A rotor disc for a disc motor

Abstract

This invention discloses a rotor disk for a disc motor, comprising: a plurality of magnet slots evenly distributed on one side of the rotor disk near the outer circumference; and a plurality of strip-shaped slots, corresponding one-to-one with the magnet slots and radially formed on the inner ring of the rotor disk, such that the strip-shaped slots penetrate the inner ring shaft hole and the magnet slots of the rotor disk. This invention provides a rotor disk for a disc motor that does not alter the original overall rotor structure. Through the slotted design of the inner ring of the rotor, with the number of slots matching the number of magnets, the eddy current path generated by the magnets is interrupted, thereby preventing the generation of eddy currents at the source and reducing rotor losses.

Description

Technical Field

[0001] This invention relates to the field of disc motor technology, and more specifically to a rotor disc for a disc motor. Background Technology

[0002] Disc motors, also known as axial flux motors, are mainly used in hybrid electric vehicle drive systems, electric drive axle hub powertrains, and three-in-one powertrains where structural size restrictions are high or power performance is required. They are suitable for new energy vehicles such as electric racing cars, high-performance coupes, and electric commercial vehicles.

[0003] Disc motors are primarily used in the low-to-medium speed range. To increase operating speed, one current method is to improve cooling to dissipate generated heat and reduce rotor eddy current losses. This can be achieved by internal oil injection or by adding cooling ducts. While improved cooling allows disc motors to operate at higher speeds, the limited size and cooling efficiency of disc motors restrict the speed increase and cannot meet current industry demands.

[0004] Therefore, how to provide a disc motor that can operate at high speeds to meet current industry needs has become an urgent problem to be solved. Summary of the Invention

[0005] In view of this, embodiments of the present invention provide a rotor disk for a disc motor to solve the problem that disc motors in the prior art are limited by size and heat dissipation efficiency, and cannot meet the current industry requirements for high-speed operation.

[0006] This invention provides a rotor disc for a disc motor, comprising:

[0007] Several magnetic slots are evenly distributed on one side of the rotor disk near the outer circumference;

[0008] Several strip grooves, corresponding one-to-one with several magnet slots, are radially opened on the inner ring of the rotor disk, so that the strip grooves pass through the inner ring shaft hole and the magnet slot of the rotor disk.

[0009] Optionally, it also includes:

[0010] Clearance holes are provided at the four vertices of each magnet slot.

[0011] Optionally, the magnet slots are axially extended on the rotor disk, and there are partition bars of the same width between two adjacent magnet slots.

[0012] Optionally, it also includes:

[0013] A pair of limiting strips are set on the edge of the partition strip; wherein the limiting strips are set on the same side of the rotor disc; the limiting strips are used to place the magnets.

[0014] Optionally, it also includes:

[0015] The magnetic steel pressure plate is fixed to the partition strip by bolts; the magnetic steel pressure plate is used to fix two adjacent magnets.

[0016] Optionally, it also includes:

[0017] T-shaped positioning blocks are assembled at the strip slots and magnet slots; the thickness of the T-shaped positioning blocks is the same as the thickness of the rotor disk; the length of the ribs of the T-shaped positioning blocks is the same as the width of the corresponding position of the magnet slots; the main body width of the T-shaped positioning blocks is the same as the width of the strip slots; the main body of the T-shaped positioning blocks is locked in the strip slots to eliminate the inner ring annular gap; the T-shaped positioning blocks are made of insulating material.

[0018] Optionally, it also includes:

[0019] An insulating ring is fixed on the inner ring of the inner ring; several T-shaped positioning blocks are fixed on the insulating ring; or, several T-shaped positioning blocks and the insulating ring are an integral structure.

[0020] Optionally, it also includes:

[0021] The first connecting seat is fixed to one side of the rotor disc by bolts;

[0022] Specifically, the contact surface between the first connecting seat and the rotor disk is treated with insulating spraying; the first connecting seat is fixedly connected to the motor shaft; the inner ring protrusion of the first connecting seat is in close contact with the inner side of the inner ring; an outward-folding structure is provided on one side of the insulating ring, and the outward-folding structure is sandwiched between the inner rings of the first connecting seat.

[0023] Optionally, it also includes:

[0024] The second connecting seat is fixed to one side of the rotor disc by bolts; the second connecting seat is fixedly connected to the motor shaft;

[0025] The third connecting seat is fixed to the other side of the rotor disc by bolts;

[0026] Insulating spraying is applied to the contact surfaces of the second connecting seat and the rotor disk, as well as the contact surfaces of the third connecting seat and the rotor disk; the inner ring protrusions of the second connecting seat and the third connecting seat are in close contact with the inner side of the inner ring of the rotor disk; the second connecting seat and the third connecting seat are partially pressed together with the T-shaped positioning block.

[0027] Optionally, the opening position of the corresponding strip slot is determined according to the center line of each magnet slot; each strip slot is located on the diameter of the rotor disk.

[0028] Beneficial effects of the embodiments of the present invention:

[0029] This invention provides a rotor disc for a disc motor. Without changing the original overall rotor structure, the rotor inner ring is slotted, with the number of slots matching the number of magnets. This breaks the eddy current path generated by the magnets, thereby preventing the generation of eddy currents from the source and greatly reducing rotor eddy current losses. Attached Figure Description

[0030] The features and advantages of the invention will be more clearly understood by referring to the accompanying drawings, which are schematic and should not be construed as limiting the invention in any way. In the drawings:

[0031] Figure 1 A schematic diagram of a rotor disk body structure for a disc motor according to an embodiment of the present invention is shown.

[0032] Figure 2 This invention provides a side view of the assembly of a rotor disk and magnets for a disc motor according to an embodiment of the invention.

[0033] Figure 3 A structural diagram of a T-shaped positioning block for a disc motor is shown in an embodiment of the present invention;

[0034] Figure 4 An assembly side view of a rotor disk for a disc motor according to an embodiment of the present invention is shown;

[0035] Figure 5 A structural diagram of a connector for a disc motor is shown in an embodiment of the present invention;

[0036] Figure 6 An assembly side view of a rotor disk for a disc motor according to another embodiment of the present invention is shown;

[0037] Figure 7 An exploded view of the assembly of a rotor disc for a disc motor according to an embodiment of the present invention is shown. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] This invention provides a rotor disk for a disc motor, comprising a plurality of magnetic steel grooves 1 and a plurality of strip grooves 3. The magnetic steel grooves 1 are evenly distributed on the side of the rotor disk near the outer circumference 2. The strip grooves 3 correspond one-to-one with the plurality of magnetic steel grooves 1 and are radially opened on the inner ring 4 of the rotor disk, such that the strip grooves 3 pass through the inner ring shaft hole of the rotor disk and the magnetic steel grooves 1.

[0040] In this embodiment, strip grooves are formed in the inner ring of the rotor, and the number of strip grooves is the same as the number of magnets, such as... Figure 1 and Figure 2 As shown, the inner ring 4 is evenly cut by the strip groove 3, thus breaking the eddy current path generated by the magnet and preventing the generation of eddy currents from the source.

[0041] As an optional implementation, it also includes clearance holes 5, which are provided at the four vertices of each magnet slot 1.

[0042] In this embodiment, as Figure 1 As shown, clearance holes 5 are provided around the magnet groove 1 to prevent the four ends of the magnet from being squeezed during the rotation of the rotor disc, which would cause the magnet to break.

[0043] As an optional implementation, the magnet slot 1 is axially extended on the rotor disk, and there is a partition bar 6 of the same width between two adjacent magnet slots 1.

[0044] In this embodiment, as Figure 1 As shown, the shape of the magnet slot 1 is an isosceles trapezoid. In a specific embodiment, the rotor disk is integrally formed.

[0045] As an optional implementation, it further includes: a pair of limiting strips 7, disposed on the edge of the partition strip 6. The limiting strips 7 are located on the same side of the rotor disc. The limiting strips 7 are used to place the magnets 8. A magnet pressure plate 9 is fixed to the partition strip 6 by bolts; the magnet pressure plate 9 is used to fix two adjacent magnets 8.

[0046] In this embodiment, as Figure 1 and Figure 2 As shown, the limiting strip 7, together with the magnetic steel pressure plate 9, achieves the function of fixing and assembling the magnetic steel 8.

[0047] As an optional implementation, a T-shaped positioning block 10 is also included, which is assembled at the strip groove 3 and the magnet groove 1. The thickness of the T-shaped positioning block 10 is the same as the thickness of the rotor disk; the rib length of the T-shaped positioning block 10 is the same as the width of the corresponding position of the magnet groove 1; the main body width of the T-shaped positioning block 10 is the same as the width of the strip groove 3; the main body of the T-shaped positioning block 10 is engaged in the strip groove 3 to eliminate the inner ring annular gap; the T-shaped positioning block 10 is made of insulating material.

[0048] In this embodiment, as Figure 2 and Figure 3 As shown, the T-shaped positioning block 10 is made of high-strength PPS material, which can provide support and cushioning to prevent the magnet from breaking due to impact.

[0049] In a specific embodiment, the thickness of the T-shaped positioning block is optimally the same as or close to the thickness of the rotor disk, and the thickness of the ribs assembled at the magnet slots is set according to the size of the rotor disk. In a specific embodiment, the thickness of the T-shaped positioning block is selected between 1.5mm and 4mm, mainly for support and buffering purposes, to prevent the rotor disk from deforming under stress, which could lead to magnet breakage.

[0050] As an optional implementation, it also includes an insulating ring fixed on the inner ring of the inner ring 4, and a plurality of T-shaped positioning blocks 10 fixed on the insulating ring; or, the plurality of T-shaped positioning blocks 10 and the insulating ring are an integral structure.

[0051] In this embodiment, the strength of the rotor disk is increased by using an insulating ring and a T-shaped positioning block.

[0052] As an optional implementation, a first connecting seat 11 is also included, which is fixed to one side of the rotor disk by bolts. The contact surface between the first connecting seat 11 and the rotor disk is treated with insulating spraying; the first connecting seat 11 is fixedly connected to the motor shaft; the inner ring protrusion of the first connecting seat 11 is in close contact with the inner side of the inner ring 4; an outward-folding structure is provided on one side of the insulating ring, and the outward-folding structure is sandwiched between the inner rings 4 of the first connecting seat.

[0053] like Figure 4 As shown, in this embodiment, the aforementioned integrated T-shaped positioning block and insulating ring structure allows for the connection of the rotor disk and the shaft using only one connecting base plate. The inner ring of the first connecting base 11 has a threaded structure, or it can be fixedly connected to the motor shaft by welding. The first connecting base 11 and the rotor disk are fixed with bolts. In a specific embodiment, the inner ring protrusion of the first connecting base 11 is nested within the inner ring of the insulating ring, and the insulating ring is nested within the inner ring of the rotor disk, with all three in close contact, thereby increasing the strength of the inner ring. Insulating spraying is applied to the contact surface between the first connecting base 11 and the rotor disk to ensure that the eddy current path is broken, achieving complete blockage of the eddy current path.

[0054] As an optional implementation, it also includes a second connecting seat 12 and a third connecting seat 13, wherein the second connecting seat is fixed to one side of the rotor disk by bolts; the second connecting seat 12 is fixedly connected to the motor shaft; the third connecting seat 13 is fixed to the other side of the rotor disk by bolts; insulating spraying is performed on the contact surfaces of the second connecting seat 12 and the rotor disk and the contact surfaces of the third connecting seat 13 and the rotor disk; the inner ring protrusions of the second connecting seat 12 and the third connecting seat 13 are in close contact with the inner side of the inner ring 4 of the rotor disk; the second connecting seat 12 and the third connecting seat 13 are partially pressed together with the T-shaped positioning block 10.

[0055] In this embodiment, as Figures 5 to 7 As shown, two connecting seats are set on both sides of the rotor disk. On the one hand, the strength of the inner ring of the rotor disk is improved so that it can achieve high-speed operation of the motor rotor. On the other hand, the T-shaped positioning block is pressed to fix the structure.

[0056] As an optional implementation, the first connecting seat 11 and the motor shaft are an integral structure. The first connecting seat 11 does not have an inner ring protrusion, and the first connecting seat 11 is not subjected to insulating spraying treatment. An insulating gasket is provided between the first connecting seat 11 and the rotor disk to ensure that the two are insulated.

[0057] As an optional implementation, the third connecting seat 13 and the motor shaft are an integral structure. The third connecting seat 13 does not have an inner ring protrusion, and the third connecting seat 13 is not subjected to insulating spraying treatment. Figure 7 As shown, an insulating gasket 14 is provided between the rotor disc and the third connecting seat 13 to prevent them from conducting.

[0058] Table 1 Comparison results between conventional disc motors and the disc motor of this embodiment

[0059]

[0060] As shown in Table 1, the disc motor provided in this embodiment exhibits a reduction of eddy current losses of 67W at a speed of 1500rpm and a power of 21kW, corresponding to an efficiency improvement of 0.3%. At a speed of 2500rpm and a power of 35kW, the eddy current losses are reduced by 205W, resulting in an efficiency improvement of 0.53%. At 2500rpm and a power of 21kW, the eddy current losses are reduced by 169W, resulting in an efficiency improvement of 0.76%. At 2500rpm and a power of 35kW, the eddy current losses are reduced by 442W, resulting in an efficiency improvement of 1.2%. These data demonstrate that the rotor motor of this embodiment exhibits significant advantages at high speeds and high power.

[0061] With the rotor disc provided in this embodiment, the maximum operating speed of the disc motor can be doubled, from the current 3500-4000rpm to 6500-7000rpm, and the power can be increased by 30%-40%. Under the same power conditions, the size of the motor can be reduced by 15-20%, which can further improve the application coverage of the motor.

[0062] Furthermore, the rotor disk provided in this embodiment, without increasing material costs, has strip grooves formed on the inner ring of the rotor disk to block the eddy current path. The corresponding structural reinforcement scheme for forming the strip grooves also uses cost-effective PPS plastic, which comprehensively optimizes the strength and balance of the rotor disk and can avoid the risk of the rotor disk cracking at high speed.

[0063] This invention provides a rotor disc for a disc motor. Without changing the original overall rotor structure, the rotor inner ring is slotted, with the number of slots matching the number of magnets. This breaks the eddy current path generated by the magnets, thereby preventing the generation of eddy currents from the source and greatly reducing rotor eddy current losses.

[0064] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A rotor disc for a disc motor, characterized in that, include: Several magnetic slots (1) are evenly distributed on the side of the rotor disk near the outer circumference (2); Several strip grooves (3) are radially opened on the inner ring (4) of the rotor disk, corresponding one-to-one with several magnetic steel grooves (1), so that the strip grooves (3) pass through the inner ring shaft hole of the rotor disk and the magnetic steel grooves (1). T-shaped positioning blocks (10) are assembled at the strip groove (3) and the magnet groove (1); the thickness of the T-shaped positioning blocks (10) is the same as the thickness of the rotor disk; the rib length of the T-shaped positioning blocks (10) is the same as the width of the corresponding position of the magnet groove (1); the main body width of the T-shaped positioning blocks (10) is the same as the width of the strip groove (3); the main body of the T-shaped positioning blocks (10) is engaged in the strip groove (3) to eliminate the deformation gap of the inner ring (4); the T-shaped positioning blocks (10) are made of insulating material. An insulating ring is fixed on the inner ring of the inner ring (4); several T-shaped positioning blocks (10) are fixed on the insulating ring; or, several T-shaped positioning blocks (10) and the insulating ring are an integral structure.

2. The rotor disc for a disc motor according to claim 1, characterized in that, Also includes: The clearance holes (5) are provided at the four vertices of each of the magnet slots (1).

3. The rotor disc for a disc motor according to claim 1, characterized in that, The magnetic steel groove (1) is axially opened on the rotor disk, and there is a partition strip (6) of the same width between two adjacent magnetic steel grooves (1).

4. The rotor disc for a disc motor according to claim 3, characterized in that, Also includes: A pair of limiting strips (7) are provided on the edge of the partition strip (6); wherein the limiting strips (7) are provided on the same side of the rotor disk; the limiting strips (7) are used to place the magnet (8).

5. The rotor disc for a disc motor according to claim 4, characterized in that, Also includes: The magnetic steel pressure plate (9) is fixed to the partition strip (6) by bolts; the magnetic steel pressure plate (9) is used to fix two adjacent magnetic steels (8).

6. The rotor disc for a disc motor according to claim 1, characterized in that, Also includes: The first connecting seat (11) is fixed to one side of the rotor disc by bolts; Among them, the contact surface between the first connecting seat (11) and the rotor disk is treated with insulating spraying; the first connecting seat (11) is fixedly connected to the motor shaft; the inner ring protrusion of the first connecting seat (11) is in close contact with the inner side of the inner ring (4); an outward flip structure is provided on one side of the insulating ring, and the outward flip structure is sandwiched between the inner ring (4) of the first connecting seat.

7. The rotor disc for a disc motor according to claim 6, characterized in that, Also includes: The second connecting seat (12) is fixed to one side of the rotor disc by bolts; the second connecting seat (12) is fixedly connected to the motor shaft; The third connecting seat (13) is fixed to the other side of the rotor disk by bolts; Insulation spraying is performed on the contact surfaces of the second connecting seat (12) and the rotor disk, and on the contact surfaces of the third connecting seat (13) and the rotor disk; the inner ring protrusions of the second connecting seat (12) and the third connecting seat (13) are in close contact with the inner side of the inner ring (4) of the rotor disk; the second connecting seat (12) and the third connecting seat (13) are partially pressed together with the T-shaped positioning block (10).

8. The rotor disc for a disc motor according to claim 1, characterized in that, The opening position of the corresponding strip groove (3) is determined according to the center line of each of the magnet slots; each of the strip grooves (3) is located on the diameter of the rotor disk.

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