Rotor with inclined angle side surface and lamination made of rotor
By designing rotor disk teeth with roughly arched shape and trimming the sides, the problem of conductive material damage when the rotor disk rotates is solved, and a deflected channel without exposing sharp corners is achieved to ensure the integrity of the conductive material.
Patent Information
- Application Number
- CN202311433989.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-06-22
- Filing Date
- 2023-10-31
- Publication Date
- 2024-12-24
AI Technical Summary
When constructing the rotor, rotation of adjacent disks causes damage to the conductive material during winding and exposed sharp edges.
A rotor disk is designed with the transverse portions of the teeth having a generally arched shape and by trimming the sides form a non-90-degree angle to the top or bottom surface, thereby forming a skewed channel when stacking to avoid exposure of sharp corners.
The effect of not damaging the conductive material during the rotor disk stacking and winding is achieved, providing a rotation gap without exposing sharp corners to ensure the integrity of the conductive material.
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Figure CN119182242A_ABST
Abstract
Description
Technical Field
[0001] The technical field generally relates to rotors that can be used in brushless and brushed electric motors, and more particularly to rotors having angled side surfaces. Background Art
[0002] The rotor may include a stack of disks having an annular body portion having a through hole formed therein to accommodate a shaft of an electric motor. A plurality of spaced-apart teeth may extend radially from the annular body portion. Adjacent teeth of the disks are separated from each other by a gap at the end of each tooth. In some configurations of stacked disks used to construct the rotor, the gap must be increased to allow the conductive material to be wound through each gap and into the space separating adjacent teeth. However, when the disks are stacked so that adjacent disks rotate relative to each other, sharp edges are exposed, which may damage the conductive material during the winding process.
[0003] It is therefore desirable to provide a rotor disk such that a plurality of such rotor disks may be stacked wherein adjacent disks are rotated relative to one another to provide skewed channels formed by gaps between rotor teeth without exposing sharp corners of the rotor teeth which could damage the conductive material during the winding process. Summary of the invention
[0004] Variations may include a product comprising a rotor disk and a plurality of spaced-apart teeth, the rotor disk having a central body portion and having a through hole formed therein, the plurality of spaced-apart teeth extending radially from the central body portion, wherein each of the plurality of teeth comprises an elongated stem portion having a first end at the central body portion, and wherein the elongated stem portion extends radially to a second end terminating at a transverse portion, the transverse portion may have a generally arcuate shape and extend from a first side edge of the stem portion in a first direction and from a second side edge of the stem portion in an opposite second direction, the first end of the transverse portion having a first side surface that is not formed at a 90 degree angle relative to a top surface or a bottom surface of the rotor disk and the second end of the transverse portion having a second side surface that is not formed at a 90 degree angle relative to the top surface or the bottom surface, the transverse portions of adjacent teeth forming a gap therebetween.
[0005] Variations may include a product comprising a plurality of rotor disks and a plurality of spaced apart teeth, each rotor disk having a central body portion and having a through hole formed therein, the plurality of spaced apart teeth extending radially from the central body portion, wherein each of the plurality of teeth comprises an elongated stem portion having a first end at the central body portion, and wherein the elongated stem portion extends radially to a second end terminating in a transverse portion, the transverse portion may have a generally arcuate shape and extend from a first side edge of the stem portion in a first direction and from a second side edge of the stem portion in an opposite second direction, the first end of the transverse portion having a first side that is not formed at a 90 degree angle relative to a top surface or a bottom surface of the rotor disk and the second end of the transverse portion having a second side that is not formed at a 90 degree angle relative to the top surface or the bottom surface, the transverse portions of adjacent teeth forming a gap therebetween, wherein the plurality of rotor disks are stacked on top of each rotor disk while the adjacent rotor disks are rotated relative to each other such that the gaps between the transverse portions of adjacent teeth on each disk are aligned with the gaps between the transverse portions of adjacent teeth on adjacent rotor disks to form an skewed channel extending through the longitudinal length of the plurality of rotor disks.
[0006] Variations may include a method including providing a rotor disk and a plurality of spaced apart teeth, the rotor disk having a central body portion and having a through hole formed therein, the plurality of spaced apart teeth extending radially from the central body portion, wherein each of the plurality of teeth includes an elongated stem portion having a first end at the central body portion, and wherein the elongated stem portion extends radially to a second end terminating at a transverse portion, the transverse portion may have a generally arcuate shape and extend from a first side edge of the stem portion in a first direction and from a second side edge of the stem portion in an opposite second direction, the first end of the transverse portion having a first side formed at a 90 degree angle relative to a top surface or a bottom surface of the rotor disk and the second end of the transverse portion having a second side formed at a 90 degree angle relative to the top surface or the bottom surface, the transverse portions of adjacent teeth forming a gap therebetween; trimming the first side of the transverse portion such that the trimmed first side forms an angle other than 90 degrees with the top surface or the bottom surface, and trimming the second side of the transverse portion such that the trimmed second side forms an angle other than 90 degrees with the top surface or the bottom surface. BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Exemplary embodiments will be described hereinafter in conjunction with the following drawings, wherein like numerals represent like elements, and wherein:
[0008] Exemplary embodiments will be described hereinafter in conjunction with the following drawings, wherein like numerals represent like elements, and wherein:
[0009] Figure 1A is a partial cross-sectional view of adjacent teeth of a rotor disk;
[0010] Figure 1B is a partial cross-sectional view of a stack of rotor disks;
[0011] Figure 2 is a plan view of a rotor disk according to one embodiment;
[0012] Figure 3A is a partial side view of adjacent teeth of a rotor disk according to one embodiment;
[0013] Figure 3B is a partial side view of a stack of rotor disks according to one embodiment;
[0014] Figure 4 is a partial side view of a rotor according to one embodiment, the rotor comprising a plurality of stacked rotor disks having a motor shaft received therein;
[0015] Figure 5A is a partial side view of a method including stamping a rotor disk according to one embodiment;
[0016] Figure 5B is a partial side view of a method including trimming a first tooth of two adjacent teeth of a rotor disk according to one embodiment; and
[0017] Figure 5C is a partial side view of a method including trimming a second tooth of two adjacent teeth of a rotor disk according to one embodiment. DETAILED DESCRIPTION
[0018] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, summary or the following detailed description.
[0019] refer to Figure 1A , the rotor disk 10' may be formed by stamping a relatively thin flat metal piece using a stamping tool that moves in a vertical direction relative to a top surface 38' and an opposing bottom surface 40' of the flat metal piece 10'. The stamping process forms the rotor disk 10' wherein a first vertical edge 30' extends between the top surface 38' and the opposing bottom surface 40' of the thin flat metal piece at a first end 26' of a transverse portion 24' of a first tooth, and a second vertical edge 32' extends between the top surface 38' and the opposing bottom surface 40' of the thin flat metal piece at a second end 28' of a transverse portion 24' of a second tooth proximate the first tooth. Reference Figure 1BWhen multiple rotor disks 10' are stacked together and adjacent rotor disks 10' are rotated relative to each other, the stack of rotor disks 10' forms a deflected channel 46' that runs through the axial length of the stack of rotor disks. However, the top surface 38', vertical edges 30', 32' and bottom surface 40' at each end of the transverse portion 24' form sharp corners 42', 44', which may damage the wire material when it is wound on the stack of rotor disks.
[0020] Figure 2 is a plan view of a rotor disk 10 according to one embodiment. A variation of the rotor disk 10 may include a central body portion 12 that may have a generally annular shape and may have a through hole 14 formed therein to accommodate a shaft of an electric motor. A plurality of spaced apart teeth 16 may extend radially from the central body portion 14. Each tooth 16 may have a T-like shape, wherein each tooth 16 may include an elongated stem portion 18 having a first end 20 at the central body portion 12. The stem portion 18 may extend radially to a second end 22 that terminates at a transverse portion 24. The transverse portion 24 may have a generally arcuate shape and may extend from a first side edge 19 of the stem portion 18 in a first direction and may extend from a second side edge 21 of the stem portion 18 in an opposite second direction. Adjacent spaced apart teeth 16 may form a cavity 34 for accommodating conductive wiring placed through a gap 36 between the transverse portions 24 of adjacent teeth 16. The rotor disk 10 may be an integral, single-piece stamped, thin metal piece.
[0021] refer to Figure 3A , the first end 26 and the second end 28 of the lateral portion 24 can be trimmed to provide a first side 30 and a second side 32 that are not formed at a 90 degree angle relative to the top surface 38 of each lateral portion 24. In various variations, the angle A formed by the top surface 38 and the first side 30 is greater than 90 degrees, and the angle B formed by the top surface 38 and the second side 32 is less than 90 degrees. In various variations, the angle A formed by the top surface 38 and the first side 30 and the angle B formed by the top surface 38 and the second side 32 are complementary or nearly complementary to each other. In various variations, the first side or edge 30 is parallel to the second side or edge 32.
[0022] refer to Figure 3B , various variations may include a product comprising a plurality of rotor disks 10, such as Figure 3AAs described in , a plurality of rotor disks are stacked on top of each other, wherein each disk is rotated relative to an adjacent disk, so that a skewed channel 46 is formed through the gaps 36 between the transverse portions 24 of adjacent teeth of each rotor disk 10. In various variations, the rotor disks are rotated so that the plurality of first sides 30 of the plurality of rotor disks are in a first imaginary plane, and the plurality of second sides 32 are in a second imaginary plane, and wherein the first imaginary plane and the second imaginary plane are parallel to each other. In various variations, a plurality of stacked rotor disks 10 are stacked on top of each other, wherein each disk is rotated relative to an adjacent disk, so that a skewed channel 46 is formed by the gaps 36 between the transverse portions 24 of adjacent teeth of each rotor disk 10, and so that no sharp corners 42, 44 are exposed in the skewed channel 46 at the first end 26 or the second end 28, respectively. The channel 46 is skewed relative to the longitudinal axis running through the stacked rotor disks.
[0023] refer to Figure 4 , various variations may include a rotor 72, the rotor including a plurality of rotor disks 10, the plurality of rotor disks stacked on top of each other, wherein each disk rotates relative to an adjacent disk, such that a skewed channel 46 is formed by gaps 36 between transverse portions 24 of adjacent teeth of each rotor disk 10, and such that no sharp corners 42, 44 are exposed in the skewed channel 46 at the first end 26 or the second end 28, respectively. The plurality of disks may be laminated together with a dielectric material. An electric motor shaft 74 may be housed in the plurality of disks 10 and secured to the plurality of disks. The channel 46 is skewed relative to a longitudinal axis running through the stacked rotor disks. A vehicle may include an electric motor having an electric motor shaft 74 secured to a plurality of rotor disks 10, the plurality of rotor disks stacked on top of each other, wherein each disk rotates relative to an adjacent disk, such that a skewed channel 46 is formed by gaps 36 between transverse portions 24 of adjacent teeth of each rotor disk 10, and such that no sharp corners 42, 44 are exposed in the skewed channel 46 at the first end 26 or the second end 28, respectively.
[0024] refer to Figure 5A , Figure 5B and Figure 5C , various variations may include methods of stamping an integral single-piece thin metal piece 8 into a rotor disk 10 that can be used in an electric motor. The stamping method can produce Figure 2 , Figure 3A , Figure 3B and Figure 4 The rotor disk 10 described. Figure 5AAs shown, the thin metal piece 8 can be placed on a punch base 48 having a through hole or recess 50 formed therein. The bottom surface 40 of the thin metal piece 8 can rest on the punch base 48, and a punch tool 52 can be moved toward the thin metal piece 8 to engage its top surface 38. The punch tool 52 can have an elongated protrusion 51 having a first side 54 and a second side 56 perpendicular to the top surface 38 of the thin metal piece 8. The punch tool 52 can be advanced so that the first elongated protrusion 51 cuts through the thickness of the thin metal piece 8.
[0025] In various variations, Figure 5A The method shown can be used to generate Figure 2 However, the following description of the rotor disk FIG. 5A to FIG. 5B The method described in the diagram can be used in reference Figure 2 The process is performed on a prefabricated rotor disk as described, wherein a first end 26 of a transition portion 24 of a first tooth may be overcut at a 90 degree angle to a top surface 38 of the rotor disk, and an opposing second end 28 of a transition portion 24 adjacent a second tooth may be undercut at a 90 degree angle to a top surface 38 of another rotor disk.
[0026] like Figure 5B As shown above, Figure 5A The rotor disk produced by the described method or a rotor disk prefabricated by another method can be placed on the first tool base 64. The first punching tool 58 can be provided with a first elongated protrusion 57 having a first side 60 executed at an angle other than 90 degrees relative to the top surface 58 of the thin metal piece 8. The first elongated protrusion 57 may include a second side 62 formed at an angle perpendicular to the top surface 38 of the thin metal piece 8 (rotor disk) and such that the second side 62 of the first elongated protrusion 57 can move along the second side 30' of the thin metal piece 8 cut by the first punching tool 52. When the first punching tool 58 is advanced through the metal piece 8, the first side 60 trims the second end 32 of the transverse portion 24 of the first tooth in the adjacent tooth to provide the trimmed second side 32 of the transverse portion 24. The trimmed second side 32 of the transverse portion 24 and the top surface 38 form an angle other than 90 degrees.
[0027] like Figure 5CAs shown, the thin metal piece 8 (rotor disk) having the trimmed second side 32 can then be placed above a second punching tool 66, which can include a second elongated protrusion 61 having a first side edge 68, the first side edge being constructed and arranged to slide along or avoid contact with the second side 32 of the transverse portion 24 of the first tooth cut by the second punching tool 58. The second elongated protrusion 61 can have a second side 70 formed at an angle other than 90 degrees relative to the bottom surface 40 of the transverse portion 24. The second punching base 76 can be pushed toward the thin metal piece 8 (rotor disk) to press the rotor disk against the second cutting tool 61, so that the trimmed first side 30 of the transverse portion 24 of the second tooth in the adjacent tooth is cut at an angle other than 90 degrees relative to the top surface 38 of the transverse portion 24. It can be used Figure 5A , Figure 5B and Figure 5C The method may also include stacking a plurality of disks on top of each other and rotating each adjacent disk so that the gaps 36 between the lateral portions 24 of adjacent teeth are formed as shown in FIG. Figure 4 The skewed passage 46 is shown extending through the axial length of a stack of multiple rotor disks 10. Multiple rotor disks 10 may be laminated together and an electric motor shaft 74 may be received in a through hole 14 formed in each rotor disk.
[0028] Although at least one exemplary embodiment has been proposed in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that the exemplary embodiment or multiple exemplary embodiments are only examples and are not intended to limit the scope, applicability or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide a convenient roadmap for implementing the exemplary embodiment or multiple exemplary embodiments for those skilled in the art. It should be understood that various changes can be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the attached claims and their legal equivalents.
[0029] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that the embodiments are merely examples and are not intended to limit the scope, applicability or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide a convenient roadmap for implementing the embodiments for those skilled in the art. It should be understood that various changes may be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the attached claims and their legal equivalents.
Claims
1. A product comprising: A rotor disk and a plurality of spaced-apart teeth, the rotor disk having a central body portion and having through holes formed therein, the plurality of spaced-apart teeth extending radially from the central body portion, wherein each of the plurality of teeth comprises an elongated stem portion having a first end at the central body portion, and wherein the elongated stem portion extends radially to a second end terminating in a transverse portion, the transverse portion having a generally arcuate shape and extending from a first side edge of the stem portion in a first direction and from a second side edge of the stem portion in an opposite second direction, the first end of the transverse portion having a first side surface not formed at a 90 degree angle relative to a top surface or a bottom surface of the rotor disk and the second end of the transverse portion having a second side surface not formed at a 90 degree angle relative to the top surface or the bottom surface, the transverse portions of adjacent teeth forming a gap therebetween.
2. The product according to claim 1, wherein An angle A formed by the top surface of the lateral portion and the first side surface is greater than 90 degrees, and an angle B formed by the top surface of the lateral portion and the second side surface is less than 90 degrees.
3. The product according to claim 1, wherein: An angle A formed by the top surface and the first side surface and an angle B formed by the top surface and the second side surface are complementary or nearly complementary to each other.
4. The product according to claim 1, wherein: The central body portion has a generally annular shape.
5. The product according to claim 1, wherein The rotor disk is an integral, one-piece stamped, thin metal piece.
6. A method comprising: providing a rotor disk and a plurality of spaced apart teeth, the rotor disk having a central body portion and having through holes formed therein, the plurality of spaced apart teeth extending radially from the central body portion, wherein each of the plurality of teeth comprises an elongated stem portion having a first end at the central body portion, and wherein the elongated stem portion radially extends to a second end terminating in a transverse portion, the transverse portion having a generally arcuate shape and extending from a first side edge of the stem portion in a first direction and from a second side edge of the stem portion in an opposite second direction, the first end of the transverse portion having a first side formed at a 90 degree angle relative to a top surface or a bottom surface of the rotor disk and the second end of the transverse portion having a second side formed at a 90 degree angle relative to the top surface or the bottom surface, the transverse portions of adjacent teeth forming a gap therebetween; trimming the first side surface of the transverse portion so that the trimmed first side surface forms an angle other than 90 degrees with the top surface or the bottom surface; as well as The second side surface of the lateral portion is trimmed so that the trimmed second side surface forms an angle other than 90 degrees with the top surface or the bottom surface.
7. The method according to claim 6, wherein: An angle A formed by the top surface of the lateral portion and the trimmed first side surface is greater than 90 degrees, and an angle B formed by the top surface of the lateral portion and the trimmed second side surface is less than 90 degrees.
8. The method according to claim 6, wherein: An angle A formed by the top surface and the trimmed first side surface and an angle B formed by the top surface and the trimmed second side surface are complementary or nearly complementary to each other.
9. The method according to claim 6, wherein: Trimming the second side of the transverse portion includes subsequently placing the rotor disk on a first punch tool base, moving a punch tool having a first elongated protrusion, the first elongated protrusion having a first side formed at an angle other than 90 degrees relative to the top surface of the rotor disk, the first elongated protrusion having a second side formed at an angle perpendicular to the top surface of the rotor disk, and enabling the second side of the first elongated protrusion to move along the second side of the transverse portion of the rotor disk so that the first side of the elongated protrusion trims an end of the transverse portion of a first tooth of an adjacent tooth to provide a trimmed second side of the transverse portion.
10. The method according to claim 9, wherein: Trimming the first side of the transverse portion includes: placing the rotor disk on a second stamping tool, the second stamping tool including a second slender protrusion, the second slender protrusion having a first side edge, the first side edge being constructed and arranged to slide along or avoid contact with the trimmed second side of the transverse portion of the first tooth trimmed by the first stamping tool, the second slender protrusion having a second side formed at an angle other than 90 degrees relative to the bottom surface of the transverse portion; pushing a second stamping base toward the rotor disk to press the rotor disk against the second stamping tool so that the first side of the transverse portion of a second tooth in an adjacent tooth is cut at an angle other than 90 degrees relative to the top surface of the transverse portion.