Magnet rotor assembly with deformable end ring

Abstract

A magnet rotor assembly includes a rotor core having a rotor core length along a longitudinal axis. A plurality of partial abrasive magnets are disposed within the rotor core at partial abrasive magnet locations having a magnet length extending along the longitudinal axis, a first partial abrasive magnet end, and a second partial abrasive magnet end. A deformable end ring is disposed at an end of the rotor core to retain a portion of the abrasive magnet within the rotor core. The deformable end ring includes a plurality of deformable regions. Each of the deformable regions corresponds to a partial abrasive magnet position. The partial abrasive magnets have associated magnet lengths that are greater than the rotor core length, and partial abrasive magnet ends of the partial abrasive magnets abut against the first deformable region of the deformable end ring, thereby causing deformation of the first deformable region.

Description

Technical Field

[0001] The technical field generally relates to rotor assemblies, and more specifically to magnet rotor assemblies with deformable end rings. Background Technology

[0002] Magnet rotor assemblies typically consist of high-energy magnets with high coercivity and low-energy magnets with low coercivity. The magnets are housed within the rotor core of the magnet rotor assembly. An example of a low-energy magnet is a ferrite magnet. Completely grinding the ends of the low-energy magnets so that their ends are flush with the end faces of the rotor core can be a significant factor in the resource consumption of the low-energy magnet manufacturing process.

[0003] Accordingly, it is desirable to provide a magnet rotor assembly with deformable end rings. Other desirable features and characteristics will become apparent from the accompanying drawings and the foregoing technical and background information, based on the following detailed description and the appended claims. Summary of the Invention

[0004] A magnet rotor assembly includes: a rotor core having a rotor core length along a longitudinal axis; a plurality of partially ground magnets disposed within the rotor core at a plurality of partially ground magnet positions, each of the plurality of partially ground magnets having an associated magnet length extending along the longitudinal axis, a first partially ground magnet end, and a second opposing partially ground magnet end; and a first deformable end ring disposed at a first end of the rotor core to retain the plurality of partially ground magnets within the rotor core. The first deformable end ring includes a plurality of first deformable regions, each of the plurality of first deformable regions corresponding to one of the plurality of partially ground magnet positions. The first partially ground magnets of the plurality of partially ground magnets have an associated magnet length greater than the rotor core length, and the first partially ground magnet end of the first partially ground magnet abuts against a first deformable region of the plurality of first deformable regions of the first deformable end ring, thereby causing deformation of the first deformable region of the first deformable end ring.

[0005] In at least one embodiment, the magnet rotor assembly further includes a second deformable end ring disposed at a second end of the rotor core to engage with the first deformable end ring, thereby retaining a plurality of partially polished magnets within the rotor core. The second deformable end ring includes a plurality of second deformable regions, each corresponding to one of the plurality of partially polished magnet locations. A second partially polished magnet among the plurality of partially polished magnets has an associated magnet length greater than the length of the rotor core, and the end of the second partially polished magnet abuts against a first deformable region within the plurality of second deformable regions of the second deformable end ring, thereby causing deformation of the first deformable region of the second deformable end ring.

[0006] In at least one embodiment, the magnet rotor assembly further includes a plurality of fully polished magnets disposed at a plurality of fully polished magnet locations within the rotor core. Each of the plurality of fully polished magnets has an associated magnet length extending along a longitudinal axis equal to the length of the rotor core, a first fully polished magnet end, and a second opposing fully polished magnet end. A first deformable end ring includes a non-deformable region, and the first fully polished magnet ends of the plurality of fully polished magnets are positioned adjacent to the non-deformable region of the first deformable ring.

[0007] In at least one embodiment, the non-deformable region has a first thickness, and each of the plurality of first deformable regions has a second thickness, the first thickness being greater than the second thickness.

[0008] In at least one embodiment, each of the plurality of first deformable regions of the first deformable ring has at least one partial cutout extending into the first deformable end ring.

[0009] In at least one embodiment, each of the plurality of first deformable regions of the first deformable ring has at least one through-hole extending through the first deformable end ring.

[0010] In at least one embodiment, each of the plurality of first deformable regions of the first deformable ring is a cantilever beam.

[0011] In at least one embodiment, each of the plurality of first deformable regions includes a cavity with a depth that is the difference between the rotor core length and the maximum permissible magnet length of the plurality of partially ground magnets.

[0012] In at least one embodiment, the first deformable end ring includes a plurality of closed-cell foam caps, each of which is disposed in a corresponding one of a plurality of first deformable regions, and the first part of the grinding magnet abuts against the first closed-cell foam cap disposed in the first deformable region of the plurality of deformable regions of the first deformable end ring, thereby causing deformation of the first deformable region.

[0013] In at least one embodiment, a plurality of partially polished magnets have a first coercivity, and a plurality of fully polished magnets have a second coercivity, the second coercivity being higher than the first coercivity.

[0014] In at least one embodiment, the magnet rotor assembly further includes at least one of a shim, a spring, and an elastomeric material disposed in at least one of the plurality of first deformable regions, and a third partial grinding magnet of the plurality of partial grinding magnets has an associated magnet length less than the length of the rotor core, and a first partial grinding magnet end of the third partial grinding magnet abuts against at least one of the shim, spring, and elastomeric material disposed on at least one of the plurality of first deformable regions to maintain the positioning of the third partial grinding magnet within the rotor core.

[0015] In at least one embodiment, the rotor core includes a plurality of poles, and the number of the plurality of first deformable regions is equal to the number of the plurality of poles.

[0016] In at least one embodiment, the plurality of partially ground magnets are ferrite magnets.

[0017] An integrated permanent magnet motor including a magnet rotor assembly includes: a stator assembly and a magnet rotor assembly rotatable relative to the stator assembly. The magnet rotor assembly includes: a rotor core having a rotor core length along a longitudinal axis; a plurality of partially ground magnets disposed at a plurality of partially ground magnet positions within the rotor core, each of the plurality of partially ground magnets having an associated magnet length extending along the longitudinal axis, a first partially ground magnet end, and a second opposing partially ground magnet end; and a first deformable end ring disposed at a first end of the rotor core to retain the plurality of partially ground magnets within the rotor core. The first deformable end ring includes a plurality of first deformable regions, each of the plurality of first deformable regions corresponding to one of the plurality of partially ground magnet positions. The first partially ground magnets of the plurality of partially ground magnets have an associated magnet length greater than the rotor core length, and the first partially ground magnet end of the first partially ground magnet abuts against a first deformable region of the plurality of first deformable regions of the first deformable end ring, thereby causing deformation of the first deformable region of the first deformable end ring.

[0018] In at least one embodiment, the built-in permanent magnet motor further includes a plurality of fully ground magnets disposed at a plurality of fully ground magnet locations within the rotor core, each of the plurality of fully ground magnets having an associated magnet length equal to the length of the rotor core extending along a longitudinal axis, a first fully ground magnet end, and a second opposing fully ground magnet end. A first deformable end ring includes a non-deformable region, and the first fully ground ends of the plurality of fully ground magnets are positioned adjacent to the non-deformable region of the first deformable ring.

[0019] In at least one embodiment, the non-deformable region has a first thickness, and each of the plurality of first deformable regions has a second thickness, the first thickness being greater than the second thickness.

[0020] In at least one embodiment, each of the plurality of first deformable regions of the first deformable ring has at least one partial cutout extending into the first deformable end ring.

[0021] In at least one embodiment, each of the plurality of first deformable regions of the first deformable ring has at least one through-hole extending through the first deformable end ring.

[0022] In at least one embodiment, each of the plurality of first deformable regions of the first deformable ring is a cantilever beam.

[0023] A vehicle including a built-in permanent magnet motor includes: a stator assembly and a magnet rotor assembly rotatable relative to the stator assembly. The magnet rotor assembly includes: a rotor core having a rotor core length along a longitudinal axis; a plurality of partially ground magnets disposed at a plurality of partially ground magnet positions within the rotor core, each of the plurality of partially ground magnets having an associated magnet length extending along the longitudinal axis, a first partially ground magnet end, and a second opposing partially ground magnet end; and a first deformable end ring disposed at a first end of the rotor core to retain the plurality of partially ground magnets within the rotor core. The first deformable end ring includes a plurality of first deformable regions, each of the plurality of first deformable regions corresponding to one of the plurality of partially ground magnet positions. The first partially ground magnets of the plurality of partially ground magnets have an associated magnet length greater than the rotor core length, and the first partially ground magnet end of the first partially ground magnet abuts against a first deformable region of the plurality of first deformable regions of the first deformable end ring, thereby causing deformation of the first deformable region of the first deformable end ring. Attached Figure Description

[0024] Exemplary embodiments will now be described in conjunction with the following figures, wherein the same numerals denote the same elements, and wherein:

[0025] Figure 1 It is a functional block diagram of a vehicle including a built-in permanent magnet motor according to at least one embodiment;

[0026] Figure 2 This is a functional block diagram of a built-in permanent magnet motor according to at least one embodiment;

[0027] Figure 3 It is a functional block diagram of a side view of the rotor core of a magnet rotor assembly according to at least one embodiment;

[0028] Figure 4 This is an exemplary illustration of a magnet rotor assembly according to at least one embodiment, the magnet rotor assembly including a deformable end ring, the deformable end ring including a plurality of deformable regions;

[0029] Figure 5 It is a functional block diagram representation of a deformable end ring including multiple thinned deformable regions according to at least one embodiment;

[0030] Figure 6 It is a functional block diagram representation of a deformable end ring including multiple deformable regions according to at least one embodiment;

[0031] Figure 7 It is a functional block diagram representation of a deformable end ring comprising multiple deformable regions in the form of a cantilever beam, according to at least one embodiment;

[0032] Figure 8 This is a functional block diagram representation of a deformable end ring including multiple closed-cell foam caps according to at least one embodiment; and

[0033] Figure 9 It is a functional block diagram of a side view of the end of a portion of a grinding magnet adjacent to and abutting a closed-cell foam cover according to at least one embodiment. Detailed Implementation

[0034] The following detailed description is merely exemplary in nature and is not intended to limit application and use. Furthermore, it is not intended to be bound by any express or implied theory presented in the foregoing technical field, background art, summary of the invention, or the following detailed description. As used herein, the term module refers to an application-specific integrated circuit (ASIC), electronic circuitry, a processor (shared, dedicated, or grouped) and memory executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components providing the described functionality.

[0035] This document describes embodiments of the present disclosure in terms of functional and / or logical block components and various processing steps. It should be understood that such block components can be implemented by any number of hardware, software, and / or firmware components configured to perform specified functions. For example, embodiments of the present disclosure can employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, etc., which can perform various functions under the control of one or more microprocessors or other control devices. Furthermore, those skilled in the art will understand that embodiments of the present disclosure can be practiced in combination with any number of systems, and the systems described herein are merely exemplary embodiments of the present disclosure.

[0036] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the system (and its various operating components) are not described in detail herein. Furthermore, the connecting lines shown in the various figures included herein are intended to illustrate exemplary functional relationships and / or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of this disclosure.

[0037] refer to Figure 1 This diagram illustrates a functional block diagram of a vehicle including a built-in permanent magnet motor 100 according to at least one embodiment. The vehicle 10 typically includes a chassis 12, a body 14, front wheels 16, and rear wheels 18. Although the vehicle 10 is described as a passenger car in the illustrated embodiment, the vehicle 10 can be other types of vehicles, including trucks, sport utility vehicles (SUVs), and recreational vehicles (RVs).

[0038] In various embodiments, the body 14 is arranged on the chassis 12 and substantially surrounds the components of the vehicle 10. The body 14 and the chassis 12 may together form a frame. The wheels 16-18 are each rotatably coupled to the chassis 12 near a corresponding corner of the body 14.

[0039] In various embodiments, vehicle 10 is an autonomous or semi-autonomous vehicle that is automatically controlled to transport passengers and / or goods from one place to another. For example, in an exemplary embodiment, vehicle 10 is a so-called Level 2, Level 3, Level 4, or Level 5 automation system. Level 2 automation means that the vehicle assists the driver in various driving tasks under the supervision of the driver. Level 3 automation means that the vehicle can take over all driving functions in certain situations. All major functions are automatic, including braking, steering, and acceleration. At this level, the driver can completely let go until the vehicle otherwise informs the driver. Level 4 system indicates “high automation”, referring to the driving mode-specific performance of the automated driving system for all aspects of dynamic driving tasks, even if the human driver does not respond appropriately to intervention requests. Level 5 system indicates “full automation”, referring to the full-time performance of the automated driving system for all aspects of dynamic driving tasks under all road and environmental conditions that can be managed by a human driver.

[0040] As shown in the figure, vehicle 10 typically includes a propulsion system 20, a drivetrain 22, a steering system 24, a braking system 26, a sensor system 28, an actuator system 30, at least one data storage device 32, at least one controller 34, and a communication system 36. The controller 34 is configured to implement an automated driving system (ADS). The propulsion system 20 is configured to generate power to propel the vehicle. In various embodiments, the propulsion system 20 may include an integrated permanent magnet motor 100 (also referred to as an integrated permanent magnet motor), such as a traction motor, a fuel cell propulsion system, and / or any other type of propulsion configuration. The integrated permanent magnet motor 100 includes a magnet rotor assembly. The magnet rotor assembly includes deformable end rings. The drivetrain 22 is configured to transmit power from the propulsion system 20 to the wheels 16-18 according to a selectable speed ratio. According to various embodiments, the drivetrain 22 may include a step-ratio automatic transmission, a continuously variable transmission (CVT), or other suitable transmission. The braking system 26 is configured to provide braking torque to the wheels 16-18. In various embodiments, braking system 26 may include friction brakes, brake-by-wire brakes, regenerative braking systems such as motors, and / or other suitable braking systems.

[0041] Steering system 24 is configured to influence the positioning of wheels 16. Although depicted for illustrative purposes as including a steering wheel and steering column, in some embodiments contemplated within the scope of this disclosure, steering system 24 may not include a steering wheel and / or steering column. Steering system 24 includes a steering column coupled to axle 50 associated with the front wheels 16 via, for example, a rack and pinion or other mechanism (not shown). Alternatively, steering system 24 may include a steer-by-wire system comprising an actuator associated with each of the front wheels 16.

[0042] The sensor system 28 includes one or more sensing devices 40a-40n that sense observable conditions of the external and / or internal environments of the vehicle 10. The sensing devices 40a-40n may include, but are not limited to, radar, lidar, global positioning system, optical camera, thermal imager, ultrasonic sensor, steering wheel sensor, and / or other sensors.

[0043] The vehicle dynamics sensor provides vehicle dynamics data including longitudinal velocity, yaw rate, lateral acceleration, and longitudinal acceleration. The vehicle dynamics sensor may include wheel sensors that measure information relating to one or more wheels of the vehicle 10. In one embodiment, the wheel sensors include wheel velocity sensors coupled to each of the wheels 16-18 of the vehicle 10. Furthermore, the vehicle dynamics sensor may include one or more accelerometers (provided as part of an inertial measurement unit (IMU)) that measure information relating to the acceleration of the vehicle 10. In various embodiments, the accelerometers measure one or more acceleration values ​​of the vehicle 10, including lateral and longitudinal acceleration and yaw rate. In at least one embodiment, the vehicle dynamics sensor provides vehicle movement data.

[0044] The actuator system 30 includes one or more actuator devices 42a-42n that control one or more vehicle features, such as, but not limited to, one or more wheels 16-18, a propulsion system 20, a transmission system 22, a steering system 24, and a braking system 26. In various embodiments, vehicle features may also include interior and / or exterior vehicle features, such as, but not limited to, doors, trunks, and cabin features (not numbered) such as air, music, lighting, etc.

[0045] Communication system 36 is configured to wirelessly communicate information to and from other entities, such as, but not limited to, other vehicles (“V2V” communication), infrastructure (“V2I” communication), remote systems, and / or personal devices. In an exemplary embodiment, communication system 36 is a wireless communication system configured to communicate via a wireless local area network (WLAN) using the IEEE 802.11 standard or by using cellular data communication. However, additional or alternative communication methods (such as dedicated short-range communication (DSRC) channels) are also considered to be within the scope of this disclosure. A DSRC channel refers to a one-way or two-way short-to-medium-range wireless communication channel specifically designed for automotive use and with a corresponding set of protocols and standards.

[0046] Data storage device 32 stores data for use in the ADS of vehicle 10. In various embodiments, data storage device 32 stores a defined map of the navigable environment. In various embodiments, the defined map may be predefined by and obtained from a remote system. For example, the defined map may be assembled by a remote system and communicated to vehicle 10 (wirelessly and / or via wire) and stored in data storage device 32. It is understood that data storage device 32 may be part of controller 34, separate from controller 34, or part of controller 34 and a separate system.

[0047] The controller 34 includes at least one processor 44 and a computer-readable storage device or medium 46. The processor 44 may be any custom or commercially available processor, central processing unit (CPU), graphics processing unit (GPU), auxiliary processor among several processors associated with the controller 34, semiconductor-based microprocessor (in the form of a microchip or chipset), macroprocessor, any combination thereof, or any device generally used for executing instructions. The computer-readable storage device or medium 46 may include volatile and non-volatile memory such as read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operational variables when the processor 44 is powered off. The computer-readable storage device or medium 46 may be implemented using any of several known memory devices such as PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combined memory device capable of storing data (some of which represent executable instructions used by the controller 34 to control the vehicle 10).

[0048] The instructions may include one or more separate programs, each comprising an ordered list of executable instructions for implementing logical functions. When executed by processor 44, the instructions receive and process signals from sensor system 28, execute logic, calculations, methods, and / or algorithms for automatically controlling components of vehicle 10, and generate control signals to actuator system 30 based on the logic, calculations, methods, and / or algorithms to automatically control components of vehicle 10. Although in Figure 1 Only one controller 34 is shown, but embodiments of vehicle 10 may include any number of controllers 34 that communicate via any suitable communication medium or combination of communication media and cooperate to process sensor signals, perform logic, calculations, methods and / or algorithms, and generate control signals to automatically control the features of vehicle 10. In various embodiments, the controllers(s) 34 are configured to implement ADS.

[0049] refer to Figure 2 A functional block diagram of an embedded permanent magnet motor 100 according to at least one embodiment is shown. The embedded permanent magnet motor 100 includes a housing 102. A stator assembly 104 and a magnet rotor assembly 106 are disposed within the housing 102. The magnet rotor assembly 106 is disposed within a central opening of the stator assembly 104 and is rotatable relative to the stator assembly 104. A longitudinal axis 108 extends along the length of the rotor core of the magnet rotor assembly 106. The magnet rotor assembly 106 includes a rotor core and a plurality of partially ground magnets and fully ground magnets disposed within the rotor core. The magnet rotor assembly 106 includes two deformable end rings disposed at both ends of the rotor core.

[0050] refer to Figure 3 This diagram shows a functional block diagram of a side view of the rotor core 300 of a magnet rotor assembly 106 according to at least one embodiment. The rotor core 300 may also be referred to as a rotor stack. The rotor core 300 includes a plurality of partially ground magnets 302a, 302b, 302c, 302d and a plurality of fully ground magnets 304a, 304b. The partially ground magnets 302a, 302b, 302c, 302d are disposed at partially ground magnet locations within the rotor core 300. The fully ground magnets 304a, 304b are disposed at fully ground magnet locations within the rotor core 300.

[0051] In at least one embodiment, the partially polished magnet is a low-energy magnet, while the fully polished magnet is a high-energy magnet. High-energy magnets have higher coercivity than low-energy magnets. Examples of low-energy magnets are ferrite magnets. Examples of high-energy magnets include, but are not limited to, samarium-cobalt magnets, neodymium magnets, high-energy-density permanent magnets, and rare-earth permanent magnets.

[0052] The rotor core 300 has a rotor core length 308. The rotor core length 308 extends along the longitudinal axis 108. Fully ground magnets 304a and 304b have fully ground magnet ends. The fully ground magnet ends are flush with the end faces of the rotor core 300. Each of the fully ground magnets 304a and 304b has a magnet length extending along the longitudinal axis 108. The magnet length of the fully ground magnets 304a and 304b is equal to the rotor core length 308.

[0053] Partially ground magnets 302a, 303b, 302c, and 302d have partially ground magnet ends. Each of the partially ground magnets 302a, 303b, 302c, and 302d has a magnet length extending along the longitudinal axis 108. One or more of the partially ground magnets 302a, 303b, and 302d have a magnet length greater than the rotor core length 308. In at least one embodiment, one or more of the partially ground magnets 302c have a magnet length less than the rotor core length 308. The grinding process for partially grinding low-energy magnets produces partially ground magnets 302a, 303b, 302c, and 302d that can have different lengths. The different lengths of the partially ground magnets 302a, 303b, 302c, and 302d produced by the partial grinding process are unpredictable.

[0054] Although Figure 3 The rotor core 300 is shown as comprising four partially ground magnets 302a, 303b, 302c, and 302d, but alternative embodiments of the rotor core 300 may include more or fewer partially ground magnets. Although Figure 3The rotor core 300 is shown to include two fully polished magnets 304a, 304b, but alternative embodiments of the rotor core 300 may include more or fewer fully polished magnets.

[0055] refer to Figure 4 An exemplary illustration of a magnet rotor assembly 106 according to at least one embodiment is shown. The magnet rotor assembly includes two deformable end rings 400a and 400b, each deformable end ring including a plurality of deformable regions 402. A rotor core 300 is disposed within a housing 102 of the magnet rotor assembly 106. The magnet rotor assembly 106 includes two deformable end rings 400a and 400b. A first deformable end ring 400a is disposed at a first end of the rotor core 300, and a second deformable end ring 400b is disposed at a second end of the rotor core 300. The first and second ends of the rotor core 300 are opposite ends of the rotor core 300. The first deformable end ring 400a and the second deformable end ring 400b cooperate to retain partially ground magnets 302a, 302b, 302c, 302d and fully ground magnets 304a, 304b within the rotor core 300.

[0056] The first deformable end ring 400a includes a plurality of deformable regions 402. For convenience, the deformable regions 402 of the deformable end ring 400a are depicted using rectangles. Each of a plurality of partially polishing magnets 302a, 302b, 302c, 302d is disposed at a corresponding partially polishing magnet position within the rotor core 300. Each of the plurality of deformable regions 402 corresponds to one of the partially polishing magnet positions. In at least one embodiment, the number of deformable regions 402 in the first deformable end ring 400a is equal to the number of partially polishing magnets 302a, 302b, 302c, 302d disposed within the rotor core 300. The rotor core 300 includes a plurality of poles. In at least one embodiment, the number of deformable regions 402 in the first deformable end ring 400a is equal to the number of the plurality of poles in the rotor core 300. The second deformable end ring 400b includes a deformable region 402 that is similar in size and positioning to the deformable region 402 shown in the first deformable end ring 400a.

[0057] The rotor core 300 has a rotor core length 308. When the partially ground magnets 302a, 302b, and 302d have a magnet length greater than the rotor core length 308, one or both ends of the partially ground magnets 302a, 302b, and 302d extend beyond one or both of the rotor core end faces. (Return to Reference) Figure 3Partially polished magnet 302a has a partially polished magnet end extending beyond the end face of the first rotor core. Partially polished magnet 302b has a partially polished magnet end extending beyond the end face of the second rotor core opposite to the end face of the first rotor core. Partially polished magnet 302d has a first partially polished magnet end extending beyond the end face of the first rotor core and a second partially polished magnet end extending beyond the surface of the second rotor core.

[0058] When a portion of the polishing magnet 302a has a polishing magnet end that extends beyond the end face of the first rotor core, this portion of the polishing magnet end abuts against a corresponding deformable region 402 of the first deformable end ring 400a that is associated with the position of the portion of the polishing magnet 302a. The force exerted by the portion of the polishing magnet end against the deformable region 402 of the first deformable end ring 400a causes deformation of the deformable region 402. The deformation of the deformable region 402 accommodates the portion of the polishing magnet that extends beyond the surface of the first rotor core.

[0059] When the partial polishing magnet 302b has a polishing magnet end that extends beyond the end face of the second rotor core, this partial polishing magnet end abuts against a corresponding deformable region 402 of the second deformable end ring 400b, which is associated with the position of the partial polishing magnet 302b. The force exerted by the partial polishing magnet end against the deformable region 402 of the second deformable end ring 400b causes deformation of the deformable region 402. The deformation of the deformable region 402 accommodates the portion of the partial polishing magnet that extends beyond the surface of the second rotor core.

[0060] In some cases, the partial polishing magnet 302d has a first partial polishing magnet end extending beyond the end face of the first rotor core and a second partial polishing magnet end extending beyond the surface of the second rotor core. The partial polishing magnet end extending beyond the end face of the first rotor core abuts against a corresponding deformable region 402 of the first deformable end ring 400a associated with the position of the partial polishing magnet 302d. The force exerted by the partial polishing magnet end against the deformable region 402 of the first deformable end ring 400a causes deformation of the deformable region 402. The deformation of the deformable region 402 accommodates the portion of the partial polishing magnet extending beyond the surface of the first rotor core. The partial polishing magnet end extending beyond the end face of the second rotor core abuts against a corresponding deformable region 402 of the second deformable end ring 400b associated with the position of the partial polishing magnet 302d. The force exerted by the partial polishing magnet end against the deformable region 402 of the second deformable end ring 400b causes deformation of the deformable region 402. The deformation of deformable region 402 accommodates part of the extension of the polished magnet beyond the surface of the second rotor core.

[0061] Although the first deformable end ring 400a is in Figure 4The ring is shown to include eight deformable regions 402, but alternative embodiments of the deformable ring may include more or fewer deformable regions.

[0062] refer to Figure 5 A functional block diagram representation of a deformable end ring 400 (400a and 400b, collectively referred to as 400) comprising a plurality of thinned deformable regions 500 according to at least one embodiment is shown. The deformable end ring 400 is a metallic deformable end ring. The deformable end ring 400 includes a plurality of deformable regions 402 and non-deformable regions 502. The non-deformable regions 502 have a first thickness. The deformable regions 402 are thinned deformable regions 500. The thinned deformable regions 500 have a second thickness. The second thickness of the thinned deformable regions 500 is less than the first thickness of the non-deformable regions 502. Forces applied by the ends of the partially polished magnets 302a, 302b, and 302d against the thinned deformable regions 500 cause deformation of the thinned deformable regions 500. The deformation of the thinned deformable regions 500 accommodates portions of the partially polished magnets extending beyond the rotor core surface.

[0063] Each of the plurality of partially ground magnets 302a, 302b, 302c, and 302d is disposed at a partially ground magnet position within the rotor core 300. The position of each of the plurality of thinned deformable regions 500 corresponds to one of the partially ground magnet positions. Although the deformable end ring 400 is in Figure 5 The ring is shown to include eight deformable regions 402, but alternative embodiments of the deformable ring may include more or fewer deformable regions.

[0064] refer to Figure 6 This diagram illustrates a functional block diagram representation of a deformable end ring 400 (400a and 400b, collectively referred to as 400) comprising a plurality of deformable regions 402 according to at least one embodiment. The deformable end ring 400 is a metallic deformable end ring. In at least one embodiment, each of the deformable regions 402 includes one or more partial cutouts 600 extending into but not completely through the deformable end ring 400. Forces exerted by the partial polishing magnet ends 302a, 302b, 302d against the one or more partial cutouts 600 cause deformation of the deformable region 402. The deformation of the deformable region 402 accommodates portions of the partial polishing magnets extending beyond the rotor core surface.

[0065] In at least one embodiment, each of the deformable regions 402 includes one or more through-holes 600 extending completely through the deformable end ring. Forces exerted by the partial polishing magnet ends of the partial polishing magnets 302a, 302b, 302d against the one or more through-holes 600 cause deformation of the deformable region 402. The deformation of the deformable region 402 accommodates portions of the partial polishing magnets that extend beyond the rotor core surface.

[0066] Each of the plurality of partially ground magnets 302a, 302b, 302c, and 302d is disposed at a partially ground magnet position within the rotor core 300. The position of each of the plurality of deformable regions 402, including the partial cutout 600 or through-cut 600, corresponds to one of the partially ground magnet positions. Although the deformable end ring 400 is in Figure 6 The ring is shown to include eight deformable regions 402, but alternative embodiments of the deformable ring may include more or fewer deformable regions.

[0067] refer to Figure 7 This diagram illustrates a functional block representation of a deformable end ring 400 (400a and 400b, collectively referred to as 400) comprising a plurality of deformable regions 402 in the form of a cantilever beam 700 according to at least one embodiment. The deformable end ring 400 is a metallic deformable end ring. In at least one embodiment, each of the deformable regions 402 includes a cantilever beam 700. Forces exerted by the ends of the partially polishing magnets 302a, 302b, and 302d against the cantilever beam 700 cause deformation of the cantilever beam 700. The deformation of the cantilever beam 700 in the deformable region 402 accommodates portions of the partially polishing magnets that extend beyond the rotor core surface.

[0068] The deformable end ring 400 includes a plurality of deformable regions 402 and non-deformable regions 702. In at least one embodiment, the non-deformable regions 702 have a first thickness. The cantilever beam 700 in the deformable regions 402 is thinned. The thinned cantilever beam 700 has a second thickness. The second thickness of the thinned cantilever beam 700 is less than the first thickness of the non-deformable regions 702.

[0069] Each of the multiple partially polishing magnets 302a, 302b, 302c, and 302d is positioned at a partially polishing magnet location within the rotor core 300. The position of each of the multiple cantilever beams 700 corresponds to one of the partially polishing magnet locations. Although the deformable end ring 400 is... Figure 7 The diagram is shown to include eight cantilever beams 700, but alternative embodiments of the deformable ring may include more or fewer cantilever beams.

[0070] refer to Figure 8A functional block diagram representation of a deformable end ring 400 (400a and 400b, collectively referred to as 400) comprising a plurality of closed-cell foam caps 800 according to at least one embodiment is shown. The deformable end ring 400 is a composite deformable end ring. The composite deformable end ring has a metal end ring base 802, on which the plurality of closed-cell foam caps 800 are disposed. In at least one embodiment, the plurality of closed-cell foam caps 800 are attached to the metal end ring base 802 using an adhesive. Examples of materials used to manufacture the closed-cell foam caps 800 include, but are not limited to, polyurethane, epoxy resin, silicone, ethylene-vinyl acetate (EVA), polyethylene, and polystyrene.

[0071] Each of a plurality of partially ground magnets 302a, 302b, 302c, and 302d is disposed at a partially ground magnet position within the rotor core 300. The position of each of a plurality of closed-cell foam caps 800 corresponds to one of the partially ground magnet positions. The force exerted by the ends of the partially ground magnets 302a, 302b, and 302d against the closed-cell foam caps 800 causes deformation of the closed-cell foam caps 800. The deformation of the closed-cell foam caps 800 in the deformable region 402 accommodates the portion of the partially ground magnet extending beyond the rotor core surface. Although the deformable end ring 400 is in Figure 8 The image is shown to include a closed-cell foam cap 800, but alternative embodiments of the deformable ring may include more or fewer closed-cell foam caps 800.

[0072] refer to Figure 9 A functional block diagram showing a side view of the end 900 of a portion of the abrasive magnet 402 (402a, 402b, 402d, collectively referred to as 400) adjacent to and abutting a closed-cell foam cap 800 according to at least one embodiment.

[0073] In at least one embodiment, each of the plurality of deformable regions 402 includes a recess. The rotor core 300 has a rotor core length 308. Although the magnet lengths of the partially ground magnets 402a, 402b, 402c, 402d vary, there are manufacturing tolerances specifying the maximum permissible magnet lengths of the partially ground magnets 402a, 402b, 402c, 402d. Each recess has a recess depth. The recess depth is the difference between the rotor core length 308 and the maximum permissible magnet length of the partially ground magnets 402a, 402b, 402c, 402d.

[0074] When the ends of some of the grinding magnets 302a, 302b, and 302d extend beyond the rotor core surface, these ends extend into recesses provided in the deformable region 402. The recesses in the deformable region 402 accommodate the portions of the grinding magnets that extend beyond the rotor core surface.

[0075] In at least one embodiment, one or more of the partially polished magnets 302c have a magnet length less than the rotor core length 308. In at least one embodiment, the deformable end ring 400 (400a and 400b, collectively referred to as 400) includes a shim disposed in the deformable region 402, corresponding to the partially polished magnet position of the partially polished magnet 302c having a magnet length less than the rotor core length 308. The partially polished magnet end of the partially polished magnet 302c abuts against the shim. The shim maintains the positioning of the partially polished magnet 302c within the rotor core 300.

[0076] In at least one embodiment, one or more of the partially polished magnets 302c have a magnet length less than the rotor core length 308. In at least one embodiment, the deformable end ring 400 (400a and 400b, collectively referred to as 400) includes a spring disposed in the deformable region 402, corresponding to the partially polished magnet position of the partially polished magnet 302c having a magnet length less than the rotor core length 308. The partially polished magnet end of the partially polished magnet 302c abuts against the spring. The spring maintains the positioning of the partially polished magnet 302c within the rotor core 300.

[0077] In at least one embodiment, one or more of the partially polished magnets 302c have a magnet length less than the rotor core length 308. In at least one embodiment, the deformable end ring 400 (400a and 400b, collectively referred to as 400) includes an elastomeric material disposed in the deformable region 402, corresponding to the partially polished magnet position of the partially polished magnet 302c having a magnet length less than the rotor core length 308. The partially polished magnet ends of the partially polished magnet 302c abut against the elastomeric material. The elastomeric material maintains the positioning of the partially polished magnet 302c within the rotor core 300.

[0078] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the exemplary embodiments or multiple exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiments or multiple exemplary embodiments. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A magnet rotor assembly, comprising: A rotor core having a rotor core length along a longitudinal axis; Multiple partial grinding magnets are disposed at multiple partial grinding magnet positions within the rotor core, each of the multiple partial grinding magnets having an associated magnet length extending along the longitudinal axis, a first partial grinding magnet end, and a second opposing partial grinding magnet end; as well as A first deformable end ring, disposed at a first end of the rotor core, is used to retain the plurality of partially ground magnets within the rotor core. The first deformable end ring includes a plurality of first deformable regions, and each of the plurality of first deformable regions corresponds to one of the plurality of partially ground magnet positions. The first of the plurality of partial grinding magnets has an associated magnet length greater than the rotor core length, and the first part of the first grinding magnet abuts against a first deformable region of the plurality of first deformable regions of the first deformable end ring, thereby causing deformation of the first deformable region of the first deformable end ring.

2. The magnet rotor assembly of claim 1, further comprising a second deformable end ring disposed at a second end of the rotor core to engage with the first deformable end ring, thereby retaining the plurality of partial grinding magnets within the rotor core, and wherein: The second deformable end ring includes a plurality of second deformable regions, and each of the plurality of second deformable regions corresponds to one of the plurality of partially ground magnet positions. The second of the plurality of partial grinding magnets has an associated magnet length greater than the rotor core length, and the end of the second partial grinding magnet abuts against a first deformable region in the plurality of second deformable regions of the second deformable end ring, thereby causing deformation of the first deformable region of the second deformable end ring.

3. The magnet rotor assembly of claim 1, further comprising a plurality of fully ground magnets disposed at a plurality of fully ground magnet positions within the rotor core, each of the plurality of fully ground magnets having an associated magnet length equal to the length of the rotor core extending along the longitudinal axis, a first fully ground magnet end, and a second opposing fully ground magnet end, and The first deformable end ring includes a non-deformable region, and the first fully polished magnet ends of the plurality of fully polished magnets are positioned adjacent to the non-deformable region of the first deformable ring.

4. The magnet rotor assembly of claim 3, wherein the non-deformable region has a first thickness, and each of the plurality of first deformable regions has a second thickness, the first thickness being greater than the second thickness.

5. The magnet rotor assembly of claim 3, wherein each of the plurality of first deformable regions of the first deformable ring has at least one partial cutout extending into the first deformable end ring.

6. The magnet rotor assembly of claim 3, wherein each of the plurality of first deformable regions of the first deformable ring has at least one through-hole extending through the first deformable end ring.

7. The magnet rotor assembly of claim 3, wherein each of the plurality of first deformable regions of the first deformable ring comprises a cantilever beam.

8. The magnet rotor assembly of claim 3, wherein each of the plurality of first deformable regions includes a recess having a recess depth, the recess depth being the difference between the rotor core length and the maximum permissible magnet length of the plurality of partially ground magnets.

9. The magnet rotor assembly according to claim 3, wherein: The first deformable end ring includes a plurality of closed-cell foam caps, wherein each of the plurality of closed-cell foam caps is disposed in a corresponding one of the plurality of first deformable regions, and The first part of the grinding magnet abuts against the first closed-cell foam cap disposed in the first deformable region of the plurality of deformable regions of the first deformable end ring, thereby causing deformation of the first deformable region.

10. The magnet rotor assembly of claim 3, wherein the plurality of partially ground magnets have a first coercivity and the plurality of fully ground magnets have a second coercivity, the second coercivity being higher than the first coercivity.

11. The magnet rotor assembly of claim 1, further comprising at least one of a gasket, a spring, and an elastomeric material disposed in at least one of the plurality of first deformable regions, and The third of the plurality of partial grinding magnets has an associated magnet length less than the length of the rotor core, and the first part of the third part of the grinding magnet abuts against at least one of the gasket, the spring, and the elastomeric material disposed on at least one of the plurality of first deformable regions to maintain the positioning of the third part of the grinding magnet within the rotor core.

12. The magnet rotor assembly of claim 1, wherein the rotor core comprises a plurality of poles, and the number of the plurality of first deformable regions is equal to the number of the plurality of poles.

13. The magnet rotor assembly according to claim 1, wherein the plurality of partially ground magnets are ferrite magnets.

14. The magnet rotor assembly of claim 1, wherein the magnet rotor assembly is rotatable relative to the stator assembly.

15. The magnet rotor assembly of claim 1, wherein the magnet rotor assembly is a component of an embedded permanent magnet motor.

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