Rotor disc of an axial field electric machine, method of manufacture and rotor assembly
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ZHEJIANG PANGOOD POWER TECH CO LTD
- Filing Date
- 2023-04-12
- Publication Date
- 2026-07-24
Smart Images
Figure CN116345754B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of axial magnetic field motors, and more particularly to a rotor disk, manufacturing method, and rotor assembly of an axial magnetic field motor. Background Technology
[0002] Axial field motors, also known as disc motors, have advantages such as small axial dimensions, high torque density, high power density, and high efficiency, and are widely used in electric vehicles, general industrial applications, and household appliances. When an axial field motor is running, the rotor is rotating and simultaneously subjected to gravity, bearing support force, centrifugal force, torque, and eccentric magnetic pull. Maintaining stable and vibration-free rotation requires close and consistent fit among all rotor components.
[0003] refer to Figures 1 to 9 Existing rotors generally include several magnets 1, a retainer 2, and a fixing ring 3. The magnets 1 are integral structures and are magnetized, with their magnetic poles distributed axially. Grooves a are respectively formed on both sides of the magnets 1 circumferentially. The support rod 22 of the retainer 2 has bosses b corresponding to the grooves a. The grooves a and bosses b cooperate to axially fix the magnets 1. The existing rotor manufacturing method is as follows: First, using the groove a and the boss b, a magnet 1 is inserted between each pair of adjacent support rods 22 to ensure the axial direction of the magnet 1 is fixed. Several magnets 1 have their magnetic poles spaced apart. (See [reference]). Figure 5 .
[0004] Next, the fixing ring 3 is fitted onto the outer periphery of the retainer 2 so that the magnet 1 is radially limited between the fixing ring 3 and the disc 21 of the retainer 2, thus obtaining the rotor disc. (Refer to...) Figure 3 .
[0005] Finally, the rotor disk is assembled onto the rotor shaft 6 and secured using bolts 4 and washers 5 to obtain the rotor assembly. (Refer to...) Figure 1 and Figure 2 .
[0006] Although the groove a and the boss b can be used to fix the magnet 1 axially, and the magnet 1 can be circumferentially confined between two adjacent support rods 22, and the magnet 1 can be radially confined between the disk 21 and the fixing ring 3, it has the following drawbacks: 1. Due to factors such as size limitations, strength requirements, and product cost, the retainer 2 is manufactured by prepreg lamination molding followed by machining, and the fixing ring 3 is manufactured by prepreg winding molding followed by machining. It is evident that both the retainer 2 and the fixing ring 3 are made of prepreg, resulting in high material costs. In particular, the retainer 2, due to its unique shape, includes the disc 21 and the support rod 22, with protrusions b arranged on both circumferential sides of the support rod 22, leading to low material utilization and further increasing component costs.
[0007] 2. Both the retainer 2 and the fixing ring 3 require compression molding followed by machining. Stacking or winding materials before placing them in the mold consumes a significant amount of time, directly leading to low production efficiency. The dimensional accuracy of compression-molded parts is not high, necessitating machining to adjust dimensions, further reducing production efficiency and increasing production costs.
[0008] 3. To ensure a tight fit between the magnet 1, the retainer 2, and the fixing ring 3, all assembly contact surfaces must be coated with glue before assembly, resulting in low production efficiency, inability to automate, and high manual assembly costs.
[0009] 4. The magnetic pole orientation of the magnet 1 is required during assembly, so the orientation of the magnetic pole needs to be distinguished during assembly, which reduces production efficiency.
[0010] 5. Because the magnet 1 is magnetic, multiple magnets 1 will attract each other. Improper operation during assembly may cause the magnets 1 to become difficult to separate or even pinch and injure the operator.
[0011] 6. The existing technical route involves many assembly processes. In order to ensure assembly accuracy, the assembly dimensions of each component are required to be high, resulting in a low part qualification rate and high production management difficulty. Summary of the Invention
[0012] To address the aforementioned problems, this invention provides a rotor disk, manufacturing method, and assembly for an axial magnetic field motor that improves production efficiency and reduces manufacturing difficulty.
[0013] According to one object of the present invention, the present invention provides a rotor disk for an axial magnetic field motor, comprising: The stacking unit includes two semi-finished products with different magnetization directions. Each semi-finished product includes several pre-magnetized magnets arranged at circumferential intervals. The N and S poles of the pre-magnetized magnets in each semi-finished product are oriented in the same direction. Several semi-finished products are stacked together by staggering the pre-magnetized magnets to obtain the stacking unit. The N and S poles of two adjacent pre-magnetized magnets in the stacking unit are oriented in opposite directions. A composite body that combines two of the semi-finished products.
[0014] In a preferred embodiment, the semi-finished product further includes a prefabricated bracket connected between the pre-charged magnets. The prefabricated bracket has several slots located between two adjacent pre-charged magnets to accommodate the pre-charged magnet of another semi-finished product.
[0015] In a preferred embodiment, the pre-magnetized magnet has filling grooves on both sides of its circumference, and the prefabricated bracket is filled in the filling grooves.
[0016] In a preferred embodiment, positioning holes are provided on both sides of the pre-magnetized magnet in the circumferential direction. The positioning holes penetrate the pre-magnetized magnet in the axial direction and are used for positioning.
[0017] In a preferred embodiment, the prefabricated bracket is offset from the axial center of the pre-magnetized magnet, and when the two semi-finished products are stacked facing each other, each of the pre-magnetized magnets remains on the same horizontal plane.
[0018] In a preferred embodiment, the assembly includes an axial joint and an outer ring joint. The axial joint is connected to both sides of the stacked unit. The axial joint at least partially covers the surfaces of the pre-magnetized magnet and the prefabricated bracket. The outer ring joint is connected to the outer periphery of the stacked unit. The outer ring joint is annular and wraps around the radial outer side of the pre-magnetized magnet. The axial joint and the outer ring joint are integrally formed.
[0019] According to another objective of the present invention, the present invention also provides a method for manufacturing an axial magnetic field motor rotor disk, comprising the following steps: a. Provide two semi-finished products with opposite magnetization directions. The semi-finished products include a number of pre-magnetized magnets arranged at circumferential intervals. The N and S poles of the pre-magnetized magnets in each semi-finished product are oriented in the same direction. b. Two semi-finished products with different magnetization directions are stacked together in a staggered manner using the pre-magnetized magnets to obtain a stacked unit. The N and S poles of two adjacent pre-magnetized magnets in the stacked unit are oriented in opposite directions. c. Form a composite body combining the stacked units and obtain a rotor disk.
[0020] In a preferred embodiment, the semi-finished product further includes a prefabricated support frame connected between the pre-magnetized magnets, thus step a includes: a1. A prefabricated support is formed between the unmagnetized magnets that make up the semi-finished product for bonding; a2. Magnetize the combined structure of the prefabricated bracket and the unmagnetized magnet as a whole to obtain a semi-finished product with the premagnetized magnet 111 having the same magnetization direction.
[0021] In a preferred embodiment, the prefabricated support has a plurality of slots, the slots being located between two adjacent pre-magnetized magnets, and thus step b includes: The two semi-finished products are stacked facing each other by having the pre-charged magnet of one semi-finished product correspond to the slot of the other semi-finished product.
[0022] In a preferred embodiment, the outer surface of the assembly is provided with a slot corresponding to the positioning hole, and the process further includes the following after step c: A filler is provided inside the slot.
[0023] According to another objective of the present invention, the present invention also provides an axial magnetic field motor rotor assembly, including the rotor disk of the above embodiment. The axial magnetic field motor rotor assembly further includes a rotor shaft, bolts and a washer, the rotor disk being sleeved on the rotor shaft and fixed by the bolts and the washer.
[0024] Compared with existing technologies, this technical solution has the following advantages: Both the semi-finished product and the assembly can be injection molded, which reduces assembly steps, simplifies the process route, and improves production efficiency.
[0025] Using injection molds to produce rotor discs results in better consistency of components and improves the product qualification rate.
[0026] The semi-finished product is magnetized as a whole to obtain a semi-finished product with the magnetization direction of the pre-magnetized magnets being consistent, which reduces the difficulty of the magnetization process.
[0027] The rotor disk is first formed as a whole and then magnetized as a whole, which eliminates the steps of distinguishing the magnetic pole orientation and inserting each magnet into the outer periphery of the cage one by one. This not only improves assembly efficiency, but also prevents the magnets from attracting each other, thus avoiding the phenomenon of being difficult to separate or even pinching and injuring the operator.
[0028] The semi-finished product and the composite are made of common engineering plastic materials, which not only meet the strength requirements but also significantly reduce material costs.
[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description
[0030] Figure 1 This is a schematic diagram of the existing rotor structure; Figure 2 An exploded view of the existing rotor; Figure 3 This is a schematic diagram of the existing rotor disk structure; Figure 4 for Figure 3 Sectional view along the AA direction; Figure 5 This is a schematic diagram of the existing cage and magnets after assembly; Figure 6 This is a schematic diagram of the assembly process of an existing cage and magnets; Figure 7 A 3D diagram of an existing magnet; Figure 8 This is the front view of the existing magnet; Figure 9 A side view of an existing magnet; Figure 10 This is a schematic diagram of the rotor disk described in this invention; Figure 11 This is a schematic diagram of the structure of the overlapping unit described in this invention; Figure 12 This is a front view of the semi-finished product described in this invention; Figure 13 This is a back view of the semi-finished product described in this invention; Figure 14 This is a schematic diagram of the structure of the pre-magnetized magnet described in this invention; Figure 15 This is a schematic diagram of the rotor assembly described in this invention; Figure 16 This is an exploded view of the rotor assembly described in this invention.
[0031] In the diagram: 1 Magnet, 2 Cage, 21 Disc, 22 Support rod, 3 Fixing ring, 4 Bolt, 5 Pad, 51 Pad through hole, 6 Rotor shaft, 61 Stepped plate, 62 Shaft body, 63 Threaded hole, 100 Stacked unit, 110 Semi-finished product, 111 Pre-charged magnet, 111a Filling groove, 111b Positioning hole, 112 Prefabricated bracket, 112a Ring body, 112b Circumferential limit body, 112b1 Rod body, 112c Through hole, 113 Slot, 200 Connecting body, 201 Slot hole, 210 Axial connection, 220 Outer ring connection, 1000 Rotor disc, 1001 Mounting hole, 1002 Center hole. Detailed Implementation
[0032] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.
[0033] First Embodiment like Figures 10 to 13 As shown, the method for manufacturing the rotor disk of the axial magnetic field motor includes the following steps: a. Provide two semi-finished products 110 with opposite magnetization directions. Each semi-finished product 110 includes a plurality of pre-magnetized magnets 111 arranged at circumferential intervals. The N and S poles of the pre-magnetized magnets 111 in each semi-finished product 110 are oriented in the same direction. b. Two semi-finished products 110 with different magnetization directions are stacked together in a staggered manner through the pre-magnetized magnets 111 to obtain a stacked unit 100, wherein the N and S poles of two adjacent pre-magnetized magnets 111 in the stacked unit 100 are oriented in opposite directions. c. Form a composite body 200 that incorporates the composite unit 100, and obtain a rotor disk.
[0034] By staggering and stacking the pre-magnetized magnets 111 of two semi-finished products 110 with opposite magnetization directions, a stacked unit 100 is obtained in which the magnetic poles of the pre-magnetized magnets 111 are arranged at intervals. The magnetization direction of the pre-magnetized magnets 111 of each semi-finished product 110 is consistent, that is, the semi-finished product 110 is magnetized as a whole, which reduces the difficulty of the magnetization process. Compared with the existing rotor forming process, the step of distinguishing the magnetic pole orientation and inserting each magnet into the outer periphery of the cage is omitted, which not only improves the assembly efficiency, but also prevents the magnets from attracting each other, thus preventing the phenomenon of difficulty in separation or even pinching and injuring the operator. Finally, the composite 200 is injection molded onto the stacking unit 100 to obtain the rotor disk. The semi-finished product 110 and the composite 200 can both be injection molded, prepreg molded, or molded from short fiber resin material. That is, the rotor disk is produced using injection molds, which ensures that the components of the rotor disk have good consistency, improves the product qualification rate, reduces assembly steps, avoids increasing material costs due to the use of prepreg molding process, and improves production efficiency.
[0035] like Figures 11 to 13 As shown, the semi-finished product 110 also includes a prefabricated support 112, which is connected between the pre-magnetized magnets 111. Therefore, step a includes: a1. A prefabricated bracket 112 is formed between the unmagnetized magnets that make up the semi-finished product 110 for bonding; a2. Magnetize the combined structure of the prefabricated support 112 and the unmagnetized magnet to obtain a semi-finished product 110 with the magnetization direction of the pre-magnetized magnet 111 in the same direction.
[0036] The prefabricated support 112 can be made of plastic injection molding, prepreg molding, or short-fiber resin molding. Among these methods, injection molding reduces material costs and avoids the problem of low material utilization compared to the existing method of making retainers using prepreg. It also eliminates the steps of molding and machining, thereby improving production efficiency.
[0037] Taking injection molding as an example, in step a1, multiple unmagnetized magnets are placed and positioned in the first injection mold according to predetermined positions. After the first injection mold closes, the plastic material enters the first injection mold under certain temperature and pressure and fills the spaces between the unmagnetized magnets. After the plastic material cools, the first injection mold is opened to obtain the integrated structure combining the unmagnetized magnets and the prefabricated support 112. (Refer to...) Figure 12 and Figure 13 .
[0038] refer to Figure 14 As the unmagnetized magnet forming the pre-magnetized magnet 111, a positioning hole 111b is provided on each of its two circumferential sides. The positioning hole 111b penetrates the magnet axially and is located in the middle of the magnet. The first injection mold may be provided with a first positioning structure adapted to the positioning hole 111b, such as a positioning post. This ensures that the magnet can be stably positioned in the first injection mold, thereby ensuring product consistency. The cross-section of the positioning hole 111b may be semi-circular, but is not limited to this.
[0039] Continue to refer to Figure 14 The magnet is provided with filling grooves 111a on both sides of its circumference. In step a1, the injection molding material is filled into the filling grooves 111a to strengthen the bonding between the magnet and the prefabricated bracket 112 and prevent the magnet from loosening or even falling off after long-term use.
[0040] Specifically, the cross-section of the filling groove 111a can be semi-circular and penetrate the magnet radially. Similarly, the cross-sectional shape of the filling groove 111a can also be square or triangular, etc., and of course, there can be multiple filling grooves 111a.
[0041] In step a2, the overall structure obtained in step a1 is magnetized so that the magnet has an axially distributed magnetic field, that is, the magnet forms the pre-magnetized magnet 111, and the magnetization direction of each pre-magnetized magnet 111 is consistent.
[0042] As can be seen, the semi-finished product 110 utilizes the method of forming the whole first and then magnetizing it as a whole. Compared with the method of magnetizing first and then assembling in the prior art, it omits the steps of distinguishing the magnetic pole orientation and inserting each magnet into the outer periphery of the cage one by one, as well as the step of applying glue. This effectively reduces the production difficulty and solves the problems of not being able to achieve automation and high manual assembly costs.
[0043] like Figure 12 and Figure 13As shown, the prefabricated bracket 112 has several slots 113, which are located between two adjacent pre-magnetized magnets 111. Therefore, step b includes: The two semi-finished products 110 are stacked facing each other by means of the pre-charged magnet 111 of one semi-finished product 110 corresponding to the slot 113 of the other semi-finished product 110.
[0044] The prefabricated support 112 can be a sheet structure, which includes a ring 112a and several sets of circumferential limiting bodies 112b. The several sets of circumferential limiting bodies 112b are circumferentially spaced and connected to the outer periphery of the ring 112a. Each set of circumferential limiting bodies 112b corresponds to a pre-charged magnet 111. A slot 113 is formed between two adjacent sets of circumferential limiting bodies 112b.
[0045] Furthermore, each set of circumferential limiting bodies 112b includes two rods 112b, which are connected to the outer periphery of the ring body 112a, and the two rods 112b are respectively injection molded on both sides of the pre-charged magnet 111.
[0046] It can be seen that the installation area of the pre-magnetized magnet 111 is defined between the two rods 112b of each set of circumferential limiting bodies 112b. The two circumferential sides of the pre-magnetized magnet 111 are respectively connected to the two rods 112b of the circumferential limiting bodies 112b. The radial inner side of the pre-magnetized magnet 111 is connected to the outer periphery of the ring body 112a. The radial outer side of the pre-magnetized magnet 111 is roughly flush with the outer periphery of the rods 112b and is completely exposed to the outside, and is subsequently encapsulated by the injection molding of the assembly 200.
[0047] The slot 113 is defined between two adjacent rods 112b located at different axial limiting bodies 112b, and the slot 113 is used to place a pre-charged magnet 111 of another semi-finished product 110.
[0048] The pre-magnetized magnet 111 is trapezoidal, meaning its width gradually increases radially from the inside to the outside. The radially inner side of the pre-magnetized magnet 111 is connected to the periphery of the ring 112a, and the two circumferential sides of the pre-magnetized magnet 111 are respectively connected to the rod 112b. In step b, by having the pre-magnetized magnet 111 of one semi-finished product 110 correspond to the slot 113 of another semi-finished product 110, the pre-magnetized magnets 111 of the two sequentially injection-molded products 110 are staggered. Then, the magnetization directions of the pre-magnetized magnets 111 of the two semi-finished products 110 are stacked opposite each other, thus achieving a stacked arrangement of the two semi-finished products 110. This results in a stacked unit 100 with the magnetic poles of the pre-magnetized magnets 111 arranged at intervals. (Refer to...) Figure 11 The magnetization directions of two adjacent pre-magnetized magnets 111 are opposite.
[0049] It should be noted that the prefabricated bracket 112 is offset from the axial center of the pre-magnetized magnet 111, so that when the two semi-finished products 110 are stacked facing each other, the pre-magnetized magnets 111 can remain on the same horizontal plane. It can be seen that the filling groove 111a is offset from the axial center of the pre-magnetized magnet 111, as shown in the reference... Figure 14 There are two filling grooves 111a, and the two filling grooves 111a are located on both sides of the axial center position of the pre-charged magnet 111.
[0050] In step c, the composite 200 is also injection molded from plastic material. Steps b and c can be performed in a second injection mold, whereby the pre-charged magnets 111 of the two semi-finished products 110 are staggered and stacked facing each other, and arranged in the second injection mold. Then, injection molding material for forming the composite 200 is injected into the second injection mold, and the composite 200 is obtained by pulling it apart in the second injection mold. Figure 10 The rotor disk 1000 is shown.
[0051] The injection molding material is filled between the prefabricated supports 112 and wraps around the surface of the stacking unit 100 to join the two composite bodies 200 together. Preferably, see reference... Figure 12 The prefabricated support 112 has several through holes 112c to increase the bonding ability between the prefabricated support 112 and the assembly 200. The through holes 112c can be located on the ring 112a, and the several through holes 112c are arranged at circumferential intervals.
[0052] like Figure 10 and Figure 11As shown, the assembly 200 includes an axial joint portion 210 and an outer ring joint portion 220. The axial joint portion 210 is injection molded on both axial sides of the stacking unit 100. The axial joint portion at least partially covers the surfaces of the pre-charged magnet 111 and the prefabricated bracket 112. The outer ring joint portion 220 is injection molded on the outer periphery of the stacking unit 100. The outer ring joint portion 220 is annular and wraps around the radially outer side of the pre-charged magnet 111. The axial joint portion 210 and the outer ring joint portion 220 are integrally injection molded.
[0053] The gap between the pre-magnetized magnet 111 of one semi-finished product 110 and the prefabricated bracket 112 of another semi-finished product 110, as well as the interior of the through hole 112c of the prefabricated bracket 112, are completely filled by the axial joint 210 through injection molding, ensuring that the two stacked units 100 are firmly joined and improving the bonding ability between the connector 200 and the stacked unit 100. Preferably, the connector 200 completely covers the surfaces of the pre-magnetized magnet 111 and the prefabricated bracket 112.
[0054] The axial joint portion 210 is away from the outer surface of the overlapping unit 100 and is flush with the axial side surface of the outer ring joint portion 220. That is, the sum of the thicknesses of the two axial joint portions 210 and the overlapping unit 100 is equal to the thickness of the outer ring joint portion 220, thereby obtaining a result as shown in the figure. Figure 10 The rotor disk is shown. The width of the outer ring joint 220 is relatively small, sufficient to radially limit the pre-magnetized magnet 111. (As shown...) Figure 11 As shown, the prefabricated supports 112 of the two semi-finished products 110 are stacked axially, that is, two rods 112b are arranged between two adjacent pre-magnetized magnets 111. The two rods 112b are located at the middle position of the pre-magnetized magnets 111 in the axial direction and do not completely block the positioning holes 111b. At this time, the positioning holes 111b can continue to be used to position the stacked unit 100. That is, the second injection mold is provided with a second positioning structure adapted to the positioning holes 111b, wherein each of the second positioning structures is inserted into the positioning holes 111b of two adjacent pre-magnetized magnets 111. The cross-section of the second positioning structure is elongated. After the assembly 200 is injection molded and the second positioning structure is removed, a slot 201 is formed on the outer surface of the assembly 200. The slot 201 corresponds to the positioning holes 111b, and the shape of the slot 201 is adapted to the shape of the second positioning structure. After step c, the following is also included: A filler is provided inside the slot 201. By providing the filler, air can be isolated to prevent the pre-magnetized magnet 111 from rusting. The filler can be glue.
[0055] refer to Figure 10 and Figure 11 The composite 200 not only fills the space between the two semi-finished products 110, but also completely encloses the two semi-finished products 110, resulting in the following: Figure 10 The rotor disk shown is completely enclosed by the pre-magnetized magnet 111, which ensures the fixation effect of the pre-magnetized magnet 111 while improving production efficiency. The rotor disk has a disc-shaped structure, and its radial dimension is much larger than its axial dimension.
[0056] Both the semi-finished product 110 and the combined body 200 are injection molded. The stacking unit 100 is formed by stacking two semi-finished products 110. Both the stacking and injection molding steps can be performed by a robot, realizing automation, which not only improves production efficiency, but also solves the problem of high manual assembly costs.
[0057] In summary, both the semi-finished product 110 and the assembly 200 are injection molded, reducing assembly steps, simplifying the process route, and improving production efficiency. Using injection molds to produce the rotor disc ensures better consistency among components, increasing the product qualification rate. Magnetizing the semi-finished product 110 as a whole, resulting in a semi-finished product 110 with pre-magnetized magnets 111 having the same magnetization direction, reduces the difficulty of the magnetization process. Compared to existing rotor molding processes, it eliminates the steps of distinguishing the magnetic pole orientation and individually inserting each magnet into the outer periphery of the cage, not only improving assembly efficiency but also preventing the magnets from attracting each other, thus avoiding separation difficulties or even injury to operators. Furthermore, the semi-finished product 110 and the assembly 200 use ordinary engineering plastic materials, which meets strength requirements while significantly reducing material costs.
[0058] Second Embodiment like Figures 10 to 13 As shown, the rotor disk 1000 of the axial magnetic field motor includes: The stacking unit 100 mainly consists of two semi-finished products 110 with different magnetization directions. Each semi-finished product 110 includes several pre-magnetized magnets 111 arranged at circumferential intervals. The N and S poles of the pre-magnetized magnets 111 in each semi-finished product 110 are oriented in the same direction. Several semi-finished products 110 are stacked together by staggering the pre-magnetized magnets 111 to obtain the stacking unit 100. The N and S poles of two adjacent pre-magnetized magnets 111 in the stacking unit 100 are oriented in opposite directions. Combined body 200, which combines two of the semi-finished products 110.
[0059] The rotor disk 1000 of the axial magnetic field motor can be manufactured by the manufacturing method of the rotor disk of the axial magnetic field motor. The beneficial effects of the rotor disk 1000 can be referred to the manufacturing method of the rotor disk of the axial magnetic field motor, that is, the rotor disk is made of ordinary engineering plastics, which can meet the strength requirements, greatly reduce the material cost, and realize automation, etc.
[0060] like Figures 11 to 13 As shown, the semi-finished product 110 also includes a prefabricated bracket 112, which is connected between the pre-charged magnets 111. The prefabricated bracket 112 has a plurality of slots 113, which are located between two adjacent pre-charged magnets 111 to accommodate the pre-charged magnets 111 of another semi-finished product 110.
[0061] like Figure 14 As shown, the pre-magnetized magnet 111 has filling grooves 111a on both sides of its circumference. The prefabricated bracket 112 is filled in the filling grooves 111a to strengthen the connection between the magnet and the prefabricated bracket 112 and prevent the magnet from loosening or even falling off after long-term use.
[0062] Continue to refer to Figure 14 The pre-charged magnet 111 has positioning holes 111b on both circumferential sides. The positioning holes 111b penetrate the magnet axially and are located in the middle of the magnet. Positioning injection molding is performed using the positioning holes 111b, including the injection molding of the semi-finished product 110 and the assembly 200, to ensure product consistency and thus improve the product qualification rate.
[0063] The connector 200 is used to connect the two semi-finished products 110 to fix the two semi-finished products 110. Of course, the connector 200 may partially or completely cover the surface of the stacking unit 100.
[0064] Third Embodiment like Figure 15 and Figure 16 As shown, the axial magnetic field motor rotor assembly includes the rotor disk 1000 of the above embodiment. The axial magnetic field motor rotor assembly also includes a rotor shaft 6, bolts 4 and pads 5. The rotor disk 1000 is sleeved on the rotor shaft 6 and fixed by the bolts 4 and the pads 5.
[0065] like Figure 10As shown, a central hole 1002 is provided on the rotor disk 1000, and the central hole 1002 is located at the center of the rotor disk 1000. The rotor shaft 6 includes a shaft body 62 and a stepped plate 61 connected to the shaft body 62. During assembly, the shaft body 62 passes through the central hole 1002 of the rotor disk 1000, and the stepped plate 61 and the pad 5 are clamped on both axial sides of the rotor disk 1000. Then, the stepped plate 61, the rotor disk 1000, and the pad 5 are connected by the bolts 4 to complete the assembly of the rotor assembly. (Refer to...) Figure 15 and Figure 16 .
[0066] Continue to refer to Figure 10 The rotor disk 1000 is also provided with a plurality of mounting holes 1001, which surround the central hole 1002. The mounting holes 1001 are used for the bolt 4 to pass through. Similarly, the pad 5 is provided with a pad through hole 51 through which the bolt 4 passes, and the stepped plate 61 is provided with a threaded hole 63 for the bolt 4 to be screwed in.
[0067] The embodiments described above are only used to illustrate the technical ideas and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. The scope of patent application of the present invention should not be limited by these embodiments. That is, any equivalent changes or modifications made in accordance with the spirit disclosed in the present invention still fall within the patent scope of the present invention.
Claims
1. A rotor disk (1000) for an axial magnetic field motor, characterized in that, include: The stacking unit (100) includes two semi-finished products (110) with different magnetization directions. Each semi-finished product (110) includes a plurality of pre-magnetized magnets (111) arranged at circumferential intervals. The N and S poles of the pre-magnetized magnets (111) of each semi-finished product (110) are oriented in the same direction. The plurality of semi-finished products (110) are stacked together by means of the pre-magnetized magnets (111) in a staggered manner to obtain the stacking unit (100). The N and S poles of two adjacent pre-magnetized magnets (111) of the stacking unit (100) are oriented in opposite directions. A composite (200) that combines two of the semi-finished products (110). The semi-finished product (110) also includes a prefabricated bracket (112), which is connected between the pre-magnetized magnets (111). The pre-magnetized magnets (111) and the prefabricated bracket (112) are injection molded together. The sum of the thicknesses of the two prefabricated supports (112) is less than the thickness of the pre-magnetized magnet (111); The radial outer side of the pre-magnetized magnet (111) is roughly flush with the outer periphery of the prefabricated bracket (112) and is fully exposed.
2. The rotor disk (1000) of the axial magnetic field motor as described in claim 1, characterized in that, The prefabricated support (112) has a plurality of slots (113) located between two adjacent pre-charged magnets (111) to accommodate the pre-charged magnet (111) of another semi-finished product (110).
3. The rotor disk (1000) of the axial magnetic field motor as described in claim 2, characterized in that, The pre-charged magnet (111) has filling grooves (111a) on both sides of its circumference, and the prefabricated bracket (112) is filled in the filling grooves (111a).
4. The rotor disk (1000) of the axial magnetic field motor as described in claim 2, characterized in that, The prefabricated bracket (112) is offset from the center position of the pre-magnetized magnet (111) in the axial direction. When the two semi-finished products (110) are stacked in opposite directions, each of the pre-magnetized magnets (111) remains on the same horizontal plane.
5. The rotor disk (1000) of the axial magnetic field motor as described in claim 1, characterized in that, The assembly (200) includes an axial joint (210) and an outer ring joint (220). The axial joint (210) is connected to both sides of the stacked unit (100). The axial joint at least partially covers the surfaces of the pre-charged magnet (111) and the prefabricated bracket (112). The outer ring joint (220) is connected to the outer periphery of the stacked unit (100). The outer ring joint (220) is annular and wraps around the radial outer side of the pre-charged magnet (111). The axial joint (210) and the outer ring joint (220) are integrally formed.
6. A method for manufacturing a rotor disk of an axial magnetic field motor, characterized in that, Includes the following steps: a. Provide two semi-finished products (110) with opposite magnetization directions. The semi-finished products (110) include a plurality of pre-magnetized magnets (111) arranged circumferentially, and the N and S poles of the pre-magnetized magnets (111) of each semi-finished product (110) are oriented in the same direction. b. Two semi-finished products (110) with different magnetization directions are stacked together by the pre-magnetized magnets (111) in a staggered manner to obtain a stacked unit (100). The N and S poles of two adjacent pre-magnetized magnets (111) of the stacked unit (100) are oriented in opposite directions. c. Form a composite body (200) that incorporates the composite unit (100), and obtain a rotor disk; The semi-finished product (110) further includes a prefabricated bracket (112), which is connected between the pre-magnetized magnets (111), and step a includes: a1. A prefabricated bracket (112) is formed by injection molding between the unmagnetized magnets constituting the semi-finished product (110). The sum of the axial dimensions of the two prefabricated supports (112) is less than the axial dimension of the pre-magnetized magnet (111); The radial outer side of the pre-magnetized magnet (111) is roughly flush with the outer periphery of the prefabricated bracket (112) and is fully exposed.
7. The method for manufacturing the rotor disk of an axial magnetic field motor as described in claim 6, characterized in that, Step a further includes: a2. The combined structure of the prefabricated bracket (112) and the unmagnetized magnet is magnetized as a whole to obtain a semi-finished product (110) with the magnetization direction of the premagnetized magnet (111) in the same direction.
8. The method for manufacturing the rotor disk of an axial magnetic field motor as described in claim 7, characterized in that, The prefabricated support (112) has several slots (113) located between two adjacent pre-magnetized magnets (111), and step b includes: The two semi-finished products (110) are stacked facing each other by means of the pre-charged magnet (111) of one semi-finished product (110) corresponding to the slot (113) of the other semi-finished product (110).
9. The method for manufacturing the rotor disk of an axial magnetic field motor as described in claim 6, characterized in that, The pre-charged magnet (111) has positioning holes (111b) on both sides of its circumference. The positioning holes (111b) penetrate the pre-charged magnet (111) along the axial direction and are used for positioning.
10. The method for manufacturing the rotor disk of an axial magnetic field motor as described in claim 9, characterized in that, The assembly (200) has a slot (201) on its outside that corresponds to the positioning hole (111b), and after step c, the following is also included: A filler is provided inside the slot (201).
11. An axial magnetic field motor rotor assembly, comprising a rotor disk (1000) as described in any one of claims 1 to 5, the axial magnetic field motor rotor assembly further comprising a rotor shaft (6), bolts (4) and a pad (5), the rotor disk (1000) being sleeved on the rotor shaft (6) and fixed by the bolts (4) and the pad (5).