Low-loss motor rotor core and manufacturing method thereof

Abstract

The invention discloses a low-loss motor rotor core, which comprises a magnet yoke part and a plurality of L-shaped rotor tooth parts, the magnet yoke part is formed by winding a section of iron core body for multiple circles along a vortex-shaped line track, and the adjacent circles of iron core bodies are attached to each other; each circle of iron core body is provided with a plurality of L-shaped iron core pole shoes which are uniformly distributed along the circumferential direction, the phase angles between the iron core pole shoes of each circle are equal, and the corresponding iron core pole shoes of each circle are sequentially laminated to form the rotor tooth part; a section of iron core body is wound for multiple circles along the vortex-shaped line track to form the magnet yoke part, and the iron core pole shoes on all circles of iron core bodies are stacked in a one-to-one correspondence mode to form the rotor tooth part, so that compared with an existing iron core structure formed by stacking a plurality of iron core units, the manufactured motor rotor iron core has the advantages that the blanking waste part can be reduced, the production cost is reduced, and the production efficiency is improved. And meanwhile, a plurality of iron core units do not need to be separated for lamination, so that the iron core is more convenient to manufacture, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a low-loss motor rotor core and a manufacturing method thereof. Background Art

[0002] In traditional motor design, the rotor core is usually composed of a series of silicon steel sheets with uniform thickness, which are stacked and fixed to form a complete rotor core; the purpose of this design is to reduce eddy current loss and hysteresis loss, thereby improving the efficiency of the motor.

[0003] However, this structure has problems of low material utilization and high production cost. At the same time, since silicon steel sheets need to be stacked layer by layer, the production efficiency of the rotor core is low. Summary of the invention

[0004] The purpose of the present invention is to overcome the above-mentioned shortcomings and provide a low-loss motor rotor core and a manufacturing method thereof, which can reduce the waste part caused by punching, improve material utilization, and reduce production costs. At the same time, there is no need to divide it into multiple core units for stacking, which makes it more convenient to manufacture and thus improves production efficiency.

[0005] To achieve the above object, the specific scheme of the present invention is as follows:

[0006] A first aspect of the present invention provides a low-loss motor rotor core, comprising a yoke portion and a plurality of L-shaped rotor tooth portions;

[0007] The yoke part is formed by winding a section of an iron core body along a spiral line trajectory for multiple turns, and the iron core bodies of adjacent turns are in contact with each other; each turn of the iron core body is provided with a plurality of L-shaped iron core pole shoes evenly distributed along the circumferential direction, the phase angles between the iron core pole shoes of each turn are equal, and the iron core pole shoes corresponding to each turn are stacked in sequence to form the rotor tooth part.

[0008] The present invention further comprises a covering section extending from the bottom core pole shoe; the covering section covers the outside of the rotor tooth section along the shape of the rotor tooth section, and the terminal end face of the covering section is flush with the end face of the yoke section.

[0009] The present invention further comprises a first fastening hole at the end of the covering section, and a second fastening hole is provided on the yoke part corresponding to each covering section; the second fastening hole penetrates each circle of the core body; and a locking assembly is connected between the first fastening hole and the second fastening hole.

[0010] The present invention further comprises a locking assembly comprising a bolt and a nut; the bolt passes through a first fastening hole and a second fastening hole in sequence from the outside of the covering section toward the center of the yoke part, and the nut is threadedly connected to the bolt and is located on the inner side of the yoke part.

[0011] A second aspect of the present invention provides a method for manufacturing a low-loss motor rotor core as described above, comprising the following steps:

[0012] Pretreatment: Clean, degrease and rust the silicon steel sheet to ensure that the surface of the silicon steel sheet is clean and flat;

[0013] Punching pole shoes: according to the processing size of the rotor core, the punching parameters are calculated, and the punching parameters include the pole shoe length and the pole shoe spacing; according to the punching parameters, a section of the core body and several groups of steel sheet pole shoes connected to one side of the core body are punched out on the pre-treated silicon steel plate, each group of steel sheet pole shoes includes multiple steel sheet pole shoes, and the number of groups of steel sheet pole shoes is equal to the number of windings of the rotor core, so as to obtain the rotor core of the first form;

[0014] Bending process: With the intersection between the steel pole shoe and the core body as the fulcrum, the steel pole shoe is bent 90 degrees to form an L-shaped core pole shoe, thus obtaining the second form of the rotor core;

[0015] Rolling forming: The rotor core of the second form is wound multiple times from the inside to the outside along the spiral line trajectory, and the corresponding core pole shoes between each circle are overlapped in sequence to form the rotor tooth part, thereby obtaining the rotor core of the third form.

[0016] The present invention further includes surface treatment: performing rust-proof treatment on the rotor core of the third form.

[0017] The present invention further includes, in the step of punching out the pole shoes, punching out a covering section extending from the end of the steel sheet pole shoes on the first group of steel sheet pole shoes;

[0018] The method also includes coating and shaping: coating the coating section along the shape of the rotor tooth part on the outer side of the rotor tooth part.

[0019] The present invention further punches out a first fastening hole at the end of each cladding section, and punches out a second fastening hole at a position of the core body corresponding to each steel sheet pole shoe; the corresponding first fastening hole and second fastening hole are fixedly connected together by a locking assembly, and then the rotor core is shaped.

[0020] The present invention further comprises a locking assembly comprising a bolt and a nut; the bolt passes through a first fastening hole and a second fastening hole in sequence from the outside of the covering section toward the center of the yoke part, and the nut is threadedly connected to the bolt and is located on the inner side of the yoke part.

[0021] The beneficial effects of the present invention are as follows: the present invention adopts a section of iron core body to be wound multiple times along a spiral line trajectory to form a yoke part, and the iron core pole shoes on each circle of the iron core body are stacked one by one to form a rotor tooth part. Compared with the existing iron core structure composed of multiple iron core units stacked together, the motor rotor core made in this way can reduce the punching waste part, improve material utilization, and reduce production costs. At the same time, there is no need to divide it into multiple iron core units for stacking, which makes it more convenient to manufacture, thereby improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a structural schematic diagram of the rotor core of the motor of the present invention;

[0023] Figure 2 is a top view of the rotor core of the motor of the present invention;

[0024] Figure 3 is a cross-sectional view of the rotor core of the motor of the present invention;

[0025] Figure 4 is a schematic structural diagram of a motor rotor core according to a first embodiment of the present invention;

[0026] Figure 5 is a schematic structural diagram of a motor rotor core according to a second embodiment of the present invention;

[0027] Figure 6 is a schematic structural diagram of a motor rotor core according to a third aspect of the present invention;

[0028] Figure 7 is a schematic diagram of the rotor tooth portion of the present invention;

[0029] Explanation of the reference numerals: 1. yoke part; 11. core body; 2. rotor tooth part; 21. core pole shoe; 22. cladding section; 23. steel sheet pole shoe; 31. first fastening hole; 32. second fastening hole; 41. bolt; 42. nut. DETAILED DESCRIPTION

[0030] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments, but the implementation scope of the present invention is not limited thereto.

[0031] like Figures 1 to 6 As shown, a low-loss motor rotor core described in this embodiment includes a yoke portion 1 and a plurality of L-shaped rotor tooth portions 2;

[0032] The yoke part 1 is formed by winding a section of an iron core body 11 along a spiral line trajectory for multiple turns, and the iron core bodies 11 of adjacent turns are close to each other; each turn of the iron core body 11 is provided with a plurality of L-shaped iron core pole shoes 21 evenly distributed along the circumferential direction, the phase angles between the iron core pole shoes 21 of each turn are equal, and the length of the iron core pole shoes 21 of each turn gradually increases from the inside to the outside; the iron core pole shoes 21 corresponding to each turn are stacked in sequence to form the rotor tooth part 2.

[0033] In this embodiment, a section of the core body 11 is wound along a spiral line trajectory for multiple turns to form the yoke part 1, and the core pole shoes 21 on each turn of the core body 11 are stacked one by one to form the rotor tooth part 2. Compared with the existing core structure composed of multiple stacked core units, the motor rotor core made in this way can reduce the waste part caused by punching, improve material utilization, and reduce production costs. At the same time, there is no need to separate it into multiple core units for stacking, which makes it more convenient to manufacture, thereby improving production efficiency.

[0034] like Figure 1 , Figure 3 and Figure 6 As shown, in the embodiment of the low-loss motor rotor core, in some embodiments, the core pole shoe 21 at the bottom layer is extended with a cladding section 22; the cladding section 22 is clad on the outside of the rotor tooth section 2 along the shape of the rotor tooth section 2, and the end surface of the cladding section 22 is flush with the end surface of the yoke section 1. In this embodiment, the cladding section 22 is provided to enhance the structural stability of the rotor tooth section 2.

[0035] like Figures 1 to 6 As shown, in some embodiments of the low-loss motor rotor core described in this embodiment, a first fastening hole 31 is provided at the end of the cladding section 22, and the yoke part 1 is provided with a second fastening hole 32 corresponding to each cladding section 22; the second fastening hole 32 penetrates each circle of the core body 11; and a locking assembly is connected between the first fastening hole 31 and the second fastening hole 32. In this embodiment, by providing the first fastening hole 31 and the second fastening hole 32, the yoke part 1 and the rotor tooth part 2 are fixed as a whole by using the locking assembly, thereby further improving the structural stability of the motor rotor core.

[0036] like Figures 1 to 3 As shown, the low-loss motor rotor core described in this embodiment, specifically, the locking assembly includes a bolt 41 and a nut 42; the bolt 41 passes through the first fastening hole 31 and the second fastening hole 32 in sequence from the outside of the covering section 22 toward the center of the yoke part 1, and the nut 42 is threadedly connected to the bolt 41 and is located on the inner side of the yoke part 1. During manufacturing, the bolt 41 passes through the first fastening hole 31 and the second fastening hole 32, and then the nut 42 is screwed on the bolt 41, so that the yoke part 1 and the rotor tooth part 2 are firmly integrated into a whole, and the structural stability is higher.

[0037] like Figures 1 to 7 As shown, this embodiment also provides a method for manufacturing a low-loss motor rotor core, comprising the following steps:

[0038] Pretreatment: Clean, degrease and rust the silicon steel sheet to ensure that the surface of the silicon steel sheet is clean and flat; specifically, select silicon steel sheets of appropriate specifications as raw materials and perform pretreatment such as cleaning, degreasing and rust removal.

[0039] Punching pole shoes: According to the machining dimensions of the rotor core, the punching parameters are calculated. The punching parameters include pole shoe length h, pole shoe spacing d, pole shoe width D, and yoke width b.

[0040] Specifically, the bending radius r n =r0-(n-1)×t, bending length Pole shoe length h n =a0+L n , the number of rotor teeth y = 360° / γ; where n represents the number of rotor turns, n = 1, 2, 3, ...; r n represents the bending radius of the n-th iron core pole shoe; t represents the steel plate thickness; a0 represents the length of the straight line segment of the rotor tooth; Ln represents the length of the bent portion of the n-th iron core pole shoe; r0 represents the maximum bending radius of the iron core pole shoe; h n It is represented by the pole shoe length of the iron core pole shoe of the nth circle; γ is represented by the phase angle between adjacent pole shoes; n, t, r0, D, b, a0, γ are all preset constants;

[0041] According to the above parameters, the pole shoe spacing d of the core pole shoe i =S i ; Where i represents the serial number of the pole shoe spacing, i = 1, 2, 3..., ny-1; S i It is expressed as the arc length of the vortex line between the ith core pole shoe and the i+1th core pole shoe;

[0042] Specifically, the plane vortex line is an Archimedean spiral, and the polar coordinate equation of the Archimedean spiral is r=aθ, which is converted into a rectangular coordinate parameter equation of x=aθcosθ, y=aθsinθ, where a is a constant and θ is a parameter.

[0043] For the parametric equation x=x(θ), y=y(θ), the arc length is calculated as:

[0044] calculate and

[0045] Derivative x = aθcosθ:

[0046] According to the product rule (uv)'=u'v+uv', where u=aθ, v=cosθ, we can get:

[0047] Derivative y = aθsinθ:

[0048] Similarly, we can get:

[0049] Will and Substituting into the arc length formula we get:

[0050]

[0051] for The calculation can be done by substitution or other integration techniques;

[0052] Let θ = tanu, then dθ = sec 2 udu, we can get:

[0053]

[0054] ∫sec 3 The points of udu are: Substituting θ = tanu back, we get the arc length S i The final expression of is:

[0055] Right now:

[0056] Among them, β = α + γ; thus the arc length S in the given angle interval [α, β] is obtained i ; Then the pole shoe spacing d between each adjacent core pole shoe is obtained i =S i ;

[0057] Then, a section of the core body 11 and a plurality of groups of steel sheet pole shoes 23 connected to one side of the core body 11 are punched out from the pretreated silicon steel plate according to the punching parameters, each group of steel sheet pole shoes 23 includes a plurality of steel sheet pole shoes 23, and the number of groups of steel sheet pole shoes 23 is equal to the number of windings of the rotor core, thereby obtaining a rotor core of the first form;

[0058] Bending process: according to the blanking parameters, the steel sheet pole shoe 23 is bent 90 degrees with the intersection between the steel sheet pole shoe 23 and the core body 11 as the fulcrum to form an L-shaped core pole shoe 21, thereby obtaining the second form of the rotor core;

[0059] Rolling forming: The rotor core of the second form is wound multiple times from the inside to the outside along the spiral line trajectory, and the corresponding core pole shoes 21 between each circle are overlapped in sequence to form the rotor tooth part 2, thereby obtaining the rotor core of the third form.

[0060] In this embodiment, a section of the core body 11 is wound along a spiral line trajectory for multiple turns to form the yoke part 1, and the core pole shoes 21 on each turn of the core body 11 are stacked one by one to form the rotor tooth part 2. Compared with the existing core structure composed of multiple stacked core units, the motor rotor core made in this way can reduce the waste part caused by punching, improve material utilization, and reduce production costs. At the same time, there is no need to separate it into multiple core units for stacking, which makes it more convenient to manufacture, thereby improving production efficiency.

[0061] The manufacturing method of this embodiment also includes surface treatment: anti-rust treatment of the rotor core of the third form, such as spraying insulating paint or phosphating treatment, to improve the corrosion resistance and insulation performance of the motor rotor core; heat treatment or coating can also be performed to improve the performance and durability of the rotor core.

[0062] In the manufacturing method of this embodiment, in the step of punching out the pole shoes, the covering section 22 extending from the end of the steel sheet pole shoe 23 is punched out on the first group of steel sheet pole shoes 23;

[0063] It also includes wrapping and shaping: wrapping the wrapping section 22 along the shape of the rotor tooth part 2 on the outside of the rotor tooth part 2; in this way, each core pole shoe 21 is more closely attached to each other, thereby enhancing the structural stability.

[0064] Specifically, the coating section length Z is obtained by the following formula:

[0065] Z=(a0-1 / 2r n+1 )+b+3L n+1 +[(n+1)t-2r n+1 ]; At this time, the pole shoe length is h n =a0+L n +Z;

[0066] like Figures 1 to 6 As shown, the manufacturing method of this embodiment punches out a first fastening hole 31 at the end of each cladding section 22, and punches out a second fastening hole 32 at the position of each steel sheet pole shoe 23 in the core body 11; the diameter m of the first fastening hole 31 and the second fastening hole 32 is a preset constant; the corresponding first fastening hole 31 and the second fastening hole 32 are fixedly connected together by a locking assembly, so that the yoke part 1 and the rotor tooth part 2 are firmly integrated as a whole, further improving the structural stability of the motor rotor core; and then the rotor core is shaped to ensure the overall roundness and structural stability of the motor rotor core.

[0067] like Figures 1 to 3 As shown, in the manufacturing method of this embodiment, the locking assembly includes a bolt 41 and a nut 42; the bolt 41 passes through the first fastening hole 31 and the second fastening hole 32 in sequence from the outside of the covering section 22 toward the center of the yoke part 1, and the nut 42 is threadedly connected to the bolt 41 and is located on the inner side of the yoke part 1. During manufacturing, the bolt 41 passes through the first fastening hole 31 and the second fastening hole 32, and then the nut 42 is screwed on the bolt 41, so that the yoke part 1 and the rotor tooth part 2 are firmly integrated into a whole, and the structural stability is higher.

[0068] The above description is only a preferred embodiment of the present invention. Therefore, any equivalent changes or modifications made according to the structure, characteristics and principles described in the scope of the patent application of the present invention are included in the protection scope of the patent application of the present invention.

Claims

1. A low-loss motor rotor core, characterized in that: It includes a yoke portion and a plurality of L-shaped rotor tooth portions; The yoke part is formed by winding a section of an iron core body along a spiral line trajectory for multiple turns, and the iron core bodies of adjacent turns are in contact with each other; each turn of the iron core body is provided with a plurality of L-shaped iron core pole shoes evenly distributed along the circumferential direction, the phase angles between the iron core pole shoes of each turn are equal, and the iron core pole shoes corresponding to each turn are stacked in sequence to form the rotor tooth part.

2. A low-loss motor rotor core according to claim 1, characterized in that: The iron core pole shoe at the bottom layer is extended with a covering section; the covering section covers the outer side of the rotor tooth part along the shape of the rotor tooth part, and the terminal end surface of the covering section is flush with the end surface of the yoke part.

3. A low-loss motor rotor core according to claim 2, characterized in that: A first fastening hole is provided at the end of the covering section, and a second fastening hole is provided on the yoke part corresponding to each covering section; the second fastening hole penetrates each circle of the core body; a locking component is connected between the first fastening hole and the second fastening hole.

4. A low-loss motor rotor core according to claim 3, characterized in that: The locking assembly includes a bolt and a nut; the bolt passes through the first fastening hole and the second fastening hole in sequence from the outside of the covering section toward the center of the yoke part, and the nut is threadedly connected to the bolt and is located on the inner side of the yoke part.

5. A method for manufacturing a low-loss motor rotor core as claimed in claim 1, characterized in that: The steps include: Pretreatment: Clean, degrease and rust the silicon steel sheet to ensure that the surface of the silicon steel sheet is clean and flat; Punching pole shoes: according to the processing size of the rotor core, the punching parameters are calculated, and the punching parameters include the pole shoe length and the pole shoe spacing; according to the punching parameters, a section of the core body and several groups of steel sheet pole shoes connected to one side of the core body are punched out on the pre-treated silicon steel plate, each group of steel sheet pole shoes includes multiple steel sheet pole shoes, and the number of groups of steel sheet pole shoes is equal to the number of windings of the rotor core, so as to obtain the rotor core of the first form; Bending process: With the intersection between the steel pole shoe and the core body as the fulcrum, the steel pole shoe is bent 90 degrees to form an L-shaped core pole shoe, thus obtaining the second form of the rotor core; Rolling forming: The rotor core of the second form is wound multiple times from the inside to the outside along the spiral line trajectory, and the corresponding core pole shoes between each circle are overlapped in sequence to form the rotor tooth part, thereby obtaining the rotor core of the third form.

6. The manufacturing method according to claim 5, characterized in that: It also includes surface treatment: anti-rust treatment is performed on the rotor core of the third form.

7. The manufacturing method according to claim 5, characterized in that: In the step of punching out the pole shoes, a covering section extending from the end of the steel sheet pole shoes is punched out on the first group of steel sheet pole shoes; The method also includes coating and shaping: coating the coating section along the shape of the rotor tooth part on the outer side of the rotor tooth part.

8. The manufacturing method according to claim 7, characterized in that: A first fastening hole is punched out at the end of each cladding section, and a second fastening hole is punched out at a position of the core body corresponding to each steel sheet pole shoe; The corresponding first fastening holes and the second fastening holes are fixedly connected together through the locking assembly, and then the rotor core is shaped.

9. The manufacturing method according to claim 8, characterized in that: The locking assembly includes a bolt and a nut; the bolt passes through the first fastening hole and the second fastening hole in sequence from the outside of the covering section toward the center of the yoke part, and the nut is threadedly connected to the bolt and is located on the inner side of the yoke part.

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