Punching sheet structure, motor and vehicle

Abstract

The invention discloses a punching sheet structure, a motor and a vehicle. The punching sheet structure comprises a stator punching sheet and a rotor punching sheet arranged in the stator punching sheet. Each tooth boot of the stator punching sheet is provided with a first auxiliary groove and a second auxiliary groove. A rotor excircle of the rotor punching sheet is provided with a third auxiliary groove, a fourth auxiliary groove and a fifth auxiliary groove. The first auxiliary slot is arranged at the intersection of the tooth center line of the stator tooth and the stator inner circle, and the second auxiliary slot is arranged between the tooth center line of the stator tooth and the slot center line of the stator slot; the third auxiliary groove is arranged at the intersection of the Q shaft and the outer circle of the rotor, the fourth auxiliary groove is arranged at the intersection of the D shaft and the outer circle of the rotor, and the fifth auxiliary groove is arranged between the third auxiliary groove and the fourth auxiliary groove. According to the invention, the electromagnetic force density and the torque ripple of the motor in the full rotating speed section can be greatly reduced, and the NVH performance of the motor is greatly improved.

Description

Technical Field

[0001] This invention relates to vehicle drive systems, specifically to a lamination structure, a motor, and a vehicle. Background Technology

[0002] In the field of new energy vehicles, range-extended hybrid electric vehicles (REEVs) utilize an engine combined with a P1 range extender generator to form the range-extending functional unit. The primary function of the P1 generator is to replenish the battery's charge when it is depleted, driven by the engine in high-efficiency operation, thus alleviating range anxiety caused by a depleted battery. The P1 generator requires high fuel-to-electric conversion efficiency to achieve lower engine fuel consumption and longer range; it also needs excellent NVH performance to provide a smoother and more comfortable experience closer to pure electric drive; and it must minimize the size and weight of the P1 generator to achieve a low-cost, lightweight design. Currently, the REEV market trend is positive. However, mainstream P1 generators, whether water-cooled or oil-cooled, have a maximum efficiency of ≤96%, and the motor suffers from excessive primary electromagnetic force, leading to breathing mode resonance and poor NVH. Furthermore, with the rapid growth of REEVs, range extender generators face cost reduction pressures, forcing motor manufacturers to sacrifice efficiency or NVH performance to reduce material costs, which hinders technological breakthroughs in motor development. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide a lamination structure, a motor and a vehicle that can significantly reduce the electromagnetic force density and torque pulsation of the motor across the entire speed range, and significantly improve the NVH performance of the motor.

[0004] A lamination structure according to the present invention includes a stator lamination and a rotor lamination disposed within the stator lamination; the stator lamination includes a stator yoke, and a plurality of stator teeth are evenly spaced along its circumference within the stator yoke, and a tooth shoe is provided on the side of each stator tooth near the inner circle of the stator; a stator slot is formed between the stator yoke and two adjacent stator teeth; the rotor lamination is provided with a central hole and a plurality of permanent magnet poles evenly disposed circumferentially outside the central hole, and the permanent magnet poles include permanent magnet slots and permanent magnets disposed within the permanent magnet slots;

[0005] Each of the toothed shoes is provided with a first auxiliary groove and a second auxiliary groove, and the outer circumference of the rotor lamination is provided with a third auxiliary groove, a fourth auxiliary groove and a fifth auxiliary groove;

[0006] The first auxiliary groove is located at the intersection of the center line of the stator tooth and the inner circle of the stator, and the second auxiliary groove is located between the center line of the stator tooth and the center line of the stator groove.

[0007] The third auxiliary slot is located at the intersection of the Q-axis and the outer circle of the rotor, the fourth auxiliary slot is located at the intersection of the D-axis and the outer circle of the rotor, and the fifth auxiliary slot is located between the third and fourth auxiliary slots; wherein, the Q-axis is the center line between two adjacent permanent magnets, and the D-axis is the radial center line of the permanent magnet.

[0008] Furthermore, the rotor lamination has two fifth auxiliary slots on each magnetic pole, and the two fifth auxiliary slots are symmetrically arranged on both sides of the D-axis. The angle between the midpoint of the two fifth auxiliary slots and the line connecting the center of the shaft hole is γ, and 0.2*(360° / P)≤γ≤0.95*(360° / P).

[0009] Where P is the number of magnetic poles, P = 2 * m, and m is an integer not less than 3.

[0010] Furthermore, both the permanent magnet groove and the permanent magnet are in the shape of an "I". The angle between the two ends of the permanent magnet on the side away from the axial hole and the line connecting the center of the axial hole is β, and 0.8*(360° / P)≤β≤0.9*(360° / P).

[0011] Furthermore, each of the toothed shoes has two second auxiliary grooves, and the two second auxiliary grooves are symmetrically arranged on both sides of the center line of the stator teeth; the angle between the midpoint of the two second auxiliary grooves and the line connecting the center of the stator is α, and α≤360° / S-φ;

[0012] Where S is the number of stator slots, S = 6 * n, n is an integer not less than 2, φ is the included angle of the stator slot opening, and the center of the stator circle coincides with the center of the shaft hole.

[0013] Furthermore, each of the stator slots is provided with two symmetrical shoulders about the center line of the slot. Both shoulders are protrusions that extend toward the center line of the slot and protrude from the stator slot.

[0014] Furthermore, the width of the stator slot is B, and the distance between the vertex of the shoulder and the centerline of the slot is L1; a slot opening is formed between two adjacent toothed shoes, the distance between the side of the slot opening facing closer to the stator yoke and the side of the stator slot facing closer to the stator yoke is the slot depth H, and the distance between the side of the slot opening facing closer to the stator yoke and the vertex of the shoulder is L2; ​​wherein, L1≤B / 2, L2≤H / 2.

[0015] Furthermore, a flat copper wire is arranged between the side of the slot facing closer to the stator yoke and the side of the stator slot facing closer to the stator yoke; no flat copper wire is arranged between the side of the slot facing closer to the stator yoke and the shoulder.

[0016] Furthermore, the outer contour of the shoulder is a continuous curve or multiple segments of straight lines connected in sequence; the first auxiliary groove, the second auxiliary groove, the third auxiliary groove, the fourth auxiliary groove and the fifth auxiliary groove are arc-shaped grooves, triangular grooves or polygonal grooves.

[0017] An electric motor according to the present invention includes the above-described lamination structure.

[0018] One type of vehicle according to the present invention includes the aforementioned motor.

[0019] The beneficial effects of this invention are:

[0020] (1) The present invention uses the design of opening the first auxiliary slot and the second auxiliary slot with the tooth shoe on the stator lamination, and the design of opening the third auxiliary slot, the fourth auxiliary slot and the fifth auxiliary slot on the rotor lamination. By rationally designing the slot shape, number and spatial position of the auxiliary slots, the motor using the lamination structure of the present invention can significantly reduce torque pulsation and cogging torque. Its core indicator, electromagnetic force density, breaks through the industry-leading level. At the same time, the NVH performance of the motor using the lamination structure of the present invention is greatly improved.

[0021] (2) The stator lamination of the present invention adopts a slot shoulder design, which extends the distance between the flat copper wire and the rotor, and at the same time shortens the height dimension of the flat copper wire in the radial direction, reduces the loss of the skin depth in the flat copper wire, thereby reducing the AC coefficient, reducing AC loss, and improving efficiency. Attached Figure Description

[0022] To make the objectives, technical solutions, and beneficial effects of this invention clearer, the following figures are provided for illustration:

[0023] Figure 1 This is a schematic diagram of the stator and rotor lamination structure of one of the magnetic poles of the present invention;

[0024] Figure 2 for Figure 1 Add structural schematic diagrams for the Q-axis, D-axis, tooth centerline, and groove centerline;

[0025] Figure 3 This is a schematic diagram of the stator lamination for one of the magnetic poles of the present invention;

[0026] Figure 4 for Figure 1 Add a structural diagram with Q-axis, D-axis, tooth centerline, groove centerline, and angle annotations;

[0027] Figure 5 This is a schematic diagram of the structure of a rotor lamination for one of the magnetic poles of the present invention;

[0028] Figure 6 for Figure 1Add a structural diagram with Q-axis, D-axis, and angle annotations;

[0029] Figure 7 Simulation data diagrams showing the amount of copper used and the highest efficiency of the motor applying the lamination structure of this invention;

[0030] Figure 8 Simulation data diagram of electromagnetic force density of motor using the lamination structure of the present invention;

[0031] Figure 9 The image shows simulation data of the noise of a motor using the lamination structure of this invention at different speeds.

[0032] The following labels are shown in the attached diagram:

[0033] 1-Stator lamination, 101-Stator yoke, 102-Stator tooth, 103-Tooth shoe, 104-Stator slot, 105-Flat copper wire, 106-First auxiliary slot, 107-Second auxiliary slot, 108-Shoulder, 109-Tooth center line, 110-Slot center line;

[0034] 2-Rotor lamination, 201-Shaft hole, 202-Permanent magnet slot, 203-Permanent magnet, 204-Third auxiliary slot, 205-Fourth auxiliary slot, 206-Fifth auxiliary slot. Detailed Implementation

[0035] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0036] like Figures 1-6 As shown, this embodiment presents a lamination structure applied to a 72-slot 24-pole motor. The lamination structure includes a stator lamination 1 and a rotor lamination 2 disposed within the stator lamination 1. The stator lamination 1 includes a stator yoke 101, with multiple stator teeth 102 evenly spaced along its circumference. A toothed shoe 103 is provided on the side of each stator tooth 102 closest to the inner circle of the stator. A stator slot 104 is formed between the stator yoke 101 and two adjacent stator teeth 102. The rotor lamination 2 has a central hole 201 and multiple permanent magnet poles evenly arranged circumferentially outside the central hole 201. Each permanent magnet pole includes a permanent magnet slot 202 and a permanent magnet 203 disposed within the permanent magnet slot 202.

[0037] Each of the toothed shoe 103 is provided with a first auxiliary groove 106 and a second auxiliary groove 107, and the rotor outer circle of the rotor lamination 2 is provided with a third auxiliary groove 204, a fourth auxiliary groove 205 and a fifth auxiliary groove 206.

[0038] The first auxiliary groove 106 is disposed at the intersection of the tooth center line 109 of the stator tooth 102 and the inner circle of the stator, and the second auxiliary groove 107 is disposed between the tooth center line 109 of the stator tooth 102 and the groove center line 110 of the stator groove 104.

[0039] The third auxiliary groove 204 is located at the intersection of the Q-axis and the outer circle of the rotor, the fourth auxiliary groove 205 is located at the intersection of the D-axis and the outer circle of the rotor, and the fifth auxiliary groove 206 is located between the third auxiliary groove 204 and the fourth auxiliary groove 205; wherein, the Q-axis is the center line between two adjacent permanent magnets 203, and the D-axis is the radial center line of the permanent magnet 203.

[0040] In this embodiment, the rotor lamination 2 has two fifth auxiliary slots 206 on each magnetic pole. The two fifth auxiliary slots 206 are symmetrically arranged on both sides of the D-axis. The angle between the midpoint of the two fifth auxiliary slots 206 and the center of the rotor is γ, and 0.2*(360° / P)≤γ≤0.95*(360° / P), preferably 0.35*(360° / P)≤γ≤0.8*(360° / P); where P is the number of magnetic poles, P=2*m, and m is an integer not less than 3. When P=24, 3°≤γ≤14.25°, and γ is preferably 5.25°-12°, for example, γ can be 7°, 10°, 12°, etc.

[0041] In this embodiment, both the permanent magnet slot 202 and the permanent magnet 203 are in the shape of an "I". The angle between the two ends of the permanent magnet 203 on the side away from the axial hole 201 and the line connecting the center of the axial hole 201 is β, and 0.8*(360° / P)≤β≤0.9*(360° / P). When P=24, 12°≤β≤13.5°, for example, β can be 12.5°, 12.7°, 13°, etc.

[0042] In this embodiment, each of the toothed shoes 103 has two second auxiliary grooves 107, and the two second auxiliary grooves 107 are symmetrically arranged on both sides of the tooth centerline 109 of the stator tooth 102; the angle between the midpoint of the two second auxiliary grooves 107 and the line connecting the stator center is α, and α≤360° / S-φ; where S is the number of stator grooves 104, S=6*n, n is an integer not less than 2, φ is the groove opening angle of the stator groove 104, and the stator center coincides with the center of the axial hole 201. The groove opening of the stator groove 104 is formed between two adjacent toothed shoes 103, so the groove opening angle of the stator groove 104 is the angle between the facing sides of two adjacent toothed shoes 103. When S=72, α≤5-φ, if φ=1°, then α≤4, and α can be 2°, 3°, etc.

[0043] In this embodiment, the first auxiliary groove 106, the second auxiliary groove 107, the third auxiliary groove 204, the fourth auxiliary groove 205 and the fifth auxiliary groove 206 are arc-shaped grooves, triangular grooves or polygonal grooves. Preferably, each auxiliary groove is an arc-shaped groove, and secondly preferably, each auxiliary groove is a triangular groove.

[0044] The depth and width of the recesses in the first auxiliary groove 106, the second auxiliary groove 107, the third auxiliary groove 204, the fourth auxiliary groove 205, and the fifth auxiliary groove 206 are not limited.

[0045] The stator lamination 1 employs a design with a first auxiliary slot 106 and a second auxiliary slot 107 formed by a toothed shoe 103. This, combined with the third auxiliary slot 204, fourth auxiliary slot 205, and fifth auxiliary slot 206 formed on the rotor lamination 2, demonstrates a significant reduction in torque pulsation and cogging torque in the motor using this lamination structure through a rational design of the slot shape, number, and spatial arrangement. Its core indicator, electromagnetic force density, surpasses industry-leading levels. Simulation analysis further supports this. Figure 8 The horizontal axis represents the motor speed (in rpm), and the vertical axis represents the electromagnetic force density (in N / m³). 2 The blue line graph shows the simulation data of the 72nd order electromagnetic force density of the motor using the lamination structure of this embodiment at different speeds, and the red line graph shows the simulation data of the 144th order electromagnetic force density of the motor using the lamination structure of this embodiment at different speeds. Figure 8 As shown, the stator auxiliary slots combined with the rotor auxiliary slots can achieve a breathing mode of <800 N / m. 2 (lower than the industry standard of 1500 N / m) 2 The non-breathing mode is less than 2500 N / m. 2 (lower than the industry standard of 3000 N / m) 2 This effectively suppresses the excitation source and improves NVH (Noise, Vibration, and Harshness). Simultaneously, the NVH performance of the motor using the lamination structure of this embodiment is significantly improved, as demonstrated by simulation analysis of the direct performance indicator, noise. Figure 9 The horizontal axis represents motor speed (rpm), and the vertical axis represents noise level (dB). The blue line graph shows the simulation data of noise at different speeds for a 72nd-order motor using the lamination structure of this embodiment; the red line graph shows the simulation data of noise at different speeds for a 144th-order motor using the lamination structure of this embodiment; and the yellow line graph shows the composite simulation data of noise at different orders for the motor using the lamination structure of this embodiment at different speeds. Figure 9As shown, the industry standard for range-extended P1 motors is ≥75dB. The motor using the lamination structure of this embodiment achieves a maximum noise level of ≤72dB, with localized speed range noise below 65dB, demonstrating significant improvement and greatly enhancing product competitiveness. Therefore, the motor using the lamination structure of this embodiment can minimize electromagnetic force density and torque ripple across the entire speed range, maximizing NVH performance.

[0046] In this embodiment, each stator slot 104 is provided with two shoulders 108 symmetrical about the slot centerline 110. Both shoulders 108 are protruding structures that extend toward the slot centerline 110 and protrude from the stator slot 104.

[0047] The stator lamination 1 adopts an in-slot shoulder 108 design, which extends the distance between the flat copper wire 105 and the rotor, while shortening the radial height of the flat copper wire 105 and reducing the skin depth. The loss within the flat copper wire 105 is reduced, thereby lowering the AC coefficient, reducing AC losses, and improving efficiency. The permanent magnet 203 of the rotor lamination 2 adopts an "I" shape with a larger pole arc coefficient. Combined with the optimized design of the magnetic isolation bridge, and the shoulder 108 design within the stator slot 104, the amount of flat copper wire 105 used is reduced, saving core design costs while maintaining high-performance output. Among these, the skin depth... Π is taken as 3.14, f is the magnetic field frequency, μ is the magnetic permeability, and σ is the electrical conductivity.

[0048] In this embodiment, the width of the stator slot 104 is B, and the distance between the vertex of the shoulder 108 and the centerline 110 of the slot is L1; a slot opening of the stator slot 104 is formed between two adjacent toothed shoes 103, and the distance between the side of the slot opening facing the stator yoke 101 and the side of the stator slot 104 facing the stator yoke 101 is the slot depth H, and the distance between the side of the slot opening facing the stator yoke 101 and the vertex of the shoulder 108 is L2; ​​wherein, L1≤B / 2, L2≤H / 2, preferably L1≤B / 5, L2≤H / 5, for example, L1 can be B / 6, B / 9, etc., and L2 can be H / 6, H / 9, etc.

[0049] In this embodiment, the space for storing the flat copper wire 105 in the motor with the lamination structure is reduced from B*H to B*(H-L2). The radial height of each of the 8 layers of flat copper wire 105 is reduced by (H-L2) / 8, improving the current distribution of high-frequency current inside the flat copper wire 105, thereby achieving higher efficiency with lower copper consumption. Simulation analysis shows that... Figure 7The left vertical axis represents the amount of copper used (in kg), and the right vertical axis represents the maximum efficiency. The left bar chart shows the amount of copper used in a conventional motor (without a shoulder), and the right bar chart shows the amount of copper used in a motor using the lamination structure of this embodiment. The left end of the line graph shows the maximum efficiency of a conventional motor (without a shoulder), and the right end of the line graph shows the maximum efficiency of a motor using the lamination structure of this embodiment. Figure 7 As shown, the highest efficiency increased from 95.9% to 96.2%, and the amount of copper used decreased from 4 kg to 3.6 kg.

[0050] In this embodiment, a flat copper wire 105 is arranged between the side of the slot facing closer to the stator yoke 101 and the side of the stator slot 104 facing closer to the stator yoke 101; no flat copper wire 105 is arranged between the side of the slot facing closer to the stator yoke 101 and the shoulder 108.

[0051] In this embodiment, the outer contour of the shoulder 108 is a continuous curve or multiple straight lines connected in sequence.

[0052] One type of motor in this embodiment includes the above-described lamination structure. The motor can be a range extender generator or a motor for other purposes.

[0053] One vehicle in this embodiment includes the aforementioned electric motor. The vehicle can be a range-extended hybrid electric vehicle or a vehicle with other power types.

[0054] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A lamination structure, comprising a stator lamination and a rotor lamination disposed within the stator lamination; the stator lamination includes a stator yoke, wherein a plurality of stator teeth are uniformly spaced along its circumferential direction within the stator yoke, and a toothed shoe is provided on the side of each stator tooth near the inner circle of the stator, and a stator slot is formed between the stator yoke and two adjacent stator teeth; the rotor lamination is provided with a central hole and a plurality of permanent magnet poles uniformly disposed circumferentially outside the central hole, wherein each permanent magnet pole includes a permanent magnet slot and a permanent magnet disposed within the permanent magnet slot; Its features are: Each of the toothed shoes is provided with a first auxiliary groove and a second auxiliary groove, and the outer circumference of the rotor lamination is provided with a third auxiliary groove, a fourth auxiliary groove and a fifth auxiliary groove; The first auxiliary groove is located at the intersection of the center line of the stator tooth and the inner circle of the stator, and the second auxiliary groove is located between the center line of the stator tooth and the center line of the stator groove. The third auxiliary slot is located at the intersection of the Q-axis and the outer circle of the rotor, the fourth auxiliary slot is located at the intersection of the D-axis and the outer circle of the rotor, and the fifth auxiliary slot is located between the third and fourth auxiliary slots; wherein, the Q-axis is the center line between two adjacent permanent magnets, and the D-axis is the radial center line of the permanent magnet.

2. The lamination structure according to claim 1, characterized in that: The rotor lamination has two fifth auxiliary slots on each magnetic pole. The two fifth auxiliary slots are symmetrically arranged on both sides of the D-axis. The angle between the midpoint of the two fifth auxiliary slots and the line connecting the center of the shaft hole is γ, and 0.2*(360° / P)≤γ≤0.95*(360° / P). Where P is the number of magnetic poles, P = 2 * m, and m is an integer not less than 3.

3. The lamination structure according to claim 2, characterized in that: Both the permanent magnet groove and the permanent magnet are in the shape of an "I". The angle between the two ends of the permanent magnet on the side away from the axial hole and the line connecting the center of the axial hole is β, and 0.8*(360° / P)≤β≤0.9*(360° / P).

4. The lamination structure according to claim 1, characterized in that: Each of the toothed shoes has two second auxiliary grooves, and the two second auxiliary grooves are symmetrically arranged on both sides of the center line of the stator tooth; the angle between the midpoint of the two second auxiliary grooves and the line connecting the center of the stator is α, and α≤360° / S-φ; Where S is the number of stator slots, S=6*n, n is an integer not less than 2, φ is the included angle of the stator slot opening, and the center of the stator circle coincides with the center of the shaft hole.

5. The lamination structure according to claim 4, characterized in that: Each of the stator slots is provided with two symmetrical shoulders about the center line of the slot. Both shoulders are protrusions that extend toward the center line of the slot and protrude from the stator slot.

6. The lamination structure according to claim 5, characterized in that: The width of the stator slot is B, and the distance between the vertex of the shoulder and the center line of the slot is L1; a slot opening is formed between two adjacent toothed shoes, the distance between the side of the slot opening facing closer to the stator yoke and the side of the stator slot facing closer to the stator yoke is the slot depth H, and the distance between the side of the slot opening facing closer to the stator yoke and the vertex of the shoulder is L2; ​​wherein, L1≤B / 2, L2≤H / 2.

7. The lamination structure according to claim 6, characterized in that: Flat copper wires are arranged between the side of the slot facing closer to the stator yoke and the side of the stator slot facing closer to the stator yoke; no flat copper wires are arranged between the side of the slot facing closer to the stator yoke and the shoulder.

8. The lamination structure according to claim 6, characterized in that: The outer contour of the shoulder is a continuous curve or multiple segments of straight lines connected in sequence; the first auxiliary groove, the second auxiliary groove, the third auxiliary groove, the fourth auxiliary groove and the fifth auxiliary groove are arc-shaped grooves, triangular grooves or polygonal grooves.

9. An electric motor, characterized in that: Includes the lamination structure as described in any one of claims 1-8.

10. A vehicle, characterized in that: Includes the motor as described in claim 9.

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