Rotor assembly, motor and vehicle

Abstract

The invention provides a rotor assembly, a motor and a vehicle, and relates to the technical field of vehicles, the rotor assembly comprises a rotor iron core, an injection molding part, a first end plate and a second end plate, the first end plate and the second end plate are respectively arranged at two axial ends of the rotor iron core; the rotor iron core is provided with a first injection molding groove penetrating through the axial end face of the rotor iron core, at least one of the first end plate and the second end plate is provided with a second injection molding groove communicated with the first injection molding groove, and the first injection molding groove and the second injection molding groove are filled with the injection molding part. Thus, at least one of the first end plate and the second end plate can be connected with the rotor iron core into a whole in an injection molding mode, so that the overall rigidity of the rotor assembly is improved, the torsional mode of the rotor assembly and the NVH performance of the motor can be improved, and meanwhile the manufacturing cost of the rotor assembly can be reduced.

Description

Technical Field

[0001] The present invention relates to the field of vehicle technology, and in particular to a rotor assembly, a motor and a vehicle. Background Art

[0002] With the rapid development of the new energy industry, the performance requirements, NVH (Noise, Vibration, Harshness) requirements, and lightweight requirements for motors are becoming increasingly higher, which requires the motor rotor to have higher stiffness and higher torsional mode.

[0003] Currently, motor rotors typically consist of multiple core segments, each of which is press-assembled from multiple rotor laminations. To improve the rotor's stiffness and torsional modulus, the core segments are typically joined together using glue, or the stacked rotor laminations are fixed together using injection molding. However, the former requires additional adhesive and a gluing station on the production line, increasing production line and material costs, leading to higher manufacturing costs. The latter results in lower connection strength between the core segments, which in turn reduces the rotor's torsional modulus. Summary of the Invention

[0004] The problem solved by the present invention is how to improve the overall rigidity of the motor rotor and reduce the production cost.

[0005] To solve the above problems, the present invention provides a rotor assembly, a motor and a vehicle.

[0006] In the first aspect, the present invention provides a rotor assembly, including a rotor core, an injection molded part, a first end plate and a second end plate, wherein the first end plate and the second end plate are respectively arranged at the axial ends of the rotor core; the rotor core is provided with a first injection molding groove running through its axial end surface, and at least one of the first end plate and the second end plate is provided with a second injection molding groove connected to the first injection molding groove, and the injection molded part is filled in the first injection molding groove and the second injection molding groove.

[0007] Optionally, an injection hole is provided on the end surface of the first end plate and / or the second end plate provided with the second injection groove, which is away from the rotor core, and the injection hole is communicated with the corresponding second injection groove.

[0008] Optionally, the second injection groove is extended in the axial direction.

[0009] Optionally, the rotor core is further provided with mounting grooves for mounting permanent magnets, the number of the mounting grooves is the same as the number of magnetic poles of the rotor core, and the first injection molding groove is arranged corresponding to the mounting groove, and the second injection molding groove is arranged corresponding to the first injection molding groove.

[0010] Optionally, the notch of the first injection groove close to one end of the second injection groove is a first notch, the notch of the second injection groove close to one end of the first injection groove is a second notch, the area of ​​the second notch is larger than the area of ​​the first notch, and the second notch covers the first notch.

[0011] Optionally, the rotor core includes two symmetrically arranged core parts, each of the core parts includes a plurality of core segments stacked along the axial direction, each of the core segments is provided with a through slot, and the through slots of all the core segments of the two core parts are connected in sequence to form the first injection molding slot.

[0012] Optionally, in one of the core parts, the through slots on two adjacent core segments are staggered.

[0013] Optionally, the through groove is arranged to penetrate along the axial direction.

[0014] In a second aspect, the present invention provides a motor comprising the rotor assembly as described above.

[0015] In a third aspect, the present invention provides a vehicle comprising the motor as described above.

[0016] The beneficial effect of the rotor assembly of the present invention is that a first injection molding groove penetrating the axial end face of the rotor core can be provided, a second injection molding groove connected to the first injection molding groove can be provided on at least one of the first end plate and the second end plate, and injection molding material can be filled into the first injection molding groove and the second injection molding groove by injection molding to form an injection molded part, so that at least one of the first end plate and the second end plate is connected to the rotor core as a whole, so as to improve the overall stiffness of the rotor assembly, thereby improving the torsional mode of the rotor assembly and the NVH performance of the motor. Moreover, since permanent magnets such as magnetic steel are fixed by injection molding into the gaps of the magnetic steel grooves, the injection molding equipment of the magnetic steel grooves can be used at the original injection molding station on the production line to complete the injection molding of the injection molded parts, without the need to provide additional injection molding equipment or add additional stations on the production line, thereby reducing material and production line costs, thereby reducing the manufacturing cost of the rotor assembly. In addition, injection molding is used to connect at least one of the first end plate and the second end plate to the rotor core as a whole, so that part of the rotor core and the end plate is replaced by a lighter injection molding part, thereby reducing the weight of the rotor core and the end plate and facilitating a lightweight design. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Schematic diagram of the exploded structure of the rotor assembly in an embodiment of the present invention; Figure 2 is a schematic cross-sectional view of a rotor assembly according to an embodiment of the present invention; Figure 3Schematic diagram of the structure of the second end plate in an embodiment of the present invention; Figure 4 Schematic diagram of the distribution of the first injection groove, the mounting groove and the weight-reducing hole on the rotor core in an embodiment of the present invention; Figure 5 Schematic diagram of the structure when the injection molded part is connected to the first end plate and the second end plate respectively in an embodiment of the present invention; Figure 6 Schematic cross-sectional view of the rotor core, the first end plate, and the second end plate in an assembled state according to an embodiment of the present invention.

[0018] Description of reference numerals: 1. Rotor core; 11. First injection molding groove; 12. Mounting groove; 121. First V-shaped magnetic steel groove; 122. Second V-shaped magnetic steel groove; 13. Core portion; 131. Core segment; 132. Through groove; 14. Lightening hole; 2. Injection molding part; 21. First injection molding body; 22. Second injection molding body; 3. First end plate; 4. Second end plate; 5. Second injection molding groove; 6. Injection molding hole; 7. Rotating shaft. DETAILED DESCRIPTION

[0019] To make the above-mentioned objects, features, and advantages of the present invention more clearly understood, specific embodiments of the present invention are described in detail below with reference to the accompanying drawings. Although certain embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as being limited to the embodiments described herein. Instead, these embodiments are provided to provide a more thorough and complete understanding of the present invention. It should be understood that the drawings and embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0020] The term "including" and its variations used in this document are open inclusions, that is, "including but not limited to"; the term "based on" means "based at least in part on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one other embodiment"; the term "some embodiments" means "at least some embodiments"; the term "optionally" means "optional embodiments". The relevant definitions of other terms will be given in the following description. It should be noted that the concepts of "first", "second", etc. mentioned in the present invention are only used to distinguish different devices, modules or units, and are not used to limit the order or interdependence of the functions performed by these devices, modules or units.

[0021] It should be noted that the modifications of "one" and "multiple" mentioned in the present invention are illustrative rather than restrictive. Those skilled in the art should understand that unless otherwise clearly indicated in the context, it should be understood as "one or more".

[0022] In related technologies, a motor rotor typically includes multiple core segments, each of which is press-assembled from multiple rotor laminations. To improve the rotor's stiffness and torsional modulus, the core segments are typically connected together using glue, or the stacked rotor laminations are fixed by injection molding the core segments. However, the former requires additional adhesive and a gluing station on the production line, increasing production line and material costs, leading to higher manufacturing costs. The latter results in lower connection strength between the core segments, which in turn leads to lower torsional modulus of the rotor.

[0023] In response to the problems existing in the above-mentioned related technologies, embodiments of the present invention provide a rotor assembly, a motor and a vehicle.

[0024] Combine Figure 1 and Figure 2 As shown, a rotor assembly according to an embodiment of the present invention includes a rotor core 1, an injection molded part 2, a first end plate 3 and a second end plate 4, wherein the first end plate 3 and the second end plate 4 are respectively arranged at the axial ends of the rotor core 1; the rotor core 1 is provided with a first injection molding groove 11 penetrating its axial end surface, and at least one of the first end plate 3 and the second end plate 4 is provided with a second injection molding groove 5 connected to the first injection molding groove 11, and the injection molded part 2 is filled in the first injection molding groove 11 and the second injection molding groove 5.

[0025] Specifically, the rotor core 1 is provided with a first injection molding groove 11, and the first injection molding groove 11 passes through the end surfaces of the rotor core 1 at both axial ends. The first injection molding groove 11 can be a linear groove structure. In this case, the first injection molding groove 11 can be extended in the axial direction, that is, extended in a direction parallel to the axis of the rotor core 1, or can be inclined relative to the axis of the rotor core 1. The first injection molding groove 11 can also be composed of a plurality of staggered through grooves 132, such as Figure 6As shown, no specific limitation is given here. At least one of the first end plate 3 and the second end plate 4 is provided with a second injection groove 5. The second injection groove 5 can be a through-groove structure. In this case, the notch at the end of the second injection groove 5 away from the first injection groove 11 can be used as the injection port for injection molding. The second injection groove 5 can also be a non-through-groove structure. In this case, the injection port can be set on the axial end face of the end plate away from the rotor core 1, or on the circumferential side wall of the end plate, or on the circumferential side wall of the rotor core 1. In actual application, the design can be selected according to needs. The injection molded part 2 is formed by integrally connecting at least one of the first end plate 3 and the second end plate 4 to the rotor core 1 through injection molding. Before the injection molding operation, the first end plate 3, the rotor core 1, and the second end plate 4 are sequentially axially sleeved on the outside of the rotating shaft 7. Then, the first injection molding groove 11 and the second injection molding groove 5 are filled with an injection molding material such as PA66+GF30 (i.e., a nylon 66 composite material reinforced with 30% glass fiber). The cured injection molding material becomes the injection molded part 2, thereby integrally connecting at least one of the first end plate 3 and the second end plate 4 to the rotor core 1. Among them, when one of the first end plate 3 and the second end plate 4 is provided with the second injection molding groove 5, for example, only the first end plate 3 is provided with the second injection molding groove 5, at this time, one end of the injection molding part 2 is accommodated in the second injection molding groove 5 on the first end plate 3, and the other end passes through the first injection molding groove 11 of the rotor core 1 from the end of the rotor core 1 close to the first end plate 3, and extends to the end of the rotor core 1 close to the second end plate 4, so that the first end plate 3 and the rotor core 1 are connected as a whole; when both the first end plate 3 and the second end plate 4 are provided with the second injection molding groove 5, one end of the injection molding part 2 is accommodated in the second injection molding groove 5 on the first end plate 3, and the other end passes through the first injection molding groove 11 of the rotor core 1 and is accommodated in the second injection molding groove 5 on the second end plate 4, so that the first end plate 3, the rotor core 1 and the second end plate 4 are connected as a whole.

[0026] In this embodiment, a first injection molding groove 11 can be provided on the rotor core 1, passing through its axial end surface, and a second injection molding groove 5 connected to the first injection molding groove 11 can be provided on at least one of the first end plate 3 and the second end plate 4. The injection molding material is filled into the first injection molding groove 11 and the second injection molding groove 5 by injection molding to form an injection molded part 2, so that at least one of the first end plate 3 and the second end plate 4 is connected to the rotor core 1 as a whole, so as to improve the overall stiffness of the rotor assembly, thereby improving the torsional mode of the rotor assembly and the NVH performance of the motor. Moreover, since permanent magnets such as magnetic steel are fixed by injection molding into the gaps in the magnetic steel grooves, the injection molding equipment of the magnetic steel grooves can be used at the original injection molding station on the production line to complete the injection molding of the injection molded part 2. There is no need to provide additional injection molding equipment or add additional stations on the production line, thereby reducing material and production line costs, and thus reducing the manufacturing cost of the rotor assembly. In addition, the injection molded part 2 is used to connect at least one of the first end plate 3 and the second end plate 4 to the rotor core 1 as a whole, so that a part of the rotor core 1 and the end plate is replaced by the lighter injection molded part 2, thereby reducing the weight of the rotor core 1 and the end plate, facilitating the realization of a lightweight design.

[0027] Optionally, combined Figure 3 and Figure 6 As shown, an injection hole 6 is provided on the end surface of the first end plate 3 and / or the second end plate 4 provided with the second injection groove 5 away from the rotor core 1, and the injection hole 6 is communicated with the corresponding second injection groove 5.

[0028] In this optional embodiment, the injection hole 6 is provided on the end plate (i.e., the first end plate 3 and / or the second end plate 4) and is connected to the second injection groove 5 on the end plate. At the same time, the injection hole 6 passes through the end surface of the end plate away from the rotor core 1. In other words, the injection hole 6 is provided on the axial end surface of the end plate away from the rotor core 1. In this way, it is convenient to perform the injection molding operation at the end of the end plate away from the rotor core 1 to improve the convenience of injection molding. Moreover, there is no need to provide the injection hole 6 on the rotor core 1, thereby ensuring that the structures of the various rotor punchings of the rotor core 1 are basically consistent, thereby reducing the types of rotor punchings and reducing material management costs.

[0029] Optionally, combined Figure 6 As shown, the second injection groove 5 extends axially. That is, the central axis of the second injection groove 5 is parallel to the axis of the rotor core 1. In this case, the axial ends of the second injection groove 5 are connected to the injection hole 6 and the first injection groove 11, respectively. Compared with arranging the second injection groove 5 at an angle relative to the axial direction of the rotor core 1 or configuring the second injection groove 5 as a bent channel structure, this can shorten the extension length of the second injection groove 5, thereby improving injection efficiency, reducing the amount of injection material used, and lowering production costs.

[0030] Optionally, combined Figure 3 and Figure 4 As shown, the rotor core 1 is further provided with mounting grooves 12 for mounting permanent magnets. The number of the mounting grooves 12 is the same as the number of magnetic poles of the rotor core 1 , and the first injection molding groove 11 is corresponding to the mounting groove 12 , and the second injection molding groove 5 is corresponding to the first injection molding groove 11 .

[0031] In this optional embodiment, multiple mounting grooves 12 are evenly distributed along the circumference of the rotor core 1. At the same time, the number of mounting grooves 12 is the same as the number of magnetic poles of the rotor core 1, that is, the permanent magnet installed in one mounting groove 12 constitutes one magnetic pole of the rotor core 1; moreover, the first injection molding groove 11 is arranged in a one-to-one correspondence with the mounting groove 12, and the second injection molding groove 5 is arranged in a one-to-one correspondence with the first injection molding groove 11, that is, the number of first injection molding grooves 11 and mounting grooves 12 is the same as the number of second injection molding grooves 5 on an end plate. Among them, a magnetic pole can be composed of a permanent magnet, for example, a permanent magnet arranged radially forms a radial distribution, in which case the mounting groove 12 has a single groove structure; a magnetic pole can also be composed of multiple permanent magnets, for example, two permanent magnets form a tangential distribution, in which case the mounting groove 12 is composed of two grooves to form a straight groove structure, or two permanent magnets form a single V-shaped distribution, in which case the mounting groove 12 is composed of two grooves to form a single V-shaped groove structure, or four permanent magnets form a double V-shaped distribution, in which case the mounting groove 12 is composed of four grooves to form a double V-shaped groove structure. In this way, by arranging the first injection molding groove 11 in correspondence with the mounting groove 12 for mounting a permanent magnet of a magnetic pole, the number of the first injection molding groove 11 and the injection molding parts 2 filled in the first injection molding groove 11 is also the same as the number of magnetic poles of the rotor core 1, so that the rotor core 1 and the end plate can be connected into a whole using multiple injection molding parts 2 to further improve the overall stiffness of the rotor assembly, while also further reducing the weight of the rotor assembly; moreover, the multiple injection molding parts 2 are evenly distributed along the circumference of the rotor core 1, which not only ensures that the rotor core 1 and the end plate are subjected to uniform force, but also facilitates processing and manufacturing.

[0032] Further, combined with Figure 3 and Figure 4 As shown, each mounting slot 12 includes a first V-shaped magnetic steel slot 121 and a second V-shaped magnetic steel slot 122 spaced apart along the radial direction of the rotor core 1. A first injection molding slot 11 is provided between the first V-shaped magnetic steel slot 121 and the second V-shaped magnetic steel slot 122 of each mounting slot 12. This makes the rotor assembly suitable for motors with a double V-shaped magnetic pole distribution.

[0033] Optionally, combined Figure 1 and Figure 6As shown, the notch of the first injection groove 11 close to one end of the second injection groove 5 is the first notch, and the notch of the second injection groove 5 close to one end of the first injection groove 11 is the second notch. The area of ​​the second notch is larger than that of the first notch, and the second notch covers the first notch.

[0034] In this optional embodiment, since the first injection molding groove 11 passes through the end faces at both axial ends of the rotor core 1, that is, both axial ends of the first injection molding groove 11 are open, both axial ends of the first injection molding groove 11 have slots, wherein, when the second injection molding groove 5 is provided on both the first end plate 3 and the second end plate 4, the axial ends of the first injection molding groove 11 are respectively connected to the second injection molding groove 5 on the first end plate 3 and the second end plate 4. At this time, the slots at both axial ends of the first injection molding groove 11 are first slots, and when one of the first end plate 3 and the second end plate 4 is provided with the second injection molding groove 5, the slot at one end of the first injection molding groove 11 close to the second injection molding groove 5 is the first slot. At the same time, the first notch of the first injection molding groove 11 is arranged opposite the second notch of the second injection molding groove 5, and the area of ​​the second notch is larger than that of the first notch, so that the second notch completely covers the first notch. The injection molded part 2 includes a first injection molded body 21 filled in the first injection molding groove 11 and a second injection molded body 22 filled in the second injection molding groove 5. Therefore, the end surface area of ​​the second injection molded body 22 facing the first injection molded body 21 is larger than the end surface area of ​​the first injection molded body 21 facing the second injection molded body 22. In this way, when the second injection molding groove 5 is provided on both the first end plate 3 and the second end plate 4, the second injection molded bodies 22 at both ends of the injection molded part 2 can be used to clamp the rotor core 1, thereby further improving the overall rigidity of the rotor assembly.

[0035] Optionally, combined Figure 2 and Figure 6 As shown, the rotor core 1 includes two symmetrically arranged core parts 13, each core part 13 includes a plurality of core segments 131 stacked along the axial direction, each core segment 131 is provided with a through slot 132, and the through slots 132 of all the core segments 131 of the two core parts 13 are connected in sequence to form a first injection molding groove 11.

[0036] Specifically, for example Figure 2As shown, each core portion 13 includes three core segments 131. In this case, the rotor core 1 is formed by stacking a total of six core segments 131. The six core segments 131 are sequentially referred to as the first core segment, the second core segment, the third core segment, the fourth core segment, the fifth core segment and the sixth core segment in the axial direction. The first core segment is symmetrically arranged with the sixth core segment, the second core segment is symmetrically arranged with the fifth core segment, and the third core segment is symmetrically arranged with the fourth core segment. Accordingly, the through slots 132 on the first core segment are symmetrically arranged with the through slots 132 on the sixth core segment, the through slots 132 on the second core segment are symmetrically arranged with the through slots 132 on the fifth core segment, and the through slots 132 on the third core segment are symmetrically arranged with the through slots 132 on the fourth core segment. After injection molding is completed, the injection-molded segments in each through slot 132 are sequentially connected to form a first injection-molded body 21.

[0037] In this way, by designing the rotor core 1 to include two symmetrically arranged core parts 13, and designing the core part 13 to include multiple core segments 131, on the one hand, the rotor core 1 is formed by stacking multiple core segments 131, so that the rotor core 1 can be processed in sections, the production difficulty of the rotor core 1 can be reduced, and the production efficiency can be improved. On the other hand, the types of core segments 131 can be reduced, and the material management cost can be reduced. Moreover, by providing a through groove 132 on each core segment 131, and connecting the through grooves 132 of all the core segments 131 of the two core parts 13 in sequence to form a first injection molding groove 11, the first injection molding groove 11 can be processed in sections, thereby reducing the processing difficulty of the first injection molding groove 11.

[0038] Optionally, combined Figure 5 and Figure 6 As shown, in one core portion 13, the through slots 132 on two adjacent core segments 131 are staggered. The through slots 132 on two adjacent core segments 131 in one core portion 13 can be staggered along the circumferential or radial directions of the rotor core 1, without specific limitation. This allows the first injection molded body 21 filled in the first injection molding groove 11 to be formed from multiple staggered injection molding segments, creating a V-shaped structure. Furthermore, each two symmetrically arranged injection molding segments can clamp the core segment 131 located between them, thereby increasing the connection stiffness between the core segments 131 and further improving the overall stiffness of the rotor assembly.

[0039] Optionally, combined Figure 6As shown, the through slots 132 extend axially through the rotor core 1. That is, the central axis of the through slots 132 is parallel to the axis of the rotor core 1. In this case, the through slots 132 of all core segments 131 are sequentially connected axially. Compared to arranging the through slots 132 at an angle relative to the axial direction of the rotor core 1 or configuring the through slots 132 as a bent channel structure, this can shorten the extension length of the through slots 132 and, consequently, the first injection molding groove 11, thereby improving injection molding efficiency, reducing the amount of injection molding material used, and lowering production costs.

[0040] Optionally, combined Figure 4 As shown, the rotor core 1 is further provided with a plurality of weight-reducing holes 14 evenly distributed along its circumference. In this way, the weight-reducing holes 14 are utilized to further reduce the weight of the rotor core 1, ensuring that the rotor assembly meets the lightweight requirements.

[0041] A motor according to an embodiment of the present invention includes the rotor assembly described above.

[0042] The beneficial effects of the motor of this embodiment are the same as those of the above-mentioned rotor assembly and will not be described again here.

[0043] A vehicle according to an embodiment of the present invention includes the motor described above.

[0044] The beneficial effects of the vehicle of this embodiment are the same as those of the above-mentioned motor and will not be repeated here.

[0045] Although the present invention is disclosed as above, the protection scope of the present invention is not limited thereto. Those skilled in the art may make various changes and modifications without departing from the spirit and scope of the present invention, and these changes and modifications will fall within the protection scope of the present invention.

Claims

1. A rotor assembly, characterized in that: The invention comprises a rotor core (1), an injection molded part (2), a first end plate (3) and a second end plate (4), wherein the first end plate (3) and the second end plate (4) are respectively arranged at two axial ends of the rotor core (1); the rotor core (1) is provided with a first injection molding groove (11) penetrating its axial end surface, at least one of the first end plate (3) and the second end plate (4) is provided with a second injection molding groove (5) communicating with the first injection molding groove (11), and the injection molded part (2) is filled in the first injection molding groove (11) and the second injection molding groove (5).

2. The rotor assembly according to claim 1, characterized in that: An injection hole (6) is provided on the end surface of the first end plate (3) and / or the second end plate (4) provided with the second injection groove (5) away from the rotor core (1), and the injection hole (6) is communicated with the corresponding second injection groove (5).

3. The rotor assembly according to claim 1, characterized in that: The second injection groove (5) is extended in the axial direction.

4. The rotor assembly according to claim 1, characterized in that: The rotor core (1) is further provided with mounting grooves (12) for mounting permanent magnets, the number of the mounting grooves (12) being the same as the number of magnetic poles of the rotor core (1), and the first injection molding groove (11) is arranged correspondingly to the mounting groove (12), and the second injection molding groove (5) is arranged correspondingly to the first injection molding groove (11).

5. The rotor assembly according to claim 1, characterized in that: The notch of the first injection molding groove (11) close to one end of the second injection molding groove (5) is a first notch, and the notch of the second injection molding groove (5) close to one end of the first injection molding groove (11) is a second notch, the area of ​​the second notch is larger than the area of ​​the first notch, and the second notch covers the first notch.

6. The rotor assembly according to claim 1, characterized in that: The rotor core (1) comprises two symmetrically arranged core parts (13), each core part (13) comprises a plurality of core segments (131) stacked in an axial direction, each core segment (131) is provided with a through slot (132), and the through slots (132) of all the core segments (131) of the two core parts (13) are sequentially connected to form the first injection molding slot (11).

7. The rotor assembly according to claim 6, characterized in that: In one of the core parts (13), the through slots (132) on two adjacent core segments (131) are staggered.

8. The rotor assembly according to claim 6, characterized in that: The through groove (132) is arranged to penetrate along the axial direction.

9. A motor, characterized in that: Comprising a rotor assembly as described in any one of claims 1-8.

10. A vehicle, characterized in that: Comprising the motor as claimed in claim 9.

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