High-speed electric machine for motor vehicle

Abstract

The invention relates to a high-speed electric machine for a motor vehicle, comprising a stator and a rotor which is rotatably mounted relative to the stator along an axis, the stator comprising a stator yoke and stator teeth, the stator teeth being connected to the stator yoke in a force-fitting and / or form-fitting manner, the rotor comprises sheets which form a laminated core and are laminated in the axial direction, the laminated core comprises at least two receiving spaces in the radial direction relative to the axis, a permanent magnet is arranged in each receiving space, the corresponding permanent magnet is inserted in the corresponding receiving space in a force locking mode, and the permanent magnets are arranged in the receiving spaces. The laminated core with the permanent magnets has a circular outer contour in the radial direction with respect to the axis, wherein the rotor is enclosed by a retaining strip for fixing the permanent magnets in the laminated core.

Description

Technical Field

[0001] This invention relates to a high-speed motor / high-speed machine (Hochdrehzahlmaschine) for motor vehicles. Background Technology

[0002] In today's electric vehicles, high-speed motors play a decisive role due to their numerous advantages, making significant contributions to the improvement of drive technology. These motors are characterized by high power density, enabling them to deliver more power per kilogram of weight, thus significantly improving vehicle efficiency and performance. Higher speeds also mean that motors can be designed to be more compact and lighter, reducing the overall weight of the vehicle and thus increasing its driving range. High-speed motors also allow for the elimination of significant portions of the drivetrain in certain design concepts, further reducing vehicle weight and improving mechanical efficiency.

[0003] The efficient operation of these motors also reduces the need for complex thermal management systems, which in turn reduces vehicle weight. The compact design of the motors provides greater flexibility for integration into different vehicle platforms, enabling innovative and diverse vehicle designs. Overall, high-speed motors have made significant contributions to improving the efficiency, power-to-weight ratio, and overall performance of electric drive systems, resulting in better performance and longer driving ranges in modern electric vehicles. Summary of the Invention

[0004] This invention addresses the prior art challenges of providing improved motors in terms of torque and power density.

[0005] According to the present invention, for this purpose, a high-speed motor for a motor vehicle according to claim 1 and a motor vehicle having a high-speed motor according to claim 10 are provided. Advantageous embodiments can be derived from the dependent claims and the description.

[0006] This invention relates to a high-speed motor for motor vehicles.

[0007] It includes a stator and a rotor, the rotor being rotatably mounted relative to the stator along an axis, wherein the stator includes a stator yoke and a plurality of stator teeth, wherein the stator teeth are connected to the stator yoke by force-locking and / or form-locking methods, wherein

[0008] The rotor comprises laminated sheets / steel plates stacked in the axial direction to form a laminated core / laminated assembly. The laminated core includes at least two receiving spaces in the radial direction relative to the axis, and permanent magnets are arranged in each receiving space. The corresponding permanent magnets are force-locked into their respective receiving spaces.

[0009] The laminated iron core with permanent magnets has a circular outer contour in the radial direction relative to the axis, and the rotor is enclosed by a retaining band for fixing the permanent magnets in the laminated iron core.

[0010] In an advantageous embodiment, the stator may be made of or comprise electrical steel sheets.

[0011] Electrical steel sheets, also known as generator steel sheets, are specially developed ferromagnetic materials used in electrical engineering to manufacture the cores of motors. Electrical steel sheets can be composed of or contain ferrosilicon alloys. These alloys can include special magnetic properties to minimize energy losses due to eddy currents and hysteresis. One of the most important properties of electrical steel sheets is high permeability, which ensures the material can be easily magnetized with low hysteresis losses. This means that very little energy is converted into heat during remagnetization. Electrical steel sheets may also include low eddy current losses, which can be achieved through special alloys and / or thin sheet thickness and / or possible electrical insulation between the individual sheets of a laminated core. Electrical steel sheets can be produced in various shapes and qualities to meet the specific requirements of each application. The electrical steel sheets are available in cold-rolled, amorphous oriented (NGO), and grain-oriented (GO) electrical steel sheet forms.

[0012] In another advantageous embodiment, windings can be inserted between the stator teeth of the stator to generate a rotating magnetic field. The windings can be formed of continuous conductors having a rectangular or circular cross-sectional profile. These continuous conductors can also be referred to as so-called continuous shaft windings. Here, the continuous shaft windings are inserted radially from the outside between multiple stator teeth and are axially engaged with the stator yoke in a force-locking and / or form-locking manner.

[0013] In another embodiment, the conductor of the continuous shaft winding includes a cavity through which a fluid or gas can flow, and thus a high cooling capacity can be achieved due to the high heat transfer between the conductor and the fluid or gas. The conductor may be made of or comprise a conductive material such as copper or aluminum.

[0014] In another advantageous embodiment, the stator teeth may be made of or comprise cobalt iron. This increases the magnetic permeability and allows for the conduction of higher magnetic flux, meaning that more electromagnetic torque can be generated within the same mounting space of the motor.

[0015] In another embodiment, the stator yoke is made of or includes cobalt iron, which can further increase the electromagnetic torque.

[0016] Force-locked permanent magnets within the receiving space of a laminated iron core offer several advantages. Reduced magnetic flux leakage can improve the performance (especially electromagnetic torque) and efficiency of high-speed motors.

[0017] In terms of the insertion of permanent magnets into the receiving space of a rotor or rotor lamination core, the term "force-locking method" refers to the manner in which the magnet is fixed to the rotor or lamination core by a retaining band having an undersized (Untermaβ) dimension.

[0018] The magnet and the receiving space are shaped to interlock and fit together tightly, and the magnet is prevented from moving or sliding by a retaining band.

[0019] An additional significant advantage of this arrangement is the increased mechanical stability of the permanent magnets, as they are firmly integrated into the rotor or laminated core, preventing them from slipping or falling off at high speeds. This increases the overall mechanical integrity of the assembly.

[0020] In addition, the precise positioning of the magnets allows for the optimal generation and utilization of magnetic fields, which can improve the efficiency of high-speed motors.

[0021] Force-locking insertion reduces the leakage flux within the rotor lamination core, which reduces magnetic losses and thus increases the efficiency of the high-speed motor.

[0022] Another advantage is reduced vibration and associated noise, as the force-locking fixation of the magnets reduces imbalance and ensures quieter operation, while also reducing the load on the rolling bearings of high-speed motors.

[0023] Another practical advantage is the reduction in assembly work, as the force-locking insertion of the permanent magnet into the laminated core simplifies and speeds up the assembly process.

[0024] The axis of a high-speed motor is an imaginary line around which all rotating parts of the high-speed motor rotate, such as the rotor, particularly the laminated iron core, permanent magnets, and retaining belt.

[0025] Radial relative to an axis refers to the direction extending outward or inward from the axis. Radial relative to the axis means moving or arranging perpendicular to the axis, that is, along a line starting from the center of the axis.

[0026] Axial direction relative to an axis refers to the direction along the axis. Compared to "radial," which points away from or toward the axis, "axial" describes movement, force, or arrangement that extends parallel to the axis.

[0027] In another embodiment, the retaining band is designed as a carbon fiber bandage.

[0028] In another embodiment, the fiber direction of the carbon fiber bandage extends radially around the rotor.

[0029] A significant advantage of using carbon fiber straps to secure permanent magnets to laminated cores in high-speed motors may lie in the superior mechanical properties of carbon fiber. These materials are characterized by their extremely high tensile strength and stiffness, enabling them to withstand high mechanical loads. This is particularly important in high-speed motors, where high centrifugal forces exert their influence, requiring the permanent magnets to be firmly held in place.

[0030] In another embodiment, the rotor includes four, six, or eight receiving spaces, each for receiving a permanent magnet. The number of poles or pole pairs of the motor can be determined by the number of receiving spaces.

[0031] The number of pole pairs in a high-speed motor refers to the number of magnetic poles present on the rotor of the high-speed motor, more precisely, the number of north pole pairs and south pole pairs. This parameter is crucial for determining the relationship between the rotor speed and the electrical frequency of the generated or applied voltage. In other words, a pole pair consists of a north pole and a south pole. The number of pole pairs is the total number of poles divided by two. For example, a motor with four poles (two north poles and two south poles) has a pole pair count of two. The number of pole pairs has a significant impact on the operating characteristics of the motor and is directly related to the synchronous speed of the high-speed motor. For example, a pole pair count of two, or four poles, corresponds to four receiving spaces in the laminated iron core.

[0032] In another advantageous embodiment, the high-speed motor is designed as a permanent magnet synchronous motor. A permanent magnet synchronous motor (PMSM) is a special type of synchronous motor in which the magnetic field in the rotor can be generated by permanent magnets. This design can have several advantages, such as higher efficiency, lower losses, and a more compact design.

[0033] In another embodiment, the location of the receiving space on the rotor, particularly on the laminated core, can be calculated using the following equation:

[0034]

[0035] Where p corresponds to the number of pole pairs of the high-speed motor, and therefore 2*p corresponds to the number of poles, n corresponds to the consecutive number / indication of the receiving space, and θ_n corresponds to the angular position of the corresponding receiving space in degrees as a function of n.

[0036] In another embodiment, the corresponding permanent magnet is designed as a circular sector / fan or a triangle.

[0037] A circular sector is a portion of a circular surface defined by a first radius, a second radius, and an arc between the two radii. The shape of the circular sector is defined by the center of the circle and two points on the circumference of the circle. The angle between the two radii of the circular sector at the center of the circle is called the central angle, and this angle is measured in degrees (°) or radians (rad). The two distances extending from the center of the circle to two different points on the circumference are the radii defining the circular sector. The portion of the circumference of the circle between the two points on the circle and connecting the two radii is called the arc of the circular sector. In an advantageous embodiment, the first and second radii may be the same.

[0038] In another advantageous embodiment, the receiving space in the laminated core has an opening angle corresponding to the central angle of the associated permanent magnet inserted into the corresponding receiving space.

[0039] In another embodiment, the radius of the arc of the circular sector corresponds to the radius of the rotor. The radius of the arc is independent of the circular sector but is related to the axis of the high-speed motor. Therefore, the radius of the circular sector (i.e., the corresponding permanent magnet) does not necessarily correspond to the radius of the rotor.

[0040] In other words, the corresponding permanent magnet is fitted into the laminated iron core, especially into the corresponding receiving space of the laminated iron core of the rotor, so that the corresponding permanent magnet is complementary to the outer contour of the laminated iron core and thus complements the rotor as a whole to form a circular outer contour.

[0041] In another embodiment, the corresponding arc of the circular sector of the permanent magnet and the laminated core of the rotor form a circular outer contour relative to the axis. Therefore, the permanent magnet embedded in the rotor can conform to the outer radius of the rotor using its radially outward-facing side. The outward-facing side is the side that is not inserted into the receiving space or in contact with the laminated core of the rotor.

[0042] A "circular outer contour" describes the shape of an object whose outer boundary extends in a circular pattern. This means that the outer edge of the object is equidistant from the center point in all directions, making the object's shape correspond to a circle. Manufacturing tolerances should not be considered when taking a circular outer contour into account.

[0043] In another embodiment, the receiving space is triangular in shape, and the corresponding permanent magnet has a circular sector-like / quasi-sectoral profile, wherein the permanent magnet includes a first radius and a second radius, the two radii converging at a tip that inserts into the corresponding receiving space. In an advantageous embodiment, the tip of the corresponding permanent magnet may point towards the center of the rotor, particularly towards the axis. The first and second radii form a central angle α.

[0044] The present invention also relates to a high-speed motor according to at least one of the foregoing embodiments. Attached Figure Description

[0045] In the following description, the invention will be illustrated by way of example only, with reference to the accompanying drawings. The drawings show:

[0046] Figure 1 A high-speed motor for a motor vehicle according to an embodiment of the present invention; and

[0047] Figure 2 It is a permanent magnet with a circular sector-shaped profile according to an embodiment of the present invention. Detailed Implementation

[0048] Figure 1 A high-speed motor 100 for a motor vehicle is shown, comprising a stator 110 and a rotor 120, the rotor being rotatably mounted relative to the stator 110 along an axis 200. The stator 110 includes a stator yoke 111 and a plurality of stator teeth 112, wherein the stator teeth 112 are connected to the stator yoke 111 by force-locking and / or form-locking. The rotor 120 includes electrical steel sheets stacked in an axial direction to form a laminated iron core 121, wherein the laminated iron core 121 includes at least two receiving spaces 122 in a radial direction relative to the axis 200, wherein a permanent magnet 125 is arranged in each receiving space 122. Each permanent magnet 125 is inserted into the respective receiving space 122 by force-locking.

[0049] The laminated iron core 121 with permanent magnets has a circular outer profile in the radial direction relative to the axis 200, wherein the rotor 120 is enclosed by a retaining band 130 for securing the permanent magnets 125 to the laminated iron core.

[0050] The corresponding permanent magnet 125 has a circular sector-shaped profile. The permanent magnet includes a first radius 126 and a second radius 127, which converge at a tip. The first radius 126 and the second radius 127 form a central angle α at the tip. The circular sector is a portion of a circular surface defined by the first radius 126, the second radius 127, and an arc 128 located between the two radii. The first radius 126 and the second radius 127 have the same dimensions.

[0051] Figure 2 A permanent magnet 125 with a circular sector-shaped profile is shown. The permanent magnet includes a first radius 126 and a second radius 127, which converge at a tip. The first radius 126 and the second radius 127 form a central angle α. The circular sector is a portion of a circular surface defined by the first radius 126, the second radius 127, and an arc 128 located between the two radii.

[0052] This invention is not limited to the exemplary embodiments described. Within the scope of this invention, unless otherwise stated, all described and / or drawn features may be combined with each other as needed.

Claims

1. A high-speed electric motor (100) for motor vehicles, include A stator (110) and a rotor (120), the rotor being rotatably mounted relative to the stator (110) along an axis (200), wherein... The stator (110) includes a stator yoke (111) and a plurality of stator teeth (112), the stator teeth (112) being connected to the stator yoke (111) by force-locking and / or form-locking methods, wherein The rotor (120) comprises sheets stacked in the axial direction to form a laminated iron core (121), wherein The laminated core (121) includes at least two receiving spaces (122) in the radial direction relative to the axis (200), wherein A corresponding permanent magnet (125) is arranged in each receiving space (122), wherein the corresponding permanent magnet (125) is inserted into the corresponding receiving space (122) by force-locking. The laminated iron core (122) having the permanent magnet has a circular outer contour in the radial direction relative to the axis (200), wherein The rotor (120) is enclosed by a retaining band (130) for fixing the permanent magnet (125) in the laminated iron core.

2. The high-speed motor (100) for motor vehicles according to claim 1, Its features The retaining band (130) is designed as a carbon fiber bandage.

3. The high-speed motor (100) for motor vehicles according to claim 2, Its features The fiber direction of the carbon fiber bandage (130) extends radially around the rotor (120).

4. The high-speed motor (100) for a motor vehicle according to claim 1, Its features The rotor (120) includes four, six, or eight receiving spaces (122), each receiving space being used to receive a permanent magnet (125).

5. The high-speed electric motor (100) for a motor vehicle according to any one of the preceding claims, Its features The position of the receiving space (122) on the rotor (120) can be calculated using the following equation: Where 2*p corresponds to the number of magnetic poles of the high-speed motor (100), n corresponds to the number of consecutive poles of the receiving space (122), and θ_n corresponds to the angular position of the corresponding receiving space (121) as a function of n in degrees.

6. The high-speed motor for motor vehicles according to claim 5, Its features The corresponding permanent magnet (125) is designed as a circular sector.

7. The high-speed motor for motor vehicles according to claim 6, Its features The radius of the arc (128) of the circular sector corresponds to the radius of the rotor (120).

8. The high-speed motor for motor vehicles according to claim 7, Its features The corresponding arc (128) of the circular sector of the corresponding permanent magnet (125) and the laminated iron core (121) of the rotor (120) form a circular outer contour relative to the axis (200).

9. The high-speed electric motor (100) for a motor vehicle according to any one of claims 6 to 8, Its features The receiving space (122) is triangular in shape, and the corresponding permanent magnet (125) has a circular sector-shaped profile. The permanent magnet includes a first radius (126) and a second radius (127), which converge at a tip that is inserted into the corresponding receiving space (122).

10. A motor vehicle having a high-speed motor (100) according to at least one of the preceding claims.

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