Rotor lamination, rotor, electric machine, electric drive system and vehicle

Abstract

Disclosed is a rotor lamination (1), comprising: a base body (10) having a radius R1 and a base body center (O); a plurality of magnetic steel slots arranged in the base body (10), the magnetic steel slots being used for receiving magnetic steels; wherein the magnetic steel slots comprise an inner end close to the base body center and an outer end away from the base body center; wherein a radially outer edge of the base body (10) comprises an outer protrusion (130a, 130b) arranged radially adjacent to the outer end and an inner recess (140) continuously extending from the outer protrusion (130a, 130b), the outer protrusion (130a, 130b) having a maximum radius R3 relative to the base body center, the inner recess (140) having a minimum radius R2 relative to the base body center, and R2 < R1 < R3. Also disclosed is a rotor comprising the above rotor lamination. Also disclosed is an electric machine comprising the rotor. Also disclosed is an electric drive system comprising the electric machine. Also disclosed is a vehicle comprising the electric machine or the electric drive system.

Description

Technical Field

[0001] This disclosure relates to the field of electric motors, and more particularly to a rotor lamination for an electric motor rotor, and also to a rotor including such a rotor lamination, an electric motor including such a rotor, an electric drive system including such an electric motor, and a vehicle including such an electric motor or electric drive system. Background Technology

[0002] With the development of electric vehicles, the requirements for improving the NVH (Noise, Vibration, and Harshness) performance of motors are becoming increasingly stringent, demanding stricter requirements for noise reduction, vibration reduction, and smooth operation. One known method for improving NVH is to incorporate material gaps in the magnetic bridge of the rotor laminations, particularly near the outer edges of the magnet slots along the periphery of the rotor laminations. However, this material gap design has several drawbacks. First, it leads to stress concentration points, especially during high-speed motor operation where centrifugal force creates stress concentration risk points at these gaps, increasing the risk of rotor lamination fracture and resulting in a low structural strength safety factor. Second, it leads to significant losses in motor output torque and power, reducing motor efficiency. Therefore, a new rotor lamination structure is needed that can simultaneously improve NVH, ensure rotor lamination structural strength, and maintain motor power efficiency. Summary of the Invention

[0003] Therefore, this disclosure proposes a rotor lamination configuration that overcomes at least one of the technical problems in the prior art. According to one embodiment, the rotor lamination includes:

[0004] The matrix has a radius of R1 and a center.

[0005] Multiple magnetic grooves are disposed in the substrate, the magnetic grooves being used to receive magnets;

[0006] The magnetic groove includes an inner end near the center of the base and an outer end away from the center of the base;

[0007] The outer radial edge of the substrate includes an outwardly convex portion radially adjacent to the outer end and an inwardly concave portion continuously extending from the outwardly convex portion. The maximum radius of the outwardly convex portion relative to the center of the substrate is R3, and the minimum radius of the inwardly concave portion relative to the center (O) of the substrate is R2. <R1<R3。

[0008] Therefore, in the rotor laminations proposed in this disclosure, the recessed portion allows for improved NVH performance, while the convex and concave portions extend continuously to each other, more specifically, smoothly transitioning to one another, thus eliminating stress concentration points and ensuring the structural strength and safety factor of the rotor laminations. Furthermore, the continuous extension of the convex and concave portions minimizes motor torque loss and power dissipation, ensuring motor operating efficiency.

[0009] According to various embodiments, the rotor laminations proposed in this disclosure may further include one or more of the following further improvements.

[0010] According to some embodiments, each of the recessed portions transitions to a convex portion (referred to as the first adjacent convex portion) at its first circumferential end via a first transition portion, and then transitions to another convex portion (referred to as the second adjacent convex portion) at its second circumferential end opposite to the first circumferential end via a second transition portion. The second adjacent convex portion is an convex portion adjacent to the outer end of another magnet slot among the plurality of magnet slots. More specifically, the first and second transition portions are smooth transition portions, further avoiding stress concentration risk points. Furthermore, by ensuring that the recessed portions smoothly transition to their respective convex portions at both opposite circumferential ends via corresponding transition portions, NVH performance can be improved while maximizing the structural strength of the rotor laminations and minimizing motor torque loss and power loss.

[0011] According to some embodiments, the first adjacent outward protrusions and the second adjacent outward protrusions are circumferentially symmetrical about their respective inward concave portions; the first transition portion and the second transition portion are circumferentially symmetrical about their respective inward concave portions. This configuration allows for simple rotor lamination structure design and ease of processing, and further ensures the overall balanced structural strength of the rotor laminations.

[0012] According to some embodiments, each of the recessed portions transitions to a corresponding convex portion at its first circumferential end via a first transition portion, and at its second circumferential end opposite to the first axial end via a second transition portion to a portion with radius R1 at the radial outer edge of the substrate. More specifically, both the first and second transition portions are smooth transition portions, which further avoids stress concentration risk points and ensures the structural strength of the rotor laminations.

[0013] According to some embodiments, the convex portion transitions at its circumferential end opposite to the concave portion to a portion with radius R1 at the radial outer edge of the substrate via a third transition portion. More specifically, the third transition portion is a smooth transition portion, which further avoids stress concentration risk points and ensures the structural strength of the rotor laminations.

[0014] According to some embodiments, the outward convex portion and / or the inward concave portion have an arcuate shape. This construction allows for simple rotor lamination structure design and ease of processing, while effectively avoiding stress concentration risk points and ensuring structural strength.

[0015] According to some embodiments, at least one of the first transition portion, the second transition portion, and the third transition portion has an arc shape. This configuration allows for simple rotor lamination structure design and ease of manufacturing, while effectively avoiding stress concentration risks and ensuring structural strength.

[0016] In some embodiments, the shape of the protrusion follows the shape of the outer end of the corresponding magnet slot. This configuration allows the protrusion to enhance the structural strength of the rotor laminations and ensure motor performance without causing additional adverse effects on NVH performance.

[0017] According to some embodiments, the magnet slot includes at least one first magnet slot pair arranged in a V-shape, the centerline of the V-shape passing through the center of the base; wherein the concave portion of the base corresponding to the first magnet slot in the first magnet slot pair extends from the convex portion in a circumferential direction away from the centerline. This configuration allows for ensuring the operating efficiency of the motor.

[0018] According to some embodiments, each of the first magnet slot pairs shares a recess with each adjacent first magnet slot pair. This configuration simplifies the rotor lamination structure design, facilitates manufacturing, and maximizes the structural strength of the rotor laminations while minimizing motor torque loss and power dissipation, thereby improving NVH performance.

[0019] According to some embodiments, the magnet slot further includes at least one second magnet slot pair arranged in a V-shape, the second magnet slot pair being disposed radially outside the corresponding first magnet slot pair.

[0020] According to another aspect of this disclosure, a rotor is proposed that includes a plurality of rotor laminations according to any one of the above embodiments, and thus includes corresponding advantages and benefits.

[0021] According to another aspect of this disclosure, an electric motor is proposed, which includes the rotor as described above.

[0022] According to another aspect of this disclosure, an electric drive system is proposed, which includes the motor described above.

[0023] According to another aspect of this disclosure, a vehicle is proposed that includes the motor or the electric drive system described above. Attached Figure Description

[0024] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the accompanying drawings used in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of this disclosure and should not be considered as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort. In the drawings:

[0025] Figure 1 A rotor lamination according to an exemplary embodiment is schematically shown in a partial plan view;

[0026] Figure 2 The base radius, the maximum outer diameter of the convex portion, and the minimum radius of the concave portion are schematically shown in a partial plan view.

[0027] List of reference numerals

[0028] 1 rotor lamination

[0029] 10 matrix

[0030] 100a, 100b; 200a, 200b magnetic steel troughs

[0031] 100a, 100b First Magnet Slot

[0032] 200a, 200b Second Magnet Slot

[0033] 110a, 110b; 210a, 210b inner ends

[0034] 120a, 120b; 220a, 220b outer ends

[0035] 130a, 130b convex parts

[0036] 140 concave portion

[0037] 150 First Transition Section

[0038] 160 Second Transition Section

[0039] 170a, 170b Third Transition Section

[0040] O matrix center

[0041] Radius of R1 matrix

[0042] Minimum radius of the concave part of R2

[0043] The maximum radius of the outer convex part of R3 Detailed Implementation

[0044] The rotor laminations, rotor, motor, electric drive system, and vehicle according to embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. To make the objectives, technical solutions, and advantages of this disclosure clearer, the technical solutions in the embodiments of the present disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present disclosure.

[0045] Therefore, the following detailed description of embodiments of the present disclosure provided in conjunction with the accompanying drawings is not intended to limit the scope of the claimed disclosure, but merely to illustrate selected embodiments of the disclosure. All other embodiments obtained by those skilled in the art based on the embodiments of the present disclosure without inventive effort are within the scope of protection of the present disclosure.

[0046] Unless the context otherwise defines, the singular form includes the plural form. Throughout this specification, the terms “comprising,” “having,” etc., are used herein to specify the presence of the stated features, numbers, steps, operations, elements, components, or combinations thereof, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, components, or combinations thereof.

[0047] Furthermore, even though ordinal terms such as "first" and "second" may be used to describe various components, these components are not limited by these terms, and these terms are only used to distinguish one component from other components. For example, without departing from the scope of this disclosure, a first component may be referred to as a second component, and similarly, a second component may be referred to as a first component.

[0048] In the description of this invention, it should be understood that the terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the disclosed product is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only used to facilitate the description of this disclosure and to simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0049] like Figure 1-2The present disclosure schematically illustrates a rotor lamination 1. According to one embodiment, the rotor lamination 1 may include a base 10 having a radius R1 and a base center O. According to some embodiments, the base 10 is configured to have a central hole, with the base center O being the center of the central hole. It should be noted that the radius R1 of the base 10 means that the radius of a majority of the base 10 is R1, more specifically, it refers to the portion of the recess 140 of the external protrusions 130a and 130b described below. The rotor lamination 1 includes a plurality of magnet slots 100a, 100b, 200a, and 200b disposed in the base 10, the magnet slots 100a, 100b, 200a, and 200b for receiving magnets. Each magnetic groove 100a, 100b, 200a, 200b is configured to include inner ends 110a, 110b, 210a, 210b near the center O of the substrate and outer ends 120a, 120b, 220a, 220b away from the center O of the substrate. The radial outer edge of the substrate 10 includes outwardly convex portions 130a, 130b radially adjacent to the outer ends 120a, 120b, 220a, 220b, and inwardly concave portions 140 continuously extending from the outwardly convex portions 130a, 130b. The maximum radius of the outwardly convex portions 130a, 130b relative to the center O of the substrate is R3, and the minimum radius of the inwardly concave portion 140 relative to the center O of the substrate is R2. <R1<R3。

[0050] Therefore, in the rotor lamination 1 disclosed herein, the recessed portion 140 allows for improved NVH performance. The protruding portions 130a and 130b extend continuously to each other, and more specifically, smoothly transition to each other. Thus, there are no stress concentration points at the recessed portion 140 of the rotor lamination 1, thereby ensuring the structural strength and structural safety factor of the rotor lamination 1. Furthermore, the continuous extension of the protruding portions 130a and 130b and the recessed portion 140 minimizes motor torque loss and power loss, ensuring motor operating efficiency.

[0051] According to some embodiments, such as Figure 1-2 As shown, the shapes of the protrusions 130a and 130b can be configured to follow the shapes of the outer ends 120a and 120b of the corresponding magnet slots 100a and 100b. More specifically, the protrusions 130a and 130b are aligned with the outer ends 120a and 120b of the corresponding magnet slots 100a and 100b, and the outer contours of the protrusions 130a and 130b are substantially consistent with the contours of the outer ends 120a and 120b of the corresponding magnet slots 100a and 100b. This configuration allows the protrusions 130a and 130b to enhance the structural strength of the rotor laminations 1 and ensure motor performance without causing additional adverse effects on NVH performance, because the protrusions 130a and 130b do not increase the material of the rotor laminations 1, and therefore do not increase magnetic reluctance.

[0052] According to some embodiments, such as Figure 1-2 As shown, the outwardly convex portions 130a and 130b have an arcuate shape, more specifically, an arcuate outer contour. Additionally, the inwardly concave portion 140 also has an arcuate shape, more specifically, an arcuate outer contour. This construction allows for a simple design and easy processing of the rotor lamination 1 structure, while effectively avoiding stress concentration risk points and ensuring structural strength.

[0053] According to some embodiments, such as Figure 1-2 As shown, each concave portion 140 transitions to a convex portion 130b at its first circumferential end via a first transition portion 150, referred to as the first adjacent convex portion. At its second circumferential end opposite to the first circumferential end, it transitions to another convex portion 130a via a second transition portion 160, referred to as the second adjacent convex portion. The second adjacent convex portion is the convex portion 130a adjacent to the outer end 120a of another magnet slot 100a among the plurality of magnet slots. More specifically, each concave portion 140 extends continuously at its first circumferential end via the first transition portion 150 and the first adjacent convex portion 130b, and at its second circumferential end via the second transition portion 160 and the second adjacent convex portion 130a. Thus, each concave portion 140 is circumferentially located between two adjacent convex portions 130a and 130b; however, it should be noted that a concave portion does not necessarily exist between two adjacent convex portions. More specifically, the first transition portion 150 and the second transition portion 160 are smooth transition portions, which further avoids stress concentration risk points. In addition, the concave portion 140 is provided to smoothly transition to the corresponding convex portion 130a and 130b at the two opposite circumferential ends via the corresponding transition portions. This can ensure the structural strength of the rotor lamination to the greatest extent while improving NVH performance, and minimize motor torque loss and power loss.

[0054] According to some embodiments, such as Figure 1-2 As shown, the first adjacent outward protrusions 130b and the second adjacent outward protrusions 130a are circumferentially symmetrical about their respective inward concavities 140. More specifically, the first transition portion 150 and the second transition portion 160 are circumferentially symmetrical about their respective inward concavities 140. More specifically, about a radial line passing through the center O of the base and the deepest point of the inward concavity 140, the first adjacent outward protrusions 130b and the second adjacent outward protrusions 130a are mirror images of each other, and the first transition portion 150 and the second transition portion 160 are mirror images of each other about this radial line. This construction allows for simple rotor lamination structure design and ease of processing, and further ensures the overall balanced structural strength of the rotor laminations.

[0055] According to some embodiments not shown, each recess 140 transitions at its first circumferential end to a corresponding convex portion 130b via a first transition portion, and at its second circumferential end opposite the first axial end, transitions via a second transition portion to a portion of the radial outer edge of the base 10 having a radius R1. More specifically, both the first and second transition portions are smooth transition portions, which avoids stress concentration risk points and ensures the structural strength of the rotor laminations.

[0056] According to some embodiments, such as Figure 1 As shown, the convex portions 130a and 130b transition to portions with radius R1 at the radial outer edge of the base 10 via third transition portions 170a and 170b at their circumferential ends opposite to the concave portion 140. More specifically, the third transition portions 170a and 170b are smooth transition portions, which further avoids stress concentration risk points and ensures the structural strength of the rotor laminations.

[0057] According to some embodiments, such as Figure 1 As shown, at least one of the first transition section 150, the second transition section 160, and the third transition sections 170a and 170b has an arc shape. This structure allows for simple rotor lamination design and easy processing, while effectively avoiding stress concentration risks and ensuring structural strength.

[0058] According to some embodiments, such as Figure 1-2 As shown, the magnet slots include at least one first pair of magnet slots 100a and 100b arranged in a V-shape, the centerline of which passes through the center O of the base; wherein, the recessed portion 140 of the base 10 corresponding to the first magnet slots 100a and 100b in the first pair of magnet slots 100a and 100b extends from the convex portions 130a and 130b in a circumferential direction away from the centerline. This configuration allows for ensuring the operating efficiency of the motor.

[0059] According to some embodiments, such as Figure 1-2 As shown, each pair of first magnet slots 100a and 100b shares a recess 140 with each adjacent pair of first magnet slots 100a and 100b. This construction simplifies the rotor lamination structure design, makes manufacturing easier, and maximizes the structural strength of the rotor laminations while improving NVH performance and minimizing motor torque loss and power consumption.

[0060] According to some embodiments, the magnet groove also includes at least one pair of second magnet grooves 200a, 200b arranged in a V shape, the second magnet grooves 200a, 200b being disposed radially outside the corresponding first magnet grooves 100a, 100b.

[0061] According to another aspect of this disclosure, a rotor is proposed that includes a plurality of rotor laminations 1 according to any one of the above embodiments, and thus includes corresponding advantages and benefits.

[0062] According to another aspect of this disclosure, an electric motor is proposed, which includes the rotor as described above.

[0063] According to another aspect of this disclosure, an electric drive system is proposed, which includes the motor described above.

[0064] According to another aspect of this disclosure, a vehicle is proposed that includes the electric motor or the electric drive system described above. The vehicle may be an electrified vehicle, such as a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), a range-extended electric vehicle (REV), or a fuel cell electric vehicle (FCEV). The vehicle may also be a hydrogen fuel cell vehicle.

[0065] The foregoing description, with reference to preferred embodiments, details exemplary implementations of the rotor laminations, rotor, motor, electric drive system, and vehicle proposed by the present invention. However, those skilled in the art will understand that various modifications and alterations can be made to the above specific embodiments without departing from the concept of the present invention, and various combinations can be made to the various technical features and structures proposed by the present invention without exceeding the protection scope of the present invention.

[0066] The scope of this disclosure is not limited by the embodiments described above, but by the appended claims and their equivalents.

Claims

1. A rotor lamination (1), comprising: The matrix (10) has a radius of R1 and a matrix center (O); A plurality of magnet slots (100a, 100b; 200a, 200b) are disposed in the substrate (10), the magnet slots (100a, 100b; 200a, 200b) being used to receive magnets; The magnetic steel groove (100a, 100b; 200a, 200b) includes an inner end (110a, 110b; 210a, 210b) near the center (O) of the substrate and an outer end (120a, 120b; 220a, 220b) away from the center (O) of the substrate. The outer radial edge of the substrate (10) includes an outwardly convex portion (130a, 130b) radially adjacent to the outer ends (120a, 120b; 220a, 220b) and an inwardly concave portion (140) continuously extending from the outwardly convex portion (130a, 130b). The maximum radius of the outwardly convex portion (130a, 130b) relative to the center (O) of the substrate is R3, and the minimum radius of the inwardly concave portion (140) relative to the center (O) of the substrate is R2. <R1<R3。 2. The rotor lamination (1) according to claim 1, wherein, Each of the recesses (140) transitions to a convex portion (130b) at the first circumferential end via a first transition portion (150), referred to as the first adjacent convex portion, and at the second circumferential end opposite to the first circumferential end via a second transition portion (160) to another convex portion (130a), referred to as the second adjacent convex portion. The second adjacent convex portion is an convex portion disposed adjacent to the outer end of another magnetic groove in the plurality of magnetic grooves (100a, 100b; 200a, 200b).

3. The rotor lamination (1) according to claim 2, wherein, The first adjacent protrusion (130b) and the second adjacent protrusion (130a) are circumferentially symmetrical about each other with respect to the corresponding concave portion (140); the first transition portion (150) and the second transition portion (160) are circumferentially symmetrical about each other with respect to the corresponding concave portion (140).

4. The rotor lamination (1) according to claim 1, wherein, Each of the recesses (140) transitions to the corresponding convex portion at the first circumferential end via a first transition portion, and at the second circumferential end opposite to the first axial end via a second transition portion to a portion of the radial outer edge of the base (10) having a radius R1.

5. The rotor lamination (1) according to any one of claims 2 to 4, wherein, The convex portion (130a, 130b) transitions to the radial outer edge of the base (10) with a radius R1 at the circumferential end opposite to the concave portion (140) via a third transition portion (170a, 170b).

6. The rotor lamination (1) according to any one of claims 1 to 4, wherein, The convex portion (130a, 130b) and / or the concave portion (140) have an arcuate shape.

7. The rotor lamination (1) according to claim 5, wherein, At least one of the first transition portion (150), the second transition portion (160), and the third transition portion (170a, 170b) has an arc shape.

8. The rotor lamination (1) according to any one of claims 1 to 4, wherein, The shape of the protrusions (130a, 130b) follows the shape of the outer ends (120a, 120b) of the corresponding magnetic grooves (100a, 100b).

9. The rotor lamination (1) according to any one of claims 1 to 3, wherein, The magnet slots include at least one pair of first magnet slots (100a, 100b) arranged in a V-shape, the center line of the V-shape passing through the center (O) of the base. The concave portion (140) of the substrate (10) corresponding to the first magnet groove (100a, 100b) extends from the convex portion (130a, 130b) in a circumferential direction away from the center line.

10. The rotor lamination (1) according to claim 9, wherein, Each of the first magnet slots (100a, 100b) pairs shares a recess (140) with each of the adjacent first magnet slots (100a, 100b) pairs.

11. The rotor lamination (1) according to claim 9, wherein, The magnet slot also includes at least one pair of second magnet slots (200a, 200b) arranged in a V-shape, the second pair of magnet slots (200a, 200b) being disposed radially outside the corresponding pair of first magnet slots (100a, 100b).

12. A rotor comprising a plurality of rotor laminations (1) according to any one of claims 1 to 11.

13. An electric motor comprising the rotor according to claim 12.

14. An electric drive system comprising the motor according to claim 13.

15. A vehicle comprising the electric motor of claim 13 or the electric drive system of claim 14.

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