structure 33 along the circumference of the fixing sleeve 31. The inner walls 3301 of the 2P composite magnetic concentration components 330 are spliced into an inner ring wall of the magnetic concentration structure 33, and the outer walls 3303 of the 2P composite magnetic concentration components 330 are spliced into an outer ring wall of the magnetic concentration structure 33.

[0069] In a conventional technology, when a disc motor is manufactured, a silicon steel sheet is wound to form a whole ring-shaped rotor core, and a magnetic steel is embedded in the rotor core. However, when the silicon steel sheet is wound to form a whole ring-shaped rotor core, the inner ring wall and the outer ring wall of the rotor core are in an Archimedes spiral, instead of a circular arc. Therefore, the inner ring wall and the outer ring wall of the rotor core need to be finished (for example, ground) to ensure the coaxiality of the rotor, so that the rotor core can be matched with other rotor structural members (for example, a rotor fixing sleeve).

[0070] The magnetic aggregation structure 33 is formed by 2P composite magnetic aggregation components 330 along the circumference of the fixing sleeve 31, rather than being formed by winding into an integral structure. In this way, the inner wall 3301 and the outer wall 3303 of each composite magnetic aggregation component 330 can be well connected with the side wall of the accommodation groove 310, improving the connection stability between the magnetic aggregation structure 33 and the fixing sleeve 31 (or other rotor structure, such as the rotating shaft), and further improving the strength of the rotor 30. Since it is not necessary to wind the silicon steel sheet into an integral annular structure, and it is not necessary to finish the inner ring wall and the outer ring wall of the rotor to ensure the coaxiality of the rotor, the preparation difficulty and assembly difficulty of the magnetic aggregation structure 33 are reduced.

[0071] The fixing sleeve 31 is made of high-strength material which is not magnetically conductive and not electrically conductive. The magnetic aggregation structure 33 is fixed on the fixing sleeve 31, and the fixing sleeve 31 can reduce the magnetic leakage of the rotor 30, thereby improving the output torque of the rotor 30.

[0072] The fixing sleeve 31 is generally annular. Please refer to Figure 5a and Figure 5b The fixing sleeve 31 includes an inner ring 312, an outer ring 314, and 2P ribs 316. The inner ring 312 is used to limit the movement of the composite magnetic aggregation component 330 along the radial direction towards the inside of the fixing sleeve 31 (i.e. the direction of the outer ring 314 towards the inner ring 312). The outer ring 314 is sleeved outside the inner ring 312, and the outer ring 314 is used to limit the movement of the composite magnetic aggregation component 330 along the radial direction towards the outside of the fixing sleeve 31 (i.e. the direction of the inner ring 312 towards the outer ring 314). The 2P ribs 316 are fixedly connected between the inner ring 312 and the outer ring 314. The 2P ribs are arranged along the circumference of the fixing sleeve 31 and are spaced apart from each other. Each adjacent two ribs 316, the inner ring 312 and the outer ring 314 together enclose an accommodation groove 310. In other words, the fixing sleeve 31 includes 2P accommodation grooves 310 arranged along the circumference of the fixing sleeve 31.

[0073] The rib 316 extends along the radial direction of the fixing sleeve 31. In the present application, the so-called radial direction refers to the diameter direction. Each rib 316 includes a positioning column 3162 and a limiting rib 3164 protruding from the side of the positioning column 3162 towards the accommodation groove 310. The positioning column 3162 is used to position the composite magnetic aggregation component 330 when the composite magnetic aggregation component 330 is assembled in the corresponding accommodation groove 310, improving the assembly convenience of the composite magnetic aggregation component 330 on the fixing sleeve 31, and also improving the assembly efficiency and assembly precision of the rotor 30. The limiting rib 3164 is used to limit the movement of the composite magnetic aggregation component 330 along the axial direction of the rotor 30, so as to improve the positional stability between the composite magnetic aggregation component 330 and the fixing sleeve 31, thereby improving the stability and reliability of the rotor 30.

[0074] The fixed sleeve 31 is also provided with cooling channels 318 for circulating cooling medium (e.g., cooling oil). In some embodiments of this application, the number of cooling channels 318 is 2P, with one opening of the cooling channel 318 located on the side of the outer ring 314 away from the inner ring 312, and another opening of the cooling channel 318 located on the side of the inner ring 312 away from the outer ring 314. The cooling channels 318 extend along the positioning post 3162 to transport the cooling medium from the outer ring 314 to the inner ring 312. In other embodiments of this application, the number of cooling channels 318 is not limited, and the cooling channels 318 are provided with multiple interconnected sub-channels, each of which can be provided on the inner ring 312, the outer ring 314, and the ribs 316. Because the fixed sleeve 31 can circulate cooling medium, the heat dissipation performance of the rotor 30 is improved, thereby improving the reliability of the rotor 30.

[0075] Each composite magnetic concentrator 330 is fixedly housed within a corresponding receiving slot 310. (See also...) Figure 7 , Figure 8 and Figure 9 For easy distinction, Figure 7 The permanent magnet structure 332 in the image is a gray area. The permanent magnet structure 332 includes a central axial permanent magnet unit 3322 and two side permanent magnet units 3324. Along the axial direction of the rotor 30, the central axial permanent magnet unit 3322 is located between the two side permanent magnet units 3324. In some embodiments of this application, the two side permanent magnet units 3324 located on either side of the central axial permanent magnet unit 3322 are symmetrical about the central axial permanent magnet unit 3322, which is beneficial for improving the stability of the rotor 30's output torque. In other embodiments of this application, the two side permanent magnet units 3324 located on either side of the central axial permanent magnet unit 3322 may not be symmetrical about the central axial permanent magnet unit 3322. The central axial permanent magnet unit 3322 and each side permanent magnet unit 3324 together form a receiving space 300 for embedding the soft magnetic structure 334.

[0076] Each side permanent magnet unit 3324 includes an inner permanent magnet 3326 and two outer permanent magnets 3328. The housing space 300 includes a first housing space 301 and a second housing space 303.

[0077] In the axial direction of the rotor 30, the inner side permanent magnet 3326 is arranged between the intermediate axial permanent magnet unit 3322. The outer side permanent magnet 3328 is arranged perpendicularly to the intermediate axial permanent magnet unit 3322. In the axial direction of the rotor 30, the intermediate axial permanent magnet unit 3322 is located between the inner side permanent magnets 3326 of the two side permanent magnet units 3324. In the circumferential direction of the rotor 30, the intermediate axial permanent magnet unit 3322 and the inner side permanent magnet 3326 are both located between the two outer side permanent magnets 3328, and the intermediate axial permanent magnet unit 3322, the inner side permanent magnet 3326, and the two outer side permanent magnets 3328 together enclose a first receiving space 301. The first receiving space 301 is used to fill the soft magnetic structure 334. In other embodiments of the present application, the outer side permanent magnet 3328 can not be perpendicular to the intermediate axial permanent magnet unit 3322.

[0078] Each inner side permanent magnet 3326 includes a side axial permanent magnet 3329 and two inner side permanent magnets 3330. In each inner side permanent magnet 3326, in the circumferential direction of the rotor 30, the side axial permanent magnet 3329 is fixedly connected between the two inner side permanent magnets 3330. In other words, in the circumferential direction of the rotor 30, a first end of the side axial permanent magnet 3329 is fixedly connected to one inner side permanent magnet 3330, and a second end of the side axial permanent magnet 3329 is fixedly connected to the other inner side permanent magnet 3330. The side axial permanent magnet 3329 is arranged perpendicularly to the inner side permanent magnet 3330. In some other embodiments of the present application, the side axial permanent magnet 3329 can not be arranged perpendicularly to the inner side permanent magnet 3330.

[0079] The side of the side axial permanent magnet 3329 facing away from the intermediate axial permanent magnet unit 3322 and the two inner side permanent magnets 3330 together enclose a second receiving space 303. The second receiving space 303 is used to embed the soft magnetic structure 334. In some embodiments of the present application, the inner side permanent magnet 3330 is perpendicular to the side axial permanent magnet 3329. In some other embodiments of the present application, the inner side permanent magnet 3330 can not be perpendicular to the side axial permanent magnet 3329.

[0080] In each composite magnetic assembly 330, in the circumferential direction of the rotor 30, the two side permanent magnet units 3324 are located at the same end of the intermediate axial permanent magnet unit 3322, and the outer side permanent magnet 3328 and the intermediate axial permanent magnet unit 3322 together enclose a limiting groove 305, and the limiting rib 3164 is received in the limiting groove 305, so that the composite magnetic assembly 330 cannot move in the axial direction of the rotor 30, thereby improving the stability of the composite magnetic assembly 330 on the fixing sleeve 31.

[0081] The soft magnetic structure 334 includes two first soft magnets 3344 and two second soft magnets 3346. Each first soft magnet 3344 is embedded in a corresponding first receiving space 301, and each second soft magnet 3346 is embedded in the second receiving space 303.

[0082] The intermediate axial permanent magnet unit 3322, the outer permanent magnet 3328, the side axial permanent magnet 3329, the two inner permanent magnets 3330, the two first soft magnets 3344, and the two second soft magnets 3346 can be directly compression molded, and then the intermediate axial permanent magnet unit 3322, the outer permanent magnet 3328, the side axial permanent magnet 3329, and the two inner permanent magnets 3330 are combined to form the composite magnetic assembly 330, so as to facilitate the preparation and assembly of the composite magnetic assembly 330 and the rotor 30.

[0083] As shown in Figure 10 , the arc of the intermediate axial permanent magnet unit 3322 is a1°, and the arc of the side axial permanent magnet 3329 is a2°. As shown in Figure 11 , the arc of the outer permanent magnet 3328 is b1°, and the arc of the inner permanent magnet 3330 is b2°. In each adjacent two composite magnetic assemblies 330, along the circumferential direction of the rotor 30, the arc of the two inner permanent magnets 3330 of the two adjacent composite magnetic assemblies 330 is c1°, and the arc between the outer permanent magnet 3328 on the first side of the first composite magnetic assembly 330 and the outer permanent magnet 3328 on the second side of the second composite magnetic assembly 330 is c2°.

[0084] Please refer to Figure 12 , the thickness of the side axial permanent magnet 3329 along the axial direction of the rotor 30 is L1, and the thickness of the intermediate axial permanent magnet unit 3322 along the axial direction of the rotor 30 is L2. The thickness of the inner permanent magnet 3330 along the axial direction of the rotor 30 is d1, and the thickness of the outer permanent magnet 3328 along the axial direction of the rotor 30 is d2. The thickness of the second soft magnet 3346 located in the second receiving space 303 along the axial direction of the rotor 30 is e1. The thickness of the part of the first soft magnet 3344 located between the side axial permanent magnet 3329 and the intermediate axial permanent magnet unit 3322 along the axial direction of the rotor 30 is e2. The parameters a1°, a2°, b1°, b2°, c1°, c2°, L1, L2, e1, and e2 can be set as needed. Due to the many optimized parameters, the optimization space of the rotor 30 is large, and the design is more flexible. After determining the value range of each parameter, the permanent magnet consumption, torque output, and direct and quadrature axis inductance of the motor obtained under the cooperation of various parameters can be obtained.

[0085] Each two adjacent composite magnetic components 330 form a pair of magnetic poles, i.e., a complete magnetic circuit loop N-S, wherein one composite magnetic component 330 is N pole and the other composite magnetic component 330 is S pole, and the magnetization directions of the same pole are the same. Please refer to Figure 13 , Figure 13 for the magnetic circuit diagram of the magnetization directions of the permanent magnet structures under the same pair of magnetic poles.

[0086] Since the rotor 30 adopts the magnetic concentration structure, the side part of the middle axial permanent magnet unit 3322 is further provided with a side permanent magnet unit 3324, so that the air gap magnetic flux waveform of the disc motor 100 is close to a sine wave, the output torque can be increased, the torque fluctuation can be reduced, and compared with the peak value of the air gap magnetic flux of the surface-mounted disc motor of the same specification, which is about 0.69T (as shown in Figure 14a ), the peak value of the air gap magnetic flux of the disc motor 100 provided by the embodiment of the present application can reach 1.15T (as shown in Figure 14b ).

[0087] The number of axial permanent magnets (including the middle axial permanent magnet unit 3322 and the side axial permanent magnet 3329) is N (N is an odd number), and the magnetization directions of the same pole are the same. Along the axial direction of the rotor 30, the axial permanent magnets are symmetrically distributed along the limiting ribs 3164 of the fixed sleeve 31, and the soft magnetic composite material is arranged between the axial permanent magnets, and the arc of the middle axial permanent magnet unit 3322 is larger, i.e., a (N-1) / a1>1.

[0088] The number of soft magnets (including the first soft magnet 3344 and the second soft magnet 3346) is N±1 (N is the number of axial permanent magnets), and the soft magnets are embedded between the axial permanent magnets.

[0089] In other embodiments of the present application, as shown in Figure 15a , the inner permanent magnet 3330 can be omitted, the middle axial permanent magnet unit 3322 is arranged perpendicularly to the outer permanent magnet 3328, and the side axial permanent magnet 3329 is substantially parallel to the middle axial permanent magnet unit 3322.

[0090] In other embodiments of the present application, as shown in Figure 15b , the outer permanent magnet 3328 is not arranged perpendicularly to the middle axial permanent magnet unit 3322, along the circumferential direction of the rotor, the two outer permanent magnets 3328 located at the same end of one middle axial permanent magnet unit 3322 are fixedly connected, and the limiting groove can be omitted. The inner permanent magnet 3330 and the side axial permanent magnet 3329 are inclined to intersect, and the inner permanent magnet 3330 and the side axial permanent magnet 3329 form an obtuse angle.

[0091] In other embodiments of the present application, as shown in Figure 15cAs shown, the outer side permanent magnet 3328 can be omitted, the side axial permanent magnet 3329 is arranged substantially perpendicular to the inner side permanent magnet 3330, and the side axial permanent magnet 3329 is arranged substantially parallel to the middle axial permanent magnet unit 3322.

[0092] In other embodiments of the present application, as shown in Figure 15d The side permanent magnet unit 3324 can be omitted, and the outer side permanent magnet 3328 is arranged substantially perpendicular to the middle axial permanent magnet unit 3322.

[0093] In other embodiments of the present application, as shown in Figure 15e The outer side permanent magnet 3328 and the inner side permanent magnet 3330 can be omitted, and the middle axial permanent magnet unit 3322 is located between the two side axial permanent magnets 3329 along the axial direction of the rotor.

[0094] In other embodiments of the present application, as shown in Figure 16 The receiving groove 310 is not a through groove penetrating the fixing sleeve 31 along the axial direction of the rotor, and the fixing sleeve 31 further comprises 2P partition layers 319, each partition layer 319 is fixedly connected to two adjacent rib strips 316, and each partition layer 319 is received in a corresponding receiving groove 310 to separate the receiving groove 310 into a first receiving sub-groove 3110 and a second receiving sub-groove (not shown in the figure) along the axial direction of the rotor. It should be understood that the first receiving sub-groove 3110 and the second receiving sub-groove are respectively formed on the two sides of the partition layer 319 along the axial direction of the rotor.

[0095] Please refer to Figure 17Each composite magnetic component 330 includes a first magnetic member 3305 fixedly received in the first receiving sub-slot 3110 and a second magnetic member 3306 fixedly received in the second receiving sub-slot. Both the first magnetic member and the second magnetic member include mutually embedded permanent magnetic structures and soft magnetic structures. The permanent magnetic structures include a middle axial permanent magnetic unit 3322 and a side permanent magnetic unit 3324. In the axial direction of the rotor, the middle axial permanent magnetic unit 3322 and the side permanent magnetic unit 3324 are arranged. The partition layer 319 is located between the middle axial permanent magnetic unit 3322 of the first magnetic member 3305 and the middle axial permanent magnetic unit 3322 of the second magnetic member 3306. In the axial direction of the rotor, the side permanent magnetic unit 3324 of the first magnetic member 3305 is located on the side of the middle axial permanent magnetic unit 3322 of the first magnetic member 3305 away from the partition layer 319, and the side permanent magnetic unit 3324 of the second magnetic member 3306 is located on the side of the middle axial permanent magnetic unit 3322 of the second magnetic member 3306 away from the partition layer 319. In the axial direction of the rotor 30, the structure of the first magnetic member 3305 and the structure of the second magnetic member 3306 are symmetrical about the partition layer 319, which is beneficial to improve the stability of the rotor output torque. In other embodiments of the application, the structure of the first magnetic member 3305 and the structure of the second magnetic member 3306 can not be symmetrical about the partition layer 319. The middle axial permanent magnetic unit 3322 and the side permanent magnetic unit 3324 jointly form a first receiving space 301 for embedding part of the soft magnetic structure.

[0096] The side permanent magnetic unit 3324 further includes an inner side permanent magnetic piece 3326 and two outer side permanent magnetic pieces 3328. The side axial permanent magnetic body 3329 and the two inner side permanent magnetic bodies 3330 jointly enclose a second receiving space 303 on the side away from the middle axial permanent magnetic unit 3322, for embedding part of the soft magnetic structure.

[0097] The foregoing embodiments are equivalent to being divided into two layers in the axial direction of the fixed sleeve 31, each layer having 2P receiving sub-slots, and the magnetic members formed by the permanent magnetic structures and the soft magnetic structures can be fixed in the receiving sub-slots by bonding, and then the whole is filled. The fixed sleeve 31 further includes 2P partition layers 319, which can strengthen the overall strength of the fixed sleeve 31 and improve the reliability of the rotor and the disc motor.

[0098] It can be understood that the application does not limit the structure of the permanent magnetic structure and the soft magnetic structure, and the permanent magnetic structure and the soft magnetic structure can be mutually embedded.

[0099] In the present application, through the arrangement of the magnetic type permanent magnet, cooperating with the special rotor core structure, the built-in structure of the permanent magnet is realized. Compared with the surface-mounted permanent magnet rotor, the saliency effect of the motor is obvious, and the advantage of generating large reluctance torque is obtained, and the output torque of the rotor is improved. Each pair of magnetic poles is composed of multiple soft magnetic materials and permanent magnetic materials, and the process is simple; the method of combining permanent magnets with different shapes and magnetizing methods is adopted to form a composite magnetic structure, and a large saliency ratio is set, the magnetic circuit forms a complete magnetic loop through the soft magnetic material, the permanent magnet and the stator, the main magnetic flux is increased, the leakage magnetic flux is reduced, the purpose of magnetic aggregation is achieved, and the air gap magnetic flux density is improved; and the permanent magnet realizes the built-in structure, the motor has obvious saliency effect, good flux weakening performance and large reluctance torque.

[0100] It should be understood that expressions such as "include" and "may include" used in the present application indicate the presence of the disclosed functions, operations or constituent elements, and do not limit one or more additional functions, operations and constituent elements. In the present application, terms such as "include" and / or "have" can be interpreted to mean that a specific characteristic, number, operation, constituent element, component or combination thereof is present, but cannot be interpreted to exclude the presence or addition of one or more other characteristics, numbers, operations, constituent elements, components or combinations thereof.

[0101] In addition, in the present application, the expression "and / or" includes any and all combinations of the associated listed terms. For example, the expression "A and / or B" can include A, can include B, or can include both A and B.

[0102] In the present application, expressions including ordinal numbers such as "first" and "second" can modify elements. However, such elements are not limited by the above expressions. For example, the above expressions do not limit the order and / or importance of the elements. The above expressions are used to distinguish one element from other elements. For example, the first user device and the second user device indicate different user devices, although the first user device and the second user device are both user devices. Similarly, the first element can be referred to as the second element, and similarly, the second element can be referred to as the first element, without departing from the scope of the present application.

[0103] When a component is referred to as being "connected" or "accessed" to other components, it should be understood that the component is not only directly connected or accessed to the other components, but another component can also exist between the component and the other components. On the other hand, when a component is referred to as being "directly connected" or "directly accessed" to other components, it should be understood that there is no component between them.

[0104] The above merely provides the specific implementation of the present application, but the protection scope of the present application is not limited to this. Any person skilled in the art can easily think of the changes or replacements within the technical range disclosed by the present application, which should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A rotor for use in a disc-type electric machine, characterized by The application relates to a rotor of a rotating electric machine, comprising: a fixing sleeve, which comprises 2P accommodating grooves arranged along the circumference of the fixing sleeve, wherein P is an integer greater than or equal to 1; and a magnetic structure, which comprises 2P composite magnetic components, each of which is fixedly accommodated in a corresponding accommodating groove, wherein each composite magnetic component comprises a soft magnetic structure and a permanent magnetic structure which are embedded in each other, the permanent magnetic structure comprises a middle axial permanent magnetic unit and side permanent magnetic units which are distributed on one side or both sides of the middle axial permanent magnetic unit along the axial direction of the rotor, the side permanent magnetic unit comprises an inner side permanent magnetic piece and two outer side permanent magnetic pieces, along the circumferential direction of the rotor, the middle axial permanent magnetic unit and the inner side permanent magnetic piece are located between the two outer side permanent magnetic pieces, along the axial direction of the rotor, the inner side permanent magnetic piece and the middle axial permanent magnetic unit are arranged in a spaced mode, and the middle axial permanent magnetic unit, the inner side permanent magnetic piece and the two outer side permanent magnetic pieces jointly form a first accommodating space, and the soft magnetic structure comprises a first soft magnetic body which is embedded in the first accommodating space.

2. The rotor of claim 1, wherein The inner side permanent magnetic piece comprises a side axial permanent magnetic body and two inner side permanent magnetic bodies, along the circumferential direction of the rotor, the side axial permanent magnetic body is connected between the two inner side permanent magnetic bodies, and the side of the side axial permanent magnetic body which is away from the middle axial permanent magnetic unit and the two inner side permanent magnetic bodies jointly form a second accommodating space, the soft magnetic structure further comprises a second soft magnetic body which is embedded in the second accommodating space.

3. The rotor of any one of claims 1 to 2, wherein The accommodating grooves are through grooves which penetrate through the fixing sleeve along the axial direction of the rotor, the number of the side permanent magnetic units is two, and along the axial direction of the rotor, the two side permanent magnetic units are respectively located on the two sides of the middle axial permanent magnetic unit.

4. The rotor of claim 3, wherein Along the axial direction of the rotor, the two side permanent magnetic units located on the two sides of the middle axial permanent magnetic unit are symmetrical about the middle axial permanent magnetic unit.

5. The rotor of any one of claims 1 to 2, wherein The fixing sleeve further comprises 2P separating layers, each of which is located in the accommodating groove and is used for separating the accommodating groove into a first accommodating sub-groove and a second accommodating sub-groove along the axial direction of the rotor, each composite magnetic component comprises a first magnetic member and a second magnetic member, the first magnetic member is fixedly accommodated in the first accommodating sub-groove, the second magnetic member is fixedly accommodated in the second accommodating sub-groove, and the first magnetic member and the second magnetic member both comprise a soft magnetic structure and a permanent magnetic structure which are embedded in each other; along the axial direction of the rotor, the separating layer is located between the middle axial permanent magnetic unit of the first magnetic member and the middle axial permanent magnetic unit of the second magnetic member, the side permanent magnetic unit of the first magnetic member is located on the side of the middle axial permanent magnetic unit of the first magnetic member which is away from the separating layer, and the side permanent magnetic unit of the second magnetic member is located on the side of the middle axial permanent magnetic unit of the second magnetic member which is away from the separating layer.

6. The rotor of claim 5, wherein Along the axial direction of the rotor, the structure of the first magnetic member and the structure of the second magnetic member are symmetrical about the separating layer.

7. The rotor of any one of claims 1-2, wherein The fixing sleeve comprises an inner ring, an outer ring and 2P ribs, the outer ring is sleeved outside the inner ring, 2P ribs are fixedly connected between the inner ring and the outer ring, 2P ribs are arranged at intervals along the circumference of the fixing sleeve, and each adjacent two ribs, the inner ring and the outer ring jointly form the accommodation groove.

8. The rotor of claim 7, wherein Each rib comprises a positioning column and a limiting rib protruding from the side of the positioning column towards the accommodation groove, and the limiting rib is used for limiting the composite magnetic component.

9. The rotor of claim 8, wherein Each composite magnetic component is provided with a limiting groove, and the limiting rib is accommodated in the limiting groove.

10. The rotor of any one of claims 1-2, wherein The fixing sleeve is further provided with a cooling channel for circulating cooling medium.

11. A disc-type motor characterized by comprising: The disc motor comprises two stators, a rotor according to any one of claims 1-10, a rotating shaft and a shell, the rotor is located between the two stators in the axial direction of the disc motor, the rotating shaft is arranged through the two stators and the rotor, the rotating shaft is connected with the rotor to rotate together with the rotor, and the shell is sleeved outside the two stators, the rotor and the rotating shaft.

12. An electric motor drive system characterized by, The disc motor according to claim 11, a controller and a battery, the controller is electrically connected with the disc motor, and the battery is electrically connected with the disc motor.

13. A vehicle characterized by comprising: The motor driving system according to claim 12 and a vehicle frame, the motor driving system is installed on the vehicle frame.

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