Electric machine with rotor blocks

Abstract

The electric machine (102) includes a housing including a stator (106) and a rotor (104) disposed inside the stator (106). The rotor (104) includes a rotor lamination (108) and a rotor shaft (110). The rotor lamination (108) includes a plurality of slots for housing a plurality of magnets (112). The rotor shaft (110) is mechanically coupled with the rotor lamination (108), and the rotor (104) rotates in response to a magnetic field of the stator (106). At least two rotor blocks (114) are positioned at opposite ends along an axis of rotation of the rotor lamination (108). The at least two rotor blocks (114) are positioned between an inner surface of the rotor lamination (108) and an outer surface of the rotor shaft (110). The at least two rotor blocks (114) include a plurality of air channels (116) and a flow channel.

Description

Technical Field

[0001] This invention relates to an electric motor with a rotor block. Background Technology

[0002] An electric motor includes a rotor assembly disposed within a stator. The rotor includes a rotor shaft and rotor laminations with magnets. The rotor has a balance disc, spacer rings, and multiple air passages. The rotor laminations contain multiple slots for receiving multiple magnets. Due to the multiple air passages, the rotor laminations are insufficiently cooled, resulting in inadequate heat dissipation management. Inadequate heat dissipation management causes several problems, which the present invention solves by means of the claims.

[0003] According to prior art DE102009047677, the rotor (4) has a shaft (5) and balance discs (6) which are electrically and / or mechanically isolated from permanent magnets (15). The balance discs are arranged at a distance from the permanent magnets such that there is no direct contact between the discs and the permanent magnets. The discs include grooves (7) in the permanent magnet region such that the grooves are arranged at a distance from the permanent magnets. An insulator is arranged between the discs and the permanent magnets, the insulator being designed as an insulating foil and the discs. The insulator is provided with plastic, a metal selected from iron, steel or aluminum. The invention also includes an independent claim for an electric motor comprising a stator. Attached Figure Description

[0004] Embodiments of this disclosure are described with reference to the following figures.

[0005] Figure 1A An exploded view of an electric motor according to an embodiment of the present invention is shown; Figure 1B An electric motor rotor block according to an embodiment of the present invention is shown; Figure 2A An electric motor rotor shaft according to an embodiment of the present invention is shown, and Figure 2B An assembly view of a motor according to an embodiment of the present invention is shown. Detailed Implementation

[0006] Figure 1AAn exploded view of an electric motor 102 according to an embodiment of the present invention is shown. The electric motor 102 includes a stator 106 and a rotor 104 located within the stator 106. The rotor 104 includes rotor laminations 108 and a rotor shaft 110. The rotor laminations 108 include a plurality of slots to receive a plurality of magnets 112. The rotor shaft 110 is mechanically connected to the rotor laminations 108. The rotor 104 rotates in response to the magnetic field of the stator 106. The motor is characterized in that at least two rotor blocks 114 are positioned at opposite ends along the axis of rotation of the rotor laminations 108, and at least two rotor blocks 114 are positioned between the inner surface of the rotor laminations 108 and the outer surface of the rotor shaft 110. The stator 106 and the rotor 104 are enclosed within a housing. The at least two rotor blocks 114 have a split design and are located within the rotor laminations in contact with each other.

[0007] Figure 1B A rotor block 114 of a motor 102 according to an embodiment of the present invention is shown. Each of at least two rotor blocks 114 includes a hollow body 120 located within an annular region 118 defined around the hollow body 120. The hollow body 120 receives or accommodates a rotor shaft 110. The annular region 118 is defined between a first end 122 and a second end 124 of each of the at least two rotor blocks 114. The rotor shaft 110 is locked to the at least two rotor blocks 114 by an auxiliary locking mechanism. This auxiliary locking mechanism enables precise installation of each of the at least two rotor blocks 114 and contributes to a secure fixation and optimal alignment with the rotor shaft 110.

[0008] According to an embodiment of the invention, each of the at least two rotor blocks 114 includes an annular region 118 comprising a plurality of air passages 116 extending from a first end 122 to a second end 124. Openings of the plurality of air passages 116 are formed on the side surfaces of the first end 122 and the second end 124. The plurality of air passages 116 are capable of dissipating heat generated during the operation of the generator 102 and maintaining the temperature of the generator 102 within operating limits.

[0009] According to an embodiment of the invention, each of at least two rotor blocks 114 engaged with the rotor shaft 110 includes a flow channel for circulating fluid within the rotor laminations 108. This flow channel includes a set of main channels 126 and a set of auxiliary channels 128. The set of main channels 126 is defined between first ends 122 and second ends 124 of the at least two rotor blocks 114 and is formed on the outer surfaces of the at least two rotor blocks 114; the set of auxiliary channels 128 is formed between the second ends 124 of the at least two rotor blocks 114 and at the abutments of the second ends 124 of the at least two rotor blocks 114.

[0010] Figure 2AA rotor shaft 110 of an electric motor 102 according to an embodiment of the present invention is shown. The rotor shaft 110 includes at least one inner bore 202 formed through a central axis 210 of the rotor shaft 110. The rotor shaft 110 includes a plurality of holes 204 formed on the outer circumferential surface of the rotor shaft 110. The plurality of holes 204 extend inward and connect to the at least one inner bore 202. The at least one inner bore 202 and the plurality of holes 204 allow fluid to flow through a set of auxiliary channels 128 to a set of main channels 126. The plurality of holes 204 are disposed at any location on the outer circumferential surface of the rotor shaft 110, these locations being selected from the group consisting of: at the middle of the rotor shaft 110 and at either end of the rotor shaft 110. The set of main channels 126 and the set of auxiliary channels 128 guide the fluid and control the volume of the fluid in the vicinity of the plurality of magnets 112, and improve thermal efficiency.

[0011] According to an embodiment of the present invention, the set of auxiliary channels 128 includes a first portion 130 and a second portion 132. The first portion 130 is disposed on a first rotor block of at least two rotor blocks 114, and the second portion 132 is disposed on a second rotor block of at least two rotor blocks 114. The set of auxiliary channels 128 is formed once the second ends 124 of the first rotor block and the second ends 124 of the second rotor block are in contact with each other.

[0012] According to an embodiment of the invention, the first end 122 of each of at least two rotor blocks 114 is located outside the rotor lamination 108, and the second end 124 of each of at least two rotor blocks 114 is adjacent to each other inside the rotor lamination 108.

[0013] According to an embodiment of the invention, the first end 122 includes a plurality of protrusions 134 formed on its circular edge, these protrusions being perpendicular to the side surfaces of each of at least two rotor blocks 114. Each of the plurality of protrusions 134 contributes to the balance of the rotor 104 during operation. In other words, the plurality of protrusions 134 function as a balance disc in a conventional motor. The plurality of protrusions 134 can be adjusted to a desired balance level, which can be selected from either a positive balancing method or a negative balancing method. By simultaneously achieving both positive and negative balancing methods through the plurality of protrusions 134, the need for a balance disc is eliminated.

[0014] According to an embodiment of the invention, a boss 136 is provided at one end of the main channel 126 facing the first end 122. The boss 136 is defined at an angle to guide fluid flow to the stator 106 during operation. The boss 136 is disposed between each of two protrusions 134. The boss 136 allows fluid to be directly splashed onto the windings of the stator 106. Fluid enters at least one inner hole 202 and flows through a plurality of holes 204, through the set of auxiliary channels 128 to the set of main channels 126, and is directly splashed onto the windings of the stator 106 via the boss 136. The fluid can cool the motor 102, promote localized cooling, and prevent thermal degradation.

[0015] According to an embodiment of the present invention, at least one keyway groove 138 is provided on the inner surface of the rotor lamination 108, and at least one keyway groove 140 is provided on the outer surface of each of the at least two rotor blocks 114. At least two rotor blocks 114 are locked to the rotor lamination 108 by inserting at least one key within the at least one keyway groove 138 and at least one keyway groove 140. Similarly, at least one auxiliary keyway groove 142 is provided on the inner surface of the at least two rotor blocks 114, and at least one auxiliary keyway groove 208 is provided on the outer surface of the rotor shaft 110. At least two rotor blocks 114 are locked to the rotor shaft 110 by inserting at least one auxiliary keyway groove 142 and at least one auxiliary key within the at least one auxiliary keyway groove 208.

[0016] According to an embodiment of the invention, at least one keyway 138, at least one keyway 140, and at least one key constitute part of a main locking mechanism. This main locking mechanism provides a robust locking mechanism between at least two rotor blocks 114 and the rotor laminations 108. This ensures precise alignment and torque transmission between the rotor laminations 108 and the at least two rotor blocks 114, thereby reducing the risk of slippage during high-speed operation of the motor 102. At least one auxiliary keyway 140 is optimized to maintain structural integrity and reduce mechanical stress concentration, thereby improving the durability of the rotor laminations 108 during long-term operating cycles. The rotor laminations 108 consist of multiple rotor laminations made of electrical steel of different grades and thicknesses. The rotor laminations 108 are manufactured using processes selected from the group consisting of segmented, slinky, and stamping processes, which should not be construed as limiting.

[0017] According to an embodiment of the invention, at least one auxiliary keyway 142, at least one auxiliary keyway 208, and at least one auxiliary key constitute part of an auxiliary locking mechanism. This auxiliary locking mechanism provides a robust locking mechanism between at least two rotor blocks 114 and the rotor shaft 110. This locking device enables precise installation of each of the at least two rotor blocks 114 and contributes to secure fixation and optimal alignment with the rotor shaft 110. This ensures mechanical stability and operational integrity during operation of the motor 102.

[0018] According to an embodiment of the invention, the motor 102 includes a stator 106 and a rotor 104 disposed within the stator 106. The rotor 104 includes rotor laminations 108 and a rotor shaft 110. The rotor laminations 108 include a plurality of slots for receiving a plurality of magnets 112. The rotor shaft 110 is mechanically connected to the rotor laminations 108, and the rotor 104 rotates in response to a magnetic field of the stator 106. The motor is characterized in that at least two rotor blocks 114 are positioned at opposite ends along the axis of rotation of the rotor laminations 108. The at least two rotor blocks 114 are positioned between an inner surface of the rotor laminations 108 and an outer surface of the rotor shaft 110. The at least two rotor blocks 114 include a hollow body 120 located within an annular region 118 defined around a hollow body 120. The annular region 118 is defined between a first end 122 and a second end 124 of each of the at least two rotor blocks 114, and the hollow body 120 receives the rotor shaft 110. The annular region 118 of each of the at least two rotor blocks 114 includes a plurality of air passages 116 extending from a first end 122 and to a second end 124. Openings of the plurality of air passages 116 are formed on the side surfaces of the first end 122 and the second end 124.

[0019] According to an embodiment of the invention, the motor 102 includes a stator 106 and a rotor 104 disposed within the stator 106. The rotor 104 includes rotor laminations 108 and a rotor shaft 110. The rotor laminations 108 include a plurality of slots for receiving a plurality of magnets 112. The rotor shaft 110 is mechanically connected to the rotor laminations 108, and the rotor 104 rotates in response to a magnetic field of the stator 106. The motor is characterized in that at least two rotor blocks 114 are positioned at opposite ends along the axis of rotation of the rotor laminations 108. The at least two rotor blocks 114 are positioned between an inner surface of the rotor laminations 108 and an outer surface of the rotor shaft 110. The at least two rotor blocks 114 include a hollow body 120 located within an annular region 118 defined around a hollow body 120. The annular region 118 is defined between a first end 122 and a second end 124 of each of the at least two rotor blocks 114, and the hollow body 120 receives the rotor shaft 110. At least two rotor blocks 114, engaging with rotor shaft 110, include flow channels for circulating fluid into the interior of rotor laminations 108. These flow channels include a set of main channels 126 and a set of auxiliary channels 128. The set of main channels 126 is defined between a first end 122 and a second end 124 of the outer surfaces of the at least two rotor blocks 114. The set of auxiliary channels 128 is formed between the second ends 124 of the at least two rotor blocks 114 and at the abutments of the second ends 124 of the at least two rotor blocks 114.

[0020] According to an embodiment of the invention, each of at least two rotor blocks 114 includes an annular region 118 comprising a plurality of air passages 116 extending from a first end 122 to a second end 124. In existing designs, the rotor lamination 108 includes a plurality of air passages 116, but in this invention, the plurality of air passages 116 are formed in at least two rotor blocks 114. Removing the plurality of air passages 116 from the rotor lamination 108 results in an increase in the diameter of the rotor lamination 108. The increased diameter includes at least two rotor blocks 114 engaging with the rotor shaft 110, including flow channels for circulating fluid within the rotor lamination 108. The flow channels include a set of main channels 126 and a set of auxiliary channels 128. These flow channels facilitate fluid circulation to flow closer to the plurality of magnets 112, which act as hot spots in the rotor lamination 108. This ensures efficient heat dissipation and solves a range of thermal management challenges. This minimizes the risk of thermal saturation and enables reliable operation under dynamic load conditions. Introducing aluminum into the manufacture of at least two rotor blocks 114 reduces the demand for electrical steel, resulting in lower costs. Aluminum is also highly recyclable compared to other materials required for manufacturing the at least two rotor blocks 114, which helps improve material lifecycle management and reduce environmental impact.

[0021] According to an embodiment of the invention, the first ends 122 of at least two rotor blocks 114 include a plurality of protrusions 134. In existing designs, the rotor shaft 110 is integrated with the balance disc and spacer ring, but in this invention, the plurality of protrusions 134 improves balancing performance and eliminates the need for the balance disc and spacer ring, thereby reducing the number of components. The reduced weight resulting from eliminating the spacer ring and balance disc consequently reduces the load on at least one bearing, which helps extend bearing life and reduce maintenance requirements.

[0022] Figure 2B An assembly view of a motor 102 according to an embodiment of the present invention is shown. However, the wiring connections of the stator 106 are not shown in the figure. The rotor shaft 110 is locked within at least two rotor blocks 114 using at least one main keyway 140 and at least one main key groove 138, and the rotor shaft 110 integrally formed with the at least two rotor blocks 114 is locked within rotor laminations 108 using at least one auxiliary keyway 208 and at least one auxiliary key groove 142 and at least one auxiliary key. During operation of the motor 102, the rotor 104 rotates in response to the magnetic field of the stator 106.

[0023] When the rotor shaft is assembled into the rotor block, the auxiliary channel is aligned with multiple holes.

[0024] According to an embodiment of the invention, the operation of an electric motor is disclosed. The motor 102 has a split rotor block and an integrated cooling system. Here, the split rotor block refers to a first rotor block and a second rotor block of at least two rotor blocks 114. Fluid is introduced into at least one inner hole 202 formed through the central axis 210 of the rotor shaft 110, and the fluid circulates within this at least one inner hole 202. A plurality of holes 204 are formed on the outer circumference of the rotor shaft 110, allowing fluid flow through the rotor shaft 110 and through a set of auxiliary channels 128 to a set of main channels 126. The set of main channels 126 allows fluid flow through at least one gap between the at least two rotor blocks 114 and the rotor laminations 108. The first ends 122 of the at least two rotor blocks 114 include a plurality of protrusions 134 formed on their circular edges, these protrusions 134 being perpendicular to the side surfaces of each of the at least two rotor blocks 114. A boss 136 is disposed between each of the two protrusions 134, and the boss 136 is defined at an angle to guide fluid flow toward the stator 106 during operation of the motor 102. Fluid splashed onto the windings of the stator 106 accumulates in the lower part of the housing. The housing includes at least one outlet through which fluid flows into the oil pan.

[0025] It should be understood that the embodiments described in the above specification are merely illustrative and do not limit the scope of the invention. Many such embodiments, as well as other modifications and changes to the embodiments described in the specification, are conceivable. The scope of the invention is defined only by the scope of the claims.

Claims

1. An electric motor (102), comprising: Stator (106), and A rotor (104) disposed inside the stator (106) includes rotor laminations (108) and a rotor shaft (110). The rotor laminations (108) include multiple slots for accommodating multiple magnets (112). The rotor shaft (110) is mechanically connected to the rotor laminations (108). The rotor (104) rotates in response to the magnetic field of the stator (106). The rotor (104) is characterized in that... At least two rotor blocks (114) are located at opposite ends along the rotation axis of the rotor lamination (108), and the at least two rotor blocks (114) are located between the inner surface of the rotor lamination (108) and the outer surface of the rotor shaft (110).

2. The motor (102) as described in claim 1, wherein, Each of the at least two rotor blocks (114) includes a hollow body (120) and an annular region (118) defined around the hollow body (120), the hollow body (120) receiving the rotor shaft (110), and the annular region (118) being defined between a first end (122) and a second end (124) of each of the at least two rotor blocks (114).

3. The motor (102) as described in claim 2, wherein, The annular region (118) of each of the at least two rotor blocks (114) includes a plurality of air passages (116) extending from the first end (122) to the second end (124), wherein the openings of the plurality of air passages (116) are formed on the side surfaces at the first end (122) and the second end (124).

4. The motor (102) of claim 2, wherein the at least two rotor blocks (114) engaged with the rotor shaft (110) include flow channels for circulating fluid to the interior of the rotor laminations (108), wherein the flow channels include a set of main channels (126) and a set of auxiliary channels (128), wherein The set of main channels (126) is defined between the first end (122) and the second end (124) and is formed on the outer surface of the at least two rotor blocks (114), and The set of auxiliary channels (128) are formed between the second ends (124) of the at least two rotor blocks (114) and at the adjoining points of the second ends (124) of the at least two rotor blocks (114).

5. The motor (102) as claimed in claim 4, wherein the rotor shaft (110) comprises: a. At least one inner hole (202) formed through the central axis (210) of the rotor shaft (110), and b. A plurality of holes (204) formed on the outer circumferential surface of the rotor shaft (110), the plurality of holes (204) extending inward and connected to the at least one inner hole (202), wherein the at least one inner hole (202) and the plurality of holes (204) allow the fluid to flow through a set of auxiliary channels (128) to the set of main channels (126).

6. The motor (102) of claim 4, wherein the set of auxiliary channels (128) includes a first portion (130) and a second portion (132), the first portion (130) being formed on a first rotor block of the at least two rotor blocks (114), and the second portion (132) being formed on a second rotor block of the at least two rotor blocks (114).

7. The motor (102) as described in claim 2, wherein, The first end (122) of each of the at least two rotor blocks (114) is located outside the rotor lamination (108), and the second end (124) of each of the at least two rotor blocks (114) is adjacent to each other inside the rotor lamination (108).

8. The motor (102) of claim 2, wherein the first end (122) includes a plurality of protrusions (134) formed on the circular edge of the side surface of each of the at least two rotor blocks (114) and perpendicular to the side surface of each of the at least two rotor blocks (114), (stop), wherein each of the plurality of protrusions (134) contributes to balancing the rotor (104) during operation.

9. The motor (102) of claim 4, wherein the plurality of protrusions (134) are located at one end of the main channel (126) facing the first end (122), and the plurality of protrusions (134) are arranged at an angle to guide the fluid toward the stator (106) during the operation.

10. The motor (102) as claimed in claim 1, wherein, At least one keyway groove (138) is provided on the inner surface of the rotor lamination (108), and at least one keyway groove (140) is provided on the outer surface of each of the at least two rotor blocks (114), wherein the at least two rotor blocks (114) are locked to the rotor lamination (108) by inserting at least one key into the at least one keyway groove (138) and the at least one keyway groove (140); and wherein at least one auxiliary keyway groove (142) is provided on the inner surface of the at least two rotor blocks (114), and at least one auxiliary keyway groove (208) is provided on the outer surface of the rotor shaft (110), wherein the at least two rotor blocks (114) are locked to the rotor shaft (110) by inserting at least one auxiliary key into the at least one auxiliary keyway groove (142) and the at least one auxiliary keyway groove (208).

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