Energy-saving rotor of permanent magnet motor

Abstract

The invention discloses an energy-saving rotor of a permanent magnet motor, and relates to the technical field of motor rotors, the energy-saving rotor comprises a rotor shaft, the outer surface of the rotor shaft is sleeved with a rotor iron core, the rotor iron core adopts a sectional laminated structure and is formed by sequentially arranging three iron core units along the axial direction of the rotor shaft, and an insulating spacer is arranged between every two adjacent iron core units. Each iron core unit is formed by laminating a plurality of silicon steel sheets; a plurality of uniformly distributed permanent magnets are embedded in the outer surface of the rotor core, a magnetic isolation block is arranged between every two adjacent permanent magnets, the outer surface of the rotor core is sleeved with a protection assembly, and a heat dissipation assembly is arranged between the rotor shaft and the rotor core. The rotor is reasonable in structural design, all parts are easy to assemble, the rotor iron core is laminated in a sectional mode, machining and maintenance are convenient, the rotor is suitable for batch production, and the rotor has good industrialization prospects.

Description

Technical Field

[0001] This invention relates to the field of motor rotor technology, and more particularly to an energy-saving rotor for a permanent magnet motor. Background Technology

[0002] Permanent magnet motors, a common type of motor, generate a magnetic field using permanent magnets made of rare earth or other materials. This magnetic field interacts with the relative motion between the rotor and stator to produce electromagnetic force, thus achieving efficient energy conversion. Compared to traditional excitation motors, permanent magnet motors have higher efficiency and power density, but there is still room for improvement in energy consumption due to the rotor structure design.

[0003] Existing permanent magnet motor rotors mostly use integral iron core stacking, resulting in significant eddy current losses and insufficient assembly stability of the permanent magnets, making them prone to circumferential or axial movement. The heat dissipation structure design is simplistic, and heat accumulation can easily lead to demagnetization of the permanent magnets. Furthermore, protection under high-speed conditions is inadequate, and magnetic leakage is a prominent issue, thus limiting the motor's energy efficiency and service life.

[0004] The overall iron core has high axial eddy current loss and large iron loss; the reliability of the permanent magnet and the iron core is poor, and the serious magnetic leakage leads to low utilization rate; the heat dissipation efficiency is low, and the permanent magnet is prone to demagnetization due to high temperature; the permanent magnet is prone to fly out when rotating at high speed, and the protection and insulation performance need to be improved, making it difficult to balance energy saving and stability. Summary of the Invention

[0005] The purpose of this invention is to solve the problems existing in the prior art, and to propose an energy-saving rotor for a permanent magnet motor.

[0006] To address the problems existing in the prior art, the present invention adopts the following technical solution: An energy-saving rotor for a permanent magnet motor includes a rotor shaft, on the outer surface of which a rotor core is fitted. The rotor core adopts a segmented stacked structure, consisting of three core units arranged sequentially along the axial direction of the rotor shaft. Insulating pads are provided between adjacent core units. Each core unit is formed by stacking several silicon steel sheets. Several uniformly distributed permanent magnets are embedded in the outer surface of the rotor core, with magnetic isolation blocks provided between adjacent permanent magnets. A protective assembly is fitted on the outer surface of the rotor core, and a heat dissipation assembly is provided between the rotor shaft and the rotor core.

[0007] Preferably, the outer diameter of the rotor core is 120mm and the length is 150mm; the insulating gasket is made of high-temperature resistant epoxy resin material with a thickness of 0.2mm; the thickness of the silicon steel sheet is 0.35mm, and the surface of the silicon steel sheet is provided with an insulating coating with a thickness of 0.03mm.

[0008] Preferably, the permanent magnet has a fan-shaped structure with a central angle of 40° and a thickness of 20mm. The surface is coated with a 0.05mm thick epoxy resin insulating protective layer. The magnetic shielding block is made of 1Cr18Ni9Ti non-magnetic stainless steel with a thickness of 3mm.

[0009] Preferably, the outer circumference of the silicon steel sheet is uniformly provided with a plurality of first V-shaped grooves, the included angle of the first V-shaped grooves is 60° and the depth is 25mm, and the inner walls of the first V-shaped grooves are provided with a plurality of first anti-slip protrusions with a height of 1mm on both sides.

[0010] Preferably, the permanent magnet is embedded in the corresponding first V-shaped groove by an interference fit. Several first anti-slip grooves with a depth of 1.1mm are opened on both sides of the permanent magnet, and the first anti-slip grooves thereon engage with the corresponding first anti-slip protrusions.

[0011] Preferably, the outer diameter of the insulating pad is smaller than the outer diameter of the silicon steel sheet, and the outer circumference of the insulating pad is uniformly provided with a plurality of second V-shaped grooves, the included angle of the second V-shaped grooves is 60° and the depth is 20mm, and the inner walls of the second V-shaped grooves are provided with a plurality of second anti-slip protrusions with a height of 1mm on both sides.

[0012] Preferably, the magnetic shielding block is embedded in the corresponding second V-shaped groove by an interference fit. Several second anti-slip grooves with a depth of 1.1mm are opened on both sides of the magnetic shielding block, and the second anti-slip grooves on it engage with the corresponding second anti-slip protrusions.

[0013] Preferably, the protective component includes an inner buffer layer and an outer protective sleeve. The inner buffer layer is made of silicone rubber elastic insulating material with a thickness of 0.8 mm and is wrapped around the outer surface of the rotor core. The outer protective sleeve is made of T700 carbon fiber reinforced composite material with a thickness of 2 mm and is wrapped around the outer side of the inner buffer layer. It is manufactured by a winding molding process.

[0014] Preferably, the rotor shaft is made of 40Cr alloy material, and the surface is heat-treated to achieve a hardness of HRC28-32. The rotor shaft has axial heat dissipation holes inside, and a number of radial heat dissipation holes that are distributed in a continuous manner with the axial heat dissipation holes are formed on the outer surface of the rotor shaft.

[0015] Preferably, the heat dissipation component includes trapezoidal heat dissipation channels and heat dissipation holes. The silicon steel sheet has a plurality of trapezoidal heat dissipation channels evenly distributed in the circumference. Each trapezoidal heat dissipation channel has a heat dissipation connection hole that communicates with the radial heat dissipation hole. Each trapezoidal heat dissipation channel has heat dissipation holes that are distributed through the outer edge of the silicon steel sheet. The two sides of the silicon steel sheet have a plurality of first heat dissipation channels that correspond one-to-one with the heat dissipation holes. The insulating pad has a plurality of trapezoidal connecting holes evenly distributed around its circumference, which are distributed through the trapezoidal heat dissipation channels. The two sides of the insulating pad have a plurality of second heat dissipation channels that correspond one-to-one with the first heat dissipation channels.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. In this invention, a segmented iron core stacking and insulating gasket design is adopted to effectively reduce axial eddy current loss. The insulating coating of silicon steel sheets suppresses inter-sheet eddy currents and reduces iron loss. The V-shaped groove and anti-slip snap-fit ​​structure improves assembly stability, and the magnetic shielding block reduces magnetic leakage, significantly improving the utilization rate of permanent magnets and helping the rotor to save energy and improve efficiency. 2. In this invention, the protective components are adapted to high-speed operating conditions. The inner silicone rubber buffer layer relieves thermal and mechanical stress, and the outer carbon fiber sheath provides high-strength constraint to prevent the permanent magnet from flying out. The multi-part insulation protection design improves operational reliability, and the material selection takes into account both high temperature resistance and non-magnetic properties to extend the service life of the components. 3. In this invention, the three-dimensional heat dissipation system enhances heat conduction. The axial and radial heat dissipation holes, trapezoidal channels, and connecting holes form a through flow channel, reducing the working temperature of the permanent magnet and the iron core; preventing the permanent magnet from demagnetizing, further improving the energy-saving effect, and providing a key guarantee for the long-term efficient and stable operation of the motor. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a cross-sectional view of the overall structure of the present invention; Figure 3 This is a schematic diagram of the rotor shaft and rotor core structure of the present invention; Figure 4 This is a schematic diagram of the rotor shaft and core unit structure of the present invention; Figure 5 For the present invention Figure 4 A cross-sectional diagram of the structure; Figure 6 For the present invention Figure 5 Explosion-proof diagram of the structure; Figure 7 This is a cross-sectional schematic diagram of the rotor shaft structure of the present invention; Figure 8 This is a schematic diagram of the silicon steel sheet structure of the present invention; In the diagram, the numbers represent: 100, rotor shaft; 101, axial heat dissipation hole; 102, radial heat dissipation hole; 200, rotor core; 201, core unit; 202, insulating pad; 203, silicon steel sheet; 204, first V-shaped groove; 205, first anti-slip protrusion; 300, permanent magnet; 301, magnetic shielding block; 302, first anti-slip groove; 303, second anti-slip groove; 400, inner buffer layer; 401, outer protective sleeve; 500, trapezoidal heat dissipation channel; 501, heat dissipation connection hole; 502, heat dissipation fine hole; 503, first heat dissipation flow channel; 600, trapezoidal connecting hole; 601, second heat dissipation flow channel; 602, second V-shaped groove; 603, second anti-slip protrusion. Detailed Implementation

[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0019] Example: This example provides an energy-saving rotor for a permanent magnet motor. See [link to example]. Figures 1 to 8 Specifically, it includes a rotor shaft 100, on the outer surface of which a rotor core 200 is fitted. The outer diameter of the rotor core 200 is 120mm and its length is 150mm. The rotor core 200 adopts a segmented stacked structure, consisting of three core units 201 arranged sequentially along the axial direction of the rotor shaft 100. This effectively reduces axial eddy current losses and improves efficiency. An insulating gasket 202 is provided between adjacent core units 201. The insulating gasket 202 is made of high-temperature resistant epoxy resin material with a thickness of 0.2mm. The core unit 201 is made of several silicon steel sheets 203 stacked together. The thickness of the silicon steel sheets 203 is 0.35mm. The surface of the silicon steel sheets 203 is provided with an insulating coating with a thickness of 0.03mm, which can suppress inter-sheet eddy currents and reduce iron loss. The outer surface of the rotor core 200 is inlaid with several uniformly distributed permanent magnets 300. The permanent magnets 300 have a fan-shaped structure with a central angle of 40° and a thickness of 20mm. The surface is coated with a 0.05mm thick epoxy resin insulating protective layer. Magnetic isolation blocks 301 are set between adjacent permanent magnets 300 to reduce magnetic leakage and improve the utilization rate of permanent magnets 300. Magnetic isolation blocks 301 are made of 1Cr18Ni9Ti non-magnetic stainless steel with a thickness of 3mm. The outer surface of the rotor core 200 is fitted with protective components. The protective components include an inner buffer layer 400 and an outer protective sleeve 401. The inner buffer layer 400 is made of silicone rubber elastic insulating material with a thickness of 0.8 mm. It is wrapped around the outer surface of the rotor core 200 to buffer the thermal and mechanical stress between the permanent magnet 300 and the outer protective sleeve 401 when the rotor rotates at high speed, and to increase insulation. The outer protective sleeve 401 is made of T700 carbon fiber reinforced composite material with a thickness of 2 mm. It is wrapped around the outer side of the inner buffer layer 400 and is processed by winding molding process. It provides the high-strength constraint required for high-speed rotation, prevents the permanent magnet 300 from flying out, and protects the internal structure. A heat dissipation component is provided between the rotor shaft 100 and the rotor core 200.

[0020] In the specific implementation process, such as Figure 6 and Figure 8 As shown, the outer circumference of the silicon steel sheet 203 is uniformly provided with a number of first V-shaped grooves 204. The included angle of the first V-shaped grooves 204 is 60° and the depth is 25mm. The inner walls of the first V-shaped grooves 204 are provided with a number of first anti-slip protrusions 205 with a height of 1mm on both sides. The permanent magnet 300 is embedded in the corresponding first V-shaped groove 204 by an interference fit. Several first anti-slip grooves 302 with a depth of 1.1mm are opened on both sides of the permanent magnet 300, and the first anti-slip grooves 302 on them engage with the corresponding first anti-slip protrusions 205 to prevent the permanent magnet 300 from moving circumferentially and axially. The outer diameter of the insulating pad 202 is smaller than the outer diameter of the silicon steel sheet 203. The outer circumference of the insulating pad 202 is uniformly provided with a number of second V-shaped grooves 602. The included angle of the second V-shaped grooves 602 is 60° and the depth is 20mm. The inner walls of the second V-shaped grooves 602 are provided with a number of second anti-slip protrusions 603 with a height of 1mm on both sides. The magnetic shielding block 301 is embedded in the corresponding second V-shaped groove 602 by an interference fit. Several second anti-slip grooves 303 with a depth of 1.1mm are opened on both sides of the magnetic shielding block 301, and the second anti-slip grooves 303 on it engage with the corresponding second anti-slip protrusions 603 to fix the magnetic shielding block 301.

[0021] It should be noted that: such as Figure 6 and Figure 8 As shown, the heat dissipation assembly includes a trapezoidal heat dissipation channel 500 and a trapezoidal connecting hole 600. The rotor shaft 100 is made of 40Cr alloy material, and the surface is heat treated to achieve a hardness of HRC28-32. An axial heat dissipation hole 101 is provided inside the rotor shaft 100, and a number of radial heat dissipation holes 102 are provided on the outer surface of the rotor shaft 100 in a continuous manner with the axial heat dissipation hole 101. The axial heat dissipation hole 101 and the radial heat dissipation hole 102 constitute a part of the heat dissipation, which helps to introduce the cooling medium and enhance the heat dissipation inside the rotor. The silicon steel sheet 203 has several trapezoidal heat dissipation channels 500 evenly distributed around its circumference. Each trapezoidal heat dissipation channel 500 has a heat dissipation connection hole 501 that communicates with the radial heat dissipation hole 102. Each trapezoidal heat dissipation channel 500 has heat dissipation fine holes 502 that are distributed through the outer edge of the silicon steel sheet 203. Several first heat dissipation flow channels 503 that correspond one-to-one with the heat dissipation fine holes 502 are opened on both sides of the silicon steel sheet 203. The insulating pad 202 has several trapezoidal connecting holes 600 evenly distributed around its circumference, which are distributed through the trapezoidal heat dissipation channel 500. The two sides of the insulating pad 202 have several second heat dissipation channels 601 that correspond one-to-one with the first heat dissipation channel 503. This significantly enhances the heat dissipation capacity inside the rotor and reduces the working temperature of the permanent magnet 300 and the rotor core 200, which is crucial for energy saving and preventing demagnetization.

[0022] The assembly process in this embodiment is as follows: First, several silicon steel sheets 203 are stacked and formed to form a single iron core unit 201. Then, insulating pads 202 are placed between adjacent iron core units 201 and stacked sequentially along the rotor shaft 100 axis to form a complete rotor iron core 200. Then, the rotor iron core 200 is assembled and fixed to the rotor shaft 100. Next, the permanent magnet 300 is embedded into the first V-shaped groove 204 of the silicon steel sheet 203 by an interference fit, ensuring that the first anti-slip groove 302 of the permanent magnet 300 is precisely engaged with the first anti-slip protrusion 205 on the inner wall of the first V-shaped groove 204. Subsequently, a magnetic isolation block 301 is installed between adjacent permanent magnets 300. The magnetic isolation block 301 is embedded into the second V-shaped groove 602 of the insulating pad 202 in an interference fit manner, so that the second anti-slip groove 303 of the magnetic isolation block 301 is tightly engaged with the second anti-slip protrusion 603 on the inner wall of the second V-shaped groove 602. Next, the inner buffer layer 400 is evenly wrapped around the outer surface of the rotor core 200. Then, the outer protective sleeve 401 is processed by winding molding and wrapped around the outer side of the inner buffer layer 400. Finally, the assembly status of each component is fully inspected to confirm that all components are assembled in place and fit reliably, thus completing the overall assembly.

[0023] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An energy-saving rotor for a permanent magnet motor, comprising a rotor shaft (100), characterized in that: The rotor core (200) is fitted on the outer surface of the rotor shaft (100). The rotor core (200) adopts a segmented stacked structure and is composed of three core units (201) arranged sequentially along the axial direction of the rotor shaft (100). An insulating gasket (202) is provided between adjacent core units (201). The core unit (201) is made of several silicon steel sheets (203) stacked together. Several uniformly distributed permanent magnets (300) are embedded on the outer surface of the rotor core (200). A magnetic shielding block (301) is provided between adjacent permanent magnets (300). A protective component is fitted on the outer surface of the rotor core (200). A heat dissipation component is provided between the rotor shaft (100) and the rotor core (200).

2. The energy-saving rotor of a permanent magnet motor according to claim 1, characterized in that: The insulating pad (202) is made of high-temperature resistant epoxy resin material, the surface of the silicon steel sheet (203) is provided with an insulating coating, and the surface of the permanent magnet (300) is sprayed with an epoxy resin insulating protective layer.

3. The energy-saving rotor of a permanent magnet motor according to claim 1, characterized in that: The silicon steel sheet (203) has a plurality of first V-shaped grooves (204) evenly distributed on the outer circumference, and a plurality of first anti-slip protrusions (205) are provided on both sides of the inner wall of the first V-shaped groove (204).

4. The energy-saving rotor of a permanent magnet motor according to claim 3, characterized in that: The permanent magnet (300) is embedded in the corresponding first V-shaped groove (204) by an interference fit. Several first anti-slip grooves (302) are provided on both sides of the permanent magnet (300), and the first anti-slip grooves (302) on it engage with the corresponding first anti-slip protrusions (205).

5. The energy-saving rotor of a permanent magnet motor according to claim 1, characterized in that: The outer diameter of the insulating pad (202) is smaller than the outer diameter of the silicon steel sheet (203). The outer circumference of the insulating pad (202) is uniformly provided with a number of second V-shaped grooves (602). The inner walls of the second V-shaped grooves (602) are provided with a number of second anti-slip protrusions (603) on both sides.

6. The energy-saving rotor of a permanent magnet motor according to claim 5, characterized in that: The magnetic shielding block (301) is embedded in the corresponding second V-shaped groove (602) by an interference fit. Several second anti-slip grooves (303) are provided on both sides of the magnetic shielding block (301), and the second anti-slip grooves (303) on it engage with the corresponding second anti-slip protrusions (603).

7. The energy-saving rotor of a permanent magnet motor according to claim 1, characterized in that: The protective assembly includes an inner buffer layer (400) and an outer protective sleeve (401). The inner buffer layer (400) is made of silicone rubber elastic insulating material and is wrapped around the outer surface of the rotor core (200). The outer protective sleeve (401) is made of carbon fiber reinforced composite material and is wrapped around the outer side of the inner buffer layer (400). It is manufactured by a winding molding process.

8. The energy-saving rotor of a permanent magnet motor according to claim 1, characterized in that: The rotor shaft (100) has an axial heat dissipation hole (101) inside, and a plurality of radial heat dissipation holes (102) are provided on the outer surface of the rotor shaft (100) in a continuous manner with the axial heat dissipation hole (101).

9. The energy-saving rotor of a permanent magnet motor according to claim 8, characterized in that: The heat dissipation assembly includes trapezoidal heat dissipation channels (500) and heat dissipation holes (502). The silicon steel sheet (203) is uniformly provided with a plurality of trapezoidal heat dissipation channels (500) in the circumferential direction. Each trapezoidal heat dissipation channel (500) is provided with a heat dissipation connection hole (501) communicating with the radial heat dissipation hole (102). Each trapezoidal heat dissipation channel (500) is provided with heat dissipation holes (502) that are distributed through the outer edge of the silicon steel sheet (203). The two sides of the silicon steel sheet (203) are provided with a plurality of first heat dissipation channels (503) that correspond one-to-one with the heat dissipation holes (502).

10. An energy-saving rotor for a permanent magnet motor according to claim 9, characterized in that: The insulating pad (202) has a plurality of trapezoidal connecting holes (600) evenly distributed around its circumference, which are distributed in connection with the trapezoidal heat dissipation channel (500). The insulating pad (202) has a plurality of second heat dissipation channels (601) on both sides that correspond one-to-one with the first heat dissipation channel (503).

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