A non-metallic axial motor flux disk rotor assembly and method of assembly

Abstract

The application relates to a non-metal axial motor magnetic flux disc rotor assembly and an assembling method thereof, the magnetic flux disc rotor assembly comprising a magnetic flux disc, a pressing plate and a plurality of magnetic steels; a plurality of through grooves are arranged on the magnetic flux disc at intervals in the circumferential direction; the plurality of magnetic steels are arranged in the through grooves respectively; and the pressing plate is combined with the magnetic flux disc and clamps the magnetic steels. The non-metal axial motor magnetic flux disc rotor assembly provided by the application can fix the magnetic steels by designing the pressing plate to clamp the magnetic steels on the magnetic flux disc, so that the magnetic steels can be fixed and prevented from falling off in the axial direction of the magnetic flux disc; and the magnetic steels are also reinforced in the radial direction, so that the magnetic steels are prevented from moving straight up and down on the magnetic flux disc and falling off due to magnetic attraction, and the motor is prevented from being damaged.

Description

Technical Field

[0001] This application relates to a non-metallic axial motor flux disk rotor assembly and its assembly method, and is applicable to the field of motor technology. Background Technology

[0003] In existing electric motor flux disk rotor assemblies, the magnets are typically mounted directly on the flux disk. However, due to assembly issues, the magnets cannot be completely fixed to the flux disk. During motor rotation, the magnets easily loosen along the axial and radial directions of the flux disk, severely affecting motor performance and causing damage. Furthermore, existing flux disks are often designed to be quite thick to secure the magnets, resulting in a larger distance between the magnets and the iron core, increasing magnetic leakage and reducing motor performance.

[0004] Therefore, the prior art requires a non-metallic axial motor magnetic flux disk rotor assembly and its assembly method to achieve the fixation of the magnetic flux disk's magnets. Summary of the Invention

[0006] The purpose of this application is to design a non-metallic axial motor flux disk rotor assembly and its assembly method, aiming to solve the problem of fixing the magnets in existing flux disks.

[0007] This application relates to a non-metallic axial motor magnetic flux disk rotor assembly, the magnetic flux disk rotor assembly including a magnetic flux disk, a pressure plate and a plurality of magnets; the magnetic flux disk is provided with a plurality of through slots spaced along its circumference; the plurality of magnets are respectively disposed in each through slot; the pressure plate is engaged with the magnetic flux disk and clamps each magnet.

[0008] In some embodiments, the pressure plate includes a first annular pressure plate and a second annular pressure plate; the first annular pressure plate and the second annular pressure plate are respectively provided with chamfers; the first annular pressure plate and the second annular pressure plate are joined on both sides of the magnetic flux disk and clamp the magnets through their respective chamfers; the magnets are clamped between the chamfers of the first annular pressure plate and the chamfers of the second annular pressure plate.

[0009] In some implementations, the pressure plate is bolted to the edge of the magnetic flux disk.

[0010] In some implementations, the magnets are fan-ring or fan-shaped structures; multiple magnets are evenly distributed around the circumference of the magnetic flux disk.

[0011] In some embodiments, the magnet is bonded to the through groove; the two sides of the magnet protrude from the two sides of the magnetic flux disk.

[0012] In some implementations, the magnetic flux disk and the pressure plate are both made of non-metallic materials.

[0013] In some embodiments, the flux disk rotor assembly further includes a motor connector and a locking ring; the motor connector includes a motor shaft and a flange, the flange and the motor shaft being an integral structure; the motor shaft passes through the center of the flux disk and is clamped onto the flux disk by the locking ring; the flux disk is located between the flange and the locking ring; the locking ring is sleeved on the motor shaft; the flange and the locking ring are connected by locking bolts.

[0014] In some implementations, a flat key is provided between the magnetic flux disk and the motor shaft; the flat key is used to limit circumferential movement between the magnetic flux disk and the motor shaft.

[0015] In some embodiments, the motor shaft and locking ring are made of metal materials, such as 40Cr, 25CrMnTi, or 20CrNiMo.

[0016] This application also provides a method for assembling a non-metallic axial motor flux disk rotor assembly, the assembly method comprising the following steps: S1: Apply glue to the mating surfaces of the magnet and the magnetic flux disk through the slot, and then glue the magnet into the through slot so that the magnet and the magnetic flux disk are assembled together. S2: Join the two pressure plates onto the magnetic flux disk, clamp the magnets by the chamfer of the pressure plates, and then lock the two pressure plates with bolts; S3: Assemble the motor shaft and the key together; S4: Then assemble the assembled magnetic flux disk and motor shaft; S5: Install the locking ring onto the motor shaft, and finally use this locking bolt to lock the motor shaft, magnetic flux disk and locking ring together to complete the overall assembly.

[0017] The non-metallic axial motor flux disk rotor assembly and its assembly method proposed in this application have the following technical advantages: (1) The non-metallic axial motor flux disk rotor assembly proposed in this application uses a pressure plate to clamp the magnets on the flux disk, which can fix the magnets and prevent them from falling off in the axial direction of the flux disk; and also reinforces the magnets in the radial direction, preventing the magnets from moving straight up and down on the flux disk and falling off due to magnetic attraction, which would damage the motor.

[0018] (2) The non-metallic axial motor magnetic flux disk rotor assembly proposed in this application uses a pressure plate to clamp the magnets on the magnetic flux disk, which reduces the thickness of the magnetic flux disk, reduces the overall thickness of the rotor assembly, and reduces the distance between the magnet 4 and the iron core to reduce magnetic leakage and improve motor efficiency.

[0019] (3) The assembly method of the non-metallic axial motor magnetic flux disk rotor assembly proposed in this application has a simple magnetic flux disk rotor assembly structure, which is convenient to assemble and can effectively improve the assembly efficiency and performance of the motor. Attached Figure Description

[0021] Figure 1 This is a partial cross-sectional view of a non-metallic axial motor flux disk rotor assembly according to this application.

[0022] Figure 2 This is a schematic diagram of a non-metallic axial motor flux disk rotor assembly according to this application.

[0023] Figure 3 This application Figure 2 A cross-sectional view along AA.

[0024] Figure 4 This is a schematic diagram of the magnetic flux disk structure of this application.

[0025] In the diagram: 1. Motor shaft; 11. Flange; 2. Magnetic flux disk; 21. Disc; 22. Ring; 23. Through groove; 24. Spoke; 3. Pressure plate; 4. Magnet; 5. Locking ring; 6. Flat key; 7. Locking bolt; 8. Chamfer; 9. Stainless steel bolt. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in detail below with reference to the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be arbitrarily combined with each other.

[0028] like Figure 1-4 As shown, this application proposes a non-metallic axial motor flux disc rotor assembly, specifically a non-metallic axial motor flux disc rotor assembly with outer diameter clamping, to enhance the mechanical reliability of the rotor assembly during motor operation. Specifically, the flux disc rotor assembly includes a flux disc 2, a pressure plate 3, and multiple magnets 4; wherein, the flux disc 2 has multiple through slots spaced circumferentially. Each magnet 4 is disposed within a through slot 23 to form a magnet structure. The two sides of each magnet 4 are exposed on the two sides of each through slot 23. The pressure plate 3 engages with the flux disc 2 and clamps each magnet 4 to prevent loosening and detachment of the magnets 4 during rotation of the flux disc rotor assembly.

[0029] The flux disc rotor assembly proposed in this application also includes a motor connector and a locking ring 5. The motor connector includes a motor shaft 1 and a flange 11, with the flange 11 and motor shaft 1 being an integral structure. The motor shaft 1 passes vertically through the center of the flux disc 2 and is clamped onto the flux disc 2 by the locking ring 5. Specifically, the flux disc 2 is located between the flange 11 and the locking ring 5; the locking ring 5 is sleeved on the motor shaft 1 and cooperates with the flange 11 to clamp onto the flux disc 2; the flange 11 and the locking ring 5 are connected by locking bolts 7, thereby locking them onto the flux disc 2. A stator core is fitted onto the flange 11 of the motor shaft 1, and an air gap is formed between the magnet 4 and the flux disc 2. The motor shaft 1, the magnet 4, and the locking ring 5 constitute the flux disc assembly. The proposed solution uses a pressure plate 3 to clamp the magnetic flux disk 2 and fix the magnets 4 on the magnetic flux disk 2. This reduces the thickness of the magnetic flux disk 2 and the overall thickness of the magnetic flux disk assembly, thereby reducing the distance between the surface of the magnet 4 and the surface of the pressure plate 3, and further reducing the distance between the magnet 4 and the stator core to reduce magnetic leakage (referred to as air gap) and improve motor efficiency.

[0030] This application's solution uses a pressure plate 3 to clamp the magnetic flux disk 2 and fix the magnets 4 on the magnetic flux disk 2, enhancing the mechanical reliability of the rotor assembly during motor operation. By fixing the magnets 4 axially with the pressure plate 3, the magnets 4 are prevented from falling off the magnetic flux disk 2 in the axial direction, and the pressure plate 3 also reinforces the magnets 4 radially, preventing them from moving vertically on the magnetic flux disk 2 and falling off due to magnetic attraction, which could damage the motor.

[0031] like Figure 1-3 As shown, in some embodiments, the pressure plate 3 is an annular pressure plate, which can better fit against both sides of the magnetic flux disk 2, thereby clamping all the magnets 4 as a whole. Specifically, the annular pressure plate includes a first annular pressure plate and a second annular pressure plate, and the first annular pressure plate and the second annular pressure plate are respectively provided with chamfers 8, that is, chamfers 8 are respectively provided on the inner side of the first annular pressure plate and the second annular pressure plate. Preferably, the chamfers 8 fit with the chamfers of the edges of the magnets 4 to form a stable engagement. The chamfers 8 of the first annular pressure plate and the chamfers 8 of the second annular pressure plate are mirror images of each other, which can form a stable clamping structure, thereby clamping the magnetic flux disk 2 and the magnets 4. Further, the first annular pressure plate and the second annular pressure plate are joined on both sides of the magnetic flux disk 2, and clamp the magnets 4 by their respective chamfers 8; specifically, the chamfer 8 of the first annular pressure plate clamps one side of the magnets 4, and the chamfer of the second annular pressure plate clamps the other side of the magnets 4. The magnet 4 is clamped between the chamfer 8 of the first annular pressure plate and the chamfer 8 of the second annular pressure plate. This effectively limits the movement in the axial direction and prevents the magnet from loosening or falling off during the rotation of the magnetic flux disk rotor assembly, which could damage the motor.

[0032] like Figure 1-3As shown, in some embodiments, the pressure plate 3 is bolted to the edge of the magnetic flux disk 2 for easy connection. The bolts connecting the pressure plate 3 to the magnetic flux disk 2 can be plastic bolts or stainless steel bolts 9. Specifically, the stainless steel bolts 9 pass sequentially through the first annular pressure plate, the magnetic flux disk 2, and the second annular pressure plate to clamp the magnet 4 by fixing it to the magnetic flux disk 2.

[0033] like Figure 1-4 As shown, in some embodiments, the magnet 4 can be a fan-ring structure or a fan-shaped structure. Specifically, the magnetic flux disk 2 is a disk structure, and the disk structure can be an integral structure. Specifically, the magnetic flux disk 2 includes a central disk 21 and an edge ring 22, which are connected by spokes 24, and a through groove 23 is formed between adjacent spokes 24. A plurality of magnets 4 are evenly distributed in the circumferential direction of the magnetic flux disk 2, specifically located in the through groove 23 in the circumferential direction of the magnetic flux disk 2. Further, the magnet 4 is a long strip structure and is arranged radially on the magnetic flux disk 2, so that it can be clamped between two annular pressure plates.

[0034] like Figure 1-4 As shown, in some embodiments, the magnet 4 is fixedly installed in the through groove 23 by adhesive bonding. Specifically, when installing the magnet 4, the magnet 4 is first bonded to the through groove with glue to achieve pre-positioning, and then the magnet 4 is further clamped and fixed by the pressure plate 3, thereby clamping the magnet 4 along the axial direction of the magnetic flux disk 2.

[0035] like Figure 1-3 As shown, in some embodiments, the magnetic flux disk 2 and the pressure plate 3 are made of non-metallic materials, preferably at least one of PEEK, glass fiber, carbon fiber, and PPS. The advantages of non-metallic magnetic flux disk 2 and pressure plate 3 are that they are insulating, lightweight, corrosion-resistant, and easy to process and shape, making them easier to clamp and attach to the magnet 4. They also offer advantages such as rust resistance, weight reduction, and noise reduction. This solves the problem that the greater the weight of a metal rotor during high-speed rotation, the greater its moment of inertia, resulting in a more stable structure for fixing the magnet 4. Furthermore, it addresses the issue that metallic materials can conduct magnetism, leading to internal losses, magnetic field consumption, heat generation, and reduced efficiency.

[0036] like Figure 1-3 As shown, in some embodiments, a flat key 6 is provided between the magnetic flux disk 2 and the motor shaft 1; the flat key 6 is used to restrict the circumferential movement between the magnetic flux disk 2 and the motor shaft 1 to avoid loosening between them. Specifically, the flat key 6 is disposed in the keyway of the motor shaft 1, which can serve to distribute torque and provide orientation.

[0037] like Figure 1-3As shown, in some embodiments, the motor shaft and locking ring 5 are made of metal materials, preferably 40Cr, 25CrMnTi or 20CrNiMo, which can effectively ensure the strength of the motor connector.

[0038] like Figure 1-3 As shown, the present invention also provides an assembly method for a non-metallic axial motor flux disk rotor assembly, which is used to assemble the aforementioned flux disk rotor assembly. Specifically, the assembly method includes the following processes: S1: Apply glue to the mating surfaces of magnet 4 and magnetic flux disk 2, and then glue magnet 4 into the through groove 23 of magnetic flux disk 2 so that magnet 4 and magnetic flux disk 2 are assembled together. S2: Join the two pressure plates 3 onto the magnetic flux disk 2, and clamp the magnet 4 by the chamfer of the pressure plates 3, and then lock the two pressure plates 3 with bolts; specifically, the bolts can be stainless steel bolts 9; S3: Assemble the motor shaft 1 and the flat key 6 together; the flat key 6 is set in the keyway of the motor shaft 1, which can play the role of sharing torque and orientation; S4: Then assemble the assembled magnetic flux disk 2 and motor shaft 1; S5: Install the locking ring 5 onto the motor shaft 1, and finally use the locking bolt 7 to connect the motor shaft 1, the magnetic disk 2 and the locking ring 5 together to complete the overall assembly.

[0039] The non-metallic axial motor flux disk rotor assembly and its assembly method proposed in this application have the following technical advantages: (1) The non-metallic axial motor magnetic flux disk rotor assembly proposed in this application uses a pressure plate to clamp the magnets on the magnetic flux disk, which reduces the thickness of the magnetic flux disk, reduces the overall thickness of the rotor assembly, and reduces the distance between the magnet 4 and the iron core to reduce magnetic leakage and improve motor efficiency.

[0040] (2) The non-metallic axial motor flux disk rotor assembly proposed in this application uses a pressure plate to clamp the magnets on the flux disk, which can fix the magnets and prevent them from falling off in the axial direction of the flux disk; and also reinforces the magnets in the radial direction, preventing the magnets from moving straight up and down on the flux disk and falling off due to magnetic attraction, which would damage the motor.

[0041] (3) The assembly method of the non-metallic axial motor magnetic flux disk rotor assembly proposed in this application has a simple magnetic flux disk rotor assembly structure, which is convenient to assemble and can effectively improve the assembly efficiency and performance of the motor.

[0042] Although the embodiments disclosed in this application are as described above, the content is merely for the purpose of facilitating understanding of this application and is not intended to limit this application. Any person skilled in the art to which this application pertains may make any modifications and changes in the form and details of the implementation without departing from the spirit and scope disclosed in this application; however, the scope of patent protection of this application shall still be determined by the scope defined in the appended claims.

Claims

1. A non-metallic axial motor flux disk rotor assembly, characterized in that, The flux disk rotor assembly includes a flux disk, a pressure plate, and multiple magnets; the flux disk has multiple through slots spaced along its circumference; the multiple magnets are respectively disposed in each of the through slots; the pressure plate engages with the flux disk and clamps each of the magnets.

2. The non-metallic axial motor flux disk rotor assembly according to claim 1, characterized in that, The pressure plate includes a first annular pressure plate and a second annular pressure plate; the first annular pressure plate and the second annular pressure plate are respectively provided with chamfers; the first annular pressure plate and the second annular pressure plate are joined to both sides of the magnetic flux disk, and respectively clamp the magnet through their respective chamfers; the magnet is clamped between the chamfers of the first annular pressure plate and the chamfers of the second annular pressure plate.

3. The non-metallic axial motor flux disk rotor assembly according to claim 1 or 2, characterized in that, The pressure plate is bolted to the edge of the magnetic flux disk.

4. The non-metallic axial motor flux disk rotor assembly according to claim 2, characterized in that, The magnets have a fan-ring structure or a fan-shaped structure; the multiple magnets are evenly distributed around the circumference of the magnetic flux disk.

5. The non-metallic axial motor flux disk rotor assembly according to claim 1, characterized in that, The magnet is bonded to the through groove; the two sides of the magnet protrude from the two sides of the magnetic flux disk.

6. The non-metallic axial motor flux disk rotor assembly according to claim 1, characterized in that, The magnetic flux disk and the pressure plate are both made of non-metallic materials.

7. The non-metallic axial motor flux disk rotor assembly according to claim 1, characterized in that, The flux disk rotor assembly further includes a motor connector and a locking ring; the motor connector includes a motor shaft and a flange, the flange and the motor shaft being an integral structure; the motor shaft passes through the center of the flux disk and is clamped onto the flux disk by the locking ring; the flux disk is located between the flange and the locking ring; the locking ring is sleeved on the motor shaft; the flange and the locking ring are connected by locking bolts.

8. The non-metallic axial motor flux disk rotor assembly according to claim 7, characterized in that, A flat key is provided between the magnetic flux disk and the motor shaft; the flat key is used to restrict the circumferential movement between the magnetic flux disk and the motor shaft.

9. The non-metallic axial motor flux disk rotor assembly according to claim 7, characterized in that, The motor shaft and the locking ring are made of metal materials, namely 40Cr, 25CrMnTi or 20CrNiMo.

10. A method for assembling a non-metallic axial motor flux disk rotor assembly, characterized in that, The assembly method Includes the following processes: S1: Apply glue to the mating surfaces of the magnet and the magnetic flux disk through the slot, and then glue the magnet into the through slot so that the magnet and the magnetic flux disk are assembled together; S2: Join the two pressure plates onto the magnetic flux disk, clamp the magnet by the chamfer of the pressure plates, and then lock the two pressure plates with bolts; S3: Assemble the motor shaft and the key together; S4: Then assemble the assembled magnetic flux disk and motor shaft; S5: Install the locking ring onto the motor shaft, and finally use this locking bolt to lock the motor shaft, magnetic disk and locking ring together to complete the overall assembly.

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