Spoke shaft, motor rotor structure with spoke shaft and assembly method of motor rotor structure

Abstract

The invention discloses a spoke shaft, a motor rotor structure with the spoke shaft and an assembling method of the spoke shaft, a positioning shaft shoulder is arranged on the outer surface of one end of a shaft barrel, a magnetic cake mounting key groove is formed in the outer surface of the shaft barrel in the direction parallel to the axial direction of the shaft barrel, and a pressing ring fixing structure used for fixing a pressing ring is arranged at the other end of the shaft barrel; the pressing ring fixing structure comprises a plurality of pressing ring fixing bosses arranged in the circumferential direction of the shaft barrel at intervals and a plurality of pressing ring fixing grooves located between every two adjacent pressing ring fixing bosses. A magnetic cake group formed by a plurality of magnetic cakes can be coaxially sleeved on the shaft barrel, the magnetic cakes can be radially positioned and rotationally limited on the shaft barrel through matching of magnetic cake mounting keys and magnetic cake mounting key grooves of the magnetic cakes, one end of the magnetic cake group can be axially positioned by the positioning shaft shoulder, and the other end of the magnetic cake group can be axially positioned by fixing the pressing ring fixing structure and the pressing ring. And the compression ring is fixed with the compression ring fixing boss or the compression ring fixing groove, so that the axial position of the compression ring on the shaft barrel can be changed, and the magnetic cake groups with different lengths can be axially positioned.

Description

Technical Field

[0001] The present invention relates to the technical field of motor equipment for new energy vehicles, and in particular to a spoke shaft, a motor rotor structure having the spoke shaft, and an assembly method thereof. Background Art

[0002] In the field of new energy vehicles, the range-extended generator (RAGE) is a key component, and its performance plays a decisive role in the vehicle's power output, energy consumption, and driving experience. Currently, there are two main structural forms of RAGE generator rotors for new energy vehicles. The first one includes a bearing structure connected to the resolver and a crankshaft connection secured to the crankshaft by a stopper and bolts. The outer diameter of the rotating shaft is sequentially equipped with an end plate, a rotor disk with magnets, and a pressure ring, which are secured axially with bolts. The second one does not have a bearing structure connected to the resolver, but the remaining components are similar to the first one.

[0003] From a structural design perspective, the range extender generator rotor has a relatively large outer diameter. To ensure stable support, the rotating shaft is often designed as a spoke shaft. Due to its large size, this shaft is often constructed of cast iron, formed through a casting process supplemented by machining. However, for the same electromagnetic design, separate molds are often required for generator spoke shafts with different stack lengths. The high mold costs significantly increase production costs, hindering product competitiveness and large-scale production.

[0004] In terms of motor performance, the installation accuracy of the rotor's magnetic disc poles is closely related to key performance indicators such as NVH (noise, vibration, and harshness) and efficiency. Currently, the most common method for achieving rotor disc pole skewing is to rotate or flip each stack of rotor discs, using bosses on the inner circumference of the rotor discs to mate with keyways on the outer circumference of the shaft. For schemes with dual keyways of equal width on the shaft, the angular tolerance between the two keyways significantly impacts the guaranteed accuracy of the skew angle. However, since the angular accuracy between the two keyways on the shaft depends on the precision of the machining equipment, achieving high skew accuracy in actual production is difficult, hindering the full optimization of the motor's NVH and efficiency performance. Furthermore, pursuing high-precision machining solutions not only significantly increases machining costs but also makes it difficult to ensure process stability, severely restricting the performance improvement and production efficiency of range-extended generators.

[0005] In summary, the existing new energy vehicle range-extended generator rotors have problems that need to be solved in terms of structural design, cost control, and rotor magnetic disk skew pole accuracy. It is urgent to develop new technical solutions to overcome the above defects and improve the comprehensive performance and market competitiveness of the range-extended generator. Summary of the Invention

[0006] The purpose of the present invention is to solve the shortcomings of the above-mentioned background technology and provide a spoke shaft that can adapt to rotor magnetic disks of different stack lengths and can effectively improve the installation accuracy of the rotor magnetic disk skew poles, a motor rotor structure with the spoke shaft and an assembly method thereof.

[0007] To achieve this purpose, the spoke shaft designed by the present invention includes a shaft cylinder, a positioning shoulder of an integral structure is coaxially arranged on the outer surface of one end of the shaft cylinder, a magnetic disc installation key groove is opened on the outer surface of the shaft cylinder along the axial direction thereof, and a pressure ring fixing structure for fixing the pressure ring is provided at the other end of the shaft cylinder, and the pressure ring fixing structure includes a plurality of pressure ring fixing bosses arranged at intervals in the circumferential direction of the other end of the shaft cylinder and a plurality of pressure ring fixing grooves located between two adjacent pressure ring fixing bosses; a magnetic disc group composed of a plurality of magnetic disc groups can be coaxially sleeved On the shaft cylinder, the magnetic disc can be radially positioned and rotationally limited on the shaft cylinder by cooperating with its own magnetic disc installation key and the magnetic disc installation key slot. The positioning shoulder can axially position one end of the magnetic disc group, and the pressure ring fixing structure and the pressure ring fixing can axially position the other end of the magnetic disc group. The pressure ring can be selectively fixed to the pressure ring fixing boss or the pressure ring fixing groove, and the axial position of the pressure ring on the shaft cylinder can be changed to meet the axial positioning requirements of magnetic disc groups of different lengths composed of different numbers of magnetic discs.

[0008] Furthermore, a first threaded hole is provided in the pressure ring fixing boss along the axial direction parallel to the shaft cylinder, and a second threaded hole is provided in the pressure ring fixing groove along the axial direction parallel to the shaft cylinder. The pressure ring can be selectively connected to the first threaded hole or the second threaded hole by a bolt.

[0009] Furthermore, the magnetic disk installation keyway includes a magnetic disk positioning keyway and a magnetic disk assembly keyway arranged at intervals of 180° along the circumferential outer surface of the shaft cylinder, and the magnetic disk installation key includes a first magnetic disk installation key and a second magnetic disk installation key arranged at intervals of 180° and the sum of the oblique pole angle along the inner surface of the magnetic disk along its circumferential direction. The magnetic disk can achieve radial rough positioning of the magnetic disk and the shaft cylinder through the cooperation of the first magnetic disk installation key or the second magnetic disk installation key in its own magnetic disk installation key with the magnetic disk assembly keyway, and achieve radial fine positioning and rotation limitation of the magnetic disk and the shaft cylinder through the cooperation of the remaining first magnetic disk installation key or the second magnetic disk installation key in the magnetic disk installation key with the magnetic disk positioning keyway.

[0010] Furthermore, a motor rotor structure with the above-mentioned spoke shaft includes a magnetic disc group composed of multiple annular magnetic discs and a pressure ring, the inner surface of the magnetic disc is provided with two magnetic disc mounting keys at intervals of 180° along its circumferential direction and the sum of the oblique pole angle, and an assembly mark is provided on the magnetic disc; the outer surface of the shaft cylinder is provided with two magnetic disc mounting key slots at intervals of 180° along the circumferential direction; the magnetic disc group is coaxially sleeved on the shaft cylinder, and one magnetic disc mounting key slot of the shaft cylinder cooperates with one magnetic disc mounting key of the magnetic disc to realize radial rough positioning of the magnetic disc and the shaft cylinder, and another magnetic disc mounting key slot of the shaft cylinder cooperates with another magnetic disc mounting key of the magnetic disc to realize radial fine positioning and rotation limiting of the magnetic disc and the shaft cylinder; the positioning shoulder axially positions one end of the magnetic disc group, and the pressure ring fixing boss or the pressure ring fixing groove and the pressure ring fix the other end of the magnetic disc group to axially position; the oblique pole angle of the magnetic disc can be adjusted by changing the position of the assembly mark of the magnetic disc relative to the shaft cylinder.

[0011] Furthermore, a rotor end plate is provided between one end of the magnetic cake group and the positioning shoulder, and between the other end of the magnetic cake group and the pressure ring, and the rotor end plate is coaxially sleeved on the shaft cylinder.

[0012] Furthermore, a plurality of bolt positioning brackets corresponding to the pressure ring fixing boss or the pressure ring fixing groove are arranged at intervals along the circumferential direction on the inner surface of the pressure ring, and the bolts can pass through the bolt positioning brackets and be threadedly connected to the pressure ring fixing boss or the pressure ring fixing groove.

[0013] Furthermore, the assembly mark includes a mark groove opened on the inner surface of the magnetic disk.

[0014] Furthermore, the assembly method of the motor rotor structure with the spoke shaft is as follows: the magnetic discs of the magnetic disc group are coaxially sleeved on the shaft cylinder in sequence, and the oblique pole angle of the magnetic disc is adjusted by changing the position of the assembly mark of the magnetic disc relative to the shaft cylinder; a magnetic disc installation keyway of the shaft cylinder is matched with one of the magnetic disc installation keys of the magnetic disc to realize the radial rough positioning of the magnetic disc and the shaft cylinder, and another magnetic disc installation keyway of the shaft cylinder is matched with another magnetic disc installation key of the magnetic disc to realize the radial fine positioning and rotation limitation of the magnetic disc and the shaft cylinder; the positioning shoulder axially positions one end of the magnetic disc group, and the pressure ring fixing structure and the pressure ring fixing axially position the other end of the magnetic disc group.

[0015] Furthermore, the assembly method of the motor rotor structure with a spoke shaft includes a first assembly method of assembling a first magnetic disk group with a stacking number of m, m is an integer and m>1, and a second assembly method of assembling a second magnetic disk group with a stacking number of m+n, n is an integer and n>1.

[0016] Furthermore, the first assembly method includes: sequentially coaxially sleeve the magnetic discs of the first magnetic disc group on the shaft cylinder, and adjust the oblique pole angle of the magnetic disc by changing the position of the assembly mark of the magnetic disc relative to the shaft cylinder; make one magnetic disc installation keyway of the shaft cylinder cooperate with one magnetic disc installation key of the magnetic disc to achieve radial rough positioning of the magnetic disc and the shaft cylinder, and make another magnetic disc installation keyway of the shaft cylinder cooperate with another magnetic disc installation key of the magnetic disc to achieve radial fine positioning and rotation limitation of the magnetic disc and the shaft cylinder; the positioning shoulder axially positions one end of the first magnetic disc group, and the pressure ring and the pressure ring fixing groove fix the other end of the first magnetic disc group to axially position; Furthermore, the second assembly method includes: coaxially sleeved the magnetic discs of the second magnetic disc group on the shaft cylinder in sequence, and adjusted the oblique pole angle of the magnetic disc by changing the position of the assembly mark of the magnetic disc relative to the shaft cylinder; making a magnetic disc installation key slot of the shaft cylinder cooperate with a magnetic disc installation key of the magnetic disc to realize the radial rough positioning of the magnetic disc and the shaft cylinder, and making another magnetic disc installation key slot of the shaft cylinder cooperate with another magnetic disc installation key of the magnetic disc to realize the radial fine positioning and rotation limitation of the magnetic disc and the shaft cylinder; the positioning shoulder axially positions one end of the second magnetic disc group, and the pressure ring and the pressure ring fixing boss fix the other end of the second magnetic disc group to axially position.

[0017] The beneficial effects of the present invention are as follows: the present invention effectively solves the core problems of the existing extended-range generator rotor in terms of structural design, cost control and skew accuracy through an innovative spoke shaft structure design and assembly method, as follows: 1. Flexible structural design, adaptable to magnetic disc groups of different lengths composed of different numbers of magnetic discs, reducing production costs: Adjustability of the compression ring fixing structure: Circumferentially spaced compression ring fixing bosses and grooves are located at the other end of the spoke shaft, each with a first and second threaded hole. By selectively connecting the bosses or grooves with bolts, the axial position of the compression ring can be precisely adjusted to accommodate magnetic disc stacks with varying stack sizes (e.g., m and m+n). This eliminates the need for separate molds for spoke shafts of varying lengths, reducing mold investment and significantly lowering production costs for large-scale production of multiple product sizes. The compact structure and reliable axial positioning eliminate the cumbersome adjustment process associated with traditional bolt-fastening methods.

[0018] Universal design of spoke shaft: The magnetic disc installation keyway (including positioning keyway and assembly keyway) on the outer surface of the shaft barrel is compatible with the radial positioning requirements of magnetic disc groups of different lengths. A set of spoke shafts can be adapted to multiple electromagnetic solutions, which improves the versatility of components and simplifies supply chain management.

[0019] The double-stage positioning keyway design significantly improves the installation accuracy of the oblique pole: A dual-stage radial positioning mechanism: The magnetic disc quickly achieves initial and final radial positioning through the mating of the magnetic disc mounting key and mounting keyway, improving assembly efficiency while preventing interference between the magnetic disc and the spoke shaft during assembly. This mechanism also eliminates the impact of the traditional double-keyway angular tolerance on the skew accuracy. By shifting angular accuracy control from relying on machining equipment to the keyway-key mating accuracy, it reduces machining complexity while ensuring the consistency and stability of the skew angle.

[0020] Assembly marks precisely control the pole skew angle: Marking grooves (assembly marks) are provided on the inner surface of the magnetic disc. By changing the position of the marking groove relative to the shaft (e.g., rotating or flipping the magnetic disc), the pole skew angle can be flexibly adjusted. This method eliminates the need for shaft machining accuracy and achieves high-precision pole skew solely through position calibration during assembly, significantly improving motor NVH performance and efficiency while reducing reliance on high-precision machining equipment and saving costs.

[0021] The assembly process is simplified, and production efficiency and stability are improved: Modular assembly method: The magnetic disc assembly is axially positioned at both ends by a locating shoulder and a pressure ring. Combined with radial positioning by a double-stage keyway, the assembly process requires no complex adjustments and can be quickly secured. Magnetic discs of varying lengths and numbers can be assembled by simply adjusting the pressure ring's securing position (boss or groove), eliminating the need for fixture redesign, reducing changeover time and making it suitable for mass production on assembly lines.

[0022] Guaranteed precision consistency: In traditional solutions, the angular tolerance of double keyways is limited by machining, which can easily lead to angular deviations of the skew pole. This invention reduces rework and scrap caused by precision fluctuations and improves production stability through standardized keyway and key fit and visual calibration of assembly marks.

[0023] Comprehensive performance optimization enhances market competitiveness: NVH and efficiency improvement: High-precision slanted pole installation can effectively reduce motor vibration and noise, optimize electromagnetic performance, improve energy conversion efficiency, and directly improve the vehicle's driving experience and endurance performance.

[0024] Enhanced structural reliability: The spoke shaft adopts an integrated design (the positioning shoulder and the shaft barrel are integrally formed), which reduces the number of assembly interfaces and improves the overall rigidity of the rotor, adapting to the high-speed and high-load working scenarios of the extended-range generator.

[0025] Balance between cost and efficiency: Through universal design, simplified processing procedures, improved assembly precision, and balanced low cost and high performance, it helps companies quickly respond to diverse market demands and enhance product competitiveness.

[0026] In summary, the present invention breaks through the bottleneck of structural adaptability and precision control of traditional extended-range generator rotors through the innovative combination of an adjustable pressure ring fixing structure, a two-stage positioning keyway and an assembly mark calibration mechanism, providing key technical support for the efficient and low-cost development of new energy vehicle power systems, and has significant engineering application value and market promotion potential. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 An exploded view of the motor rotor structure composed of a triple-stacked magnetic disk assembly in the present invention; Figure 2 It is a left side view of the motor rotor structure composed of three-stacked magnetic disk groups in the present invention; Figure 3 This is a front view of the motor rotor structure composed of a triple-stacked magnetic disk group in the present invention; Figure 4 This is a front view of the magnetic cake of the present invention; Figure 5 This is a front view of the shaft cylinder of the present invention; Figure 6 A radial cross-sectional view of a first stack of magnetic disks of a motor rotor structure composed of a three-stack magnetic disk assembly according to the present invention, mounted on a shaft cylinder; Figure 7 A radial cross-sectional view of the second stack of magnetic disks of the motor rotor structure composed of a three-stack magnetic disk assembly according to the present invention, mounted on the shaft cylinder; Figure 8 A radial cross-sectional view of the third stack of magnetic disks of the motor rotor structure composed of the three-stack magnetic disk group of the present invention, mounted on the shaft cylinder; Figure 9 An exploded view of the motor rotor structure composed of four stacked magnetic disk groups in the present invention; Figure 10 It is a left side view of the motor rotor structure composed of four stacked magnetic disk groups in the present invention; Figure 11 This is a front view of the motor rotor structure composed of four stacked magnetic disc groups in the present invention; Figure 12 A radial cross-sectional view of the fourth stack of magnetic disks of the motor rotor structure composed of the four-stack magnetic disk group of the present invention, mounted on the shaft cylinder; Among them, 1—shaft cylinder, 2—positioning shoulder, 3—pressure ring, 4—pressure ring fixing boss, 5—pressure ring fixing groove, 6—magnetic disc, 7—first threaded hole, 8—second threaded hole, 9—bolt, 10—magnetic disc positioning keyway, 11—magnetic disc assembly keyway, 12—magnetic disc positioning key, 13—magnetic disc assembly key, 14—rotor end plate, 15—bolt positioning bracket, 16—marking groove, 17—end plate positioning key. DETAILED DESCRIPTION

[0028] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0029] The present invention designs a spoke shaft and designs a motor rotor structure having the spoke shaft based on the spoke shaft. The motor rotor structure can adapt to the installation and positioning of magnetic disks with different stacking numbers to form motor rotor structures with different stacking numbers.

[0030] Example 1 To achieve the above objectives, a specific embodiment of a spoke shaft is provided: like Figure 1 and Figure 5 As shown, the spoke shaft includes a shaft cylinder 1, and a positioning shoulder 2 is coaxially arranged on the outer surface of one end of the shaft cylinder 1 as an integral structure. The outer surface of the shaft cylinder 1 is provided with a magnetic disc installation keyway parallel to its axial direction. The magnetic disc installation keyway includes a magnetic disc positioning keyway 10 and a magnetic disc assembly keyway 11 arranged at intervals of 180 degrees along the circumferential outer surface of the shaft cylinder 1. The width of the magnetic disc assembly keyway 11 is greater than the width of the magnetic disc positioning keyway 10. Figure 4 As shown, the magnetic disk installation key includes a first magnetic disk installation key 12 and a second magnetic disk installation key 13 arranged along the inner surface of the magnetic disk 6 (composed of an iron core and magnetic steel) along its circumferential direction at an interval of 180° and the sum of the skew angle, as shown in FIG. Figure 6 As shown, the magnetic disc 6 can realize the radial rough positioning of the magnetic disc 6 and the shaft cylinder 1 through the cooperation of its own second magnetic disc installation key 13 and the magnetic disc assembly key slot 11, or as shown in FIG. Figure 7 As shown in FIG8, the first magnetic disc installation key 12 and the magnetic disc assembly key slot 11 cooperate to achieve the radial rough positioning of the magnetic disc 6 and the shaft cylinder 1, and the magnetic disc 6 can be installed by the remaining first magnetic disc installation key 12 (as shown in FIG8). Figure 6 As shown) or the second magnetic disk installation key 13 (as Figure 7 —8) cooperates with the magnetic disk positioning keyway 10 to realize the radial precision positioning and rotation limitation of the magnetic disk 6 and the shaft cylinder 1. The other end of the shaft cylinder 1 is provided with a pressure ring fixing structure for fixing the pressure ring 3. The pressure ring fixing structure includes a plurality of pressure ring fixing bosses 4 arranged at intervals along the circumferential direction of the other end of the shaft cylinder 1 and a plurality of pressure ring fixing grooves 5 located between two adjacent pressure ring fixing bosses 4. A first threaded hole 7 is provided in the pressure ring fixing boss 4 along the axial direction parallel to the shaft cylinder 1, and a second threaded hole 8 is provided in the pressure ring fixing groove 5 along the axial direction parallel to the shaft cylinder 1. The pressure ring 3 can be selectively connected to the first threaded hole 7 (as shown in FIG. 1 ) by a bolt 9. Figure 1 —3) or the second threaded hole 8 (as shown in FIG Figure 9 —11).

[0031] A magnetic cake group composed of multiple magnetic cakes can be coaxially sleeved on the shaft cylinder 1. The magnetic cake 6 can be radially positioned and rotationally limited on the shaft cylinder 1 by cooperating with its own magnetic cake installation key and the magnetic cake installation key groove. The positioning shoulder 2 can axially position one end of the magnetic cake group. The pressure ring fixing structure and the pressure ring 3 are fixed to axially position the other end of the magnetic cake group. The pressure ring 3 can be selectively fixed to the pressure ring fixing boss 4 or the pressure ring fixing groove 5 to change the axial position of the pressure ring 3 on the shaft cylinder 1 to meet the axial positioning requirements of magnetic cake groups of different lengths composed of different numbers of magnetic cakes.

[0032] Example 2 Based on the above-mentioned spoke shaft, the following two specific embodiments of the motor rotor structure with a spoke shaft are provided: Triple-stack motor rotor structure embodiment: like Figure 1 As shown in FIG. 8 , the motor rotor structure includes a magnetic disc group consisting of three annular magnetic discs 6 and a pressure ring 3. The inner surface of each magnetic disc 6 is provided with a first magnetic disc installation key 12 and a second magnetic disc installation key 13 at intervals of 180° along its circumferential direction and the sum of the skew angle. The inner surface of each magnetic disc 6 is provided with a marking groove 16 (i.e., an assembly mark); the outer surface of the shaft cylinder 1 is provided with a magnetic disc assembly key groove 11 and a magnetic disc positioning key groove 10 at intervals of 180° along the circumferential direction. The width of the magnetic disc assembly key groove 11 is greater than the width of the magnetic disc positioning key groove 10. The three-stacked magnetic disc group is coaxially sleeved on the shaft cylinder 1, as shown in FIG. Figure 6 As shown, the second magnetic disc installation key 13 of the first stack of magnetic discs cooperates with the magnetic disc assembly key slot 11 to achieve radial rough positioning of the magnetic disc 6, and the first magnetic disc installation key 12 cooperates with the magnetic disc positioning key slot 10 to achieve radial fine positioning and rotation limit of the magnetic disc 6, as shown Figure 7 As shown, the first magnetic disc installation key 12 of the second magnetic disc stack cooperates with the magnetic disc assembly key slot 11 to achieve radial rough positioning of the magnetic disc 6, and the second magnetic disc installation key 13 cooperates with the magnetic disc positioning key slot 10 to achieve radial fine positioning and rotation limit of the magnetic disc 6, as shown Figure 8 As shown, the first magnetic disk installation key 12 of the third stack of magnetic disks cooperates with the magnetic disk assembly key slot 11 to achieve radial rough positioning of the magnetic disk 6, and the second magnetic disk installation key 13 cooperates with the magnetic disk positioning key slot 10 to achieve radial fine positioning and rotation limiting of the magnetic disk 6.

[0033] A rotor end plate 14 is provided between one end of the triple-stacked magnetic disk assembly and the positioning shoulder 2, and between the other end of the triple-stacked magnetic disk assembly and the pressure ring 3. The rotor end plate 14 is coaxially sleeved on the shaft cylinder 1. The positioning shoulder 2 axially positions one end of the triple-stacked magnetic disk assembly. A plurality of bolt positioning brackets 15 are arranged on the inner surface of the pressure ring 3 at intervals along its circumferential direction. Bolts 9 pass through the bolt positioning brackets 15 and are threadedly connected to the pressure ring fixing groove 5 to axially position the other end of the triple-stacked magnetic disk assembly.

[0034] The skew angle of the magnetic disc 6 can be adjusted by changing the position of the marking groove 16 of the magnetic disc 6 relative to the shaft cylinder 1. The skew angle of each magnetic disc of the three-stack motor rotor structure designed by the present invention is α. Figure 6 As shown, after the first stack of magnetic cakes 6 is installed on the spoke shaft, the second stack of magnetic cakes is rotated 180°+α clockwise based on the first stack of magnetic cakes and then installed on the spoke shaft (as shown in FIG. Figure 7 As shown), based on the second stack of magnetic disks, the third stack of magnetic disks is rotated 180° around the central vertical axis and installed on the spoke shaft (as shown Figure 8 As shown), the installation is completed, and by observing the marking groove 16, it can be accurately determined whether each stack of magnetic cakes is installed correctly.

[0035] Example of a quadruple-stack motor rotor structure: like Figure 9 As shown in FIG. 12 , the rotor structure is essentially the same as that of a three-stack motor, except that bolts 9 pass through bolt locating brackets 15 of pressure ring 3 and are threadedly connected to pressure ring fixing bosses 4 to axially position the other end of the four-stack magnetic disk assembly. The fourth stack of magnetic disks is equivalent to the first stack, rotated 180° around the central vertical axis and mounted on the spoke shaft.

[0036] Example 3 Based on the above-mentioned motor rotor structure with spoke shaft, a specific embodiment of an assembly method is provided: Confirm the positions of the first and second magnetic disc installation keys 12, 13, and marking grooves 16 on the inner surface of the magnetic discs, and determine the skew angle (e.g., α) and rotation direction (clockwise / counterclockwise) of each stack of magnetic discs according to design requirements. Install the rotor end plate 14, coaxially insert the first stack of magnetic discs into the shaft cylinder 1, and mate the second magnetic disc installation key 13 with the magnetic disc assembly keyway 11 of the shaft cylinder to complete the radial rough positioning of the magnetic disc 6. Push the magnetic disc 6 axially along the shaft cylinder 1 until the first magnetic disc installation key 12 is embedded in the magnetic disc positioning keyway 10 to achieve radial fine positioning and rotational limit. Adjust the positions of the other magnetic discs 6 and repeat the above steps to complete the installation of the magnetic disc group. Axial positioning is achieved by locating the shaft shoulder 2 at one end of the magnetic disc group. After installing the rotor end plate 14 at the other end, select the fixed position of the pressure ring 3 according to the number of magnetic disc stacks: if it is a magnetic disc group with a small number of stacks (e.g., three stacks), connect the pressure ring 3 to the pressure ring fixing groove 5 (second threaded hole 8) with the bolt 9 to shorten the axial fixing distance. If the magnetic disk group has multiple stacks (such as four stacks), the pressure ring 3 is connected to the pressure ring fixing boss 4 (first threaded hole 7) through the bolt 9 to extend the axial fixing distance.

[0037] The above stacking numbers are only examples. In actual applications, the fixed position (boss / groove) of the pressure ring 3 can be adjusted to adapt to magnetic disk groups with any stacking number (such as m, m+n) without replacing the spoke shaft or re-opening the mold.

[0038] In summary, the spoke shaft designed by the present invention can be adapted to multiple specifications of magnetic disc groups. Through the adjustable design of the pressure ring fixing boss 4 and the pressure ring fixing groove 5, there is no need to open molds separately for different stack lengths, and the mold cost is effectively reduced. It is especially suitable for large-scale production with rapid switching of multiple models of products. The standardized design of the magnetic disc installation keyway (magnetic disc positioning keyway 10 and magnetic disc assembly keyway 11) is compatible with magnetic discs of different electromagnetic schemes, simplifying supply chain management. The separation of coarse positioning (assembly keyway 11) and fine positioning (positioning keyway 10) changes the angle accuracy control from relying on machining equipment to the matching accuracy of a single keyway. The magnetic disc rotation angle is directly observed through the marking groove 16, so that the skew pole angle error is effectively reduced. It avoids the NVH degradation caused by the angle deviation of the double keyway in the traditional process, reduces the motor noise, and improves the assembly efficiency.

[0039] It should be noted that the description of the above technical solutions is illustrative only. This specification may be embodied in various forms and should not be construed as limiting the technical solutions set forth herein. Rather, these descriptions are provided so that the disclosure of the present invention will be thorough and complete and will fully convey the scope of the disclosure to those skilled in the art. Furthermore, the technical solutions of the present invention are limited only by the scope of the claims. Where the terms "including," "having," and "comprising" are used in this specification, further parts or other components may also be included. The terms used may generally be singular but may also represent the plural. It should be noted that although the terms "first," "second," "top," "bottom," "one side," "other side," "end," and "other end" may appear and be used in this specification to describe various components, these components and parts should not be limited by these terms. These terms are used solely to distinguish one component or part from another. For example, a first component may be referred to as a second component, and similarly, a second component may be referred to as a first component, without departing from the scope of this specification. Top and bottom components may also be interchanged or switched under certain circumstances; components at one end and at the other end may have the same or different properties.

[0040] Finally, it should be noted that the above embodiments are merely representative examples of the present invention. Obviously, the present invention is not limited to the above embodiments and is susceptible to numerous variations. Any simple modifications, equivalent variations, and modifications to the above embodiments based on the technical essence of the present invention shall be deemed to fall within the scope of protection of the present invention.

Claims

1. A spoke shaft, comprising a shaft cylinder (1), wherein a positioning shoulder (2) is coaxially arranged on the outer surface of one end of the shaft cylinder (1) and is integrally formed therewith, and a magnetic disk mounting keyway is provided on the outer surface of the shaft cylinder (1) parallel to the axial direction thereof, characterized in that: The other end of the shaft cylinder (1) is provided with a pressure ring fixing structure for fixing the pressure ring (3), and the pressure ring fixing structure comprises a plurality of pressure ring fixing bosses (4) arranged at intervals along the circumferential direction of the other end of the shaft cylinder (1) and a plurality of pressure ring fixing grooves (5) located between two adjacent pressure ring fixing bosses (4); A magnetic cake group consisting of a plurality of magnetic cakes can be coaxially sleeved on the shaft cylinder (1); the magnetic cake (6) can be radially positioned and rotationally limited on the shaft cylinder (1) by cooperating with the magnetic cake mounting key of its own and the magnetic cake mounting key slot; the positioning shoulder (2) can axially position one end of the magnetic cake group; the pressure ring fixing structure and the pressure ring (3) are fixed to axially position the other end of the magnetic cake group; the pressure ring (3) is selectively fixed to the pressure ring fixing boss (4) or the pressure ring fixing groove (5); the axial position of the pressure ring (3) on the shaft cylinder (1) can be changed to meet the axial positioning requirements of magnetic cake groups of different lengths composed of different numbers of magnetic cakes.

2. The spoke shaft according to claim 1, wherein: A first threaded hole (7) is provided in the pressure ring fixing boss (4) along an axial direction parallel to the shaft cylinder (1), and a second threaded hole (8) is provided in the pressure ring fixing groove (5) along an axial direction parallel to the shaft cylinder (1). The pressure ring (3) can be selectively connected to the first threaded hole (7) or the second threaded hole (8) by a bolt (9).

3. The spoke shaft according to claim 1 or 2, characterized in that: The magnetic disc installation keyway comprises a magnetic disc positioning keyway (10) and a magnetic disc assembly keyway (11) arranged at intervals of 180° along the circumferential outer surface of the shaft cylinder (1); the magnetic disc installation key comprises a first magnetic disc installation key (12) and a second magnetic disc installation key (13) arranged at intervals of 180° and the sum of the oblique pole angle along the inner surface of the magnetic disc (6) in the circumferential direction thereof; the magnetic disc (6) can achieve radial coarse positioning of the magnetic disc (6) and the shaft cylinder (1) by the cooperation of the first magnetic disc installation key (12) or the second magnetic disc installation key (13) in its own magnetic disc installation key with the magnetic disc assembly keyway (11); and achieve radial fine positioning and rotational limitation of the magnetic disc (6) and the shaft cylinder (1) by the cooperation of the remaining first magnetic disc installation key (12) or the second magnetic disc installation key (13) in the magnetic disc installation key with the magnetic disc positioning keyway (10).

4. A motor rotor structure having a spoke shaft according to any one of claims 1 to 3, comprising a magnetic disk group consisting of a plurality of annular magnetic disks (6) and a pressure ring (3), characterized in that: The inner surface of the magnetic disc (6) is provided with two magnetic disc installation keys at intervals of 180° along the circumferential direction thereof and the sum of the angle of the oblique pole, and the magnetic disc (6) is provided with an assembly mark; the outer surface of the shaft cylinder (1) is provided with two magnetic disc installation key slots at intervals of 180° along the circumferential direction; The magnetic disc group is coaxially sleeved on the shaft cylinder (1), and a magnetic disc installation keyway of the shaft cylinder (1) cooperates with a magnetic disc installation key of the magnetic disc (6) to achieve radial coarse positioning of the magnetic disc (6) and the shaft cylinder (1), and another magnetic disc installation keyway of the shaft cylinder (1) cooperates with another magnetic disc installation key of the magnetic disc (6) to achieve radial fine positioning and rotation limit of the magnetic disc (6) and the shaft cylinder (1); The positioning shoulder (2) axially positions one end of the magnetic disk group, and the pressure ring fixing boss (4) or the pressure ring fixing groove (5) and the pressure ring (3) are fixed to axially position the other end of the magnetic disk group; The oblique polar angle of the magnetic disc (6) can be adjusted by changing the position of the assembly mark of the magnetic disc (6) relative to the shaft cylinder (1).

5. The motor rotor structure with a spoke shaft according to claim 4, characterized in that: A rotor end plate (14) is provided between one end of the magnetic disk group and the positioning shaft shoulder (2), and between the other end of the magnetic disk group and the pressure ring (3). The rotor end plate (14) is coaxially sleeved on the shaft cylinder (1).

6. The motor rotor structure with a spoke shaft according to claim 4, characterized in that: A plurality of bolt positioning brackets (15) corresponding to the pressure ring fixing boss (4) or the pressure ring fixing groove (5) are arranged at intervals along the circumferential direction on the inner surface of the pressure ring (3), and the bolts (9) can pass through the bolt positioning brackets (15) and be threadedly connected to the pressure ring fixing boss (4) or the pressure ring fixing groove (5).

7. The motor rotor structure with a spoke shaft according to claim 4, wherein: The assembly mark comprises a mark groove (16) opened on the inner surface of the magnetic disk (6).

8. A method for assembling a motor rotor structure having a spoke shaft according to any one of claims 4 to 7, characterized in that: The magnetic discs (6) of the magnetic disc group are sequentially coaxially sleeved on the shaft cylinder (1), and the oblique polar angle of the magnetic disc (6) is adjusted by changing the position of the assembly mark of the magnetic disc (6) relative to the shaft cylinder (1); a magnetic disc installation keyway of the shaft cylinder (1) is made to cooperate with a magnetic disc installation key of the magnetic disc (6) to achieve radial rough positioning of the magnetic disc (6) and the shaft cylinder (1); another magnetic disc installation keyway of the shaft cylinder (1) is made to cooperate with another magnetic disc installation key of the magnetic disc (6) to achieve radial fine positioning and rotation limit of the magnetic disc (6) and the shaft cylinder (1); The positioning shoulder (2) axially positions one end of the magnetic disk group, and the pressure ring fixing structure and the pressure ring (3) fix the other end of the magnetic disk group axially.

9. The method for assembling a motor rotor structure having a spoke shaft according to claim 8, wherein: The method comprises a first assembling method for assembling a first magnetic cake group with m stacking number, m being an integer and m>1, and a second assembling method for assembling a second magnetic cake group with m+n stacking number, n being an integer and n>1.

10. The method for assembling a motor rotor structure with a spoke shaft according to claim 8, wherein: The first assembly method comprises: sequentially coaxially sleeve the magnetic discs (6) of the first magnetic disc group on the shaft cylinder (1), adjusting the oblique polar angle of the magnetic disc (6) by changing the position of the assembly mark of the magnetic disc (6) relative to the shaft cylinder (1); coordinating a magnetic disc installation keyway of the shaft cylinder (1) with a magnetic disc installation key of the magnetic disc (6) to achieve radial rough positioning of the magnetic disc (6) and the shaft cylinder (1), and coordinating another magnetic disc installation keyway of the shaft cylinder (1) with another magnetic disc installation key of the magnetic disc (6) to achieve radial fine positioning and rotational limit of the magnetic disc (6) and the shaft cylinder (1); the positioning shoulder (2) axially positions one end of the first magnetic disc group, and the pressure ring (3) and the pressure ring fixing groove (5) are fixed to axially position the other end of the first magnetic disc group; The second assembly method comprises: sequentially coaxially sleeve the magnetic discs (6) of the second magnetic disc group on the shaft cylinder (1), adjusting the oblique polar angle of the magnetic disc (6) by changing the position of the assembly mark of the magnetic disc (6) relative to the shaft cylinder (1); coordinating a magnetic disc installation keyway of the shaft cylinder (1) with a magnetic disc installation key of the magnetic disc (6) to achieve radial coarse positioning of the magnetic disc (6) and the shaft cylinder (1), and coordinating another magnetic disc installation keyway of the shaft cylinder (1) with another magnetic disc installation key of the magnetic disc (6) to achieve radial fine positioning and rotational limit of the magnetic disc (6) and the shaft cylinder (1); the positioning shoulder (2) axially positions one end of the second magnetic disc group, and the pressure ring (3) and the pressure ring fixing boss (4) are fixed to axially position the other end of the second magnetic disc group.

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