Split embedded magnetic circuit optimization design process

Abstract

The invention discloses a split embedded magnetic circuit optimization design process, and belongs to the technical field of motor design and manufacturing. According to the invention, a split embedded magnetic circuit optimization design process is adopted, and the embedded combination design of a high-resistance magnetic material and a high-permeability magnetic material is utilized, so that the cogging torque of the motor and the magnetic isolation groove structure of the permanent magnet rotor can be effectively improved, the magnetic circuit is optimized, the magnetic leakage is reduced, and meanwhile, the mechanical property is ensured.

Description

Technical Field

[0001] The invention belongs to the technical field of motor design and manufacturing. Background Art

[0002] With the rapid development of new energy vehicles, especially pure electric vehicles, higher requirements are placed on high-speed performance and high power density of electric vehicles. Therefore, a variety of winding schemes based on flat wire windings have emerged, including Hair-pin, i-pin, x-pin, w-pin and other schemes. W-pin is a continuous wave winding with the advantages that the entire winding has almost no welding points except the current output and input ports, but it needs to be assembled with open slots, which will increase the tooth torque. For permanent magnet rotors, in order to minimize leakage flux and improve the high-speed mechanical properties of the rotor, the magnetic resistance slot design of the rotor core structure is very demanding. In order to ensure sufficient safety, it is inevitable to form a certain magnetic circuit closure to cause leakage flux and reduce the electromechanical conversion efficiency. There are also structures with high-strength carbon fiber wound on the outside, which increases the cost and increases the air gap, which will also affect its performance. Summary of the invention

[0003] The present invention improves upon the above-mentioned problems by adopting a split embedded magnetic circuit optimization design process, which can effectively improve the motor cogging torque and the permanent magnet rotor magnetic isolation slot structure, optimize the magnetic circuit and ensure mechanical properties at the same time.

[0004] Specifically include:

[0005] 1. Stator core slot optimization

[0006] Through the split embedded combination process, the open slot can be formed into a semi-closed slot or a closed slot structure, the tooth slot torque is optimized, and it has the assembly characteristics of an open slot. Before the winding is installed, it is an open slot. After the winding is installed in the stator, the split embedded expanded tooth block is embedded with the open slot area of ​​the core to form a semi-closed slot or a closed slot structure.

[0007] The specific structure of the split embedded flared tooth block includes: a magnetic conductive block area and a non-magnetic conductive block area. The magnetic conductive block area can be formed by stacking traditional iron-based silicon steel sheets, and the thickness of the silicon steel sheets (including the insulating layer) can be the same as that of the stator core. After the pressing is completed, the two can be aligned layer by layer. Alternatively, the magnetic conductive block area can also use integral silicon steel; or, it can also be other materials such as nanocrystalline-amorphous alloys; or, it can be a highly magnetically conductive non-conductive material formed by highly magnetically conductive particles with an insulating layer coated on the surface and an adhesive.

[0008] The structural combination of the non-magnetic block area (generally a high-resistance magnetic insulating material), the magnetic block area and the stator core opening slot area will form an integrated structure to ensure its good mechanical properties. The assembly process, that is, the mutual inlay process, can be an interference fit, where the split embedded flared tooth blocks are axially inserted from both ends of the stator and tightly pressed together; or casting, glue injection, and potting can be used to form a reliable mechanical connection relationship; for example: the non-magnetic part can be potted or cast; or welding, bonding and other bonding methods can be used.

[0009] Alternatively, the magnetic conductive block area is first installed into the stator core, and then the non-magnetic conductive block area is tightly riveted and inserted to form a wedge-tight block relationship to form an overall solid structure; the addition of the non-magnetic conductive embedded block can also improve the mechanical and electromagnetic properties of the winding, as well as enhance the winding stiffness and density, reduce electromagnetic noise, and enhance the contact stress between the windings to enhance the thermal conductivity, optimize the thermal conductivity, and improve the heat dissipation effect; and the notch winding effect problem of the winding can be improved to improve efficiency;

[0010] At the same time, this solution can also further optimize the core strength stiffness in the core winding tooth area and improve safety and noise.

[0011] Second, for the rotor, high magnetic resistance materials with certain mechanical strength are inlaid and assembled according to their structure to form an integrated mechanical structure, which can improve the strength of the rotor core while ensuring that the leakage magnetic circuit is blocked.

[0012] Alternatively, an integral closed-circuit aluminum bar may be used for the rotor, and an asynchronous induction starting torque similar to that of a squirrel-cage induction motor may be obtained;

[0013] Or adopt the pouring method, potting method or glue injection method to form a reliable mechanical connection relationship;

[0014] Or welding, bonding, potting, inlay interference, etc.,

[0015] Achieve better results than wrapping with carbon fiber, and realize super magnetic blocking grooves and magnetic breaking grooves that completely cut off the magnetic circuit to improve mechanical strength;

[0016] Improve efficiency and high speed, small magnetic leakage, small air gap, good mechanical strength, low electromagnetic noise, light weight,

[0017] 3. External rotor structure: It is more appropriate to use an internal stator and external rotor for continuous wave winding, which is more convenient for the assembly of continuous wave winding. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The present invention is specifically described below in conjunction with the accompanying drawings and embodiments:

[0019] Figure 1, Schematic diagram of the optimized design structure of the stator core slot

[0020] Figure 2 , Schematic diagram of the optimized design structure of the permanent magnet rotor magnetic resistance slot

[0021] Figure 3 , Local enlarged view of embedded structure a

[0022] Figure 4 , Local enlarged view of embedded structure b

[0023] Figure 5 , Schematic diagram of the discrete state of the permanent magnet rotor permeable core (there is no conductive magnetic path between the internal and external cores of the permanent magnet, which can obtain the best electromagnetic energy conversion)

[0024] in:

[0025] 1. Stator winding core choke

[0026] 2. Stator winding core teeth

[0027] 3. Stator winding core slot

[0028] 4. Winding (flat wire winding)

[0029] 5. Split embedded flared tooth block type A

[0030] 6. Split embedded flared tooth block type B

[0031] 7. Split embedded flared tooth block C type

[0032] 8. A-type gear block magnetic block area

[0033] 9. Non-magnetic area of ​​type A gear block

[0034] 10. B-type gear block magnetic block area

[0035] 11. Non-magnetic block area of ​​type B gear block

[0036] 12. C-type gear block magnetic block area

[0037] 13. Non-magnetic area of ​​C-type gear block

[0038] 14. Internal area of ​​permanent magnet rotor core

[0039] 15. Permanent magnet rotor core external area

[0040] 16. Permanent magnet (NdFeB strong magnet)

[0041] 17. Embedded high magnetic resistance connection block type D

[0042] 18. Embedded high magnetic resistance connection block F type

[0043] 19. Embedded high magnetic resistance connection block type E

[0044] 20. Magnetic isolation slot without connection

[0045] 21. Protrusions on the outer area of ​​the permanent magnet rotor core

[0046] 22. Protrusions in the inner area of ​​the permanent magnet rotor core

[0047] 23. Concave and convex areas of the F-type connection block and the external core

[0048] 24. F-type connection block and internal core connection protrusion DETAILED DESCRIPTION

[0049] The present invention improves upon the above-mentioned problems by adopting a split embedded magnetic circuit optimization design process, which can effectively improve the motor cogging torque and the permanent magnet rotor magnetic isolation slot structure, optimize the magnetic circuit and ensure mechanical properties at the same time.

[0050] Specifically include:

[0051] 1. Stator core slot optimization

[0052] Through the split embedded combination process, the open slot can be formed into a semi-closed slot or a closed slot structure, the tooth slot torque is optimized, and it has the assembly characteristics of an open slot. Before the winding is installed, it is an open slot. After the winding is installed in the stator, the split embedded expanded tooth block is embedded with the open slot area of ​​the core to form a semi-closed slot or a closed slot structure.

[0053] The specific structure of the split embedded flared tooth block includes: a magnetic conductive block area and a non-magnetic conductive block area. The magnetic conductive block area can be formed by stacking traditional iron-based silicon steel sheets, and the thickness of the silicon steel sheets (including the insulating layer) can be the same as that of the stator core. After the pressing is completed, the two can be aligned layer by layer. Alternatively, the magnetic conductive block area can also use integral silicon steel; or, it can also be other materials such as nanocrystalline-amorphous alloys; or, it can be a highly magnetically conductive non-conductive material formed by highly magnetically conductive particles with an insulating layer coated on the surface and an adhesive.

[0054] The structural combination of the non-magnetic block area (generally a high-resistance magnetic insulating material), the magnetic block area and the stator core opening slot area will form an integrated structure to ensure its good mechanical properties. The assembly process, that is, the mutual inlay process, can be an interference fit, where the split embedded flared tooth blocks are axially inserted from both ends of the stator and tightly pressed together; or casting, glue injection, and potting can be used to form a reliable mechanical connection relationship; for example: the non-magnetic part can be potted or cast; or welding, bonding and other bonding methods can be used.

[0055] Alternatively, the magnetic conductive block area is first installed into the stator core, and then the non-magnetic conductive block area is tightly riveted and inserted to form a wedge-tight block relationship to form an overall solid structure; the addition of the non-magnetic conductive embedded block can also improve the mechanical and electromagnetic properties of the winding, as well as enhance the winding stiffness and density, reduce electromagnetic noise, and enhance the contact stress between the windings to enhance the thermal conductivity, optimize the thermal conductivity, and improve the heat dissipation effect; and the notch winding effect problem of the winding can be improved to improve efficiency;

[0056] At the same time, this solution can also further optimize the core strength stiffness in the core winding tooth area and improve safety and noise.

[0057] Corresponding attachment Figure 1 In the exhibition, a variety of split embedded flared tooth blocks are shown, including:

[0058] 5. Split embedded flared tooth block type A

[0059] 6. Split embedded flared tooth block type B

[0060] 7. Split embedded flared tooth block C type

[0061] Second, for the rotor, high magnetic resistance materials with certain mechanical strength are inlaid and assembled according to their structure to form an integrated mechanical structure, which can improve the strength of the rotor core while ensuring that the leakage magnetic circuit is blocked.

[0062] Alternatively, an integral closed-circuit aluminum bar may be used for the rotor, and an asynchronous induction starting torque similar to that of a squirrel-cage induction motor may be obtained;

[0063] Or adopt the pouring method, potting method or glue injection method to form a reliable mechanical connection relationship;

[0064] Or welding, bonding, potting, inlay interference, etc.,

[0065] Achieve better results than wrapping with carbon fiber, and realize super magnetic blocking grooves and magnetic breaking grooves that completely cut off the magnetic circuit to improve mechanical strength;

[0066] Improve efficiency and high speed, small magnetic leakage, small air gap, good mechanical strength, low electromagnetic noise, light weight,

[0067] like Figure 2 , 3 ,4, shows a variety of embedded structures, including:

[0068] 17. Embedded high magnetic resistance connection block type D

[0069] 18. Embedded high magnetic resistance connection block F type

[0070] 19. Embedded high magnetic resistance connection block type E

[0071] A safe and stable mechanical structure can be formed while achieving an ideal magnetic isolation groove effect.

[0072] 3. External rotor structure: It is more suitable for continuous wave winding to use internal stator and external rotor, which is more convenient for the assembly of continuous wave winding;

[0073] The above motor design principles can be applied to electric motors and generators.

[0074] Note: Two-phase and three-phase motors can be used first, and the winding wiring will be simpler.

[0075] For the convenience of description, this patent application unfolds the core into a plane to illustrate its structural principle.

[0076] In the above-mentioned corresponding scheme, there are isolation gaps between the layers of the ultra-flat wire windings, and cooling medium can be introduced into the gaps to increase the heat dissipation effect. Please refer to the relevant text.

[0077] Note: The motor described above can also be designed as a counter-rotating dual-rotor motor configuration (see the prior application), or can be: a single-dual-rotor motor, a double-dual-rotor motor, a triple-dual-rotor motor, or a multi-dual-rotor motor; a single-dual-rotor motor: one inner rotor and one outer rotor; a double-dual-rotor motor: including two outer rotors or inner rotors with the same rotation direction, as shown in Figures 26 and 27, Figure 26 includes an intermediate single-winding rotor with a bidirectional magnetic flux and an inner and outer double-magnetic steel rotor. Since the inner and outer double-magnetic steel rotors rotate in the same direction, they can be fixedly connected as one, and a counter-rotating dual-rotor motor is formed with the intermediate single-winding rotor through a reversing mechanism, and the power density can be doubled; Figure 27: includes an intermediate single-magnetic steel rotor with a bidirectional magnetic flux and an inner and outer double-winding rotor; similarly: since the inner and outer double-winding rotors rotate in the same direction, they can be fixedly connected as one, and a counter-rotating dual-rotor motor is formed with the intermediate single-magnetic steel rotor through a reversing mechanism, and the power density can be doubled; or, according to the schemes shown in Figures 20 to 25, a two-side power flow output architecture is formed, which has an electromagnetic differential torque vector distribution function, light weight and high power density.

[0078] The above principle also applies to axial flux motors; and contra-rotating twin-rotor motors; and internal and external dual flux types;

[0079] The axial flux motor can refer to the relevant scheme of the prior application, that is: two or more relatively independent axial flux windings and permanent magnets (or non-permanent magnet current excitation windings) are arranged according to the corresponding phase difference angles, and controlled according to the complementary waveform relationship, and the same effect can be obtained. Since the axial force of the axial flux motor is very large, a double-disc and multi-disc method is basically used to balance the axial force, and the geometric dimensions of the axial flux motor have the characteristics of short axial dimensions. Therefore, it is more conducive to the design of a compact high-power density motor using the double-disc or multi-disc scheme described in this patent application.

[0080] It can be a single-rotor or dual-rotor motor, as well as dual-rotor or counter-rotating dual-rotor motors.

[0081] The electromagnetic wire can be round wire or flat wire; the current waveform can be: square wave, square wave + composite wave, sine wave;

[0082] Regarding the method of introducing the rotor winding current of a dual-rotor motor from the outside, please refer to the prior applications (202211030428.1 Dynamic and static physical ports of dual-rotor motor current, 202211098410.5 Constant magnetic resistance rotating transformer and core design and manufacturing method) and the related schemes below.

[0083] The above solution can also be used in conventional single-rotor motors, such as replacing existing brushless solutions, brushed solutions, etc.

[0084] Note: The above scheme is applicable to all types of motors and generators, including asynchronous motors, synchronous motors, brushless motors, brushed motors, induction motors, permanent magnet motors, switched reluctance motors, etc.

[0085] The three-phase line mentioned above can be the input and output wiring harness end of a three-phase motor, a three-phase induction asynchronous motor, a brushless DC motor, or a permanent magnet synchronous motor.

[0086] Alternatively, the dynamic and static port connection method of this article can also be a sliding brush method, or a sliding carbon brush solution that is easy to disassemble and replace.

[0087] Note: The names of the dynamic and static physical ports described in this article are relative, and they are mutual and interchangeable in their specific implementation; the inner and outer rotors are relative names, and they have interactive mechanical properties and can be each other's inner and outer rotors.

[0088] To keep the illustration simple and with few lines, it is not drawn according to standard engineering drawings. It is only a schematic diagram for explanation. The content described can be accurately identified in combination with the accompanying figures in the context;

[0089] Notes:

[0090] The part numbers in the drawings are marked with the same serial numbers for common parts in different drawings, while different serial numbers are used for related equivalent functional parts in specific drawings. This is entirely for the purpose of cooperating with the instructions to more clearly and accurately describe the working principles.

[0091] All the design ideas, structures, methods, and theories given in this article can be used to guide the design. The technical contents disclosed in the form of design theories, methods, implementation models, structures, principle diagrams, structural diagrams, schematic diagrams, mechanism diagrams, specific embodiments, etc. can be used to specifically design and manufacture various types of engine devices. The implementation mechanisms listed in this patent are all typical examples. The specific facility plans and mechanism types are not listed here in full. Any cross-reorganization, mutual reference design, combination mechanism plan and various application field examples of any design theory, idea, method, model, mechanism, component disclosed in this article are all within the scope of protection of this property right. Any behavior of using this principle for design and application without authorization is an infringement. For example: the relevant design theories and methods are applicable to traditional motors, generators and other similar power sources.

[0092] The purpose of the drawings of this patent is only to briefly explain the facility concept and principle structure of this patent, aiming to clearly express the patent disclosure content with a minimum of drawings, clearly express the key structure, and adopt a "detailed and simple" expression method, that is: the combination of simple drawings and detailed drawings; at the same time, in order to reduce the amount of drawings, the illustrations of similar structures no longer draw other direction views and cross-sectional, enlarged and other detailed drawings; and the standard parts, general parts, and parts without specific meanings and special functions in the text are all named and numbered uniformly in different drawings to make them more concise and clear. Please refer to each other when viewing the drawings.

Claims

1. A split embedded magnetic circuit optimization design process, characterized by: The split embedded magnetic circuit optimization design process is adopted, and the mosaic combination design of high magnetic resistance material and high magnetic permeability material is utilized to effectively improve the motor cogging torque and permanent magnet rotor magnetic isolation slot structure, optimize the magnetic circuit and ensure the mechanical properties at the same time.

2. According to claim 1, a split embedded magnetic circuit optimization design process is characterized by: Through the split embedded combination process, the open slot can be formed into a semi-closed slot or a closed slot structure, the tooth slot torque is optimized, and it has the assembly characteristics of an open slot. Before the winding is installed, it is an open slot. After the winding is installed in the stator, the split embedded expanded tooth block is embedded with the open slot area of ​​the core to form a semi-closed slot or a closed slot structure. The specific structure of the split embedded flared tooth block includes: a magnetic conductive block area and a non-magnetic conductive block area. The magnetic conductive block area can be formed by stacking traditional iron-based silicon steel sheets. The thickness of the silicon steel sheets (including the insulating layer) can be the same as that of the stator core. After the press-fitting is completed, the two can be aligned layer by layer. The structural combination of the non-magnetic conductive block area (generally a high-resistance magnetic insulating material) and the magnetic conductive block area and the stator core opening slot area will form an integrated structure to ensure its good mechanical properties. The assembly process, that is, the mutual inlay process, can be an interference fit, and the split embedded flared tooth block is axially inserted from both ends of the stator and then tightly pressed together; or casting, glue injection, and potting methods can be used to form a reliable mechanical connection relationship; such as: the non-magnetic conductive part can be potted or cast; or welding, bonding and other bonding methods can be used. Alternatively, the magnetic conductive block area is first installed into the stator core, and then the non-magnetic conductive block area is tightly riveted and inserted to form a wedge-tight block relationship to form an overall solid structure; the addition of this non-magnetic embedded block can also improve the mechanical and electromagnetic properties of the winding, as well as enhance the winding stiffness and density, reduce electromagnetic noise, and enhance the contact stress between windings to enhance thermal conductivity, optimize thermal conductivity, and improve heat dissipation; and the notch winding effect problem of the winding can be improved to improve efficiency.

3. According to the split embedded magnetic circuit optimization design process of claim 1, it is characterized in that: The rotor can be assembled and combined with high magnetic resistance materials with certain mechanical strength according to its structure to form an integrated mechanical structural component, thereby improving the strength of the rotor core while ensuring that the leakage magnetic circuit is blocked.

4. According to the split embedded magnetic circuit optimization design process of claim 1, it is characterized in that: The rotor can also use an integral closed-circuit aluminum bar to obtain an asynchronous induction starting torque similar to that of a squirrel-cage induction motor.

5. According to the split embedded magnetic circuit optimization design process of claim 1, it is characterized in that: Use casting, potting, or glue injection to form a reliable mechanical connection; or welding, bonding, potting, or inlay interference, etc. It achieves better results than wrapping with carbon fiber, and realizes super magnetic blocking grooves and magnetic breaking grooves that completely cut off the magnetic circuit to improve mechanical strength; it can form a safe and stable mechanical structure while achieving an ideal magnetic isolation groove effect.

6. The split embedded magnetic circuit optimization design process according to claim 1 is characterized by: A variety of split embedded flared tooth blocks can be used, specifically including: split embedded flared tooth block type A, split embedded flared tooth block type B, and split embedded flared tooth block type C.

7. The split embedded magnetic circuit optimization design process according to claim 1 is characterized by: Can be A variety of embedded structures, including: embedded high-resistance magnetic connection block type D, embedded high-resistance magnetic connection block type F, embedded high-resistance magnetic connection block type E.

8. The split embedded magnetic circuit optimization design process according to claim 1 is characterized by: For the outer rotor structure, it is more appropriate to use an inner stator and outer rotor for the continuous wave winding, which is more convenient for the assembly of the continuous wave winding.

9. The split embedded magnetic circuit optimization design process according to claim 1 is characterized by: The magnetic conductive block area may also be made of integral silicon steel; or other materials such as nanocrystalline-amorphous alloy; Alternatively, it is a highly magnetically conductive non-conductive material formed by highly magnetically conductive particles with an insulating layer coated on the surface and a binder.

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