Rotor lamination core with end laminations for electric machine rotor
By designing the narrowing recess on the end stack of the rotor laminate core, the problem of the rotor magnet falling during assembly is solved, ensuring assembly stability and avoiding the formation of bubbles in the potting compound.
Patent Information
- Application Number
- CN202411816822.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-12-12
- Filing Date
- 2024-12-11
- Publication Date
- 2025-06-13
AI Technical Summary
During the rotor assembly process, the rotor magnet is prone to fall or slide from the rotor laminate core due to gravity, resulting in unstable assembly.
A rotor laminate core having a tip laminate is designed, which is arranged on the axial side of the rotor laminate core and has a narrowing recess to prevent the rotor magnet from sliding off.
Effectively prevent the rotor magnet from sliding or falling from the rotor laminate core during assembly, and avoid bubble formation when the potting compound flows in.
Smart Images
Figure CN120150447A_ABST
Abstract
Description
Field of the Invention
[0001] The present invention relates to a rotor lamination core for an electric motor rotor, the rotor lamination core having a plurality of rotor laminations axially stacked on one another, and each rotor lamination having recesses (or holes), wherein the recesses form magnet slots for receiving rotor magnets. The present invention also relates to a rotor for an electric motor, an electric motor having the rotor, a vehicle having the electric motor, and a method for manufacturing a rotor for an electric motor. Background Art
[0002] A permanent magnet-excited rotor according to the prior art has a rotor lamination core having a plurality of rotor laminations axially stacked on one another, wherein the axial direction extends parallel to the rotation axis of the rotor.
[0003] A plurality of permanent magnets (referred to as "rotor magnets") for generating a rotor magnetic field are arranged in the rotor lamination core. The rotor lamination core has magnet slots for receiving the rotor magnets, each magnet slot extending from one axial side of the rotor lamination core to its opposite axial side. In addition, the rotor has a rotor shaft that axially extends through a central channel opening in the rotor lamination core.
[0004] When manufacturing the rotor, the rotor magnets can be arranged in the rotor lamination core before the rotor lamination core is mounted on the rotor shaft.
[0005] This procedure is followed especially in the case of a so-called "bevelled" rotor. A plurality of rotor lamination cores or rotor segments are mounted on the rotor shaft of such a rotor, wherein the magnetic poles of one rotor lamination core are rotated about the rotation axis of the rotor relative to the magnetic poles of another rotor lamination core.
[0006] In order to arrange the rotor magnets in the rotor lamination core, the rotor lamination core is oriented such that its rotation axis extends vertically. Then the rotor magnets are inserted into the magnet slots of the rotor lamination core from above. There is a risk that the rotor magnets may fall out or slip out of the rotor lamination core due to gravity. This risk also exists in another manufacturing step in which the rotor lamination core is pushed onto the rotor shaft from above, and this risk exists during the transportation of the rotor lamination core for this manufacturing step.
[0007] After all the rotor lamination cores have been fixed on the rotor shaft, the rotor magnets can be potted with a potting compound in order to reliably fix the rotor magnets such that the rotor magnets do not become loose or fall off during the operation of the electric motor. Summary of the Invention
[0008] It is an object of the present invention to prevent the rotor magnets of a rotor from falling out of the rotor lamination core of the rotor during the assembly of the rotor.
[0009] This object is achieved by a rotor lamination core according to the invention, which has end laminations that are arranged on the axial sides of the rotor lamination core and have another recess that is axially aligned with the recesses in adjacent rotor laminations and is narrowed relative to the recesses in adjacent rotor laminations.
[0010] During the assembly of the rotor, when the rotor lamination core is oriented such that its axis of rotation extends vertically and the end laminations are located on the bottom side of the rotor lamination core, the narrowed portion prevents the rotor magnets inserted into the magnet slots from slipping or falling out of the rotor lamination core. During the subsequent potting of the rotor magnets, the recesses in the end laminations also allow the liquid potting compound to flow out of the rotor lamination core downward, thus avoiding the formation of unwanted air bubbles in the potting compound remaining in the magnet slots.
[0011] In addition to the recesses, each rotor lamination can have additional recesses that form additional magnet slots for receiving additional rotor magnets. In the present case, the end laminations can also have additional recesses, each of which is axially aligned with the recesses in adjacent rotor laminations and is narrowed relative to that recess.
[0012] Furthermore, the rotor lamination core can have an axial channel opening through which a rotor shaft can be guided.
[0013] In one embodiment of the rotor lamination core, the recesses in the end laminations are formed in the same way as the recesses in adjacent rotor laminations, except for one or more protrusions that form the narrowed portion and project into the recesses in the end laminations. Thus, the stamping tool for manufacturing the end laminations hardly has to be modified compared to the stamping tool for manufacturing adjacent rotor laminations. The same design can be understood to mean that the two recesses have the same shape, arrangement, and alignment on the rotor lamination.
[0014] The recesses in the end laminations optionally have two edge sections that are opposite each other, and the protrusions are arranged on the two edge sections. In other words, the protrusions are distributed on the two edge sections. In this way, tilting of the rotor magnets supported against the narrowed portion can be prevented. For example, the two edge parts can be straight, where they can extend parallel to each other or form an angle. As an alternative to this, all the protrusions can also be arranged on only one edge section.
[0015] In particular, the protrusions can be arranged on the first edge section, where the point located opposite the protrusions on the second edge section is located between two protrusions arranged on the second edge section, for example, centrally between the two protrusions. In this way, with a minimum number of protrusions, in particular only three protrusions, tilting of the rotor magnets can be avoided.
[0016] In addition, a projection or each projection may have an end section in the form of a circular segment. Thus, the end section has a particularly stable design, thereby avoiding undesired bending of the end section.
[0017] This object is also achieved by a rotor according to the invention, which has a rotor shaft, and a rotor lamination core according to the invention is arranged on the rotor shaft, in particular fixed to the rotor shaft. Rotor magnets axially supported against the narrowing are received in magnet slots of the rotor lamination core. This narrowing prevents the rotor magnets from slipping or falling out of the magnet slots during rotor assembly.
[0018] In addition to the rotor magnets, additional rotor magnets may be received in the magnet slots, wherein the rotor magnets may be arranged axially in particular. Furthermore, the rotor may have additional magnet slots, and one magnet or a plurality of magnets are received in the additional magnet slots in this way.
[0019] In one embodiment of the rotor, a free space is formed between the rotor magnets and the plurality of rotor laminations axially stacked with each other, and this free space is provided for potting compound, and the rotor magnets can be potted with this potting compound. Then the recesses in the end laminations are arranged so as to be axially aligned with the free space. Thus, the potting compound that has flowed into the free space can flow out of the free space particularly easily, thereby avoiding the formation of undesired air bubbles in the potting compound remaining in the free space.
[0020] In another embodiment of the rotor, another rotor lamination core corresponding to the above-mentioned rotor lamination core is arranged on the rotor shaft. Here, the magnetic poles of the two rotor lamination cores rotate relative to each other around the rotor shaft or the axis of rotation of the rotor. In other words, the magnetic poles of one of the rotor lamination cores rotate relative to the magnetic poles of the other rotor lamination core. In this way, the rotational performance of the rotor can be improved.
[0021] In another embodiment of the rotor, each rotor magnet is potted with potting compound. Thus, the rotor magnets are reliably fixed in the rotor lamination core so that the rotor magnets do not become loose or fall off during the operation of the motor.
[0022] This object is also achieved by a motor according to the invention, which has a stator and a rotor according to the invention, and the rotor is rotatably mounted relative to the stator.
[0023] Furthermore, this object is achieved by a vehicle having a motor according to the invention, and the motor is designed to drive the vehicle.
[0024] Furthermore, this object is achieved by a manufacturing method for a rotor according to the invention, in which the following method steps are carried out:
[0025] - Orient the rotor lamination core such that the axis of rotation of the rotor lamination core extends vertically and the end lamination of the rotor lamination core is arranged on the bottom side of the rotor lamination core.
[0026] - Insert the rotor magnets into the magnet slots of the oriented rotor lamination core such that the rotor magnets are axially supported against the constricted portions.
[0027] - Orient the rotor shaft such that the rotor shaft extends vertically, and
[0028] - Push the oriented rotor lamination core with the rotor magnets onto the rotor shaft.
[0029] In an embodiment of the manufacturing method, another rotor lamination core corresponding to the rotor lamination core is pushed onto or fixed to the rotor shaft such that the magnetic poles of the two rotor lamination cores are rotated relative to each other about the rotor shaft. BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The embodiments of the present invention will be explained in more detail based on the following schematic diagrams, where:
[0031] Figure 1 is a perspective view of an inclined rotor according to the present invention,
[0032] Figure 2 shows Figure 1 the axial section of the rotor in
[0033] Figure 3 shows Figure 1 another axial section of the rotor in
[0034] Figure 4 shows Figure 1 the details of the rotor lamination of the rotor in
[0035] Figure 5 shows Figure 1 the details of the end lamination of the rotor in
[0036] LIST OF REFERENCE NUMERALS
[0037] 1 Rotor
[0038] 2 Rotor body
[0039] 3 Rotor lamination core
[0040] 4 Rotor shaft
[0041] 5 Rotor end plate
[0042] 6 Axial nut
[0043] 7 Rotor lamination
[0044] 8 Magnet slot
[0045] 9 recess
[0046] 10 rotor magnet
[0047] 11 free space
[0048] 12 end lamination
[0049] 13 recess
[0050] 14 protrusion
[0051] 15 edge section
[0052] 16 edge section Detailed implementation manner
[0053] Figure 1 A schematic perspective view of a bevelled rotor 1 according to the present invention is shown. The rotor 1 forms part of an electric motor, which also has a stator, and the rotor 1 is rotatably mounted relative to the stator.
[0054] The rotor 1 has a cylindrical rotor body 2, which has six rotor lamination cores 3 arranged adjacent to each other axially. However, the rotor according to the present invention may also have a different number of rotor lamination cores, such as one, two, three, four, five, seven, eight, nine or ten rotor lamination cores.
[0055] The rotor body 2 is mounted on a rotor shaft 4, which extends along the (virtual) rotation axis of the rotor 1 through an axial channel opening in the rotor body 2.
[0056] Each rotor lamination core 3 has a plurality of magnetic poles formed by rotor magnets (not shown), and among them, these magnetic poles rotate relative to each other around the rotor shaft 4. In particular, the magnetic poles of each rotor lamination core 3 rotate relative to the magnetic poles of at least one adjacent rotor lamination core 3. In the current case, the rotor lamination cores 3 rotate in a V-shaped manner represented by thin lines. However, the rotor lamination cores of the rotor according to the present invention may also rotate in a different manner, such as linear rotation.
[0057] In addition, two circular rotor end plates 5 are arranged on opposite axial sides of the rotor body 2. The rotor body 2 with the rotor end plates 5 is axially fixed between a shaft shoulder and a shaft nut 6. However, the rotor body according to the present invention may also be axially fixed to the rotor shaft in other ways, such as by press fit and / or without using rotor end plates.
[0058] Figure 2 Shown is Figure 1 an axial section of the rotor 1 in [reference], which passes through the rotor lamination core 3.
[0059] The rotor lamination core 3 has a plurality of rotor laminations 7 stacked axially on one another, Figure 2 only one of which is shown here, and this one rotor lamination covers the rotor lamination 7 located behind it. The rotor laminations 7 have, in particular, an identical design and are stacked uniformly. In addition, the rotor lamination core 3 has a plurality of magnet slots 8, each of which is formed by a recess 9 in the rotor lamination 7.
[0060] One rotor magnet 10 is received in each magnet slot 8. As an alternative to this, it is also possible to accommodate a plurality of rotor magnets in one magnet slot of the rotor lamination core according to the invention.
[0061] In the present case, the rotor magnets 10 are arranged in eight groups, each group comprising four rotor magnets 10 arranged in a double V-shape and forming magnetic poles. However, in the rotor lamination core according to the invention, different numbers and arrangements of magnetic poles are also possible. The rotor magnetic field is generated by the magnetic poles.
[0062] At the radial end of each rotor magnet 10, a respective free space 11 is formed, which can be filled with a potting compound, for example resin. The rotor magnets 10 are reliably fixed in the rotor lamination core 3 by the potting compound, such that the rotor magnets 10 do not become loose or fall out during operation of the electric machine.
[0063] The rotor shaft 4 is also shown, and for the sake of clarity, the hatching has been omitted. In addition to the plurality of rotor laminations 7, the rotor lamination core 3 also includes end laminations (not shown in Figure 2 ) arranged on the axial sides of the rotor lamination core 3.
[0064] Figure 3 Shown is Figure 1 another axial section of the rotor 1, which extends outside the end lamination 12.
[0065] The end lamination 12 has a plurality of recesses 13, each of which is axially aligned with the magnet slots 8 of the rotor lamination core 3 or with the recesses 9 in the adjacent rotor laminations 7 of the rotor lamination core 3. According to the invention, each recess 13 is narrowed relative to the magnet slot 8 or the associated recess 9 in the adjacent rotor lamination 7.
[0066] In the present case, each recess 13 in the end lamination 12 is formed identically to the associated recess 9 in the adjacent rotor lamination 7, except for three protrusions that form the narrowed part and project into the recess 13, which will be explained in more detail with reference to Figure 5 .
[0067] Also shown are the rotor magnets 10 received in the magnet slots 8 and the rotor shaft 4. Each of the rotor magnets 10 is axially supported against the narrowed part of the associated recess 13 or the three protrusions that form the narrowed part.
[0068] Figure 4 shows Figure 1 details of the rotor lamination 7 of the rotor lamination core 3 of the rotor 1 in
[0069] This figure particularly shows the recess 9 which, together with the same recesses 9 in other rotor laminations 7 of the rotor lamination core 3 including the rotor lamination 7, forms a magnet slot 8 for receiving the rotor magnet 10.
[0070] Each recess 9 has an elongated design and has two straight edge sections 15 opposite each other. In the present case, there are two types of recesses 9 - specifically, relatively large recesses 9 and relatively small recesses 9. The relatively large recesses 9 are arranged in pairs in a V - shape, and the relatively small recesses 9 are also arranged in pairs in a V - shape such that two relatively large recesses 9 and two relatively small recesses 9 form a double - V arrangement.
[0071] At the ends of each recess 9 there are two vacant areas which, in the fully assembled rotor 1, together with the corresponding areas of other rotor laminations 7 of the rotor lamination core 3 form a free space 11. Each free space 11 is bounded by the rotor magnet 10 and the rotor lamination core 3.
[0072] Figure 5 shows Figure 1 details of the end lamination 11 of the rotor lamination core 3 of the rotor 1 in
[0073] This figure particularly shows the recess 13, each recess 13 being aligned with the recess 9 in the adjacent rotor lamination 7 and being narrowed relative to the recess 9.
[0074] In the present case, each recess 13 in the end lamination 12 is formed in the same way as the associated recess 9 in the adjacent rotor lamination 7, except for three protrusions 14 which form a narrowed portion and project into the recess 9. Instead of three protrusions, a different number of protrusions, such as one, two, four, five or six protrusions, may also be provided.
[0075] The protrusions 14 of the recess 13 are arranged on two opposite edge sections 16 of the recess 13. As an alternative to this, the protrusions may also be arranged on only one of the two opposite edge sections of the recess.
[0076] In particular, the protrusions 14 of the recess 13 are arranged in such a way that one protrusion 14 is arranged on the first edge section 16 and the point located opposite the protrusion on the second edge section 16 is positioned centrally between two protrusions 14 on the second edge section 16. In addition, the protrusions 14 are configured such that each protrusion 14 has an end section in the form of a circular segment.
[0077] In the rotor lamination core 3, each recess 13 is axially aligned with the free space 11 of the associated magnet slot 8. In particular, the two vacant areas formed at the ends of the recess 13 are axially aligned with the free space 11.
[0078] During the manufacture of the rotor 1, the following steps may be carried out:
[0079] - Orient the rotor lamination core 3 according to the invention such that the axis of rotation of the rotor lamination core 3 extends vertically and the end lamination 12 of the rotor lamination core 3 is arranged on the bottom side of the rotor lamination core.
[0080] - Insert the rotor magnet 10 into the magnet slot 8 of the oriented rotor lamination core 3 such that the rotor magnet 10 is axially supported against the narrowed portion of the recess 13 in the end lamination 12.
[0081] - Orient the rotor shaft 4 such that the rotor shaft extends vertically, and
[0082] - Push the oriented rotor lamination core 3 with the rotor magnet 10 onto the rotor shaft 4.
[0083] In addition, another rotor lamination core 3 corresponding to the rotor lamination core 3 can be pushed onto the rotor shaft 4 such that the magnetic poles of the two rotor lamination cores 3 rotate relative to each other about the rotor shaft 4.
Claims
1. A rotor laminated core (3) for a rotor (1) of an electric machine, the rotor laminated core having a plurality of rotor laminates (7), the plurality of rotor laminates (7) being stacked axially on top of one another and each rotor laminate (7) having a recess (9), in, The recess (9) forms a magnet slot (8) for accommodating a rotor magnet (10). The rotor laminate core (3) has an end laminate (12), which is arranged on the axial side of the rotor laminate core and has another recess (13), and the other recess (13) is axially aligned with the recess (9) in the adjacent rotor laminate (7) and is narrowed relative to the recess (9) in the adjacent rotor laminate (7).
2. The rotor laminated core (3) according to claim 1, wherein: The recess (13) in the end lamination (12) is formed identically to the recess (9) in the adjacent rotor lamination (7), except for one or more protrusions (14) forming a narrowed portion and protruding into the recess (13) in the end lamination (12).
3. The rotor laminated core (3) according to claim 2, wherein: The recess (13) in the end lamination (12) has two edge sections (16) that are opposite to each other, and the projection (14) is arranged on the two edge sections (16).
4. The rotor laminated core (3) according to claim 3, wherein: A protrusion (14) is arranged on the first edge section (16), and a point on the second edge section (16) located opposite the protrusion (14) is located between two protrusions (14) arranged on the second edge section (16).
5. The rotor laminated core (3) according to any one of claims 2 to 4, wherein: Each protrusion (14) has an end section in the shape of a circle segment.
6. A rotor (1) for an electric machine, comprising a rotor shaft (4) and a rotor laminated core (3) arranged on the rotor shaft (4) according to any one of the preceding claims, wherein: A rotor magnet (10) axially bearing against the narrowed portion is accommodated in the magnet slot (8).
7. The rotor (1) according to claim 6, wherein: A free space (11) is formed between the rotor magnet (10) and the plurality of rotor laminations (7) axially stacked on one another, and a recess (13) in the end lamination (12) is axially aligned with the free space (11).
8. The rotor (1) according to claim 6 or 7, comprising a further rotor laminated core (3) corresponding to the rotor laminated core (3) and arranged on the rotor shaft (4), wherein: The magnetic poles of the two rotor laminated cores (3) rotate relative to each other around the rotor axis (4).
9. A rotor (1) according to any one of claims 6 to 8, wherein: The rotor magnets (10) are potted using a potting compound.
10. An electric machine comprising a rotor (1) according to any one of claims 6 to 9 and a stator, the rotor (1) being rotatably mounted relative to the stator. 11 . A vehicle having the electric machine according to claim 10 , wherein the electric machine is configured to drive the vehicle.
12. A method for manufacturing a rotor (1) of an electric machine according to any one of claims 6 to 9, comprising the following steps: - orienting the rotor laminated core (3) such that the axis of rotation of the rotor laminated core (3) extends vertically and the end laminations (12) of the rotor laminated core (3) are arranged on the bottom side of the rotor laminated core, - inserting the rotor magnet (10) into the magnet slot (8) of the oriented rotor laminated core (3) so that the rotor magnet (10) bears axially against the constriction, - orienting the rotor shaft (4) such that the rotor shaft (4) extends vertically, and - Pushing the oriented rotor laminated core (3) with the rotor magnets (10) onto the rotor shaft (4).
13. The manufacturing method according to claim 12, wherein: Another rotor laminated core (3) corresponding to the rotor laminated core (3) is pushed onto the rotor shaft (4) so that the magnetic poles of the two rotor laminated cores (3) rotate relative to each other around the rotor shaft (4).