Magnetic gear input rotor assembly structure

Abstract

This invention belongs to the field of aero-engine starter technology, specifically disclosing a magnetic gear input rotor assembly structure, including: a rotor shaft, with a hollow portion axially extending through the rotor shaft for an external shaft to pass through; a guide assembly disposed on the inner wall of the hollow portion, used to restrict axial movement between the external shaft and the rotor shaft when the external shaft and the rotor shaft rotate relative to each other in the circumferential direction; a magnetic portion for generating magnetic force with the external stator; and an input rotor sleeve covering the magnetic portion, wherein the distance between any point on the outer wall of the input rotor sleeve along the radial direction of the rotor shaft and the axis of the rotor shaft is a fixed value; the distance between each pair of corresponding points on the opposite surface of the external stator and the input rotor sleeve along the radial direction of the rotor shaft is equal. It has the following advantages: compared with the internal rotor of a traditional magnetic gear transmission mechanism, it improves the installation accuracy and reliability of the permanent magnet of the input rotor, ensures a better uniform air gap between the input rotor and the magnetically adjusting stator, and improves the starter's working performance.

Description

Technical Field

[0001] This invention relates to the field of aero-engine starter technology, and more specifically, to a magnetic gear input rotor assembly structure. Background Technology

[0002] The magnetic gear input rotor assembly is a key component of the air turbine starter, and its structural design has a significant impact on the overall performance of the starter. This is especially true for the magnetic gear reducer in air turbine starters, where the design of the input rotor largely determines important performance characteristics such as starter efficiency and reliability. Traditional magnetic gear reducers, due to design flaws and other limitations, exhibit some design defects when used in air turbine starters, resulting in low transmission efficiency, high permanent magnet iron loss, and poor stability, necessitating certain improvements.

[0003] Coaxial magnetic gears achieve stable energy transfer between the driving and driven gears through magnetic field coupling. The internal and external air gaps, as key locations for sufficient and effective magnetic field coupling, directly affect the working performance of the coaxial magnetic gear. Due to the influence of permanent magnet arrangement structure and machining and assembly errors, the thickness of the internal and external air gaps in coaxial magnetic gears is difficult to maintain uniformly. When non-uniform air gaps exist, the peak torque of the coaxial magnetic gear will decrease significantly, while the amplitude of pulsating torque, start-up response time, and iron loss will increase to some extent. In other words, non-uniform air gaps have a direct negative impact on various working performance characteristics of coaxial magnetic gears.

[0004] For magnetic gear transmission mechanisms, when the air gap between the input rotor and the adjusting stator is uneven, i.e., when a non-uniform air gap exists, the peak torque of the coaxial magnetic gear will decrease significantly, while the amplitude of the pulsating torque, the start-up response time, and the iron loss will increase to some extent. In other words, a non-uniform air gap has a direct negative impact on the various performance characteristics of the coaxial magnetic gear. However, most currently invented magnetic gear transmission mechanisms have not addressed the impact of non-uniform air gaps on mechanism performance. In Chinese patent CN109525094A, "A Stepping Magnetic Gear," the permanent magnet of the inner rotor is an outwardly convex tooth, but this structure easily causes uneven air gaps between the input rotor and the adjusting stator, leading to performance degradation. Summary of the Invention

[0005] The present invention aims to provide a magnetic gear input rotor assembly structure to solve or improve the problems mentioned above in the traditional magnetic gear transmission mechanism where the installation accuracy and reliability of the permanent magnet of the input rotor are low, and there is uneven air gap between the input rotor and the magnetic adjustment stator, resulting in a decrease in the working performance of the starter.

[0006] In view of this, a first aspect of the present invention is to provide a magnetic gear input rotor assembly structure.

[0007] A first aspect of the present invention provides a magnetic gear input rotor assembly structure, comprising: a rotor shaft having a hollow portion extending axially through the rotor shaft for an external shaft to pass through; a guide assembly disposed on the inner wall of the hollow portion for restricting axial movement between the external shaft and the rotor shaft when the external shaft and the rotor shaft rotate relative to each other in the circumferential direction; a magnetic portion disposed circumferentially on the side wall of the rotor shaft for generating magnetic force with an external stator to drive the rotor shaft to rotate circumferentially; and an input rotor sleeve covering the magnetic portion, wherein the distance between any point on the outer wall of the input rotor sleeve along the radial direction of the rotor shaft and the axis of the rotor shaft is a fixed value; wherein the distance between each pair of corresponding points on the opposite surface of the external stator and the input rotor sleeve along the radial direction of the rotor shaft is equal.

[0008] The magnetic gear input rotor assembly structure provided by the present invention can fix the magnetic part by providing an input rotor sleeve, effectively preventing it from falling off during high-speed rotation;

[0009] When setting the distance between various surfaces, the distance between any point on the outer wall of the input rotor sleeve along the radial direction of the rotor shaft and the axis of the rotor shaft is a fixed value, and the distance between each pair of corresponding points on the opposite surface of the external stator and the input rotor sleeve along the radial direction of the rotor shaft is equal. This ensures that the air gap between the input rotor and the external magnetic stator has good uniformity, and further enables the air turbine starter of the aero-engine to have good reliability, stability and working performance.

[0010] In addition, the technical solutions provided by embodiments of the present invention may also have the following additional technical features:

[0011] In any of the above technical solutions, an annular groove is coaxially formed on the outer wall of the rotor shaft, and at least one is formed along the axial direction of the rotor shaft. An annular rib protruding from the bottom of the annular groove is formed at both ends of the annular groove along the axial direction of the rotor shaft. The magnetic part includes an input rotor magnetic ring that abuts against the annular rib. A strain cavity is formed between the input rotor magnetic ring, the annular rib, and the annular groove.

[0012] In this technical solution, an annular rib is formed outward on the annular groove and abuts against the magnetic ring of the input rotor to achieve overall support for the magnetic part.

[0013] In any of the above technical solutions, the guide assembly includes a plurality of high-speed angular contact ball bearings disposed at the end of the hollow part, and the inner end faces of adjacent high-speed angular contact ball bearings are connected by bearing retaining rings to form a cover over the middle of the inner wall of the hollow part; wherein, the plurality of high-speed angular contact ball bearings are respectively radially opposite to the air turbine on the input rotor sleeve and the rotor shaft.

[0014] In this technical solution, multiple high-speed angular contact ball bearings are used to assemble the rotor shaft and the shaft of the external output rotor, and connect the two under relative rotation. The multiple high-speed angular contact ball bearings correspond to the air turbine on the input rotor sleeve and the rotor shaft, respectively. This allows the air turbine and the corresponding position of the rotor shaft corresponding to the magnetic part that generates torsional force corresponding to the input rotor sleeve to provide guidance and support, ensuring the stability of the rotor shaft during rotation, and further enhancing the uniformity of the gap between the input rotor sleeve and the external stator during relative rotation.

[0015] In any of the above technical solutions, the magnetic part further includes an input rotor permanent magnet assembly, which is disposed between the input rotor sheath and the input rotor magnetic ring; the input rotor permanent magnet assembly includes multiple pairs of permanent magnets arranged circumferentially along the input rotor magnetic ring assembly; wherein, along the circumferential and axial directions of the input rotor magnetic ring, the magnetic poles of adjacent permanent magnets are different.

[0016] In this technical solution, by placing the input rotor permanent magnet between the input rotor sheath and the input rotor magnetic guide ring, and using the complete inner walls of the input rotor sheath and the input rotor magnetic guide ring to clamp and limit the permanent magnet, the stability of the rotor permanent magnet during rotation is further ensured, so as to make the structure stable during long-term use.

[0017] In any of the above technical solutions, when the high-speed angular contact ball bearing corresponds radially to the input rotor sheath along the rotor shaft, the high-speed angular contact ball bearing corresponds to the strain chamber; and / or the mating gap between the same pair of permanent magnets and the annular rib are staggered along the axial direction of the rotor shaft; and / or the rotor shaft is provided with a receiving part that is connected to the end face of the input rotor magnetic ring.

[0018] In this technical solution, for the high-speed angular contact ball bearing installed radially corresponding to the input rotor sheath along the rotor shaft, by further placing the high-speed angular contact ball bearing in the strain chamber, the rotor shaft can be subjected to the eccentric force of the high-speed angular contact ball bearing, and the vibration and outward absorption can be achieved through the strain chamber. Furthermore, by keeping the annular rib away from deformation, the clearance is ensured to be uniform during high-speed operation. This further suppresses the problem that the peak torque of the coaxial magnetic gear will decrease significantly, while the amplitude of the pulsating torque, the start-up response time, and the iron loss will increase to a certain extent.

[0019] When two or more annular slots are set, the mating gaps of the two mating permanent magnets and the annular ribs are staggered along the rotor shaft axis, so that the mating gaps of the annular ribs on adjacent annular slots are staggered with the mating gaps of the permanent magnets. This ensures that the gap between the stator and the input rotor sheath remains stable and unchanged when the rotor shaft is impacted.

[0020] By setting up a receiving part, the input rotor magnetic ring can be limited and fixed, avoiding the impact of vibration generated during high-speed rotation on the position of the input rotor magnetic ring, thus stabilizing the radial relative position of the permanent magnet and the stator.

[0021] Specifically, the strain cavity is a ring, and it gradually narrows outward along the radial direction of the ring, such that the face of the strain cavity opposite to the magnetic ring of the input rotor is smaller than the end face of the strain cavity that is far away from the magnetic ring of the input rotor.

[0022] In any of the above technical solutions, an input rotor baffle is fitted at one end of the outer wall of the input rotor magnetic ring, and the input rotor baffle is used to support the permanent magnet along the axial direction of the input rotor magnetic ring; wherein, the permanent magnet is disposed in the receiving cavity formed by the input rotor magnetic ring, the input rotor baffle and the input rotor sheath.

[0023] In this technical solution, the permanent magnet can be axially supported at one end by setting an input rotor baffle, so that the position of the permanent magnet is limited in the axial direction to avoid movement caused by vibration during operation. Furthermore, the permanent magnet is installed and fixed by a receiving cavity formed by the input rotor magnetic ring, the input rotor baffle and the input rotor sheath. When there are multiple pairs of permanent magnets, it is easy to ensure that the distance between them is equal.

[0024] In any of the above technical solutions, the permanent magnet and the input rotor magnetic ring are bonded and fixed with epoxy resin adhesive; and / or the input rotor sheath is fixed and covered outside the permanent magnet by gap filler.

[0025] In this technical solution, the structural strength is guaranteed during high-speed rotation; the carbon fiber material does not affect the distribution of the air gap magnetic field; the uniformity of the air gap is guaranteed, and the negative impact of air gap non-uniformity on the working performance of the coaxial magnetic gear is reduced, specifically, the peak torque decreases, the amplitude of pulsating torque, the start-up response time increases, and the iron loss increases.

[0026] In any of the above technical solutions, the rotor adopts an integral solid permanent magnet structure, and the outer sheath is made of carbon fiber composite material. In order to protect the permanent magnet from damage by centrifugal force, the carbon fiber sheath needs to exert a certain pre-stress on the permanent magnet. Therefore, the following method is used for assembly:

[0027] One or more bundles of resin-impregnated carbon fibers are seamlessly wound onto the surface of a permanent magnet. During winding, the fiber bundles are given a sufficiently large initial tension. After curing, the carbon fiber sheath exerts a certain pre-compression stress on the permanent magnet, thereby protecting the safety of the permanent magnet.

[0028] In this technical solution, carbon fibers are tightly arranged under tension, reducing the air gap between composite layers and improving the overall performance of the protective sleeve; the winding pattern is designable, and a reasonable pattern can be designed according to different requirements to improve the strength of the product in different directions; the process can achieve integral molding, which improves the fatigue resistance of the protective sleeve compared with other processes; the binding process can achieve higher surface quality compared with other processes, which is conducive to controlling the uniformity of air gaps.

[0029] In any of the above technical solutions, the input rotor sheath is made of carbon fiber.

[0030] In this technical solution, the carbon fiber sheath is lightweight, has high tensile strength, and does not generate eddy current losses during operation. It has good temperature resistance, fast thermal conductivity, and is non-magnetic, resulting in strong dynamic balance during high-speed rotation. The permanent magnet material has high compressive strength but very low tensile strength, specifically ≤80MPa. Considering that the permanent magnet cannot withstand the enormous centrifugal force when the centrifugal force of the high-speed rotor becomes the main load, protective measures must be taken for the permanent magnet. Furthermore, the material has a certain degree of machinability, and the smooth surface quality ensures uniform air gap.

[0031] In any of the above technical solutions, the logarithm of the permanent magnet satisfies the following relationship: p in +p out =n s ; where n s The number of adjusting ring core blocks in the rotor permanent magnet assembly is the number of permanent magnets, P. in P is the logarithm of the permanent magnet. out The number of permanent magnet pairs of the output rotor where the external shaft is located.

[0032] In this technical solution, the speed ratio between the input and output rotors can be changed by altering the number of magnetic pole pairs to achieve the desired technical specifications.

[0033] In any of the above technical solutions, the magnetization angle of the circumferentially adjacent permanent magnets is set to a preset angle; wherein, the preset angle is 60°, and the permanent magnets are magnetized by arranging them in a Halbach array.

[0034] In this technical solution, the air gap magnetic field of the magnetic gear is effectively improved, and the pulsating torque is reduced; the permanent magnet Halbach array can reduce the negative effects of non-uniform air gap while improving the basic torque performance and reducing the initial start-up response time.

[0035] The first aspect of the present invention also provides an air turbine starter, comprising: a housing and guide assembly structure and a magnetic gear; wherein the magnetic gear uses an input rotor assembly structure as described in any one of the first aspects.

[0036] The first aspect of the present invention also provides an air turbine starter, which, since it includes an input rotor assembly structure, has all the beneficial effects of the input rotor assembly structure, which will not be elaborated here.

[0037] The beneficial effects of this invention compared to the prior art are as follows:

[0038] The input rotor assembly of the air turbine starter is equipped with a carbon fiber sheath, which can fix the permanent magnet assembly of the input rotor and effectively prevent it from falling off during high-speed rotation.

[0039] Meanwhile, the smooth carbon fiber sheath ensures good uniformity of the air gap between the input rotor and the magnetizing stator. The permanent magnets of the input rotor are magnetized using a Halbach array, which gives the new aero-engine air turbine starter good reliability, stability and working performance.

[0040] Additional aspects and advantages of embodiments of the invention will become apparent in the following description or may be learned by practice of embodiments of the invention. Attached Figure Description

[0041] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0042] Figure 1 This is a schematic diagram of the carbon fiber sheath structure of the input rotor assembly of the air turbine starter of the present invention;

[0043] Figure 2 This is a cross-sectional schematic diagram of the magnetic gear input rotor assembly structure of the air turbine starter of the present invention.

[0044] Figure 3 This is a schematic diagram of the magnetic gear input rotor assembly structure of the air turbine starter of the present invention.

[0045] Figure 4 This is a cross-sectional schematic diagram of the overall structure of the air turbine starter of the present invention;

[0046] Figure 5 This is a schematic diagram of the air turbine starter of the present invention;

[0047] Figure 6 This is a schematic diagram of the structure of a magnetic gear output rotor assembly according to another embodiment of the present invention;

[0048] Figure 7 This is a schematic diagram of the structure of the air turbine starter housing and guide assembly according to another embodiment of the present invention;

[0049] Figure 8This is a cross-sectional schematic diagram of the magnetic gear stator assembly structure according to another embodiment of the present invention;

[0050] Figure 9 This is a schematic diagram of the magnetic gear rotor support structure according to another embodiment of the present invention.

[0051] in, Figure 1-9 The correspondence between the reference numerals and component names in the attached drawings is as follows:

[0052] 1. Housing and guide assembly structure; 2. Input rotor assembly structure; 201. Air turbine; 202. Input rotor magnetic ring; 203. Input rotor permanent magnet assembly; 204. Input rotor sheath; 205. Input rotor baffle; 206. High-speed angular contact ball bearing; 207. Bearing retaining ring; 208. Locking ring; 209. Input rotor damper; 210. Double-layer helical elastic retaining ring; 3. Output rotor assembly structure; 4. Magnetic gear stator assembly structure. Detailed Implementation

[0053] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0054] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0055] Please see Figure 1-9 The magnetic gear input rotor assembly structure of some embodiments of the present invention is described below.

[0056] An embodiment of the first aspect of the present invention provides a magnetic gear input rotor assembly structure. In some embodiments of the present invention, such as... Figure 4-5 As shown, an air turbine starter having the magnetic gear input rotor assembly structure is provided, the air turbine starter comprising:

[0057] Housing and guide assembly structure 1 and magnetic gear;

[0058] The magnetic gear includes an input rotor assembly structure 2, an output rotor assembly structure 3, and a magnetic gear stator assembly structure 4;

[0059] The output rotor assembly structure 3, the magnetic gear stator assembly structure 4, and the input rotor assembly structure 2 are nested together and are all mounted on the housing and guide assembly structure 1.

[0060] The inner wall of the housing and guide assembly structure 1 and the outer wall of the output rotor assembly structure 3, the output rotor assembly structure 3 and the magnetic gear stator assembly structure 4, and the magnetic gear stator assembly structure 4 and the input rotor assembly structure 2 are all spaced apart to allow gas to flow through.

[0061] An embodiment of the first aspect of the present invention provides a magnetic gear input rotor assembly structure. In some embodiments of the present invention, such as... Figure 1-3 As shown, a magnetic gear input rotor assembly structure is provided, which includes:

[0062] The rotor shaft has a hollow section extending axially through it for the external shaft to pass through. A guide assembly is disposed on the inner wall of the hollow section and is used to restrict the axial movement between the external shaft and the rotor shaft when they rotate circumferentially relative to each other. A magnetic section is disposed circumferentially on the outer wall of the rotor shaft and is used to generate magnetic force with the external stator to drive the rotor shaft to rotate circumferentially. An input rotor sleeve 204 is disposed outside the magnetic section, and the distance between any point on the outer wall of the input rotor sleeve 204 and the axis of the rotor shaft along the radial direction is a fixed value. The distance between each pair of corresponding points on the opposite surface of the external stator and the input rotor sleeve 204 along the radial direction of the rotor shaft is equal.

[0063] The magnetic gear input rotor assembly structure provided by the present invention can fix the magnetic part by providing an input rotor sleeve 204, effectively preventing it from falling off during high-speed rotation.

[0064] When setting the distance between various surfaces, the distance between any point on the outer wall of the input rotor sleeve 204 along the radial direction of the rotor shaft and the axis of the rotor shaft is a fixed value, and the distance between each pair of corresponding points on the opposite surface of the external stator and the input rotor sleeve 204 along the radial direction of the rotor shaft is equal. This ensures that the air gap between the input rotor and the external magnetic adjustment stator has good uniformity, and further enables the air turbine 201 starter of the aero-engine to have good reliability, stability and working performance.

[0065] Specifically, the air turbine 201 is integrally formed on the rotor shaft.

[0066] In some embodiments, an annular groove is coaxially formed on the outer wall of the rotor shaft, and at least one is formed along the axial direction of the rotor shaft. Annular ribs protruding from the bottom of the annular groove are formed at both ends of the annular groove along the axial direction of the rotor shaft. The magnetic part includes an input rotor magnetic ring 202 that abuts against the annular ribs. A strain cavity is formed between the input rotor magnetic ring 202, the annular ribs, and the annular groove.

[0067] In this embodiment, an annular rib is formed radially outward on the annular groove and abuts against the input rotor magnetic ring 202 to achieve overall support for the magnetic part. By forming a strain cavity, the volume can be accommodated when the rotor shaft is subjected to force and undergoes radial deformation or radial thermal expansion during high-speed rotation, so as to avoid direct action on the input rotor magnetic ring 202 and further action on the input rotor sheath 204 through the input rotor permanent magnet assembly, causing unevenness on the working surface.

[0068] In some embodiments, the guide assembly includes a plurality of high-speed angular contact ball bearings 206 disposed at the end of the hollow portion, the inner end faces of adjacent high-speed angular contact ball bearings 206 being connected by bearing retaining rings 207 to form a cover over the middle of the inner wall of the hollow portion; wherein, the plurality of high-speed angular contact ball bearings 206 are respectively radially opposite to the input rotor sleeve 204 and the air turbine 201 on the rotor shaft.

[0069] In this embodiment, multiple high-speed angular contact ball bearings 206 are used to assemble the rotor shaft and the shaft of the external output rotor, and connect the two during relative rotation. The multiple high-speed angular contact ball bearings 206 correspond to the input rotor sleeve 204 and the air turbine 201 on the rotor shaft, respectively. This allows the air turbine 201 and the corresponding position of the rotor shaft corresponding to the magnetic part that generates torsional force corresponding to the input rotor sleeve 204 to provide guiding support, ensuring the stability of the rotor shaft during rotation, and further enhancing the uniformity of the gap between the input rotor sleeve 204 and the external stator during relative rotation.

[0070] Furthermore, the inner wall of the hollow section and the outer end face of the high-speed angular contact ball bearing 206 are jointly equipped with an input rotor damper 209 to suppress the vibration of the high-speed angular contact ball bearing 206 and reduce its rubbing.

[0071] Furthermore, the inner wall of the rotor shaft is fitted with a locking ring 208 for limiting the high-speed angular contact ball bearing 206.

[0072] In some embodiments, the magnetic part further includes an input rotor permanent magnet assembly 203, which is disposed between the input rotor sheath 204 and the input rotor magnetic ring 202; the input rotor permanent magnet assembly 203 includes multiple pairs of permanent magnets arranged circumferentially along the input rotor magnetic ring 202 assembly; wherein, along the circumferential and axial directions of the input rotor magnetic ring 202, the magnetic poles of adjacent permanent magnets are different.

[0073] In this embodiment, by placing the input rotor permanent magnet between the input rotor sleeve 204 and the input rotor magnetic ring 202, the permanent magnet is clamped and limited by the complete inner walls of the input rotor sleeve 204 and the input rotor magnetic ring 202, which further ensures the stability of the rotor permanent magnet during rotation, so as to make the structure stable during long-term use.

[0074] In some embodiments, when the high-speed angular contact ball bearing 206 corresponds radially to the input rotor sleeve 204 along the rotor shaft, the high-speed angular contact ball bearing 206 corresponds to the strain chamber; and / or the mating gap between the same pair of permanent magnets and the annular rib are staggered along the axial direction of the rotor shaft; and / or a receiving portion connected to the end face of the input rotor magnetic ring 202 is provided on the rotor shaft.

[0075] In this embodiment, for the high-speed angular contact ball bearing 206 installed in the radial direction of the rotor shaft corresponding to the input rotor sleeve 204, by further aligning the high-speed angular contact ball bearing 206 with the strain chamber in the radial direction of the rotor shaft, the rotor shaft can be subjected to the eccentric force of the high-speed angular contact ball bearing 206, and the vibration and outward absorption can be achieved through the strain chamber. Moreover, the annular ribs are kept away from deformation, ensuring uniform clearance during high-speed operation. This further suppresses the problem that the peak torque of the coaxial magnetic gear will decrease significantly, while the amplitude of the pulsating torque, the start-up response time, and the iron loss will increase to a certain extent.

[0076] When two or more annular slots are set, the mating gaps of the two mating permanent magnets and the annular ribs are staggered along the axial direction of the rotor shaft, so that the mating gaps of the annular ribs on the adjacent annular slots are staggered with the mating gaps of the permanent magnets, ensuring that the gap between the stator and the input rotor sleeve 204 remains stable and unchanged when the rotor shaft is impacted.

[0077] By setting up a receiving part, the input rotor magnetic ring 202 can be limited and fixed, avoiding the impact of vibration generated during high-speed rotation on the position of the input rotor magnetic ring 202, thus stabilizing the radial relative position of the permanent magnet and the stator.

[0078] Specifically, the strain cavity is a ring-shaped body that gradually narrows outward along the radial direction of the ring, such that the face of the strain cavity opposite to the input rotor magnetic ring 202 is smaller than the end face of the strain cavity that is far away from the input rotor magnetic ring 202, thereby reducing the force applied to the input rotor magnetic ring 202.

[0079] In some embodiments, an input rotor baffle 205 is fitted at one end of the outer wall of the input rotor magnetic ring 202. The input rotor baffle 205 is used to support the permanent magnet along the axial direction of the input rotor magnetic ring 202. The permanent magnet is disposed in the receiving cavity formed by the input rotor magnetic ring 202, the input rotor baffle 205 and the input rotor sheath 204.

[0080] In this embodiment, the permanent magnet can be axially supported at one end by setting the input rotor baffle 205, so that the position of the permanent magnet is limited in the axial direction to avoid movement caused by vibration during operation. Furthermore, the permanent magnet is installed and fixed by the receiving cavity formed by the input rotor magnetic ring 202, the input rotor baffle 205 and the input rotor sheath 204. When there are multiple pairs of permanent magnets, it is easy to ensure that the distance between them is equal.

[0081] In some embodiments, the permanent magnet and the input rotor magnetic ring are bonded and fixed together with epoxy resin adhesive; and / or the input rotor sheath is fixed and covered on the outside of the permanent magnet by gap filler.

[0082] In this embodiment, the structural strength is guaranteed during high-speed rotation; the carbon fiber material does not affect the distribution of the air gap magnetic field; the uniformity of the air gap is guaranteed, and the negative impact of air gap non-uniformity on the working performance of the coaxial magnetic gear is reduced, specifically, the peak torque decreases, the amplitude of pulsating torque, the start-up response time increases, and the iron loss increases.

[0083] In some embodiments, the input rotor sheath is made of carbon fiber and the surface is smoothed by a polishing process.

[0084] In this embodiment, the carbon fiber sheath is lightweight, has high tensile strength, and does not generate eddy current losses during operation. It has good temperature resistance, fast thermal conductivity, and is non-magnetic, resulting in strong dynamic balance during high-speed rotation. The permanent magnet material has high compressive strength but very low tensile strength, specifically ≤80MPa. Considering that the permanent magnet cannot withstand the enormous centrifugal force when the centrifugal force of the high-speed rotor becomes the main load, protective measures must be taken for the permanent magnet. Furthermore, the material has a certain degree of machinability, and the smooth surface quality ensures uniform air gap.

[0085] In some embodiments, the logarithm of the permanent magnet satisfies the following relationship: p in +p out =n s ; where n s The number of adjusting ring core blocks in the rotor permanent magnet assembly is the number of permanent magnets, P. in P is the logarithm of the permanent magnet. out This represents the number of permanent magnet pairs on the output rotor where the external shaft is located.

[0086] In this embodiment, the speed ratio of the input and output rotors can be changed by altering the number of pole pairs to achieve the desired technical specifications.

[0087] In some embodiments, the magnetization angle of adjacent circumferential permanent magnets is set to a preset angle; wherein, the preset angle is 60°, and the permanent magnets are arranged in a Halbach array to magnetize them.

[0088] In this embodiment, the air gap magnetic field of the magnetic gear is effectively improved, reducing pulsating torque; the permanent magnet Halbach array can mitigate the negative effects of non-uniform air gap while improving basic torque performance and reducing initial start-up response time.

[0089] An embodiment of the first aspect of the present invention provides a magnetic gear input rotor assembly structure. In some embodiments of the present invention, such as... Figure 7 As shown, an air turbine starter housing and guide assembly structure is provided within the same air turbine starter as the magnetic gear input rotor assembly structure. This air turbine starter housing and guide assembly structure includes:

[0090] Housing, input rotor assembly structure 2, output rotor assembly structure 3, and magnetic gear stator assembly 4;

[0091] The output rotor assembly structure 3, the magnetic gear stator assembly 4, and the input rotor assembly structure 2 are nested together and are all mounted in the housing;

[0092] The inner wall of the housing is spaced apart from the outer wall of the output rotor assembly 3, the output rotor assembly 3 is spaced apart from the magnetic gear stator assembly 4, and the magnetic gear stator assembly 4 is spaced apart from the input rotor assembly 2 to allow gas to flow through.

[0093] An embodiment of the first aspect of the invention provides an air turbine starter housing and guide assembly structure. In some embodiments of the invention, such as... Figure 1-3 As shown, an air turbine starter housing and guide assembly structure is provided for mounting the stator structure, input rotor assembly structure, and output rotor assembly structure. The housing and guide assembly structure includes:

[0094] The housing has an air inlet and multiple air outlets, and the inner wall of the end of the housing away from the air inlet is rotatably connected to the output rotor assembly structure.

[0095] The output rotor positioning sleeve 108 is installed inside the housing and is sleeved on the outer wall of the output rotor assembly structure.

[0096] The bearing stator 103 is coaxially disposed inside the housing. The air inlet of the housing is connected to the bearing stator 103 through the turbine guide 101, which is used to rotatably connect the turbine.

[0097] The housing is provided with a support for connecting the output rotor assembly structure at the end away from the air inlet and on the inner wall of the bearing stator 103. An annular cavity for gas flow is formed between the housing and the bearing stator 103. The annular cavity is divided into multiple flow guide cavities by the input rotor assembly structure, stator structure and output rotor assembly structure connected from the inside to the outside.

[0098] The air turbine starter housing and guide assembly structure provided by this invention has the functions of limiting rotor radial displacement and improving starter performance, enabling safe and stable operation under high speed, high temperature, and high pressure conditions. The achievable benefits include: due to the presence of the air outlet, the temperature of the expanding gas can be effectively reduced during aerodynamic and energy exchange, thereby improving working conditions and increasing impeller life and reliability. The presence of the output rotor positioning sleeve 108 limits the radial displacement of the output rotor, thus preventing rubbing and resonance. The housing also protects internal parts from damage by foreign objects and simultaneously creates an airflow channel, improving transmission performance.

[0099] The air outlet effectively controls the temperature rise of the permanent magnet during operation. In the air turbine starter, compressed air serves as the energy source, driving the turbine blades to output power and torque. Simultaneously, after expansion and cooling, it acts as a cooling medium to cool the components within the starter chamber, ensuring they operate under suitable temperature conditions. During airflow, compressed air enters from the inlet, passing sequentially through the turbine stationary and moving blades, driving the turbine blades to rotate. As the compressed air expands and cools, some flows into the outside through the front outlet of the stator casing, while the remaining air cools the magnetic reducer section through the inner and outer air gaps and the outer flow channel of the outer rotor, exiting through the rear air outlet of the air turbine starter.

[0100] Specifically, a guide cone 102 is inserted into one end of the bearing stator 103 near the air inlet;

[0101] Specifically, the output rotor assembly structure is connected to the housing at the end that passes through the housing away from the air inlet by a shaft end seal ring 107;

[0102] In some embodiments, the inner cylindrical surface of the output rotor positioning sleeve is provided with eight circumferentially evenly distributed rollers, and the output rotor positioning sleeve is fitted onto the outer cylindrical surface of the output rotor magnetic ring, which can effectively limit the radial displacement of the output rotor.

[0103] In this embodiment, when the starter is working, the rotor speed continuously increases to a critical speed, specifically 45,000 rpm. The vibration is most intense when the rotor speed exceeds this critical speed, and the rotor radial displacement is at its maximum at this point. When the rotor experiences significant radial displacement, the positioning sleeve, by fitting around the cylindrical surface outside the output rotor's magnetic ring, effectively limits the radial displacement, preventing rotor rubbing or avoiding harmful rubbing. In aero-engines, rubbing is generally divided into harmless and harmful rubbing. Harmless rubbing mainly has the following two characteristics: the blade vibration caused by rubbing is not significant; and the blade vibration caused by rubbing can gradually disappear over time. However, some rubbing that causes continuous and severe blade vibration may induce more serious problems such as blade breakage and scrapping, shaft bending, and severe vibration of the entire engine. Therefore, the positioning sleeve can effectively control rubbing, and even transform harmful rubbing into harmless rubbing by controlling its severe vibration.

[0104] The positioning sleeve can also prevent resonance to some extent. The structural design was comprehensively judged based on critical speed and modal identification. Modal calculation models were established for the inner and outer rotors respectively. The surface elements of each bearing in contact with the rotor were set as rigid bodies, and the calculated bearing stiffness was added to the corresponding reference points in the form of springs. The modal calculation results were interpreted. The first eight modes of the inner and outer rotors showed similar characteristics: the natural frequencies of the third and higher modes were much higher than the frequencies corresponding to the rotor operating speed, so the possibility of resonance was very small.

[0105] In some embodiments, the housing includes an end cover, a first stator cover 104, and a second stator cover 105;

[0106] The flow guiding cavity is located inside the first stator outer cover 104 and the second stator outer cover 105. The air outlets are respectively circumferentially arranged in the first stator outer cover 104 and the second stator outer cover 105, and the air outlets are all located at the ends of the flow guiding cavity.

[0107] The end cover includes a front cover and a rear cover 106 with an exhaust port.

[0108] Furthermore, the connection and fixing method between the first stator outer cover and the guide is threaded connection plus riveting.

[0109] In this embodiment, the housing adopts a segmented assembly structure, which facilitates installation and design. The multi-layered flow guide cavities are even located inside the first and second stator outer covers. The air outlets are respectively located on the first and second stator outer covers and correspond to the ends of the flow guide cavities. This makes the gas flow inside the multi-layered flow guide cavities more stable, avoids the outward gas flow causing airflow turbulence in the flow guide cavities, and further ensures the radial stability of the stator, inner rotor, and outer rotor with segmented flow guide cavities.

[0110] In some embodiments, the flow guide cavity includes: an inner air gap cavity located between the stator structure and the input rotor assembly structure;

[0111] The outer air gap cavity is located between the stator structure and the output rotor assembly structure, and has the same thickness as the inner air gap cavity;

[0112] The outer flow channel cavity is located between the output rotor assembly structure and the housing. The thickness of the outer flow channel cavity is greater than that of the inner air gap cavity, and the two ends of the outer flow channel cavity are circumferentially corresponding and connected to the air outlet.

[0113] In this embodiment, the multi-layered flow guide cavity is specifically divided into an inner air gap cavity, an outer air gap cavity, and an outer flow channel cavity. Since they face the inner rotor and the outer rotor respectively under the premise of facing the same stator, and both of them are in a rotating state during operation, it is necessary to keep the thickness of the outer air gap cavity and the inner air gap cavity the same along the radial direction of the stator. When facing the same internal air flow at the same time, the inner rotor and the outer rotor can be kept rotating stably at the same time.

[0114] By making the thickness of the outer flow channel cavity greater than that of the inner and outer air gap cavities, more space can be provided for the annular cavities within the first and second stator outer covers, so that some of the flowing air can be discharged from the air outlets on the first and second stator outer covers.

[0115] In some embodiments, one end of the stator structure near the air inlet protrudes axially from the input rotor assembly structure and the output rotor assembly structure; and / or

[0116] An air intake chamber is formed between the front cover and the turbine, which communicates with the air intake port. The air intake chamber corresponds to the air intake chamber and the output rotor assembly structure along the axial direction of the bearing stator 103.

[0117] In this embodiment, the stator structure is positioned so that one end near the air inlet protrudes from the input rotor assembly structure and the output rotor assembly structure. This allows for pre-guidance of the air that will flow into the inner and outer air gaps, thereby reducing turbulence at the ends of the inner and outer air gaps near the air inlet and further ensuring the stability of the airflow inside the inner and outer air gaps.

[0118] The air intake chamber, which is formed by the front cover and the turbine and communicates with the air inlet, is the initial flow channel through which the air inlet flows into the housing. The air is pressurized in this flow channel to generate thrust and ultimately drive the turbine to rotate. Therefore, the air intake chamber is arranged along the axial direction of the annular cavity to correspond to the air intake chamber and the output rotor assembly structure. This can prevent the high-pressure air from directly contacting the inner rotor, which is the internal power transmission, and ensure the stability of subsequent force transmission.

[0119] In some embodiments, an end cover axially covering the output rotor assembly structure, stator structure, input rotor assembly structure and bearing stator 103 is provided at one end of the output rotor assembly structure near the exhaust port.

[0120] The end cap is provided with a flow collection cavity that communicates with the outer air gap cavity and the outer flow channel cavity respectively.

[0121] In this embodiment, since the outer rotor needs to ultimately transmit power to the coaxial output shaft, an end cap is provided to pass through and connect the output shaft, ensuring the output of power. On the other hand, when the air inside the inner and outer air gap chambers gathers towards the exhaust port, it is first gathered to avoid the concentrated gathering of air flowing inside the multiple chambers causing internal turbulence and affecting the rotating parts of the device.

[0122] In some embodiments, the end cap is provided with a connecting hole in the axial direction for connecting the gas collector and the exhaust port, and the connecting hole is located in the axial direction of the annular cavity between the exhaust port and the external flow channel cavity.

[0123] In this embodiment, the flowing air after the inner and outer air gaps are connected by a connecting hole. Since the outer rotor is rotating during operation, the end cap with the connecting hole is also rotating. Furthermore, multiple connecting holes are equally spaced along the circumference of the end cap. The rotation of multiple connecting holes causes intermittent connection at the same circumferential position, preventing the airflow from the end cap from being a complete airflow. This helps to make the convergence between the exhaust ports more stable, avoids gas turbulence caused by mismatched connection between multiple cavities and holes, and ensures the stable rotation of the high-speed inner and outer rotors.

[0124] In some embodiments, the output rotor positioning sleeve 108 corresponds to the air outlet located on the first stator cover 104 along the radial direction of the bearing stator 103.

[0125] In this embodiment, since the high-pressure air introduced into the housing from the air inlet cavity will be split in multiple directions, and will be split by the air outlet on the first stator outer cover, the inner air gap cavity, the outer air gap cavity and the outer flow channel cavity respectively, and the air inlet cavity corresponds to the outer rotor, it is easy to cause the outer rotor to rotate unstably. Therefore, the output rotor positioning sleeve is set to correspond to the air outlet. On the one hand, it can ensure the rotation stability of the outer rotor when the high-pressure air is split, and on the other hand, it can suppress the eccentric force generated on the outer rotor when the air outlet guides the air outward, thus ensuring the rotation stability of the outer rotor.

[0126] An embodiment of the first aspect of the present invention provides a magnetic gear input rotor assembly structure. In some embodiments of the present invention, such as... Figure 6 As shown, a magnetic gear output rotor assembly structure is provided in the same air turbine starter as the magnetic gear input rotor assembly structure. This magnetic gear output rotor assembly structure includes:

[0127] The first shaft is used to connect to the external driven end and output the power generated by the output rotor assembly structure;

[0128] The second shaft body has a through hole in the first shaft body that is axially inserted for fitting the second shaft body, and the first shaft body and the second shaft body are connected by a one-way transmission.

[0129] The magnetic part is used to connect to the second shaft and transmit torsional force. The magnetic part includes multiple output rotor permanent magnet assemblies 301 and an output rotor magnetic ring 302 for connecting the output rotor permanent magnet assemblies 301 to the second shaft.

[0130] The inner wall of the output rotor magnetic ring 302 is provided with multiple grooves for installing rotor permanent magnet components along the circumferential direction, and the groove width gradually decreases from the bottom to the opening.

[0131] Multiple output rotor permanent magnet assemblies 301 are inserted into each groove along the axial direction of the second shaft, and the output rotor permanent magnet assemblies 301 are composed of at least two permanent magnets spliced ​​together along the circumferential direction of the second shaft.

[0132] The magnetic gear output rotor assembly structure provided by the present invention has multiple dovetail-shaped grooves designed on the inner wall of the magnetic guide ring 302 of the output rotor, and epoxy resin is used to bond and fix the permanent magnet assembly 301 of the output rotor, which can effectively fix the permanent magnet assembly 301 of the output rotor.

[0133] By transmitting power to the first and second shafts through a unidirectional drive configuration, the structure can be simplified while preventing the second shaft from being driven by the first shaft rotating in the opposite direction.

[0134] Furthermore, the radially magnetized permanent magnets are evenly divided into multiple blocks, which are then installed and fixed. That is, based on the aforementioned permanent magnet assembly, each individual permanent magnet is evenly divided into multiple blocks, maintaining its original mounting position for installation and fixation. After being divided, the permanent magnets are assembled into a single integral magnetic pole for installation. This reduces the eddy current losses of the permanent magnets. The circumferentially divided permanent magnet assembly of the output rotor in the improved air turbine starter magnetic gear reducer effectively reduces the iron losses of the permanent magnets.

[0135] In some embodiments, the outer wall of the second shaft has an extended edge formed outward in the circumferential direction, and the inner wall of the output rotor magnetic ring 302 has an annular groove that is connected to the edge of the extended edge, and the annular groove is connected to the groove.

[0136] The sidewall edge of the extended side is formed with a positioning plate along the circumferential direction, and a rib plate is formed between adjacent grooves to abut against the positioning plate.

[0137] In this embodiment, when the second shaft and the output rotor magnetic ring 302 are installed, the outer wall of the second shaft is extended outward to form an extension edge, which increases the circumferential installation size of the second shaft. This is beneficial for installing and connecting output rotor magnetic rings 302 with larger diameters. The output rotor magnetic ring 302 has a larger surface area for installing output rotor permanent magnet assemblies 301, so as to install more output rotor permanent magnet assemblies 301 and facilitate cooperation with the external stator. By forming a positioning plate circumferentially on the extension edge, the annular groove can be abutted to position the output rotor magnetic ring 302. After abutting, the positioning plate abuts against the rib, which can limit the output rotor permanent magnet assembly 301 placed in the groove on one side, which helps to stabilize the installation of the output rotor permanent magnet assembly 301.

[0138] Specifically, the end face of the output rotor magnetic ring 302 is provided with a notch that communicates with the annular groove, and the edge of the extended side is provided with a plug that can be inserted into the notch, so that the output rotor magnetic ring 302 and the second shaft with the extended side are engaged and fixed, and the plug and the notch are fixed in the axial direction of the output rotor magnetic ring 302 by a drilled bolt to form a fixed assembly in the axial and radial directions.

[0139] In some embodiments, the second shaft and the first shaft are connected by a transmission mechanism, which is used to make the first shaft follow the rotation of the second shaft rotating in a preset direction or to prevent the second shaft from following the rotation of the first shaft rotating in the opposite direction.

[0140] In this embodiment, the second shaft and the first shaft are connected by a transmission mechanism to achieve unidirectional transmission. This allows the transmission mechanism to make the first shaft follow the rotation of the second shaft rotating in a preset direction, or the second shaft not follow the rotation of the first shaft rotating in the opposite direction, thus preventing the second shaft from being driven to rotate by an external reverse torsional force.

[0141] Specifically, the transmission mechanism is an output clutch.

[0142] Specifically, the first shaft is the output driven shaft 306, the second shaft is the output main shaft 303, and the output shaft assembly includes the output main shaft 303, the output driven shaft 306, the output spline shaft 305, and the output clutch; the output driven shaft 306 and the output spline shaft 305 are welded to form the driven shaft weld assembly; the driven shaft weld assembly is connected to the output main shaft 303 through the output clutch; the output clutch is an overrunning clutch 304, which is a one-way clutch, thereby preventing the air turbine starter from being driven in the reverse direction.

[0143] In some embodiments, the end of the first shaft near the magnetic part extends radially outward to form a first extended edge communicating with the through hole, and the side of the extended edge near the second shaft extends axially toward the magnetic part along the second shaft to form a second extended edge.

[0144] The first extended edge, the second extended edge, and the outer wall of the second shaft together form an annular receiving cavity with an opening;

[0145] The transmission mechanism is installed at one end of the annular cavity near the second shaft.

[0146] In this embodiment, an L-shaped first extension edge is formed by extending the end of the first shaft near the magnetic part outward, thereby forming a circumferential annular inner platform in the central through hole of the first shaft. The extension edge extends towards the magnetic part near the edge of the second shaft, so that the extension edge is Z-shaped on one side after being cut along the axial direction of the first shaft. An annular recessed platform is formed near the edge of the second shaft, and the recessed platform and the annular inner platform are arranged opposite to each other, so that they cooperate with the outer wall of the second shaft to form an annular receiving cavity with an opening.

[0147] By placing the transmission mechanism at one end of the annular cavity near the second shaft, the transmission mechanism can be directly arranged between the second shaft and the first shaft in the radial direction.

[0148] In some embodiments, an angular contact ball bearing B309 for connecting the second shaft and the outer housing is disposed within the annular receiving cavity, and the outer wall of the first shaft is connected to the outer housing via an angular contact ball bearing A308, with the end face of the angular contact ball bearing A308 connected to the first extended edge; and / or

[0149] The outer wall of one end of the second shaft is connected to the central through hole through the needle roller bearing A311, and the other end of the second shaft is connected to the outer housing through the needle roller bearing B312. The transmission mechanism is located between the needle roller bearing A311 and the needle roller bearing B312.

[0150] Furthermore, bearing spacers 307 are respectively provided between the two angular contact ball bearings A308 and the two angular contact ball bearings B309 to maintain the axial distance between the two bearings;

[0151] Furthermore, a double-layer helical elastic retaining ring 310 is provided at the end of the spline shaft near the output end of the angular contact ball bearing A308 for axial positioning of the angular contact ball bearing A308;

[0152] Furthermore, the needle roller bearing A311 located between the first shaft and the second shaft is provided with a double-layer helical elastic retaining ring 313 for axial positioning of the needle roller bearing A311.

[0153] In some embodiments, the height and length of the permanent magnet are the same as the height and length of the output rotor permanent magnet assembly 301 to which it is composed, and the width of the permanent magnet is smaller than the width of the output rotor permanent magnet assembly 301 to which it is composed.

[0154] In this embodiment, when multiple permanent magnets are assembled into an output rotor permanent magnet assembly 301, the rotor permanent magnet assembly is arranged and combined in a transverse circumferential docking manner, so that the size of the rotor permanent magnet assembly increases in the width direction while the size remains unchanged in the length and height directions, so as to install it in the groove and to continuously dock and install multiple output rotor permanent magnet assemblies 301 in the same groove.

[0155] In some embodiments, each of the permanent magnets consists of two circumferentially joined individual permanent magnets to reduce iron loss without changing the volume of a single permanent magnet.

[0156] In this embodiment, the number of magnetic pole pairs on the inner rotor is 4, the number of magnetic pole pairs on the outer rotor is 29, the number of magnetic adjustment stator blocks is 33, and the specific data are shown in Table 1 when the core size, permanent magnet size and other parameters are fixed.

[0157] Table 1 shows the variation of iron loss in the permanent magnet of the external rotor, considering the circumferential segmentation of the permanent magnet.

[0158]

[0159] Table 1 shows that, under the same conditions, dividing the permanent magnet of the output rotor into circumferential blocks can effectively reduce the iron loss of the permanent magnet under different working environments.

[0160] In some embodiments, the inner diameter of the output rotor magnetic ring 302 is greater than the radial distance between the connection point where the second shaft and the first shaft are sleeved and the axis of the second shaft.

[0161] In this embodiment, by making the inner diameter of the output rotor magnetic ring 302 larger than the radial distance between the connection point where the second shaft and the first shaft are sleeved and the axis of the second shaft, the rotation of the first shaft and the second shaft located in the middle is more stable, and at the same time, increasing the lever arm is beneficial to the driving of the first shaft and the second shaft.

[0162] An embodiment of the first aspect of the present invention provides a magnetic gear input rotor assembly structure. In some embodiments of the present invention, such as... Figure 8 As shown, a magnetic gear stator assembly structure is provided in the same air turbine starter as the magnetic gear input rotor assembly structure. This magnetic gear stator assembly structure includes:

[0163] Housing, input rotor assembly structure 2, output rotor assembly structure 3, and magnetic gear stator assembly 4;

[0164] The output rotor assembly structure 3, the magnetic gear stator assembly 4, and the input rotor assembly structure 2 are nested together and are all mounted in the housing;

[0165] The inner wall of the housing is spaced apart from the outer wall of the output rotor assembly 3, the output rotor assembly 3 is spaced apart from the magnetic gear stator assembly 4, and the magnetic gear stator assembly 4 is spaced apart from the input rotor assembly 2 to allow gas to flow through.

[0166] An embodiment of the first aspect of the present invention provides a magnetic gear stator assembly structure. In some embodiments of the present invention, such as... Figure 1-2 As shown in Figure 5, a magnetic gear stator assembly structure is provided, disposed between the input rotor and the output rotor. This magnetic gear stator assembly structure includes:

[0167] The stator support frame 402 includes multiple support plates arranged circumferentially at equal intervals and multiple mounting parts, with the mounting parts disposed between two adjacent support plates.

[0168] The stator core assembly 401 includes a plurality of stator cores axially arranged at equal intervals; the stator cores are inserted into the mounting section and are interference-fitted with two adjacent support plates that make up the mounting section.

[0169] The axis of the support plate is horizontal with the axis of the stator core; a groove is formed between two adjacent stator cores and the support plate;

[0170] Stator injection molding filler 403 is used to fill the grooves;

[0171] The stator end plate 404 is used to cooperate with the stator support frame 402 to fix the stator core assembly 401 between two adjacent support plates.

[0172] The magnetic gear stator assembly structure provided by this invention eliminates the connecting bridge structure in the stator core 401, using a stator support frame 402 for fixation. This results in better torque performance, allowing the transmission of greater torque compared to structures with connecting bridges, improving torque performance by 5%-50%. Simultaneously, in terms of transmission efficiency, it improves efficiency by 3% compared to existing double connecting bridges, internal connecting bridges, and external connecting bridges. Furthermore, it reduces end magnetic leakage.

[0173] Specifically, the stator consists of a stator support frame 402, an iron core, and stator injection molding material. Permanent magnets are attached to the surfaces of both the inner and output rotors, and magnetically conductive and non-magnetically conductive material blocks are arranged alternately to form a magnetic adjustment ring. Considering the high frequency of the alternating magnetic field in the stator core, the core is made of stacked amorphous materials, resulting in relatively low losses at high frequencies. Simultaneously, the support frame is made of low-density, non-magnetically conductive 7075 aluminum alloy, which reduces the weight of the reducer and does not affect the magnetic field generated by the combined action of the inner rotor and the magnetic adjustment stator. The stator's spaced arrangement, filled with thermosetting materials, achieves both increased structural strength and weight reduction. A uniform, annular, air-filled gap exists between the inner and output rotors and the stator.

[0174] Because the torque performance requirements are low, and due to the misconception that connecting bridges increase structural strength, the absence of connecting bridges not only outperforms other structures in torque performance, but can also improve structural strength and reduce weight by modifying the structure, using support frames and thermosetting materials to fill the gaps in the support frame structure. This allows for a significant improvement in performance while maintaining the structural strength and cost requirements of structures with connecting bridges. In the air turbine starter of this invention, the magnetic gear stator assembly 4 is equipped with a stator support frame 402. This reduces the radial obstruction of the stator core along the stator support frame while ensuring the mechanical strength of the stator assembly 4, thus improving the magnetic field modulation performance of the stator core 401. Furthermore, this structure of a connecting bridge-less gear stator provides a more significant torque transmission effect. Torque performance is also one of the important performance parameters of a magnetic reducer, directly reflecting its operating characteristics, maximum operating torque, and load-bearing capacity.

[0175] In some embodiments, a plurality of bolts are mounted on the stator end plate 404, the support plate has holes along the axial direction of the stator assembly 4 that mate with the bolts, and the stator support bracket 402 has fixing holes on the side wall at one end away from the support plate; and / or

[0176] A positioning groove is provided on one end face of the stator end plate 404 near the stator support frame 402, and a positioning block is provided on the stator core 401 that is inserted into the positioning groove.

[0177] In this embodiment, the stator support frame 402 is connected to the outside by opening a fixing hole, and the stator end plate 404 is assembled and fixed to the support plate by bolts. Specifically, the axes of the holes and the fixing holes are perpendicular to each other.

[0178] The stator end plate 404 has a positioning groove. After the stator core 401 is clamped, the positioning groove and the positioning block are inserted to achieve radial positioning of the stator core 401.

[0179] In some embodiments, the stator support frame 402 is a circumferential ring structure and has an axis;

[0180] Multiple support plates are arranged circumferentially along the axis;

[0181] The mounting part is connected to the interior of the stator support frame 402, and the mounting part is arranged radially through the stator support frame 402.

[0182] In this embodiment, in order to interact with the output rotor and the input rotor, the stator support frame 402 is configured as a circumferential ring structure, so that it has a central axis;

[0183] The mounting section is arranged radially through the stator support frame 402, so that the stator core 401 can be exposed in the radial direction of the stator support frame 402 after being clamped and fixed, thereby further improving the utilization efficiency of the core.

[0184] In some embodiments, the wall thickness of the support plate gradually increases from the inside to the outside along the radial direction of the stator support frame 402, so that the support plate forms two inclined sidewalls;

[0185] The axis is located in the plane containing the inclined sidewalls of all the support plates;

[0186] The side wall of the stator core 401 that mates with the support plate is parallel to the inclined side wall, and / or the side wall of the stator core 401 that mates with the support plate is provided with a mounting groove for accommodating the end of the support plate.

[0187] In some embodiments, the groove includes a first groove and a second groove arranged radially along the stator support frame 402;

[0188] An external air gap communicating with the first groove is formed between the stator assembly 4 and the output rotor;

[0189] An internal air gap is formed between the stator assembly 4 and the input rotor, which communicates with the second groove.

[0190] In this embodiment, by dividing the groove radially into a first groove and a second groove along the stator support frame 402 and filling them with stator injection filler 403 respectively, the smoothness of the inner and outer walls of the stator support frame 402 can be optimized after the stator core assembly is installed.

[0191] In some embodiments, the outer air gap and the inner air gap are coaxially arranged with the shaft.

[0192] The outer and inner air gaps have the same thickness along the radial direction of the stator support frame 402, and the thickness of the inner air gap is calculated using the following formula:

[0193] h in =k*maxU total +Z;

[0194] Among them, h in Where is the thickness of the internal air gap, k is the safety margin factor, and maxU total Z represents the change in the thickness of the internal air gap of the input rotor during operation, and Z represents the thermal expansion of the input rotor.

[0195] The thickness of the internal air gap of the stator assembly 4, maxU total For diameters < 0.22 mm, Z = 0.15 mm, and k = 1.5, the following formula must be satisfied:

[0196] h in >0.22*1.5+0.15, considering manufacturing costs, for h in =0.5mm.

[0197] In this embodiment, firstly, during the structural design, since the design of the magnetizing stator is always accompanied by core loss, in order to reduce its loss coefficient and thus reduce its core loss, the loss coefficient is reduced in terms of material selection and size design.

[0198] Secondly, the thickness of the inner and outer air gaps in a magnetic gear reducer affects the magnetic field distribution of the system, and changes in the air gap directly affect the performance of the entire magnetic reducer. Therefore, by analyzing the following three cases: (1) the loss change when only the inner air gap is changed; (2) the loss change when only the outer air gap is changed; and (3) the loss change when both the inner and outer air gaps are changed, the relationship between magnetic loss and air gap thickness is determined. Then, by adding variables such as load and vibration in Abaqus software, the optimal air gap thickness is calculated to be 0.5 mm.

[0199] Furthermore, considering the impact of end leakage flux on torque performance, three-dimensional finite element analysis models of four different magnetic reducers with different structures were established, along with static torque variation diagrams of the output rotors of the different magnetic reducers considering end leakage flux effects. It was found that the bridgeless structure reduces the magnetic reluctance between the internal and external output rotors, allowing more magnetic flux lines to reach the permanent magnets of the output rotor, thus reducing the number of magnetic flux lines in the air domain and mitigating the end leakage flux effect.

[0200] Furthermore, regarding U total The change in the thickness of the internal air gap of the input rotor during operation is calculated using the following formula:

[0201] maxU total =u1+u2+u3;

[0202] Where u1 is the displacement change caused by centrifugal load and torque load, u2 is the displacement change caused by vibration, and u3 is the process tolerance of the reducer;

[0203] Specifically, u1, based on the finite element method (FEM) platform, observed a maximum displacement of 0.0803 mm caused by centrifugal force after applying a maximum load of 45,000 rpm. u2, also based on the FEM platform, performed harmonic response analysis on the input rotor. Since the input rotor speed of the reducer does not exceed 45,000 rpm and the highest frequency is less than 750 Hz, resonance will not occur in actual operation. Furthermore, the maximum value of the input rotor vibration displacement at 750 Hz is less than 0.0005 mm. With the stator tolerance of the magnetic ring set to 0.046 mm and the tolerance of the input rotor permanent magnet sheath set to 0.074 mm, the total tolerance u3 will not exceed 0.12 mm.

[0204] In some embodiments, the circumferential angle of the magnetic material occupying the stator assembly structure on the same stator assembly structure is θ. sp The circumferential angle of the non-magnetic material in the stator assembly structure is τ. sp If the slotting ratio of the stator assembly structure is α, then the following formula is satisfied:

[0205]

[0206] Wherein, the value of α is [0, 1], and the slotting rate α is the opening rate of the mounting part along the circumferential direction of the stator assembly structure;

[0207] It is understandable that the stator core is made of magnetically conductive material, while the support plate and filler material are made of non-magnetically conductive material;

[0208] Under the same magnetic field strength of the stator core assembly, calculate the output torque of the stator assembly structure on the input rotor and output rotor under different slotting ratios, and obtain the slotting ratio corresponding to the maximum output torque, which is α=0.45.

[0209] In this embodiment, the working condition of the gear stator is improved through certain gear stator structure optimization. The output torque under different magnetic ring slotting ratios was studied, and the optimal magnetic ring slotting ratio of 0.45 was selected, increasing the output torque by 4 Nm. The structural parameters of the magnetic stator were optimized using the surface response method and a genetic algorithm. Without reducing the peak torque of the coaxial magnetic gears, the optimal parameter combination was found, effectively improving the stability of the magnetic stator structure.

[0210] In some embodiments, the stator support frame 402 is made of 7075 aluminum alloy, the magnetic conductive part of the stator core 401 is composed of amorphous laminates stacked together, and the stator injection filler 403 is thermosetting plastic.

[0211] In this embodiment, the magnetic gear stator assembly 4 includes a stator core 4011, a stator support frame 402, a stator injection-molded filler 403, and a stator end plate 404. The stator core 401 is made of amorphous soft magnetic material, and the stator support frame 402 is made of 7075 aluminum alloy. The stator core 401 is installed in the middle of the partition of the stator support frame 402 via an interference fit, achieving uniform circumferential distribution. The stator injection-molded filler 403 is made of thermosetting plastic and fills the inner and outer gaps of the stator support frame 402, making the stator assembly 4 a cylinder. The stator end plate 404 is connected to the stator support frame 402 by bolts.

[0212] Another embodiment of the first aspect of the present invention also proposes a magnetic gear rotor support structure, such as... Figure 9 The magnetic gear rotor support structure includes:

[0213] The rotor includes an output rotor assembly structure 3 and an input rotor assembly structure 2, which are separately disposed within the housing and guide assembly structure 1 of the magnetic gear. The output rotor assembly structure 3 has a hollow portion axially provided for housing the input rotor assembly structure 2.

[0214] A first annular cavity is formed between the outer side of the input rotor assembly structure 2 and the inner side of the output rotor assembly structure 3. The radial width of the first annular cavity is equal along the circumference of the input rotor assembly structure 2.

[0215] The output rotor assembly structure 3 has a connecting part circumferentially provided at one end of the input rotor assembly structure 2 along the axial direction, and an output shaft 305 coaxial with the input rotor assembly structure 2 is provided through the connecting part.

[0216] A second annular cavity is formed between the outer side of the output shaft 305 and the inner side of the input rotor assembly structure 2. A support mechanism is provided axially within the second annular cavity for the housing and guide assembly structure 1. The support mechanism is connected to the input rotor assembly structure 2 and the output shaft 305 respectively to provide support for the output rotor assembly structure 3 and the input rotor assembly structure 2.

[0217] The magnetic gear rotor support structure provided by this invention minimizes the total length and radial dimension of the rotor, thereby reducing the total weight of the starter. Compared with traditional planetary gear starters, the magnetic gear of this invention reduces the complexity of the support structure and components. It uses a coaxial nesting method between the input and output rotors as the support scheme, which reduces the complexity of the entire system. The stator core assembly in the magnetic gear stator assembly is fixed by a stator support frame, eliminating the connecting bridge structure and further reducing the total weight of the starter.

[0218] By forming a first annular cavity for placing the stator 4 between the input rotor assembly structure 2 and the output rotor assembly structure 3, on the one hand, a gap can be formed between the stator 4 and the input rotor and the output rotor, and on the other hand, the stator 4 can be independent of the output rotor except for the magnetic field coupling, thus reducing the complexity of the entire rotor structure.

[0219] By forming a first annular cavity with a radial width equal to that of the two circumferences of the input rotor assembly structure, the inner and outer rotors do not come into direct contact during high-speed rotation, resulting in less vibration and noise.

[0220] It features overload protection; under overload conditions, the magnetic gears can protect the structure from physical damage through out-of-step operation. When an overload occurs, the net torque on the low-speed rotor suddenly increases, causing its rotational speed to decrease rapidly. The angular displacement difference between the two rotors increases rapidly. When the maximum transmitted torque is less than the load torque, the low-speed rotor continues to decelerate, and the rotor angular displacement difference continues to widen. Afterward, regardless of how the angular displacement difference changes, the transmitted torque remains less than the load torque, causing the low-speed rotor speed to decrease to zero. During this process, the transmitted torque on the high-speed rotor gradually increases, alternating between positive and negative maximum values. The above analysis shows that when an overload occurs, the low-speed rotor speed gradually decreases to zero, the high-speed rotor speed changes and begins to oscillate, and the angular displacement difference between the high-speed and low-speed rotors continuously widens. It can still operate normally after the load is removed, demonstrating the advantages of automatic overload protection.

[0221] To address the instability during rotation caused by the strong magnetism between the stator 4, input rotor assembly structure 2, and output rotor assembly structure 3, an air turbine starter based on magnetic gear transmission was developed. An output stator positioning sleeve is installed in the housing and guide assembly. Eight circumferentially evenly distributed rollers are arranged on the inner cylindrical surface of the output rotor positioning sleeve. The output rotor positioning sleeve fits onto the outer cylindrical surface of the output rotor's magnetic guide ring, effectively limiting the radial displacement of the output rotor and improving rotational stability. Simultaneously, a dovetail structure is designed on the inner surface of the output rotor's magnetic guide ring in the output rotor assembly to fix the permanent magnets of the output rotor. The output main shaft and the output driven shaft welded together in the output rotor assembly transmit power through an overrunning clutch, preventing reverse drive of the air turbine starter and further improving stability.

[0222] In some embodiments, one end of the first annular cavity is connected to the hollow portion, and the other end is connected to the interior of the housing and guide assembly structure 1.

[0223] A stator 4 is provided in the first annular cavity of the housing and guide assembly structure 1. The connection between the stator 4 and the housing and guide assembly structure 1 is located in the communication between the first annular cavity and the housing and guide assembly structure 1.

[0224] In this embodiment, the first annular cavity can not only be used for the installation of the stator 4, but also guide the internal airflow through the gap between the stator 4 and the input rotor and the output rotor. Furthermore, by fixing the stator 4 at the connection between the housing and the guide assembly structure 1 and the communication between the first annular cavity and the housing and guide assembly structure 1, the connection that affects the uniformity of the first annular cavity can be located at the end of the airflow guidance, thereby ensuring the uniformity of the gap between the stator 4 and the input rotor and the output rotor, further reducing the interference with the airflow inside the device, making the rotation of the input rotor and the output rotor more stable, and reducing energy loss and machine wear.

[0225] In some embodiments, the housing and guide assembly structure 1 includes a clamping part that is circumferentially mounted on the output shaft 305, and the clamping part is located on the side of the connecting part away from the output shaft assembly structure 3.

[0226] Two sets of first support components are provided at the assembly point between the clamping part and the output shaft 305.

[0227] In this embodiment, with the connecting part as the boundary, both the input rotor and the output rotor are located on one side of the connecting part. On the other side of the connecting part, a clamping part is provided circumferentially for guiding and clamping the output shaft 305. This provides the output rotor and output shaft 305 with guide rotation parts at both ends of the overall connection structure, further improving the stability of the high-speed working parts inside the device, reducing vibration or eccentric movement during high-speed rotation, improving transmission stability, and reducing losses.

[0228] In some embodiments, the support mechanism includes:

[0229] The stator 5 is supported, with one end away from the connecting part connected to the housing and guide assembly structure 1, and the other end located in the communication between the first annular cavity and the hollow part;

[0230] The second support assembly, at least two in number, is provided for connecting the support stator 5 and the input rotor assembly structure 2;

[0231] The third support assembly is used to connect the support stator 5 and the output shaft 305, and is located between the adjacent second support assemblies along the axial direction of the output shaft 305.

[0232] In this embodiment, the support mechanism is configured as a support stator 5 with a ring-shaped fixing structure in the middle, and a three-point support positioning structure at both the inner and outer ends of the support stator 5. Specifically, it consists of two second support components and one third support component, which are not on the same straight line. This allows the third support component and the second support component to form a stable triangular support structure at the same end, ensuring stable rotational support between the output shaft 305 of the output rotor and the input rotor during rotation.

[0233] In some embodiments, each of the first and second support components includes at least one angular contact bearing 206, and the third support component includes a needle roller bearing 312.

[0234] In this embodiment, the input rotor and the bearing stator are supported by angular contact bearings to achieve stability at higher speeds and to withstand larger loads; the output rotor and the stator are supported by needle roller bearings 312, making the radial structure of the entire coaxial structure more compact and reducing the overall mass.

[0235] In some embodiments, the input rotor assembly structure 2 is circumferentially provided with a power unit that protrudes axially from one end of the output rotor assembly structure 3, and the power unit is located on the side of the connection that is away from the output rotor assembly structure 3.

[0236] In this embodiment, the power unit is located at one end of the input rotor assembly structure 2 that protrudes from the output rotor assembly structure 3 along the axial direction, and further located on the side of the connection away from the output rotor assembly structure 3. This can reduce the influence of external airflow on the rotation of the final output rotor assembly structure 3, and further reduce the interference of flowing air on the internal rotating structure.

[0237] In some embodiments, the radial distances between the rolling element centers of the needle roller bearing 312 and the angular contact bearings 206 of the first and second support assemblies and the axis of the output shaft 305 are not equal.

[0238] In this embodiment, bearing rolling centers are set at different positions in the radial direction relative to the output axis position. This can avoid damage to the bearing structure caused by excessive axial force. At the same time, by setting multiple bearings at different radial positions, the stable rotation of the input rotor, output rotor and output shaft 305 during simultaneous rotation is ensured.

[0239] In some embodiments, the projections of the clamping part, the input rotor assembly structure 2, the output rotor assembly structure 3, and the stator 4 along the axis of the output shaft 305 of the second support assembly are all located on the connecting part;

[0240] The projections of the third support assembly and the support stator 5 along the output shaft 305 axis are both located on the output shaft 305.

[0241] In this embodiment, when arranging the structure, the annular area of ​​the connecting part is considered in advance. The projections of the clamping part, the input rotor assembly structure 2, the output rotor assembly structure 3, and the stator 4 along the axis of the output shaft 305 of the second support assembly are all located on the connecting part in the axial direction. The annular area of ​​the connecting part is limited and reduced according to the specific size of each structure in use, making the overall structure more compact and effectively reducing the radial length. Furthermore, the steps of the input rotor, stator 4, output rotor, support structure, and output shaft 305 corresponding to the support structure adopt a layered nesting structure, which can effectively reduce the defects of multi-section axial arrangement and reduce the overall axial dimension of the device.

[0242] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0243] The above embodiments are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A magnetic gear input rotor assembly structure, characterized by, include: A rotor shaft, wherein a hollow portion is provided axially through the rotor shaft for an external shaft body to pass through; A guide assembly is disposed on the inner wall of the hollow part to restrict the axial movement between the outer shaft and the rotor shaft when the outer shaft and the rotor shaft rotate relative to each other in the circumferential direction. A magnetic component is circumferentially disposed on the side wall of the rotor shaft, used to generate magnetic force with the external stator to drive the rotor shaft to rotate circumferentially; An input rotor sleeve is provided to cover the outside of the magnetic part, and the distance between any point on the outer wall of the input rotor sleeve along the radial direction of the rotor shaft and the axis of the rotor shaft is a fixed value. Wherein, the distance between each pair of corresponding points of the outer stator and the input rotor sheath on the opposite surface along the radial direction of the rotor axis is equal; The outer wall of the rotor shaft is coaxially provided with an annular groove, and at least one is provided along the axial direction of the rotor shaft. The two ends of the annular groove are formed with annular ribs protruding from the bottom of the annular groove along the axial direction of the rotor shaft. The magnetic part includes an input rotor magnetic ring that abuts against the annular ribs. A strain cavity is formed between the input rotor magnetic ring, the annular rib, and the annular groove; The guide assembly includes multiple high-speed angular contact ball bearings disposed at the end of the hollow part, and the inner end faces of adjacent high-speed angular contact ball bearings are connected by bearing retaining rings to form a cover over the middle part of the inner wall of the hollow part. Among them, multiple high-speed angular contact ball bearings are respectively aligned radially with the air turbine on the input rotor sleeve and the rotor shaft.

2. The magnetic gear input rotor assembly structure of claim 1, wherein, The magnetic part also includes an input rotor permanent magnet assembly, which is disposed between the input rotor sheath and the input rotor magnetic ring; The input rotor permanent magnet assembly includes multiple pairs of permanent magnets arranged circumferentially along the magnetic ring of the input rotor. In this case, the magnetic poles of adjacent permanent magnets are different along the circumferential and axial directions of the input rotor magnetic ring.

3. The magnetic gear input rotor assembly structure of claim 2, wherein When the high-speed angular contact ball bearing corresponds radially to the input rotor sleeve along the rotor shaft, the high-speed angular contact ball bearing corresponds to the strain chamber; and / or The mating gap between the same pair of permanent magnets and the annular rib are staggered along the axial direction of the rotor shaft; and / or The rotor shaft is provided with a receiving part that is connected to the end face of the input rotor magnetic ring.

4. The magnetic gear input rotor assembly structure of claim 2, wherein, An input rotor baffle is fitted at one end of the outer wall of the input rotor magnetic ring. The input rotor baffle is used to support the permanent magnet along the axial direction of the input rotor magnetic ring. The permanent magnet is disposed within the cavity formed by the input rotor magnetic ring, the input rotor baffle, and the input rotor sheath.

5. The magnetic gear input rotor assembly structure of claim 2, wherein, The permanent magnet is bonded and fixed to the input rotor magnetic ring using epoxy resin adhesive; and / or The input rotor sheath is fixed by prestress and covers the outside of the permanent magnet.

6. The magnetic gear input rotor assembly structure of claim 2, wherein, The input rotor sheath is made of carbon fiber.

7. The magnetic gear input rotor assembly structure according to claim 2, characterized in that, The logarithm of the permanent magnet satisfies the following relationship: ； in, The number of adjusting ring core blocks in the rotor permanent magnet assembly is the input number, which is the number of permanent magnets. For the logarithm of permanent magnets, The number of permanent magnet pairs of the output rotor where the external shaft is located.

8. An air turbine starter characterized by, Includes housing, guide assembly structure, and magnetic gear; The magnetic gear uses the input rotor assembly structure as described in any one of claims 1-7.

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