Device and method for manufacturing rotor

Abstract

An apparatus and method for manufacturing a rotor, the apparatus comprising a forming mold extending in a first direction and configured to contain a molten plastic magnetic material; the orientation mold is arranged close to the forming mold in the second direction and is configured to magnetize the molten plastic magnetic material in the forming mold; wherein the first direction is perpendicular to the second direction.

Description

Technical Field

[0001] The present invention relates to an apparatus and method for manufacturing a rotor, and more specifically, to an apparatus and method for manufacturing a rotor that is low in cost and simple in process. Background Technology

[0002] The rotor is an important component of the motor. In the existing technology, the rotor core is generally made of silicon steel sheets. The manufacturing process of the rotor usually includes cutting the magnets, magnetizing the magnets, assembling the rotor and balancing. The above manufacturing process is complicated, which increases the production cost and requires high production equipment and technical level, which is not conducive to large-scale production.

[0003] Therefore, it is desirable to propose an apparatus and method for manufacturing rotors to overcome the shortcomings of the aforementioned prior art. Summary of the Invention

[0004] According to a first aspect of the invention, an apparatus for manufacturing a rotor is provided, comprising a molding die extending along a first direction and configured to contain molten plastic-magnetic material; and an orientation die disposed adjacent to the molding die along a second direction and configured to magnetize the molten plastic-magnetic material in the molding die; wherein the first direction is perpendicular to the second direction.

[0005] According to this scheme, the rotor can be injection molded in one step, and magnetization can be completed during the molding process. First, the price of plastic magnetic materials is much lower than that of neodymium iron boron, which helps to reduce costs; second, the injection-molded rotor has higher overall uniformity, and the balance correction is simpler, or even negligible, simplifying the production process; finally, the injection-molded rotor can be used directly, avoiding rotor assembly, which also simplifies the production process and is conducive to large-scale industrial production.

[0006] In some schemes, the orientation mold may include multiple Halebec arrays along the first direction, with the forming mold located on the strong magnetic field side of the Halebec array.

[0007] According to this scheme, the Heilbeck array can enhance the magnetization of the molten plastic magnetic material in the molding die, resulting in a magnetic rotor with a stronger magnetic field.

[0008] In some schemes, each Hellbeck array sequentially includes along a first direction: a first magnetization unit configured to generate a magnetic field pointing in the first direction; a second magnetization unit configured to generate a magnetic field pointing in the second direction; a third magnetization unit configured to generate a magnetic field away from the first direction; and a fourth magnetization unit configured to generate a magnetic field away from the second direction.

[0009] In some schemes, the width of the first magnetization unit and / or the third magnetization unit along the first direction may be smaller than the width of the second magnetization unit and / or the fourth magnetization unit along the first direction.

[0010] According to this scheme, because the second magnetization unit and / or the fourth magnetization unit are wider, the magnetic field strength they generate along the second direction and away from the second direction is stronger, thus improving the performance of the magnetic rotor.

[0011] In some schemes, the number of Hellbeck arrays can be determined based on the number of rotor poles.

[0012] In some designs, the orientation mold can be made of neodymium iron boron or a magnetized coil.

[0013] In some designs, the forming mold and the orientation mold can be disc-shaped, with the first direction being the circumferential direction of the disc shape and the second direction being the axial direction of the disc shape.

[0014] According to this scheme, the manufactured rotor has an annular shape and can rotate and move relative to the stator.

[0015] In some designs, the forming mold and the orientation mold can have a cuboid shape, with the first direction being the length direction of the cuboid shape and the second direction being the height direction of the cuboid shape.

[0016] According to this scheme, the manufactured rotor has a long strip shape and can move linearly relative to the stator.

[0017] According to a second aspect of the present invention, a method for manufacturing a rotor is provided, comprising: an injection molding step of injecting molten plastic-magnetic material into a molding die extending along a first direction; a magnetization step of magnetizing the molten plastic-magnetic material in the molding die by means of an orientation die disposed adjacent to the molding die along a second direction, the first direction being perpendicular to the second direction; and a molding step of solidifying the molten plastic-magnetic material and then removing the solidified plastic-magnetic material from the molding die.

[0018] According to this scheme, the rotor can be injection molded in one step, and magnetization can be completed during the molding process. First, the price of plastic magnetic materials is much lower than that of neodymium iron boron, which helps to reduce costs; second, the injection-molded rotor has higher overall uniformity, and the balance correction is simpler, or even negligible, simplifying the production process; finally, the injection-molded rotor can be used directly, avoiding rotor assembly, which also simplifies the production process and is conducive to large-scale industrial production.

[0019] According to a third aspect of the invention, a rotor is provided, which is manufactured according to the method described in the second aspect of the invention.

[0020] According to a fourth aspect of the invention, an electric motor is provided, comprising the rotor described in the third aspect of the invention. Attached Figure Description

[0021] Figure 1 A flowchart of a method for manufacturing a rotor according to an embodiment of the present invention is shown;

[0022] Figure 2 A schematic diagram of an apparatus for manufacturing a rotor according to a first embodiment of the present invention is shown;

[0023] Figure 3 A schematic diagram of an apparatus for manufacturing a rotor according to a second embodiment of the present invention is shown.

[0024] Figure Labels

[0025] 10. Methods for manufacturing rotors

[0026] S11 First Step

[0027] S12 Second Step

[0028] S13 Third step 100 Apparatus for manufacturing rotor

[0029] 110 Molding mold

[0030] 120 Orientation Mold

[0031] 122 Heilbeck Array

[0032] 122-1 Unit 1

[0033] 122-2 Unit 2

[0034] 122-3 Unit 3

[0035] 122-4 Unit 4

[0036] 200 Apparatus for manufacturing rotors

[0037] 210 Molding Die

[0038] 220 Orientation Mold

[0039] 222 Heilbeck Array

[0040] 222-1 Unit 1

[0041] 222-2 Unit 2

[0042] 222-3 Unit 3

[0043] 222-4 Unit 4 Detailed Implementation

[0044] To make the objectives, solutions, and advantages of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Unless otherwise stated, the terms used herein have their ordinary meanings in the art. The same reference numerals in the drawings represent the same parts.

[0045] Figure 2 A schematic diagram of an apparatus 100 for manufacturing a rotor according to a first embodiment of the present invention is shown. The apparatus 100 mainly includes a molding die 110 and an orientation die 120. The molding die 110 is generally hollow and disc-shaped. Molten plastic-magnetic material, containing magnetic particles, is injected into the molding die 110 through a nozzle of an injection molding machine (not shown). The shape of the internal space of the molding die 110 that accommodates the molten plastic-magnetic material is the shape of the magnetic rotor after molding. For a disc-shaped molding die 110, a disc-shaped magnetic rotor can be manufactured accordingly, which can rotate relative to the stator (e.g., it can be used in a rotary motor). The plastic-magnetic material is magnetized simultaneously with the molding step to cause the magnetic particles constituting the plastic-magnetic material to form an ordered arrangement, thereby giving the magnetic rotor the desired magnetic properties. The above magnetization process is achieved by the orientation die 120, which is oriented along the axial direction of the molding die 110 (e.g., ...). Figure 2 The magnetic rotor (shown in the vertical direction) is positioned adjacent to the molding die 110. According to the above scheme, the magnetic rotor can be injection molded in one step, and magnetization is completed during the molding process. First, the price of the plastic magnetic material is far lower than that of neodymium iron boron, which helps reduce costs; second, the injection-molded rotor has higher overall uniformity, and balance correction is simpler, even negligible, simplifying the production process; finally, the injection-molded magnetic rotor can be used directly, avoiding magnetic rotor assembly, further simplifying the production process and facilitating large-scale industrial production.

[0046] Preferably, the orientation mold 120 may include multiple Halebeck arrays 122 along the circumferential direction, and the forming mold 110 is located on the strong magnetic field side of the Halebeck array 122. The Halebeck array 122 can enhance the magnetization of the molten plastic magnetic material in the forming mold 110, so that the manufactured magnetic rotor has a stronger magnetic field strength. Specifically, each Halebeck array 122 includes, in sequence along the circumferential direction: a first magnetization unit 122-1, a second magnetization unit 122-2, a third magnetization unit 122-3, and a fourth magnetization unit 122-4, wherein the first magnetization unit 122-1 is configured to generate a direction pointing in a first direction (e.g., as shown in the image). Figure 2 The second magnetization unit 122-2 is configured to generate a magnetic field pointing in the second direction (e.g., counterclockwise direction). Figure 2The third magnetization unit 122-3 is configured to generate a magnetic field opposite to the first direction (e.g., as shown in the downward direction). Figure 2 The fourth magnetization unit 122-4 is configured to generate a magnetic field opposite to the second direction (e.g., as shown in the clockwise direction of the magnetic field). Figure 2 (The magnetic field is shown in the upward direction). According to the above scheme, the orientation mold 120 can make the molten plastic magnetic material in the molding mold 110 have, for example, an upward magnetic field. Figure 2 The magnetic field shown has approximately U-shaped magnetic field lines that enter the molding die 110 (corresponding to the S pole of the magnetic rotor) from the fourth magnetization unit 122-4 and exit the molding die 110 (corresponding to the N pole of the magnetic rotor) from the second magnetization unit 122-2.

[0047] Preferably, the circumferential width of the first magnetizing unit 122-1 and / or the third magnetizing unit 122-3 can be smaller than the circumferential width of the second magnetizing unit 122-2 and / or the fourth magnetizing unit 122-4. Because the second magnetizing unit 122-2 and / or the fourth magnetizing unit 122-4 are wider, they generate a stronger magnetic field in the axial direction, improving the performance of the magnetic rotor. The number of Hellbeck arrays 122 can be determined based on the number of magnetic poles of the magnetic rotor to be manufactured. Furthermore, the orientation mold 120 can be constructed of neodymium iron boron or magnetized coils to generate a magnetic field capable of magnetizing the molten plastic-magnetic material in the orientation mold 110.

[0048] Figure 3 A schematic diagram of an apparatus 200 for manufacturing a rotor according to a second embodiment of the present invention is shown. The apparatus 200 of the second embodiment of the present invention has a similar configuration to the apparatus 100 of the first embodiment of the present invention. For the sake of brevity, only the differences between the apparatus 200 of the second embodiment and the apparatus 100 of the first embodiment will be described in detail below, and the similarities between the apparatus 200 of the second embodiment and the first embodiment 100 will not be repeated. The apparatus 200 mainly includes a molding die 210 and an orientation die 220. Molten plastic-magnetic material is injected into the molding die 210 through the nozzle of an injection molding machine (not shown). The plastic-magnetic material contains magnetic particles. During the molding step, the orientation die 220 magnetizes the molten plastic-magnetic material in the molding die 210 so that the magnetic particles constituting the plastic-magnetic material form an ordered arrangement, thereby giving the magnetic rotor the desired magnetic properties.

[0049] Unlike the device 100 of the first embodiment, the device 200 of the second embodiment has a generally cuboid shape, which extends along its length (e.g., as shown in the figure). Figure 3 The orientation mold 220 extends in the left-right direction (as shown), and extends in the width direction (e.g., as shown). Figure 3The mold 210 is arranged adjacent to the molding die 210 in the vertical direction shown. For the cuboid-shaped molding die 210, a cuboid-shaped magnetic rotor can be manufactured accordingly, which can move linearly relative to the stator (e.g., it can be used for a linear motor).

[0050] Preferably, the orientation mold 220 may include multiple Halebeck arrays 222 along its length, and the forming mold 210 is located on the strong magnetic field side of the Halebeck array 222. The Halebeck array 222 can enhance the magnetization of the molten plastic magnetic material in the forming mold 110, so that the manufactured magnetic rotor has a stronger magnetic field strength. Specifically, each Halebeck array 222 includes, in sequence along its length: a first magnetization unit 222-1, a second magnetization unit 222-2, a third magnetization unit 222-3, and a fourth magnetization unit 222-4, wherein the first magnetization unit 222-1 is configured to generate a direction pointing in a first direction (e.g., as shown in the image). Figure 3 The second magnetization unit 222-2 is configured to generate a magnetic field pointing in the second direction (e.g., as shown in the right direction). Figure 3 The third magnetization unit 222-3 is configured to generate a magnetic field opposite to the first direction (e.g., as shown in the downward direction). Figure 3 The fourth magnetization unit 222-4 is configured to generate a magnetic field opposite to the second direction (e.g., as shown in the left-facing magnetic field). Figure 3 (The magnetic field shown is in the upward direction).

[0051] Figure 1 A flowchart of a method 10 for manufacturing a rotor according to an embodiment of the present invention is shown. Method 10 mainly includes an injection molding step S11, a magnetization step S12, and a molding step S13. In the injection molding step S11, molten plastic-magnetic material is injected into molding molds 110 and 210. In the magnetization step S12, the molten plastic-magnetic material in the molding molds 110 and 210 is magnetized through orientation molds 120 and 220. It should be understood that, although... Figure 1 The magnetization step S12 shown occurs after the injection molding step S11, but the injection molding step S11 and the magnetization step S12 can also be performed simultaneously. In the molding step S13, the molten plastic-magnetic material is solidified, and then the solidified plastic-magnetic material is removed from the molding molds 110 and 210 to obtain the magnetic rotor to be manufactured. According to the above method 10, the magnetic rotor can be formed in one injection molding process, and the magnetization step S12 is performed simultaneously in the molding step S11. First, the price of plastic-magnetic material is much lower than that of neodymium iron boron, which helps to reduce costs; second, the overall uniformity of the injection-molded rotor is higher, the balance correction is simpler, and the balance correction process can even be ignored, simplifying the production process; finally, the injection-molded magnetic rotor can be used directly, avoiding magnetic rotor assembly, which also simplifies the production process and is conducive to large-scale industrial production.

[0052] This document describes in detail several exemplary embodiments of the present invention with reference to preferred embodiments. However, those skilled in the art will understand that various modifications and alterations can be made to the above specific embodiments without departing from the concept of the present invention, and various technical features and structures proposed in the present invention can be combined without exceeding the protection scope of the present invention, which is determined by the appended claims.

Claims

1. An apparatus for manufacturing a rotor, comprising: a forming mold extending in a first direction and configured to accommodate a molten plastic magnetic material; an orientation mold disposed next to the forming mold in a second direction and configured to magnetize the molten plastic magnetic material in the forming mold; wherein the first direction is perpendicular to the second direction.

2. The apparatus of claim 1, wherein the orientation mold comprises a plurality of Halbach arrays in the first direction, the forming mold being located on a side of the Halbach arrays with strong magnetic field.

3. The method of claim 2, wherein each of the Halbach arrays comprises in sequence in the first direction: a first magnetization unit configured to generate a magnetic field pointing in the first direction; a second magnetization unit configured to generate a magnetic field pointing in the second direction; a third magnetization unit configured to generate a magnetic field facing away from the first direction; a fourth magnetization unit configured to generate a magnetic field facing away from the second direction.

4. The apparatus of claim 3, wherein a width of the first magnetization unit and / or the third magnetization unit in the first direction is less than a width of the second magnetization unit and / or the fourth magnetization unit in the first direction.

5. The apparatus of claim 2, wherein a number of the Halbach arrays is determined based on a number of magnetic poles of the rotor.

6. The apparatus of claim 1, wherein the orientation mold is composed of neodymium iron boron or a magnetized coil.

7. The apparatus of claim 1, wherein the forming mold and the orientation mold have a disc shape, the first direction being a circumferential direction of the disc shape, and the second direction being an axial direction of the disc shape.

8. The apparatus of claim 1, wherein the forming mold and the orientation mold have a cuboid shape, the first direction being a length direction of the cuboid shape, and the second direction being a height direction of the cuboid shape.

9. A method for manufacturing a rotor, comprising: an injection molding step of injecting a molten plastic magnetic material into a forming mold, the forming mold extending in a first direction; a magnetization step of magnetizing the molten plastic magnetic material in the forming mold by an orientation mold disposed next to the forming mold in a second direction, the first direction being perpendicular to the second direction; a forming step of solidifying the molten plastic magnetic material and then taking out the solidified plastic magnetic material from the forming mold.

10. A rotor manufactured according to the method of claim 9.

11. An electric machine comprising the rotor of claim 10.

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