Rotor, reluctance motor, system and manufacturing method for rotor

Abstract

The invention provides a rotor assembly for a radial / axial synchronous reluctance machine, a system assembly and a method for producing the rotor assembly. The rotor assembly (100) includes an elongate body (110) having a cross-section including at least one pair of first rotor pole segments (112) and second rotor pole segments (112). The rotor assembly (100) is arranged such that, when exposed to a magnetic flux, a free end of the first rotor pole segment (112), referred to as a first free end (1122a), and a free end of the second rotor pole segment (112), referred to as a second free end (1123a), face each other, the first free ends (1122a, 1123a) being not in surface contact with each other or having a minimum surface contact (1125) with each other, and the second free ends (1123a, 1123a) being in surface contact with each other. The first free ends (1122a, 1123a) and the second free ends (1122a, 1123a) form a magnetic flux barrier for suppressing flow of magnetic flux between the first free ends (1122a, 1123a).

Description

Technical Field

[0001] The present application relates to a rotor assembly for a radial / axial synchronous reluctance machine, a system assembly and a method for producing the rotor assembly.

[0002] Similar devices can be found in EP1786088B1, EP2406870B1 or EP3128647B1. Background Art

[0003] Known rotors for synchronous reluctance machines are typically formed of a substantially cylindrical body having a plurality of high permeability soft magnetic material sections and a plurality of flux barrier sections, forming one or more pole pairs. The high permeability soft magnetic material sections and the flux barrier sections differ from each other in varying degrees of magnetic permeability, the sections having high permeability being typically designated as the d-axis of the rotor and the sections having relatively low permeability being typically designated as the q-axis of the rotor. Optimum torque production is achieved when the d-axis has as high a magnetic permeability as possible and the q-axis has as low a magnetic permeability as possible.

[0004] In practice, this is usually achieved by forming a cutout of appropriate shape in the cylindrical body and filling the cutout with air. The magnetic flux is then suppressed in the q-axis direction (ie, the magnetic resistance increases), and the magnetic permeability is therefore reduced.

[0005] However, the present inventors have discovered that such practice applied to current rotor topologies results in relatively large waste of high permeability virgin soft magnetic material and environmental pollution because more than necessary amount of high permeability virgin soft magnetic material is used.

[0006] It is an object of the present invention to provide a novel rotor topology designed to overcome the disadvantages typically associated with known rotor topologies. Summary of the invention

[0007] The present application provides a rotor assembly for a radial / axial synchronous reluctance machine, a system assembly and a method for producing the rotor assembly as described in the appended claims.

[0008] The dependent claims describe specific embodiments of the application.

[0009] These and other aspects of the present application will be apparent from and elucidated upon the embodiments described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Further details, aspects and embodiments of the present application will be described by way of example only with reference to the accompanying drawings. In the accompanying drawings, the same reference numerals are used to identify the same or functionally similar elements. The elements in the accompanying drawings are shown for simplicity and clarity and are not necessarily drawn to scale.

[0011] Figure 1 An elongated body of a rotor assembly according to the present application is shown.

[0012] Figure 2 A cross section of a four-pole rotor assembly according to the present application is shown.

[0013] Figure 3 A cross section of a pole of a rotor assembly according to the present application is shown.

[0014] Figure 4 Another cross section of a pole of a rotor assembly according to the present application is shown.

[0015] Figure 5 A cross section of a four-pole rotor assembly according to the present application is shown.

[0016] Figure 6 A cross section of a two-pole rotor assembly according to the present application is shown.

[0017] Figure 7 Another cross section of a four-pole rotor assembly according to the present application is shown.

[0018] Figure 8 System components according to the present application are shown.

[0019] Fig. 9 Shows Figure 8 A detailed view of the system components.

[0020] Fig.10 Shows Figure 8 Exploded view of the system components.

[0021] Fig.11 Shows Figure 8 Cross-section of system components.

[0022] Fig.12 Another system component according to the present application is shown.

[0023] Fig.13 Shows Fig.12 Exploded view of the system components.

[0024] Fig.14 Shows Fig.12 Cross-section of system components.

[0025] Fig.15 A cross section of a system assembly according to the present application is shown.

[0026] Fig.16 A cross section of another system assembly according to the present application is shown.

[0027] Fig.17A schematic flow chart according to the present application is shown.

[0028] Fig.18 Another schematic flow chart according to the present application is shown.

[0029] Fig.19 Shows Fig.18 A schematic diagram of at least one step of a flowchart.

[0030] Fig. 20 Shows Fig.18 A schematic diagram of at least one step of a flowchart.

[0031] Fig.21 Shows Fig.18 A schematic diagram of at least one step of a flowchart.

[0032] Fig. 22 Shows Fig.18 The result of at least one step of the schematic flow chart.

[0033] Fig.23 Shows Fig.18 A view of at least one step of a schematic flow chart of a method of manufacturing a rotor system, wherein the rotor system is arranged relative to a stator yoke. DETAILED DESCRIPTION

[0034] Because the illustrated embodiments of the present application may be largely composed of components known to those skilled in the art, details will not be explained in a greater degree than is deemed necessary to understand and appreciate the basic concepts of the present application, so as not to obscure or distract from the teachings of the present application.

[0035] The inventors have discovered that the rotor assembly of the present application requires less conductive raw material than prior art rotors.

[0036] Surprisingly, the inventors have also found that a synchronous reluctance machine comprising a rotor assembly of the present application can achieve improved performance relative to current synchronous reluctance machines, in particular with respect to torque but also with respect to torque ripple.

[0037] Rotor assembly

[0038] The present application relates to a rotor assembly for a radial synchronous reluctance motor.

[0039] Radial synchronous reluctance machines are of a known type and will not therefore be described in further detail.

[0040] refer to Figure 1 , the rotor assembly 100 includes an elongated body 110 .

[0041] - Slender body of the rotor assembly

[0042] In one embodiment, the elongated body 110 has a substantially cylindrical shape having desired dimensions.

[0043] In one example, the elongated body 110 is a tubular body.

[0044] In another example, the elongated body 110 is a hollow cylinder.

[0045] Furthermore, in the present application, the elongated body 110 has a central longitudinal axis of rotation 111 , a circumference, and a cross-section.

[0046] As used herein, the term “circumference” is defined as the circumferential surface of the elongated body 110 .

[0047] Furthermore, the cross section is seen in a plane perpendicular to the central longitudinal rotational axis 111 .

[0048] In particular, the cross section has a width dimension and a radial dimension perpendicular to the width dimension.

[0049] - Rotor pole segments

[0050] In this application, if Figure 2 As shown, a cross-section of the elongated body 110 includes at least one pair of rotor pole segments 112 , including a first rotor pole segment 112 and a second rotor pole segment 112 .

[0051] In other words, it should be appreciated that a cross-section of the elongated body 110 may include more than one pair of rotor pole segments 112 .

[0052] As used herein, the term "segment" is defined as a rotor pole that can be considered separately from other rotor poles.

[0053] In one embodiment, at least one rotor pole segment 112 is made of a relatively high permeability soft magnetic material.

[0054] In an implementation of the current embodiment, the relatively high permeability soft magnetic material is a ferromagnetic-based material.

[0055] In an example of the current implementation of the current embodiment, the ferromagnetic based material is selected from the group consisting of: ferrite, iron powder and bulk iron.

[0056] However, other materials having a magnetic permeability greater than that of air may be envisaged without requiring any substantial modification of the present application.

[0057] - Positioning of rotor pole segments

[0058] In the present application, the first and second rotor pole segments 112 are arranged relative to each other and circumferentially adjacent to each other about the central longitudinal rotation axis 111 .

[0059] With this arrangement, as rotor assembly 100 rotates, rotor pole segments 112 simultaneously rotate relative to each other while maintaining the same relative positions of rotor pole segments 112 .

[0060] In one example, the first and second rotor pole segments 112 are evenly arranged around the circumference.

[0061] - Structure of rotor pole segments

[0062] like Figure 3 As shown, in the present application, each rotor pole segment 112 includes a central region 1121 , a first outer region 1122 , and a second outer region 1123 as seen in a clockwise or counterclockwise direction of a cross section of the elongated body 110 .

[0063] In the present application, any desired ratio of different areas of each rotor pole segment 112 is contemplated without requiring any substantial modification to the present application.

[0064] Furthermore, in the present application, the central region 1121 of each rotor pole segment is flanked by the first outer region 1122 and the second outer region 1123 , such that the first outer region 1122 and the second outer region 1123 extend from the central region 1121 , respectively.

[0065] In other words, it should be understood that the first outer region 1122 and the second outer region 1123 of each rotor pole segment 112 border respective lateral sides of the central region 1121 .

[0066] In one embodiment, the first outer region 1122 and the second outer region 1123 of each rotor pole segment 112 are attached to respective lateral sides of the central region 1121 .

[0067] In another embodiment, for at least one rotor pole segment 112, the first outer region 1122 and / or the second outer region 1123 has a conical shape which gradually narrows from the central region 1121 towards its respective free end.

[0068] As used herein, the term "conical shape" is defined as a shape having a first tangent line tangent to the upper surface of the rotor pole segment 112 and a second tangent line tangent to the lower surface of the rotor pole segment 112, wherein the first tangent line and the second tangent line converge toward a single point located at or beyond the respective free ends.

[0069] In an implementation of the current embodiment, the conical shape is such that it forms an acute angle with the vertex coinciding with the respective free end.

[0070] In another implementation of the current embodiment, the tapered shape is a tapered circular shape.

[0071] From the foregoing, it should be understood that the first outer region 1122 alone, the second outer region 1123 alone, or both the first outer region 1122 and the second outer region 1123 may have a tapered shape.

[0072] In one example, the first outer region 1122 and the second outer region 1123 both have a tapered shape toward the respective free ends.

[0073] In another example, if Figure 2 and Figure 3 As shown, the first outer region 1122 has a tapered shape toward its free end, and relative to the tapered surface shape of the first outer region 1122, the second outer region 1123 has a relatively bulky surface shape toward its corresponding free end.

[0074] For example, the surface shape of the bulk includes an outwardly convex region extending toward the free end.

[0075] In another example, the second outer region 1123 has a tapered shape toward a free end thereof, and relative to the tapered surface shape of the second outer region 1123 , the first outer region 1122 has a relatively bulky surface shape toward a free end thereof.

[0076] For example, the surface shape of the bulk includes an outwardly convex region extending toward the free end.

[0077] In yet another embodiment, Figure 4 As shown, for at least one rotor pole segment 112, the angle extension of the first outer region 1122 is α 1122 Different from the angle extension α of the second outer region 1123 1123 .

[0078] In particular, the angle extension of the first outer region 1122 is α 1122 is measured from one side of the recessed portion 1126 to the first free end 1122a, while the angle extension of the second outer region 1123 is 1123 It is measured from the other side of the recessed portion 1126 to the second free end.

[0079] In the example, the angle extension of the first outer region 1122 is α 1122 Greater than the angle extension α of the second outer region 1123 1123 .

[0080] In another example, the angle extension of the second outer region 1123 is α 1123 Greater than the angle extension α of the first outer region 1122 1122 .

[0081] - Asymmetric characteristics of the rotor pole segments

[0082] In addition, in this application, if Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Fig.11 , Fig.14 , Fig.15 and Fig.16 As shown, the cross-section of each rotor pole segment 112 is asymmetrical at least with respect to a bisector 10 of the pole sector including the rotor pole segment 112 .

[0083] In one example, at least one rotor pole segment 112 is further asymmetric with respect to a bisector 1121 of a central region 1121 of the rotor pole segment 112 .

[0084] In another example, at least one rotor pole segment 112 is further asymmetric with respect to a bisector of the first outer region 1122 of the rotor pole segment 112 .

[0085] In yet another example, at least one rotor pole segment 112 is further asymmetric with respect to a bisector of the second outer region 1123 of the rotor pole segment 112 .

[0086] In yet another example, free ends of at least one rotor pole segment 112 are asymmetric to each other.

[0087] In one embodiment, all of rotor pole segments 112 are fully asymmetric.

[0088] In another embodiment, none of rotor pole segments 112 are completely asymmetric.

[0089] In yet another embodiment, at least two rotor pole segments 112 are completely asymmetric.

[0090] - Arrangement of rotor pole segments

[0091] Furthermore, in the present application, the rotor assembly 100 is arranged to operate in a predetermined manner when exposed to magnetic flux.

[0092] In practice, the free end of the first outer region 1122 of the first rotor pole segment 112 (referred to as the first free end 1122a) and the free end of the second outer region 1123 of the second rotor pole segment 112 (referred to as the second free end 1123a) face each other.

[0093] In addition, the first free end 1122a and the second free end 1123a have no surface contact with each other or have a minimum contact length 1125 extending along the radial dimension, thereby forming a flux barrier for suppressing the flow of magnetic flux between the first free end 1122a and the second free end 1123a, whereby the magnetic resistance is increased in the surface separating the first free end 1122a and the second free end 1123a or in the minimum contact length 1125.

[0094] In particular, minimum contact length 1125, when present, is designed to be so thin that it behaves magnetically as a non-magnetic material when exposed to magnetic flux.

[0095] First embodiment of the present application: Accuracy of arrangement of free ends of adjacent rotor pole segments

[0096] The inventors have discovered that a particular arrangement of the first free end 1122a and the second free end 1123a exhibits improvements with respect to torque.

[0097] - There is no surface contact between the free ends

[0098] In one embodiment, Figure 2 As shown, in the absence of surface contact between the first free end 1122a and the second free end 1123a, the angular distance between the first free end 1122a and the second free end 1123a is the predetermined angular distance 1124.

[0099] Furthermore, the rotor assembly 100 is further arranged such that a ratio of the predetermined angular distance 1124 relative to a radius of the rotor assembly 100 is between 0.1% and 20%.

[0100] In an implementation of the current embodiment, a ratio of the predetermined angular distance 1124 relative to the radius of the rotor assembly 100 is between 2% and 15%.

[0101] In another implementation of the current embodiment, a ratio of the predetermined angular distance 1124 relative to the radius of the rotor assembly 100 is between 5% and 10%.

[0102] - When there is a minimum contact length between the free ends

[0103] In another embodiment, Figure 6 As shown, when there is a minimum contact length 1125 between the first free end 1122a and the second free end 1123a, the rotor assembly 100 is also arranged so that the ratio of the radial dimension of the minimum contact length 1125 to the radius of the rotor assembly 100 is less than or equal to 10%.

[0104] In an implementation of the current embodiment, a ratio of a radial dimension of the minimum contact length 1125 relative to a radius of the rotor assembly 100 is less than or equal to 5%.

[0105] In another implementation of the current embodiment, a ratio of a radial dimension of the minimum contact length 1125 relative to a radius of the rotor assembly 100 is less than or equal to 2%.

[0106] Second embodiment of the present application: concave portion

[0107] The inventors have discovered that forming concave portions at specific locations of the rotor pole segments 112 exhibits improvements with respect to torque ripple.

[0108] In one embodiment of the present application, Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Fig. 9 , Fig.10 , Fig.11 , Fig.12 , Fig.13 , Fig.13 , Fig.15 and Fig.16 As shown, the rotor assembly 100 further includes: for at least one rotor pole segment 112 , the central region 1121 includes at least one inwardly facing recessed portion 1126 .

[0109] Preferably, the inwardly facing recessed portion 1126 is provided on the outer circumferential surface of the central region 1121 .

[0110] In an example, the inwardly facing recessed portion 1126 is U-shaped.

[0111] In another example, the inwardly facing recessed portion 1126 is V-shaped.

[0112] However, other shapes for the inwardly facing recessed portion 1126 are contemplated without requiring any substantial modification to the present application.

[0113] - Displacement of the concave part

[0114] In the implementation of the current embodiment, Figure 4 As shown, the recessed portion 1126 is provided with a bisector 11 which is angularly offset relative to the bisector 10 of the rotor pole segment 112 .

[0115] In another implementation of the current embodiment, along the radial dimension of the cross-section of the elongated body 110 , the deepest point of the depth of the recessed portion 1126 is angularly offset relative to the bisector 111 of the recessed portion 1126 .

[0116] - Island area

[0117] In another implementation of the current embodiment, Figure 4 As shown, at least one rotor pole segment 112 further includes an island region 113 facing the recessed portion 1126 and spaced apart from the recessed portion 1126 .

[0118] In one aspect of the current implementation of the current embodiment, at least one rotor pole segment 112 further includes a bridge (not shown) located between the island region 113 and the recessed portion 1126 and configured to connect the island region 113 and the recessed portion 1126 .

[0119] In particular, the bridge is designed to be so thin that when exposed to magnetic flux, the bridge behaves magnetically as a non-magnetic material.

[0120] Third embodiment of the present application: Accuracy of different regions of the cross section of the rotor pole segment

[0121] The inventors have discovered that adjusting the radius of different portions of the rotor pole segments 112 exhibits improvements with respect to torque and torque ripple.

[0122] In one embodiment, Figure 4 As shown, the cross-section of the elongated body 110 also includes a specific arrangement for at least one rotor pole segment 112 .

[0123] In particular, the first outer region 1122 has at least first and second outwardly curved sections, referred to as first and second sections 1122b, 1122c.

[0124] In particular, the first section 1122b is closer to the central area 1121 than the second section 1122c.

[0125] Furthermore, the second outer region 1123 has at least one outwardly curved section, referred to as a third section 1123 b .

[0126] Furthermore, the first section 1122b, the second section 1122c, and the third section 1123b each have a substantially constant radius of curvature.

[0127] Furthermore, the first section 1122b and the second section 1122c have a first radius r1 and a second radius r2, respectively.

[0128] In particular, the second radius r2 is equal to or longer than the first radius r1.

[0129] Finally, the third section 1123b has a third radius r3 that is different from the second radius r2.

[0130] In the example of the present embodiment, the first radius r1 is substantially equal to the rotor radius of the central longitudinal rotation axis 111 .

[0131] In another example of the current embodiment, the second radius r2 is substantially equal to the third radius r3.

[0132] In yet another example of the current embodiment, the second radius r2 is substantially smaller than the third radius r3.

[0133] In yet another example of the current embodiment, the second radius r2 is substantially longer than the third radius r3.

[0134] In an implementation of the current embodiment, the first section 1122b and the second section 1122c are connected in series via a transition portion.

[0135] In the example of the current implementation of the current embodiment, the transition portion is curved.

[0136] In another example of the current implementation of the current embodiment, the transition portion is angled.

[0137] In yet another example of the current implementation of the current embodiment, the transition portion is squared.

[0138] However, other shapes of the transition portion may be envisaged without requiring any substantial modifications to the present application.

[0139] - teeth

[0140] The inventors have discovered that forming teeth at specific locations on rotor pole segments 112 exhibits improvements with respect to torque ripple.

[0141] In the implementation of the current embodiment, Figure 5 , Figure 6 , Figure 7 , Fig.11 , Fig.14 , Fig.15 and Fig.16 As shown, the first and / or second and / or third segments 1122b, 1122c, 1123b each include at least one cutout portion forming teeth 1127, thereby locally adjusting the air gap between the rotor assembly 100 and the stator to smooth the torque and thereby reduce torque fluctuations.

[0142] In other words, it should be understood that the first segment 1122b and / or the second segment 1122c and / or the third segment 1123b may each include more than one cutout portion forming the tooth 1127.

[0143] In one aspect of an implementation of the current example, the number of cutout portions of the teeth 1127 forming the first and / or second and / or third sections 1122b, 1122c, 1123b are different from each other.

[0144] In the example of implementation of the current embodiment, the first section 1122 b includes two cutout portions forming the teeth 1127 , and the third section 1223 b includes one cutout portion forming the teeth 1127 .

[0145] In another example of implementation of the current embodiment, the first section 1122 b includes one cutout portion forming the tooth 1127 , and the third section 1223 b includes two cutout portions forming the tooth 1127 .

[0146] Fourth embodiment of the present application: Curing rotor assembly

[0147] The inventors have discovered that surrounding the rotor pole segments 112 with a hollow frame 1128 material exhibits improved robustness relative to the rotor assembly 100 .

[0148] In one embodiment, Figure 7 As shown, the cross-section of the elongated body 110 also includes at least one pair of continuous hollow material frames 1128 .

[0149] In particular, there are as many pairs of continuous hollow frames 1128 of material as there are pairs of rotor pole segments 112 .

[0150] Furthermore, each rotor pole segment 112 is circumscribed by a corresponding hollow frame 1128 .

[0151] In an implementation of the current embodiment, the material of the hollow frame 1128 is made of a non-magnetic material.

[0152] In an example, the non-magnetic material is made of aluminum.

[0153] In another example, the non-magnetic material is made of plastic.

[0154] In another example, the non-magnetic material is made of resin.

[0155] In yet another example, the non-magnetic material is made of a polymer.

[0156] However, other materials having non-magnetic conductive properties may be envisioned without requiring any substantial modification to the present application.

[0157] In another implementation of the current embodiment, the material of the hollow frame 1128 is a ferromagnetic material that is so thin that it behaves as a non-magnetic material when exposed to magnetic flux.

[0158] System including a rotor assembly

[0159] The present application also relates to a system assembly for a radial synchronous reluctance machine.

[0160] - First System

[0161] In an embodiment of a system component, such as Figure 8 , Fig. 9 , Fig.10 and Fig.11 As shown, the first system assembly 200 includes the rotor assembly 100 , a rotor shaft 210 , and a first shaft connection assembly 220 as described above.

[0162] In particular, the rotor shaft 210 is of a known type and will therefore not be described in further detail.

[0163] Preferably, the rotor shaft 210 is made of non-magnetic material.

[0164] In first system assembly 200 , first shaft connection assembly 220 is configured to connect rotor assembly 100 to rotor shaft 210 .

[0165] In one example, first shaft connection assembly 220 may be detachable from rotor assembly 100 and / or rotor shaft 210 .

[0166] In another example, the first shaft connection assembly 220 is made of a non-magnetic material.

[0167] Furthermore, in the first system assembly 200, the first shaft connection assembly 220 includes a cylindrical elongated body.

[0168] Furthermore, the rotor assembly 100 is configured around the first shaft connection assembly 220 .

[0169] In one example, the rotor assembly 100 is glued to the first shaft connection assembly 220 .

[0170] However, the rotor assembly 100 may be secured to the first shaft connection assembly 220 in any other suitable manner without requiring any substantial modifications to the present application.

[0171] Furthermore, the rotor shaft 210 is configured to protrude longitudinally from the distal end of the cylindrical elongated body such that rotation of the rotor shaft 210 causes simultaneous and synchronous rotation of the cylindrical elongated body.

[0172] In one example, the rotor shaft 210 is also configured to extend longitudinally through the cylindrical elongated body.

[0173] In an implementation of the current embodiment of the system assembly, the first shaft connection assembly 220 further includes a first flange, a second flange, and a plurality of longitudinal rods.

[0174] Furthermore, in the current implementation of the current embodiment of the system assembly, the rotor assembly 100 is configured to flank the first flange and the second flange.

[0175] Furthermore, in the current implementation of the current embodiment of the system assembly, the longitudinal rod is configured to extend through the rotor assembly 100 between the first flange and the second flange.

[0176] In another implementation of the current embodiment of the system assembly, each rotor pole segment of the rotor assembly includes a plurality of grooves extending longitudinally along all or a portion of the outer surface of the cylindrical body.

[0177] Furthermore, in the current implementation of the current embodiment of the system assembly, the shaft connection assembly includes a plurality of external teeth extending longitudinally, continuously and / or discontinuously and protruding from the outer surface of the cylindrical body.

[0178] In particular, each tooth is shaped to slidably engage and fit within a corresponding groove.

[0179] In the example, the outer teeth are made of a non-magnetic material.

[0180] In another example, the outer teeth are made of a magnetic material. In fact, since the central part of the system assembly is less sensitive magnetically, a magnetic material can be used for the outer teeth.

[0181] In an example of the current implementation of the current embodiment of the system components, as Fig. 9 , Fig.10 and Fig.11 As shown, at least one of the grooves is a dovetail groove and at least one of the outer engagement arms is a dovetail member.

[0182] In yet another implementation of the current embodiment of the system assembly, each rotor pole segment of the rotor assembly includes a plurality of teeth extending longitudinally, continuously and / or discontinuously, along all or a portion of the outer surface of the cylindrical body.

[0183] Furthermore, in the current implementation of the current embodiment of the system assembly, the shaft connection assembly includes a plurality of outer grooves extending longitudinally and protruding from the outer surface of the cylindrical body.

[0184] In particular, each tooth is shaped to slidably engage and fit within a corresponding groove.

[0185] For example, the outer teeth are made of non-magnetic material.

[0186] In an example of a current implementation of the current embodiment of the system assembly, at least one groove is a dovetail groove and at least one outer engagement arm is a dovetail member.

[0187] - Second System

[0188] In one embodiment of a system component, Fig.12 , Fig.13 and Fig.14 As shown, the second system assembly 300 includes the rotor assembly 100 , a rotor shaft 310 , and a second shaft connection assembly as described above.

[0189] In particular, the rotor shaft 310 is of a known type and will therefore not be described in further detail.

[0190] Preferably, the rotor shaft 310 is made of a non-magnetic material.

[0191] In the second system assembly 300 , the second shaft connection assembly is configured to connect the rotor assembly 100 to the rotor shaft 310 .

[0192] In one example, the second shaft connection assembly may be detachable from the rotor assembly 100 and / or the rotor shaft 310 .

[0193] In another example, the second shaft connection component is made of a non-magnetic material.

[0194] Furthermore, in the second system assembly 300 , the second shaft connection assembly includes a first flange 321 , a second flange 322 , and a plurality of longitudinal rods 323 .

[0195] Furthermore, the rotor assembly 100 is configured to be flanked by the first flange 321 and the second flange 322 .

[0196] Furthermore, the longitudinal rod 323 is configured to extend through the rotor assembly 100 between the first flange 321 and the second flange 322 .

[0197] Furthermore, the rotor shaft 310 is configured to protrude longitudinally from distal ends of the first and second flanges 321 and 322 , such that rotation of the rotor shaft 310 causes simultaneous and synchronous rotation of the first and second flanges 321 , 322 , and the rotor assembly 100 .

[0198] In one example, the rotor shaft 310 is also configured to extend longitudinally through the cylindrical elongated body 110 .

[0199] - Add permanent magnets to the system

[0200] In an embodiment of a system component, such as Fig.14 and Fig.15 As shown, the system assembly further comprises at least one permanent magnet 20 .

[0201] In other words, it should be understood that in this embodiment, the system assembly may include more than one permanent magnet 20 arranged on the d-axis.

[0202] In particular, the permanent magnets 20 are arranged at the top and / or the bottom of at least one rotor pole segment 112 so as to cooperate with the corresponding rotor pole segment 112 .

[0203] In one example, the system components of the current embodiment include one or more permanent magnets 20 arranged on the bottom of at least one rotor pole segment 112 .

[0204] In another example where the system component includes at least one inwardly facing recessed portion 1126 of the rotor pole segment 112 , the system component of the current embodiment includes one permanent magnet 20 disposed at the top of the inwardly facing recessed portion 1126 .

[0205] In the implementation of the current embodiment, the permanent magnets 20 are separated from the associated rotor pole segments 112 .

[0206] In another implementation of the current embodiment, at least a portion of the permanent magnets 20 are at least partially embedded within the associated rotor pole segment 112 .

[0207] In yet another implementation of the current embodiment, each of the one or more permanent magnets 20 has a magnetization direction, and are further arranged such that the magnetization direction of the one or more permanent magnets 20 is substantially directed toward the focusing axis located near the q-axis.

[0208] In the example of the current implementation of the current embodiment, the focus axis is the q-axis.

[0209] In another example of the current implementation of the current embodiment, the focus axis is angularly offset with respect to the q-axis by a predetermined offset angle.

[0210] For example, the predetermined offset angle is obtained according to the following formula:

[0211]

[0212] Wherein, α is the predetermined offset angle, and p is the number of pole pairs of the rotor assembly 100 .

[0213] However, other values ​​of the predetermined offset angle may be envisaged without requiring any substantial modifications to the present application.

[0214] A synchronous reluctance motor comprising a rotor assembly of the present application

[0215] The present application also relates to a synchronous reluctance machine, which comprises at least one rotor assembly 100 as described above.

[0216] In an example, a synchronous reluctance machine is a motor in a drive or assembly.

[0217] In another example, the synchronous reluctance machine is part of a motor in a drive or assembly.

[0218] For example, the motor is a single-phase motor or a multi-phase motor.

[0219] In yet another example, the synchronous reluctance machine is a generator in a drive or assembly.

[0220] In yet another example, the synchronous reluctance machine is part of a generator in a drive or assembly.

[0221] Engineering machinery including the synchronous reluctance motor of the present application

[0222] The present application also relates to an engineering machine comprising the synchronous reluctance motor as described above.

[0223] In an embodiment, the construction machine is in the form of a vehicle.

[0224] In an example, the vehicle is a ground vehicle, such as a car, cab, bus, or train.

[0225] In another example, the vehicle is a water vehicle, such as a boat, ferry, or cruiser.

[0226] In yet another example, the vehicle is an aircraft, such as an airplane, helicopter, glider, aerostat, or dirigible.

[0227] However, the construction machine may be any suitable electric machine, such as a machine tool or the like.

[0228] Method of manufacturing the rotor assembly of the present subject

[0229] The present application also relates to a method for producing a rotor assembly of a radial / axial synchronous reluctance machine.

[0230] - First manufacturing method

[0231] In a first embodiment of the manufacturing method, Fig.17 As shown, the method 400 is designed for manufacturing a rotor assembly 100 for a radial synchronous reluctance machine.

[0232] In step 410, an elongated body 110 having a central longitudinal axis of rotation 111, a circumference, and a cross-section is provided.

[0233] In step 420 , a cross-section of the elongated body 110 is defined to include at least one pair of rotor pole segments 112 , including a first rotor pole segment 112 and a second rotor pole segment 112 .

[0234] In step 430 , first and second rotor pole segments 112 are arranged relative to each other and circumferentially adjacent to each other about central longitudinal rotational axis 111 .

[0235] In step 440, each rotor pole segment 112 is defined as including a central region 1121 flanked by a first outer region 1122 and a second outer region 1123, as seen in a clockwise or counterclockwise direction of a cross-section of the elongated body 110, the first outer region 1122 and the second outer region 1123 extending from the central region 1121 respectively.

[0236] In step 450 , each rotor pole segment 112 is defined as being asymmetrical with respect to at least a bisector 10 of the pole sector including the rotor pole segment 112 .

[0237] In step 460 , the free end of the first outer region 1122 of the first rotor pole segment 112 (referred to as the first free end 1122a ) and the free end of the second outer region 1123 of the second rotor pole segment 112 (referred to as the second free end 1123a ) are arranged to face each other.

[0238] And in step 470, the first free end 1122a and the second free end 1123a are arranged so that when exposed to magnetic flux, the first free end 1122a and the second free end 1123a have no surface contact with each other or have a minimum contact length 1125 with each other, thereby forming a magnetic flux barrier for inhibiting the flow of magnetic flux between the first free end 1122a and the second free end 1123a, thereby increasing the magnetic resistance between the first free end 1122a and the second free end 1123a.

[0239] - Second manufacturing method

[0240] In a second embodiment of the manufacturing method, a method (not shown) for manufacturing a rotor assembly 100 of a radial synchronous reluctance machine is designed.

[0241] In a first step, an elongated hollow cylinder is provided having a central longitudinal axis of rotation, a circumference and a width.

[0242] In particular, the elongated hollow cylinder is made of a ferromagnetic based material.

[0243] In a second step, the width of the elongated hollow cylinder is hollowed in accordance with the pattern formed by the cross-section of the rotor assembly 100 as described above.

[0244] In an embodiment of the second step, a punching device is used to pierce the width of the elongated hollow cylinder.

[0245] In particular, the punching device is of a known type and will therefore not be described in further detail.

[0246] In an embodiment of the second step, a cutting device is used to cut off the width of the elongated hollow cylinder.

[0247] In particular, the cutting device is of a known type and will therefore not be described in further detail.

[0248] - The third manufacturing method

[0249] In an embodiment of the manufacturing method, Fig.18 As shown, method 500 is designed for manufacturing a rotor assembly for an axial synchronous reluctance machine.

[0250] In step 510, if Fig.19 As shown, at least one elongated hollow cylinder is provided, which has a central longitudinal rotation axis, a circumference, an inner surface and a width. In particular, the elongated hollow cylinder is made of a high magnetic permeability soft magnetic material.

[0251] In step 520, if Fig.19 As shown, a cross-section of a rotor assembly 100 as described above is provided.

[0252] In step 530, if Fig.19 As shown, a cross section of the rotor assembly 100 is projected onto the inner surface of the elongated hollow cylinder, thereby forming a projection pattern on the inner surface of the elongated hollow cylinder.

[0253] In step 540, if Fig. 20 and Fig.21 As shown, the projection pattern is extended along the circular cross-section of the elongated hollow cylinder in a radial direction relative to the circular cross-section, thereby forming an extended projection pattern.

[0254] In step 550, if Fig. 22 As shown, the width of the elongated hollow cylinder is excavated according to an extended projection pattern to extract the first rotor pole segment for an axial synchronous reluctance machine.

[0255] In step 560 , steps 330 to 350 are repeated to extract at least a second rotor pole segment of the axial synchronous reluctance machine.

[0256] In step 570, if Fig.23 As shown, the first rotor pole segment and the second rotor pole segment are arranged relative to each other and circumferentially adjacent to each other about the central longitudinal rotation axis.

[0257] In step 580, if Fig.23 As shown, a free end of a first outer region of a first rotor pole segment (referred to as a first free end) and a free end of a second outer region of a second rotor pole segment (referred to as a second free end) are arranged to face each other.

[0258] And in step 590, if Fig.23As shown, the first free end and the second free end are arranged so that when the first free end and the second free end are exposed to magnetic flux, the first free end and the second free end have no surface contact with each other or have a minimum contact length 1125 with each other, thereby forming a magnetic flux barrier for inhibiting the flow of magnetic flux between the first free end and the second free end, thereby increasing the magnetic resistance between the first free end and the second free end.

[0259] The description of the present application has been presented for the purpose of illustration and description, but is not intended to be exhaustive or limited to the application in the disclosed form. The embodiments are selected and described in order to better explain the principles and practical applications of the present application, and to enable technical personnel to understand the application of various embodiments with various modifications suitable for the intended specific use.

[0260] Various Other Embodiments

[0261] For example, the rotor assembly has been described as a cylindrical inner rotor.

[0262] However, a person skilled in the art can easily adapt the teachings of the present application to produce a rotor assembly in the form of an annular outer rotor.

[0263] Furthermore, a skilled person can easily adapt the teachings of the present application to manufacture a rotor assembly for a transverse synchronous reluctance motor or a mover assembly for a linear synchronous reluctance motor.

Claims

1. A rotor assembly (100) for a radial synchronous reluctance motor, the rotor assembly (100) comprising: - an elongated body (110) having a central longitudinal axis of rotation (111), a circumference and a cross-section, The cross-section of the elongated body (110) presents a width dimension and a radial dimension perpendicular to the width dimension, and the cross-section of the elongated body (110) comprises: - at least one pair of rotor pole segments (112), the at least one pair of rotor pole segments (112) comprising a first rotor pole segment (112) and a second rotor pole segment (112), the first rotor pole segment (112) and the second rotor pole segment (112) being arranged relative to each other and circumferentially adjacent to each other around the central longitudinal rotation axis (111), wherein, as seen in a clockwise or counterclockwise direction of a cross section of the elongated body (110), each rotor pole segment (112) comprises a central region (1121), the central region (1121) being flanked by a first outer region (1122) and a second outer region (1123), the first outer region (1122) and the second outer region (1123) respectively extending from the central region (1121), each rotor pole segment (112) being asymmetric at least with respect to a bisector (10) of the pole sector comprising the rotor pole segment (112), and wherein the rotor assembly (100) is arranged such that when exposed to magnetic flux, - a free end of the first outer region (1122) of the first rotor pole segment (112), referred to as the first free end (1122a), and a free end of the second outer region (1123) of the second rotor pole segment (112), referred to as the second free end (1123a), face each other, the first free end (1122a) and the second free end (1123a) having no surface contact with each other or having a minimum contact length (1125) extending along the radial dimension, thereby forming a flux barrier for inhibiting the flow of the magnetic flux between the first free end (1122a) and the second free end (1123a), thereby increasing the magnetic resistance between the first free end (1122a) and the second free end (1123a).

2. The rotor assembly (100) of claim 1, wherein: In the absence of surface contact between the first free end (1122a) and the second free end (1123a), the angular distance between the first free end (1122a) and the second free end (1123a) is a predetermined angular distance (1124), and the rotor assembly (100) is further arranged such that a ratio of the predetermined angular distance (1124) to a radius of the rotor assembly (100) is between 0.1% and 20%.

3. The rotor assembly (100) of claim 1, wherein: In the presence of a minimum contact length (1125) between the first free end (1122a) and the second free end (1123a), the rotor assembly (100) is further arranged such that a ratio of the minimum contact length (1125) relative to a radius of the rotor assembly (100) is less than or equal to 10%.

4. The rotor assembly (100) according to any one of claims 1 to 3, wherein: For at least one rotor pole segment (112), the first outer region (1122) and / or the second outer region (1123) has a conical shape which tapers from the central region (1121) towards its respective free end.

5. The rotor assembly (100) according to any one of claims 1 to 4, wherein: For at least one rotor pole segment (112), the central region (1121) comprises at least one inwardly facing recessed portion (1126), the recessed portion (1126) being provided with a bisector (11) which is angularly offset relative to a bisector (10) of the pole sector comprising the rotor pole segment (112).

6. The rotor assembly (100) of claim 5, wherein: Along the radial dimension, the deepest point of the depth of the recessed portion (1126) is relative to the bisector (11) of the recessed portion (1126).

7. A rotor assembly according to any one of claims 5 to 6, wherein: For at least one rotor pole segment (112), an angular extension α of the first outer region (1122) measured from one side of the recessed portion (1126) to the first free end (1122a) is 1122 is different from the angular extension α of the second outer region (1123) measured from the other side of the recessed portion (1126) to the second free end (1123a). 1123 .

8. The rotor assembly (100) according to any one of claims 1 to 7, wherein: The cross-section of the elongated body (110) further comprises: for at least one rotor pole segment (112), - the first outer region (1122) has at least a first outwardly curved section and a second outwardly curved section, referred to as a first section (1122b) and a second section (1122c), the first section (1122b) being closer to the central region (1121) than the second section (1122c), - the second outer region (1123) has at least one outwardly curved section, referred to as the third section (1123b), in, - the first section (1122b), the second section (1122c) and the third section (1123b) each have a substantially constant radius of curvature, - the first section (1122b) and the second section (1122c) have a first radius r1 and a second radius r2, respectively, the second radius r2 is longer than the first radius r1, and - The third section (1123b) has a third radius r3 different from the second radius r2.

9. The rotor assembly (100) of claim 8, wherein: The first segment (1122b) and / or the second segment (1122c) and / or the third segment (1123b) each include at least one cutout portion forming a tooth (1127), thereby locally adjusting an air gap between the rotor assembly (100) and the stator in order to smooth the torque, thereby reducing torque fluctuations.

10. The rotor assembly (100) according to any one of claims 1 to 9, wherein: The cross-section of the elongated body (110) further includes pairs of continuous hollow frames (1128) as many as the number of pairs of rotor pole segments (112), wherein each rotor pole segment (112) is circumscribed by a corresponding hollow frame (1128).

11. A system assembly (200) for a radial synchronous reluctance motor, the system assembly (200) comprising: - a rotor assembly (100) according to any one of claims 1 to 10, - a rotor shaft (210), and - a first shaft connection assembly (220), the first shaft connection assembly (220) being configured to connect the rotor assembly (100) to the rotor shaft (210), in, - the first shaft connection assembly (220) comprises a cylindrical elongated body, - the rotor assembly (100) is configured to connect the assembly (220) around the first shaft, and - The rotor shaft (210) is configured to protrude longitudinally from the distal end of the cylindrical elongated body such that rotation of the rotor shaft (210) causes simultaneous and synchronous rotation of the cylindrical elongated body.

12. A system assembly (300) for a radial synchronous reluctance motor, the system assembly (300) comprising: - a rotor assembly (100) according to any one of claims 1 to 10, - a rotor shaft (310), and - a second shaft connection assembly, the second shaft connection assembly being configured to connect the rotor assembly (100) to the rotor shaft (310), the second shaft connection assembly comprising a first flange (321), a second flange (322) and a plurality of longitudinal rods (323), in, - the rotor assembly (100) is configured to be flanked by the first flange (321) and the second flange (322), - the longitudinal rod (323) is configured to extend through the rotor assembly (100) between the first flange (321) and the second flange (322), and - The rotor shaft (310) is configured to protrude longitudinally from distal ends of the first flange (321) and the second flange (322), so that rotation of the rotor shaft (310) causes simultaneous and synchronous rotation of the first flange (321), the second flange (322) and the rotor assembly (100).

13. The system component (200, 300) according to any one of claims 11 to 12, further comprising at least one permanent magnet (20), which is arranged at the top and / or bottom of at least one rotor pole segment (112) so as to cooperate with the corresponding rotor pole segment (112), and the permanent magnet (20) has a magnetization direction and is arranged so that its magnetization direction substantially points to a focusing axis located near the q-axis.

14. A method (400) for producing a rotor assembly (100) for a radial synchronous reluctance motor, the method comprising: - providing (410) an elongated body (110) having a central longitudinal axis of rotation (111), a circumference and a cross-section, - defining (420) a cross-section of the elongated body (110) to present a width dimension and a radial dimension perpendicular to the width dimension and comprising at least one pair of rotor pole segments (112), the at least one pair of rotor pole segments (112) comprising a first rotor pole segment (112) and a second rotor pole segment (112), - arranging (430) the first and second rotor pole segments (112) relative to each other and circumferentially adjacent to each other about the central longitudinal rotation axis (111), - defining (440) each rotor pole segment (112) to include a central region (1121) as seen in a clockwise or counterclockwise direction of a cross section of the elongated body (110), the central region (1121) being flanked by a first outer region (1122) and a second outer region (1123), the first outer region (1122) and the second outer region (1123) respectively extending from the central region (1121), - defining (450) each rotor pole segment (112) as being asymmetrical at least relative to a bisector (10) of a pole including said rotor pole segment (112), and - arranging (460) a free end, referred to as the first free end (1122a), of the first outer region (1122) of the first rotor pole segment (112) and a free end, referred to as the second free end (1123a), of the second outer region (1123) of the second rotor pole segment (112) so as to face each other, - Arranging (470) the first free end (1122a) and the second free end (1123a) so that when exposed to a magnetic flux, the first free end (1122a) and the second free end (1123a) have no surface contact with each other or have a minimum contact length (1125) with each other extending along the radial dimension, thereby forming a flux barrier for inhibiting the magnetic flux from flowing between the first free end (1122a) and the second free end (1123a), thereby increasing the magnetic resistance between the first free end (1122a) and the second free end (1123a).

15. A method (500) for producing a rotor assembly for an axial synchronous reluctance motor, the method comprising: - providing (510) at least one elongated hollow cylinder having a central longitudinal axis of rotation, a circumference, an inner surface and a width, the elongated hollow cylinder being made of a ferromagnetic-based material, - providing (520) a cross-section of a rotor assembly (100) according to any one of claims 1 to 10, - projecting (530) a cross section of the rotor assembly (100) onto the inner surface of the elongated hollow cylinder, thereby forming a projection pattern on the inner surface of the elongated hollow cylinder, - extending (540) the projection pattern along the circular cross section of the elongated hollow cylinder in a direction radial to the circular cross section, thereby forming an extended projection pattern, - excavating (550) the width of the elongated hollow cylinder according to an extended projection pattern to extract a first rotor pole segment for an axial synchronous reluctance machine, - repeating (560) said projecting step (530) to said excavating step (550) in order to extract at least a second rotor pole segment of the axial synchronous reluctance machine, - arranging (570) the first rotor pole segment and the second rotor pole segment relative to each other and circumferentially adjacent to each other about a central longitudinal rotational axis, - arranging (580) a free end, referred to as the first free end, of the first outer region of the first rotor pole segment and a free end, referred to as the second free end, of the second outer region of the second rotor pole segment facing each other, - Arranging (590) the first free end and the second free end such that, when exposed to magnetic flux, the first free end and the second free end have no surface contact with each other or have a minimum contact length with each other extending along the radial dimension, thereby forming a flux barrier for inhibiting the magnetic flux from flowing between the first free end and the second free end, thereby increasing the magnetic resistance between the first free end and the second free end.

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