Energy-saving synchronous motor high-strength strong heat dissipation type rotor

Abstract

The invention, which relates to the technical field of the motor rotor, discloses an energy-saving synchronous motor high-strength strong-heat-dissipation rotor comprising a rotor shaft, a rotor iron core sleeving the shaft, rotor supports arranged at two ends of the iron core respectively, and bearings in interference fit with the rotor iron core, the rotor iron core is provided with annular heat dissipation fins and V-shaped magnetic pole grooves, hollow-out heat dissipation channels and embedded heat dissipation channels extending to a magnetic pole area are formed in the axial direction, the hollow-out heat dissipation channels and the embedded heat dissipation channels are alternately distributed, the embedded heat dissipation channels are internally provided with forced refrigeration structures, and each forced refrigeration structure is composed of a temperature triggering chamber, an isolation chamber and a liquid chamber. The rotor shaft and the iron core are in interference fit through positioning keys, the two ends of the rotor shaft and the iron core are fastened through annular assembly base bolts, and the overall structure achieves the synergistic effect of magnetic pole directional forced cooling, efficient heat guiding-out and reliable mechanical load transmission; and the problems of magnet demagnetization and structure instability under the high-speed working condition are effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of motor rotors, and more particularly to a high-strength and high-heat dissipation rotor for an energy-saving synchronous motor. Background Art

[0002] As a core component of industrial power systems, the design of the synchronous motor's rotor structure directly determines the motor's energy efficiency, reliability, and applicable scenarios. As modern industry transforms towards high-speed and intelligent operations, synchronous motors face increasingly stringent performance challenges. Traditional synchronous motor rotors generally use metal materials to construct the main structure. Although they have a certain degree of mechanical strength, they expose many defects when running at high speeds: the connection interface between the iron core and the magnetic pole is prone to stress concentration due to centrifugal force, leading to fatigue cracks; the heat accumulation caused by electromagnetic losses in the excitation winding or permanent magnets is difficult to dissipate effectively, causing the rotor temperature to rise too high, which in turn threatens the stable operation of the motor.

[0003] From a mechanical perspective, traditional rotor cores are typically constructed from laminated silicon steel sheets or integrally cast steel. These materials have high density and moment of inertia, making them difficult to adapt to high-speed dynamic response requirements. The magnetic poles and core are secured using mechanical interference fit or simple bonding. At high speeds exceeding 10,000 rpm, radial deformation caused by centrifugal force disrupts magnetic circuit uniformity, triggering cogging torque fluctuations and affecting motor operation stability. Furthermore, the lack of precision between the bearings and the rotor shaft can easily generate vibration and noise, which, over time, can exacerbate component wear and shorten the motor's lifespan.

[0004] In terms of heat dissipation design, traditional rotors rely on surface ribs or axial ventilation holes for passive heat dissipation, resulting in a single, inefficient heat dissipation path. For permanent magnet synchronous motors, irreversible demagnetization of permanent magnets at high temperatures is particularly problematic. The insulation layer of the excitation winding of electrically excited synchronous motors is susceptible to aging at high temperatures, leading to faults such as inter-turn short circuits. With the increasing demand for motor power density in fields such as new energy vehicles and industrial servo systems, traditional heat dissipation structures are no longer able to meet the cooling needs of high-density heat sources. There is an urgent need to introduce active cooling mechanisms and composite heat dissipation designs to build a multi-dimensional heat dissipation network.

[0005] The lack of coordination between materials and structures is also a major bottleneck in traditional designs. While the high thermal conductivity of metal materials facilitates heat dissipation, their high density and poor fatigue resistance limit the lightweighting and high-speed capabilities of motors. While non-metallic composite materials can reduce weight, their low thermal conductivity requires the design of complex heat dissipation channels, increasing structural complexity and manufacturing costs. In existing technologies, the mechanical support structure and heat dissipation system are independent of each other, lacking systematic optimization, making it difficult to achieve a balance between high strength, high heat dissipation, and lightweight. Summary of the Invention

[0006] The object of the present invention is to provide a high-strength and high-heat dissipation rotor for an energy-saving synchronous motor to solve the above-mentioned problems.

[0007] In order to achieve the above-mentioned purpose, the technical solution provided by one embodiment of the present invention is as follows:

[0008] A high-strength and highly heat-dissipating rotor for an energy-saving synchronous motor comprises a rotor shaft, a rotor core, a pair of rotor supports, and at least one bearing. A pair of symmetrically distributed positioning grooves are provided on the outer surface of the rotor shaft. The rotor core is sleeved on the outer side of the rotor shaft. A plurality of forced cooling structures are fixedly mounted on the rotor core. A pair of rotor supports are respectively fixedly mounted on both ends of the rotor core. Heat dissipation fan blades are fixedly mounted on the inner ends of the rotor supports. The bearing is sleeved on the rotor shaft and maintains an interference fit.

[0009] As a further improvement of the present invention, the rotor core includes a core body, and a plurality of heat dissipation fins distributed in a ring array are fixedly connected to the outer wall of the core body. The core body is provided with a plurality of groups of magnetic pole slots distributed in a ring array along the axial direction, and the number of magnetic pole slots in each group is two and they are distributed in a V shape, and the open side is away from the rotor shaft, and matching magnetic poles are fixedly installed in the magnetic pole slots.

[0010] As a further improvement of the present invention, the core body is further provided with a plurality of hollow heat dissipation channels along the axial direction, which are spaced apart from each group of magnetic pole slots. The hollow heat dissipation channels have embedded heat dissipation channels extending in a direction away from the rotor shaft. The forced cooling structure is fixedly installed on the inner side of the embedded heat dissipation channels. The hollow heat dissipation channels can not only reduce the overall mass of the rotor, but also serve as heat dissipation channels. The extension direction of the embedded heat dissipation channels is close to the magnetic poles. Therefore, when the forced cooling structure exerts a cooling effect, it can act on the magnetic poles faster and better, thereby avoiding demagnetization and failure of the magnetic poles.

[0011] As a further improvement of the present invention, a pair of positioning keys matching the positioning grooves are fixedly connected to the inner end of the core body, and the positioning keys are interference fit with the positioning grooves. An annular assembly seat is also fixedly installed at the upper and lower ends of the core body. A plurality of assembly holes are provided on the annular assembly seat to meet the high-strength assembly between the rotor shaft and the rotor core and avoid relative circumferential rotation.

[0012] As a further improvement of the present invention, the forced cooling structure includes a trigger chamber, an isolation chamber and a liquid chamber. At least one temperature trigger and a heat absorption component are fixedly installed in the trigger chamber. The isolation chamber is bonded between the trigger chamber and the liquid chamber. When overheating occurs at the iron core body or the magnetic pole, the temperature trigger can trigger the cooling action based on temperature perception, so that the isolation chamber barrier fails. When the trigger chamber and the liquid chamber are connected, the cooling action is triggered by the heat absorption component to achieve the purpose of rapid cooling.

[0013] As a further improvement of the present invention, the trigger chamber is located on a side away from the rotor shaft relative to the liquid chamber. The liquid chamber is filled with liquid for dissolving the heat absorbing element. The temperature trigger element punctures the isolation chamber based on a temperature-triggered deformation action. The heat absorbing element absorbs a large amount of heat after being dissolved in the liquid. When the isolation chamber barrier fails, the liquid in the liquid chamber can rely on the centrifugal force of the rotor to quickly enter the trigger chamber and fully contact the heat absorbing element, causing the heat absorbing element to dissolve and absorb a large amount of heat to achieve the purpose of rapid cooling.

[0014] As a further improvement of the present invention, the isolation chamber includes an isolation frame, and sealing rings are fixedly connected to both side walls of the isolation frame. An elastic diaphragm for separating the trigger chamber and the liquid chamber is fixedly connected to the inner end of the isolation frame. The sealing ring is used to improve the sealing at the edge of the isolation frame, and the elastic diaphragm is used to block the trigger chamber and the liquid chamber to avoid premature contact and mixing.

[0015] As a further improvement of the present invention, the temperature trigger includes a shape memory alloy trigger piece, the driving end of the shape memory alloy trigger piece is fixedly connected to a spike structure, the outer end of the spike structure is wrapped with a hot-melt isolation sleeve, and the shape memory alloy trigger piece can trigger a deformation action after sensing overheating, driving the spike structure to pierce the elastic diaphragm, and the hot-melt isolation sleeve serves the purpose of isolating the spike structure to prevent the elastic diaphragm from contacting the spike structure in advance under the action of centrifugal force and causing false triggering, which can effectively improve the triggering accuracy of forced cooling. At the same time, after overheating occurs, the hot-melt isolation sleeve will be heated and melted to expose the internal spike structure, and will not interfere with the normal triggering action of cooling.

[0016] As a further improvement of the present invention, the heat absorption component includes a heat pipe, the inner side of the heat pipe is filled with a phase change heat storage material core, the outer surface of the heat pipe is provided with a plurality of supplementary grooves, and saltpeter particles are bonded to the supplementary grooves. The phase change heat storage material core absorbs the heat generated during the operation of the rotor and releases the heat after the ambient temperature drops to reach a state of dynamic heat storage equilibrium. The saltpeter particles on the surface can absorb a large amount of heat when dissolved in the liquid to achieve the purpose of rapid cooling. In this process, the heat release phenomenon of the phase change heat storage material core will also be triggered, so that it can be restored to a solidified state where it can store heat normally, thereby improving the subsequent heat dissipation effect, especially the magnetic pole can maintain a longer cooling state after triggering the refrigeration action.

[0017] As a further improvement of the present invention, the phase change temperature of the shape memory alloy trigger piece is lower than the operating temperature threshold of the synchronous motor, and the cooling action can be triggered in advance through the deformation of the shape memory alloy trigger piece before the temperature threshold is reached. The melting point of the spike structure is lower than the phase change temperature of the shape memory alloy trigger piece, and it can melt before the shape memory alloy trigger piece is deformed, ensuring that it can smoothly drive the spike structure to pierce the sealing ring after triggering the deformation action, so that the cooling mode can be started normally.

[0018] Compared with the prior art, the advantages of the present invention are:

[0019] (1) In this solution, the rotor shaft and the rotor core are connected by an interference fit of a positioning key and high-strength bolts in an annular assembly seat to form a rigid support system, which significantly improves the rotor's resistance to centrifugal force. The precise fit between the positioning key and the positioning slot significantly improves the circumferential positioning accuracy of the magnetic poles. The displacement of the magnetic poles during high-speed rotation is significantly reduced compared to traditional structures, effectively avoiding magnetic circuit distortion and mechanical failures caused by structural deformation. The lightweight design of the heat dissipation fins and hollow heat dissipation channels reduces the overall mass of the rotor, reduces the moment of inertia, and improves the dynamic response speed and control accuracy of the motor.

[0020] (2) The forced cooling structure in this solution achieves rapid response to rotor overheating and efficient cooling by combining shape memory alloy trigger plates with saltpeter dissolution and heat absorption. When the pole temperature exceeds 80°C, the temperature can be quickly reduced in a short period of time, effectively preventing permanent magnet demagnetization or winding insulation aging. The heat dissipation fins, hollow heat dissipation channels, and embedded heat dissipation channels form a three-dimensional heat dissipation network. Under normal conditions, the heat dissipation efficiency is significantly improved compared to traditional structures. Combined with the forced cooling structure, a multi-stage cooling system of "passive heat dissipation + active cooling" is constructed to ensure that the temperature rise of the motor under rated operating conditions and overload conditions is controlled within a safe range. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 The overall structure of the present invention is shown in FIG. Figure 1 ;

[0022] Figure 2 The overall structure of the present invention is shown in FIG. Figure 2 ;

[0023] Figure 3 It is a schematic diagram of the split structure of the present invention;

[0024] Figure 4 is a cross-sectional view of the rotor core of the present invention;

[0025] Figure 5 This is a schematic structural diagram of the forced refrigeration structure of the present invention;

[0026] Figure 6This is a schematic diagram of the split structure of the forced refrigeration structure of the present invention;

[0027] Figure 7 This is a schematic structural diagram of the temperature trigger of the present invention;

[0028] Figure 8 Schematic diagram of the structure of the heat absorbing element of the present invention.

[0029] Description of the numbers in the figure:

[0030] 1. Rotor shaft; 2. Rotor core; 201. Core body; 202. Heat dissipation fins; 203. Magnetic poles; 204. Positioning key; 205. Hollow heat dissipation channel; 206. Embedded heat dissipation channel; 207. Annular assembly seat; 3. Rotor bracket; 4. Bearing; 5. Forced cooling structure; 501. Trigger chamber; 502. Isolation chamber; 5021. Isolation frame; 5022. Sealing ring; 5023. Elastic diaphragm; 503. Liquid chamber; 504. Temperature trigger; 5041. Shape memory alloy trigger piece; 5042. Spike structure; 5043. Hot-melt isolation sleeve; 505. Heat absorber; 5051. Heat pipe; 5052. Phase change thermal storage material core; 5053. Saltpeter particles; 6. Heat dissipation fan blades. DETAILED DESCRIPTION

[0031] The technical solution of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments, and all other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative work are within the scope of protection of the present invention.

[0032] Example 1:

[0033] This embodiment describes in detail the assembly relationship between the rotor shaft 1 and the rotor core 2, as well as the basic heat dissipation structure. As the core component for power transmission, the rotor shaft 1 is made of 20CrMnTi high-strength alloy steel. After carburizing and quenching at 920°C, the surface hardness of this material can reach HRC58-62, and the carburized layer depth is 0.8-1.2mm. It has excellent torsional strength and wear resistance, and can withstand alternating loads at high-speed rotation of 15,000rpm. The positioning grooves symmetrically opened on the outer surface of the rotor shaft 1 are distributed at 180°, with a groove depth of 3mm and a width of 8mm. The groove walls are precision-ground to a roughness of Ra ≤ 0.8μm, forming an interference fit with the positioning key 204 of the rotor core 2, with an interference of 0.03-0.05mm, ensuring that there is no relative sliding between the two in the circumferential direction.

[0034] The rotor core 2 includes a core body 201, and a plurality of heat dissipation fins 202 distributed in an annular array are fixedly connected to the outer wall of the core body 201. The core body 201 has a plurality of groups of magnetic pole slots distributed in an annular array along the axial direction. The number of magnetic pole slots in each group is two and they are distributed in a V shape, and the open side is away from the rotor shaft 1. Matching magnetic poles 203 are fixedly installed in the magnetic pole slots.

[0035] The core body 201 is also provided with a plurality of hollow heat dissipation channels 205 spaced apart from each group of magnetic pole slots along the axial direction. The hollow heat dissipation channel 205 has an embedded heat dissipation channel 206 extending in a direction away from the rotor shaft 1. The forced cooling structure 5 is fixedly installed on the inner side of the embedded heat dissipation channel 206. The hollow heat dissipation channel 205 can not only reduce the overall mass of the rotor, but also serve as a heat dissipation channel. The extension direction of the embedded heat dissipation channel 206 is close to the magnetic pole 203. Therefore, when the forced cooling structure 5 exerts a cooling effect, it can act on the magnetic pole 203 faster and better, thereby avoiding demagnetization and failure of the magnetic pole 203.

[0036] A pair of positioning keys 204 matching the positioning grooves are fixedly connected to the inner end of the core body 201, and the positioning keys 204 are interference fit with the positioning grooves. Annular assembly seats 207 are also fixedly installed at the upper and lower ends of the core body 201. The annular assembly seat 207 is provided with multiple assembly holes to ensure high-strength assembly between the rotor shaft 1 and the rotor core 2 and avoid relative circumferential rotation.

[0037] The rotor core 2's core body 201 is constructed from a laminate of 0.5mm-thick DW310-35 silicon steel sheets, coated with a polyimide insulating coating 0.01-0.02mm thick, which reduces eddy current losses by over 30%. The outer wall of the core body 201 is evenly distributed with 48 annular heat sink fins 202. These fins are made of 6061-T6 aluminum alloy, extruded and anodized, and are 20mm high and 4mm thick, arranged at a 30° angle along the circumference. This design utilizes the centrifugal force of the rotating rotor to create high-speed turbulent air flow along the surface of the heat sink fins 202. This improves the convection heat dissipation coefficient by 40% compared to traditional vertical fins, effectively enhancing the heat dissipation capacity of the core surface.

[0038] The core body 201 is provided with 8 groups of V-shaped magnetic pole slots along the axial direction. Each group of magnetic pole slots contains two symmetrically distributed grooves. The open side is away from the rotor shaft 1, with an angle of 120° and a groove depth of 25mm. The groove wall is processed by CNC milling, and the surface roughness Ra≤1.6μm. The magnetic pole 203 is fixedly installed in the magnetic pole slot. The magnetic pole 203 adopts N52 type neodymium iron boron permanent magnet. The magnetization direction is radial. The pole shoe part is precisely ground to form a 25° chamfer to optimize the air gap magnetic field distribution and reduce the cogging torque peak. The thermal conductive silicone is filled between the magnetic pole 203 and the magnetic pole slot. The thermal conductive silicone adopts Shin-Etsu X-23-7762 with a thermal conductivity of 6W / (m·K). The silicone contains boron nitride particle filler, which accounts for 40% by volume. It can not only ensure the continuity of the magnetic circuit, but also form an efficient heat conduction path, and transfer the heat generated by the magnetic pole 203 to the heat exchanger at a rate of 0.5K·m 2 The thermal resistance of / W is quickly transferred to the core body 201.

[0039] The core body 201 also features axially spaced hollow heat dissipation channels 205, spaced apart from the magnetic pole slots. These channels have a diameter of 12 mm and are numbered eight, evenly distributed along the circumference. Each hollow heat dissipation channel 205 extends an embedded heat dissipation channel 206 15 mm away from the rotor shaft 1, with its opening facing the side of the magnetic pole 203, forming a direct heat dissipation path to the heat source. The design of these hollow heat dissipation channels 205 reduces the overall rotor mass by 15% compared to traditional solid cores. They also provide internal circulation channels for cooling airflow, forming a coordinated internal and external heat dissipation system with the external heat dissipation fins 202, ensuring that heat within the core body 201 can be rapidly dissipated through both convection and conduction.

[0040] The positioning key 204 is forged from 45# steel with a rectangular cross section. The working surface in contact with the positioning groove is high-frequency quenched to a hardness of HRC45-50, effectively improving contact stiffness and impact resistance.

[0041] Example 2:

[0042] This embodiment describes in detail the internal structure and operating principle of the forced cooling structure 5. The forced cooling structure 5 is fixedly mounted inside the embedded heat dissipation channel 206. It adopts a modular design, with individual structural dimensions of 50mm × 30mm × 10mm. Its outer shell is made of a polycarbonate (PC) composite material reinforced with 30% glass fiber, offering high strength (tensile strength ≥ 120 MPa) and high-temperature resistance (long-term operating temperature ≤ 130°C).

[0043] The forced cooling structure 5 includes a trigger chamber 501, an isolation chamber 502 and a liquid chamber 503. At least one temperature trigger 504 and a heat absorber 505 are fixedly installed in the trigger chamber 501. The isolation chamber 502 is bonded between the trigger chamber 501 and the liquid chamber 503. When overheating occurs at the core body 201 or the magnetic pole 203, the temperature trigger 504 can trigger the cooling action based on temperature perception, so that the isolation chamber 502 fails to block. When the trigger chamber 501 and the liquid chamber 503 are connected, the cooling action is triggered by the heat absorber 505 to achieve the purpose of rapid cooling.

[0044] The trigger chamber 501 is located on the side away from the rotor shaft 1 relative to the liquid chamber 503. The liquid chamber 503 is filled with liquid for dissolving the heat absorber 505. The temperature trigger 504 punctures the isolation chamber 502 based on temperature-triggered deformation. After dissolving in the liquid, the heat absorber 505 absorbs a large amount of heat. When the isolation chamber 502 fails to provide a barrier, the liquid in the liquid chamber 503 can quickly enter the trigger chamber 501 by relying on the centrifugal force of the rotor, fully contacting the heat absorber 505, and causing the heat absorber 505 to dissolve and absorb a large amount of heat, thereby achieving the purpose of rapid cooling.

[0045] The isolation chamber 502 includes an isolation frame 5021, and sealing rings 5022 are fixedly connected to the two side walls of the isolation frame 5021. An elastic diaphragm 5023 for separating the trigger chamber 501 and the liquid chamber 503 is fixedly connected to the inner end of the isolation frame 5021. The sealing ring 5022 is used to improve the sealing performance at the edge of the isolation frame 5021, and the elastic diaphragm 5023 is used to block the trigger chamber 501 and the liquid chamber 503 to prevent premature contact and mixing.

[0046] The temperature trigger 504 includes a shape memory alloy trigger piece 5041, and the driving end of the shape memory alloy trigger piece 5041 is fixedly connected to a spike structure 5042. The outer end of the spike structure 5042 is wrapped with a hot-melt isolation sleeve 5043. The shape memory alloy trigger piece 5041 can trigger a deformation action after sensing overheating, and drive the spike structure 5042 to pierce the elastic diaphragm 5023. The hot-melt isolation sleeve 5043 serves to isolate the spike structure 5042, preventing the elastic diaphragm 5023 from contacting the spike structure 5042 in advance under the action of centrifugal force and causing false triggering, which can effectively improve the triggering accuracy of forced cooling. At the same time, after overheating occurs, the hot-melt isolation sleeve 5043 will be heated and melted to expose the internal spike structure 5042, and will not interfere with the normal triggering action of cooling.

[0047] The heat absorption component 505 includes a heat pipe 5051, the inside of which is filled with a phase change heat storage material core 5052. A plurality of replenishing grooves are provided on the outer surface of the heat pipe 5051, and saltpeter particles 5053 are bonded to the replenishing grooves. The phase change heat storage material core 5052 absorbs the heat generated during the operation of the rotor and releases the heat to reach a dynamic heat storage equilibrium state after the ambient temperature drops. The saltpeter particles 5053 on the surface can absorb a large amount of heat when dissolved in the liquid to achieve the purpose of rapid cooling. In this process, the heat release phenomenon of the phase change heat storage material core 5052 is also triggered, causing it to return to a solidified state where it can store heat normally, thereby improving the subsequent heat dissipation effect, especially the magnetic pole 203 can maintain a longer cooling state after the cooling action is triggered.

[0048] The phase change temperature of the shape memory alloy trigger piece 5041 is lower than the operating temperature threshold of the synchronous motor. The cooling action can be triggered in advance through the deformation of the shape memory alloy trigger piece 5041 before the temperature threshold is reached. The melting point of the spike structure 5042 is lower than the phase change temperature of the shape memory alloy trigger piece 5041. It can melt before the shape memory alloy trigger piece 5041 is deformed, ensuring that it can smoothly drive the spike structure 5042 to pierce the sealing ring 5022 after triggering the deformation action, so that the cooling mode can be started normally.

[0049] A temperature trigger element 504 and a heat sink 505 are located within the trigger chamber 501. The temperature trigger element 504 is a nickel-titanium shape memory alloy trigger piece 5041, with a phase transition temperature set at 80°C. Its initial state is curved, measuring 15 mm in length, 5 mm in width, and 0.3 mm in thickness. The martensitic transformation strain of this material can reach 8%, and its recovery stress is ≥50 MPa. The driving end of the shape memory alloy trigger piece 5041 is connected to a spike structure 5042, precision-machined from 304 stainless steel. The spike structure 5042 has a 30° tip angle and a 0.05 mm radius of curvature. The outer end is wrapped with a hot-melt isolation sleeve 5043, made of Wood's alloy with a melting point of 70°C (60.5°C). This ensures isolation between the spike structure 5042 and the elastic diaphragm 5023 at normal operating temperatures ≤70°C, preventing false triggering.

[0050] The isolation frame 5021 of the isolation chamber 502 is made of nylon 66 and is bonded to the trigger chamber 501 and liquid chamber 503 with sealant. Later replacement requires only the replacement of the elastic diaphragm 5023 and the saltpeter granules 5053. The elastic diaphragm 5023 is a 0.15mm thick polyimide film with a tensile strength of ≥200MPa. Both sides are sealed to the isolation frame 5021 by sealing rings 5022. The sealing rings 5022 are made of fluororubber with a Shore A hardness of 70HA and a cross-sectional diameter of 2mm. They can withstand a pressure differential of 0.6MPa and ensure complete isolation of the liquid chamber 503 from the trigger chamber 501 before triggering. The liquid chamber 503 has a volume of 8mL and is filled with deionized water with a conductivity of ≤1μS / cm. The volume ratio of the liquid chamber 503 to the trigger chamber is 2:1, ensuring sufficient liquid to react with the heat absorber.

[0051] It should be noted that a small amount of dye can be mixed into the deionized water in the liquid chamber 503, and then a transparent observation point is set on the trigger chamber 501. When the internal color changes, it can be determined that the forced refrigeration structure has been used and needs to be replaced in time.

[0052] The inner wall of heat pipe 5051 is filled with a paraffin-based phase-change material core 5052, which has a melting point of 55°C and a latent heat of 150 kJ / kg. This core absorbs and stores the continuous heat generated by the rotor's operation. Six replenishment slots are located on the outer surface of heat pipe 5051, each containing 15g of potassium nitrate granules with a particle size of 1-3mm. Potassium nitrate has a heat of solution of 340 kJ / kg and can quickly absorb large amounts of heat when mixed with water.

[0053] When the rotor temperature rises to 80°C, the shape memory alloy trigger plate 5041 undergoes a reverse martensitic phase transformation, stretching from a bent state to a straight state by 3mm, driving the spike structure 5042 to pierce the elastic diaphragm 5023. Prior to this, the hot-melt isolation sleeve 5043 melts at 70°C, ensuring that the spike structure 5042 can penetrate the elastic diaphragm 5023 smoothly. Under the influence of centrifugal force, the deionized water in the liquid chamber 503 rapidly enters the trigger chamber 501 at a speed of 5m / s, mixing and dissolving with the saltpeter particles 5053, forming a strong endothermic reaction that reduces the surface temperature of the magnetic pole 203 by 20-25°C within 10 seconds. Simultaneously, the phase change material core 5052 within the heat pipe solidifies from its liquid state, releasing stored heat, maintaining the low temperature of the trigger chamber 501, prolonging the cooling effect, and ensuring that the temperature of the magnetic pole 203 does not exceed 100°C under overload conditions.

[0054] Example 3:

[0055] This embodiment describes in detail the assembly relationship between the rotor bracket 3, the bearing 4 and the heat dissipation fan blade 6. The pair of rotor brackets 3 are made of ZL101A cast aluminum alloy, which has been heat treated to T6, with a tensile strength of ≥300MPa and a density of 2.7g / cm3 , combining high strength with lightweight properties. The rotor bracket 3 is annular, with a mounting flange at its inner end that mates with the annular assembly seat 207 of the core body 201. The flange is 12mm thick and has four evenly spaced M8 bolt holes. Bolts are 10.9-grade high-strength bolts with a preload of 60 N·m, ensuring a rigid connection between the rotor bracket 3 and the core body 201, with a coaxiality error of ≤0.03mm.

[0056] The outer end of rotor bracket 3 is machined with a bearing mounting hole. The hole diameter has an interference fit of 0.02-0.04mm with the outer ring of bearing 4. The bearing is a 6210 deep groove ball bearing. The inner ring has an interference fit with rotor shaft 1. The mating surface is coated with molybdenum disulfide grease, reducing the friction coefficient to below 0.015, effectively reducing mechanical losses. An oil slinger is installed on the inner end of the bearing seat to prevent grease leakage and guide cooling air into the heat dissipation channel inside the rotor.

[0057] The annular assembly seat 207 of the core body 201 has a thickness of 15 mm and a surface roughness of Ra≤1.6 μm. The assembly holes correspond one-to-one with the bolt holes of the rotor bracket 3, and the hole position accuracy is ±0.05 mm.

[0058] A cooling fan blade 6, consisting of 12 blades and made of a carbon fiber / epoxy resin composite material, is fixedly mounted on the inner end of the rotor bracket 3. At 8000 rpm, the airflow reaches 15 CFM, which is directed into the hollow heat dissipation channel 205. Under the centrifugal force of the rotor, this airflow mixes with the cold air discharged by the forced cooling structure 5, forming multiple cooling airflows, further improving heat dissipation efficiency.

[0059] Working principle:

[0060] When the synchronous motor is started, the rotor shaft 1 is interference-fitted with the positioning slot of the rotor core 2 via the positioning key 204, achieving circumferential fixation with an interference fit of 0.03mm, driving the rotor core 2 to rotate at high speed. Under normal operating conditions, the rotating magnetic field generated by the magnetic pole 203 couples with the stator winding through the air gap, realizing the conversion of electrical energy into mechanical energy. At this time, the heat dissipation fins 202 use the airflow generated by the rotation of the rotor for passive heat dissipation. The hollow heat dissipation channels 205 and the embedded heat dissipation channels 206 form an internal ventilation path, which removes heat from the magnetic pole 203 and the core body 201 through convection, ensuring that the rotor temperature is maintained below 70°C.

[0061] When the motor is overloaded or the cooling system's efficiency decreases, causing the rotor temperature to rise to 80°C, the forced cooling mechanism 5 activates: the shape memory alloy trigger piece 5041 of the temperature trigger element 504 undergoes a phase change due to the rising temperature, extending from its bent state and driving the spike structure 5042 to pierce the elastic diaphragm 5023. Previously, the hot-melt isolation sleeve 5043 had melted at 70°C, ensuring smooth penetration of the spike structure 5042. Centrifugal force rapidly applies deionized water to the liquid chamber 503, where it mixes with the saltpeter particles 5053. The potassium nitrate absorbs a significant amount of heat during dissolution, causing the temperature of the trigger chamber 501 and the surrounding magnetic poles 203 to drop sharply. Simultaneously, the phase change material core 5052 within the heat pipe 5051 solidifies from its liquid state, releasing stored heat, maintaining the low temperature of the trigger chamber 501, prolonging the cooling effect, and preventing demagnetization of the magnetic poles 203 due to high temperature.

[0062] The rotor bracket 3 is rigidly connected to the core body 201 through the annular assembly seat 207, which evenly transmits the centrifugal force during the rotation of the rotor to the bearing 4. The interference fit and lubrication design of the bearing 4 reduce mechanical loss. At the same time, the heat dissipation fan blades 6 can guide the airflow into the hollow heat dissipation channel 205, and under the action of the centrifugal force of the rotor, it can be mixed with the cold discharged by the forced refrigeration structure 5 to form multiple cooling airflows, thereby further improving the heat dissipation efficiency.

[0063] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, the embodiments should be considered in all respects as exemplary and non-restrictive.

[0064] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A high-strength and high-heat dissipation rotor for an energy-saving synchronous motor, characterized by: include: A rotor shaft (1), wherein the outer surface of the rotor shaft (1) is provided with a pair of symmetrically distributed positioning grooves; A rotor core (2), the rotor core (2) being sleeved on the outside of the rotor shaft (1), and a plurality of forced cooling structures (5) being fixedly mounted on the rotor core (2); A pair of rotor brackets (3) are fixedly mounted on both ends of the rotor core (2), and heat dissipation fan blades (6) are fixedly mounted on the inner ends of the rotor brackets (3); At least one bearing (4) is sleeved on the rotor shaft (1) and maintains an interference fit.

2. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 1, characterized in that: The rotor core (2) comprises a core body (201), a plurality of heat dissipation fins (202) distributed in an annular array are fixedly connected to the outer wall of the core body (201), the core body (201) is provided with a plurality of groups of magnetic pole slots distributed in an annular array along the axial direction, each group of magnetic pole slots has two magnetic pole slots and is distributed in a V-shape, with the open side away from the rotor shaft (1), and matching magnetic poles (203) are fixedly installed in the magnetic pole slots.

3. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 2, characterized in that: The core body (201) is further provided with a plurality of hollow heat dissipation channels (205) spaced apart from each group of magnetic pole slots along the axial direction. The hollow heat dissipation channels (205) are provided with embedded heat dissipation channels (206) extending in a direction away from the rotor shaft (1). The forced cooling structure (5) is fixedly mounted on the inner side of the embedded heat dissipation channel (206).

4. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 3, characterized in that: A pair of positioning keys (204) matching the positioning grooves are fixedly connected to the inner end of the core body (201), and the positioning keys (204) are interference-fitted with the positioning grooves. An annular assembly seat (207) is also fixedly mounted on the upper and lower ends of the core body (201), and a plurality of assembly holes are provided on the annular assembly seat (207).

5. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 1, characterized in that: The forced cooling structure (5) comprises a trigger chamber (501), an isolation chamber (502) and a liquid chamber (503); at least one temperature trigger component (504) and a heat absorbing component (505) are fixedly installed in the trigger chamber (501); and the isolation chamber (502) is bonded between the trigger chamber (501) and the liquid chamber (503).

6. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 5, characterized in that: The trigger chamber (501) is located on a side away from the rotor shaft (1) relative to the liquid chamber (503). The liquid chamber (503) is filled with liquid for dissolving the heat absorbing element (505). The temperature trigger element (504) punctures the isolation chamber (502) based on a temperature-triggered deformation action. The heat absorbing element (505) absorbs a large amount of heat after being dissolved in the liquid.

7. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 6, characterized in that: The isolation chamber (502) comprises an isolation frame (5021), both side walls of the isolation frame (5021) are fixedly connected to sealing rings (5022), and the inner end of the isolation frame (5021) is fixedly connected to an elastic diaphragm (5023) for separating the trigger chamber (501) and the liquid chamber (503).

8. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 7, characterized in that: The temperature triggering component (504) comprises a shape memory alloy triggering piece (5041), the driving end of the shape memory alloy triggering piece (5041) is fixedly connected to a spike structure (5042), and the outer end of the spike structure (5042) is wrapped with a hot-melt isolation sleeve (5043).

9. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 8, characterized in that: The heat absorbing element (505) comprises a heat pipe (5051), the inner side of the heat pipe (5051) is filled with a phase change heat storage material core (5052), and the outer surface of the heat pipe (5051) is provided with a plurality of supplementary grooves, and saltpeter particles (5053) are bonded in the supplementary grooves.

10. The high-strength and high-heat dissipation rotor of an energy-saving synchronous motor according to claim 9, characterized in that: The phase transition temperature of the shape memory alloy trigger piece (5041) is lower than the operating temperature threshold of the synchronous motor, and the melting point of the spike structure (5042) is lower than the phase transition temperature of the shape memory alloy trigger piece (5041).

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