An axial flux motor rotor structure

Abstract

The application relates to the technical field of electric machines, in particular to a rotor structure of an axial flux motor, which comprises a rotor support, a plurality of magnetic steel assemblies, a rotor shaft and an insulation isolation piece; the rotor support comprises an inner ring part, an outer ring part and a support part connected between the inner ring part and the outer ring part, and a magnetic steel mounting position is formed between two adjacent support parts; the magnetic steel assembly is arranged in the magnetic steel mounting position; the outer ring part is continuously and closedly arranged along the circumference of the rotor support; the inner ring part is provided with a plurality of openings, the openings extend from the inner circumferential side of the inner ring part to the corresponding magnetic steel mounting position in the radial direction; one end of the support part close to the rotor shaft is provided with a connecting hole, and the rotor shaft is fixedly connected with the rotor support through the connecting hole; and the insulation isolation piece is arranged between the rotor shaft and the rotor support. The outer ring part is continuously and closedly arranged, and the inner ring part is provided with a plurality of openings, so that the structural strength of the outer circumferential region of the rotor support is improved, the eddy current loss of the rotor structure is considered, and the structural reliability and use performance of the whole rotor are improved.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a rotor structure for an axial flux motor. Background Technology

[0002] An axial flux motor is a type of motor in which the magnetic flux is mainly distributed along the motor axis. It features a compact structure, small axial dimensions, and high power density, making it promising for applications such as robot joints, automated equipment, and others where motor size, weight, and power density are critical. The rotor of an axial flux motor typically includes a rotor support, multiple magnets mounted on the rotor support, and a rotor shaft connected to the rotor support. The rotor support is used to mount and position the magnets and transmit the torque generated by the magnets to the rotor shaft.

[0003] During the operation of an axial flux motor, the rotor needs to rotate at a high speed, and the structure located on the radially outer region of the rotor support, as well as the magnets, are subjected to significant centrifugal forces. Therefore, the rotor support needs to have good overall structural strength, especially ensuring sufficient radial load-bearing capacity in the outer periphery of the rotor support. When the rotor support is made of a conductive material, eddy currents are easily generated under the influence of a changing magnetic field, resulting in energy loss and temperature rise.

[0004] Therefore, there is an urgent need to provide an improved rotor structure for axial flux motors. While ensuring reliable installation of the magnets and reliable connection between the rotor support and the rotor shaft, the structure integrity and mechanical strength of the rotor support, especially its outer peripheral area, should be improved to meet the load-bearing requirements under high-speed rotation conditions. At the same time, the structure and conductive path of the rotor support should be rationally designed to take into account eddy current losses and simplify the connection and assembly structure between the rotor support and the rotor shaft, thereby improving the overall structural reliability and performance of the rotor. Summary of the Invention

[0005] In view of at least one of the above technical problems, the present invention provides an axial flux motor rotor structure, which improves the overall structural reliability of the rotor by structural improvements.

[0006] According to a first aspect of the present invention, an axial flux motor rotor structure is provided, comprising:

[0007] Rotor support, multiple magnet assemblies, rotor shaft, and insulating components;

[0008] The rotor support includes an inner ring portion, an outer ring portion, and a plurality of support portions connected between the inner ring portion and the outer ring portion. The plurality of support portions are arranged at intervals along the circumference of the rotor support, and a magnet mounting position is formed between two adjacent support portions.

[0009] Multiple magnet assemblies are respectively disposed in multiple magnet mounting positions, and the two circumferential sides of each magnet assembly are respectively engaged with two adjacent support portions, and the radial outer side of each magnet assembly is engaged with the outer ring portion;

[0010] The outer ring portion is continuously closed along the circumference of the rotor support;

[0011] The inner ring portion is provided with multiple openings, which extend radially from the inner circumference of the inner ring portion to the corresponding magnet mounting position, and the openings are spaced apart on opposite sides.

[0012] Each of the support portions has a connecting hole at one end near the rotor shaft, and the rotor shaft is fixedly connected to the rotor bracket through the connecting hole;

[0013] The insulating isolator is disposed between the rotor shaft and the rotor support.

[0014] In some embodiments of the present invention, a plurality of openings are arranged at circumferential intervals along the inner ring portion, and the plurality of openings correspond one-to-one with a plurality of magnet mounting positions.

[0015] In some embodiments of the invention, a gap extending circumferentially along the rotor support is formed between the opposite sides of each of the openings.

[0016] In some embodiments of the present invention, a plurality of the connecting holes are spaced apart circumferentially along the rotor support, the rotor shaft is provided with a plurality of mounting holes corresponding to the plurality of connecting holes, and the rotor shaft and the rotor support are fixedly connected by fasteners passing through the connecting holes and the mounting holes.

[0017] In some embodiments of the present invention, the insulating insulating element is an insulating gasket, which is sandwiched between the surfaces of the rotor shaft and the rotor support. The insulating gasket has a plurality of through holes corresponding to the plurality of connection holes, and the fastener passes through the through holes.

[0018] In some embodiments of the present invention, each of the magnet components includes a first magnet and a second magnet, the first magnet and the second magnet being respectively disposed on opposite sides of the rotor support, and the opposite sides of the first magnet and the second magnet being fixedly connected.

[0019] In some embodiments of the present invention, an adhesive layer is provided between the opposite sides of the first magnet and the second magnet, and the first magnet and the second magnet are fixedly connected by the adhesive layer.

[0020] In some embodiments of the present invention, each of the support portions is provided with a first mating surface and a second mating surface on both axial sides. The first mating surface and the second mating surface are both inclined relative to the axial direction of the rotor bracket. The first magnet mates with the first mating surface, and the second magnet mates with the second mating surface.

[0021] In some embodiments of the present invention, both the first magnet and the second magnet have chamfered portions on their circumferential sides. The chamfered portion of the first magnet forms an inclined surface that mates with the corresponding first mating surface, and the chamfered portion of the second magnet forms an inclined surface that mates with the corresponding second mating surface.

[0022] In some embodiments of the present invention, the first magnet and the second magnet in the same magnet assembly have the same axial magnetization direction, two adjacent magnet assemblies along the circumference of the rotor support have opposite axial magnetization directions, and a plurality of magnet assemblies are arranged at intervals along the circumference of the rotor support.

[0023] The beneficial effects of this invention are as follows: By continuously closing the outer ring along the circumference of the rotor support, the outer peripheral region of the rotor support maintains a continuous structural form, and the outer ring constrains the radially outer side of the magnet assembly, thereby improving the structural integrity and mechanical strength of the outer peripheral region of the rotor support to meet the radial load requirements under high-speed rotor rotation; by providing multiple openings extending radially from the inner circumference to the magnet mounting position in the inner ring, the discontinuous region of the rotor support is located radially inward, and the conductive path of the rotor support is adjusted while maintaining the continuous closure of the outer ring, thus balancing the mechanical strength and eddy current loss of the rotor support; by providing connecting holes at the end of each support near the rotor shaft, and fixing the rotor shaft to the rotor support through the connecting holes, the rotor support can still form a reliable connection with the rotor shaft even when the inner ring forms a discontinuous structure. While ensuring reliable installation of the magnet assembly and reliable connection between the rotor support and the rotor shaft, the structural strength of the outer peripheral region of the rotor support is improved, while eddy current loss and connection reliability of the rotor structure are also considered, thereby improving the overall structural reliability and performance of the rotor. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the rotor structure of the axial flux motor in an embodiment of the present invention;

[0026] Figure 2 This is an exploded view of the axial flux motor rotor structure in an embodiment of the present invention;

[0027] Figure 3 This is a schematic diagram of the rotor support structure in an embodiment of the present invention;

[0028] Figure 4 As described in the embodiments of the present invention Figure 3 Enlarged structural diagram at point A;

[0029] Figure 5 This is a schematic diagram of the rotor support structure in an embodiment of the present invention;

[0030] Figure 6 This is a schematic diagram of the structure of the magnet assembly in an embodiment of the present invention.

[0031] Reference numerals: 1. Rotor support; 11. Inner ring; 11a. Opening; 11b. Gap; 12. Outer ring; 13. Support; 13a. Connecting hole; 13b. First mating surface; 13c. Second mating surface; 14. Magnet mounting position; 2. Magnet assembly; 21. First magnet; 21a. Chamfered part; 22. Second magnet; 3. Rotor shaft; 31. Mounting hole; 4. Insulating gasket; 41. Through hole. Detailed Implementation

[0032] 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.

[0033] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly attached to the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0035] like Figures 1 to 6 The axial flux motor rotor structure shown includes:

[0036] The rotor support 1, multiple magnet assemblies 2, rotor shaft 3, and insulating isolator are provided. The rotor support 1 forms the mounting base for the multiple magnet assemblies 2. The multiple magnet assemblies 2 are set on the rotor support 1. The rotor shaft 3 is fixedly connected to the rotor support 1. The insulating isolator is set between the rotor shaft 3 and the rotor support 1, thereby forming a rotor structure in which the rotor support 1, magnet assemblies 2, rotor shaft 3, and insulating isolator cooperate with each other.

[0037] Rotor support 1, such as Figures 3 to 5 As shown, it includes an inner ring portion 11, an outer ring portion 12, and a plurality of support portions 13 connected between the inner ring portion 11 and the outer ring portion 12. The plurality of support portions 13 are arranged at intervals along the circumference of the rotor support 1, and a magnet mounting position 14 is formed between two adjacent support portions 13.

[0038] Multiple magnet assemblies 2 are respectively disposed in multiple magnet mounting positions 14. The two circumferential sides of the magnet assembly 2 are respectively engaged with two adjacent support parts 13, and the radial outer side of the magnet assembly 2 is engaged with the outer ring part 12. The circumferential position of the magnet assembly 2 is constrained by the adjacent support parts 13, and the radial outer side of the magnet assembly 2 is constrained by the outer ring part 12, so as to form the installation relationship between the magnet assembly 2 and the rotor support 1.

[0039] The outer ring 12 is continuously closed along the circumference of the rotor support 1, so that the radial outer periphery of the rotor support 1 maintains a continuous structural form. During rotor rotation, the continuously closed outer ring 12 can maintain the structural continuity of the outer periphery of the rotor support 1 and form a constraint on the radial outer side of the magnet assembly 2, thereby improving the structural integrity and mechanical strength of the outer periphery of the rotor support 1 to meet the radial load requirements under rotor rotation.

[0040] The inner ring 11 is provided with multiple openings 11a, such as Figure 4 As shown, the opening 11a extends radially from the inner circumferential side of the inner ring 11 to the corresponding magnet mounting position 14. The opposite sides of the opening 11a are spaced apart, so that the inner ring 11 forms a discontinuous structure at the opening 11a position. While the outer ring 12 remains circumferentially continuous and closed, the discontinuous area of ​​the rotor support 1 is set on the radially inner side. The conductive path in the rotor support 1 is configured through the discontinuous structure of the inner ring 11, thereby maintaining the structural continuity of the outer circumferential area while taking into account the eddy current loss in the rotor support 1.

[0041] Each support 13 has a connecting hole 13a at one end near the rotor shaft 3. (Continue referring to...) Figure 4The rotor shaft 3 is fixedly connected to the rotor support 1 through the connecting hole 13a, so that the end of the support part 13 near the rotor shaft 3 forms the connection position between the rotor support 1 and the rotor shaft 3. Even with the opening 11a provided in the inner ring part 11, the rotor support 1 can still form a fixed connection with the rotor shaft 3 through the connecting hole 13a on the support part 13, thereby forming a stable connection between the rotor support 1 and the rotor shaft 3.

[0042] An insulating isolator is disposed between the rotor shaft 3 and the rotor support 1. The rotor shaft 3 and the rotor support 1 are fixedly connected to each other while being isolated by the insulating isolator. The insulating isolator and the opening 11a on the inner ring 11 work together to configure the conductive path in the rotor structure, so as to further take into account the eddy current loss in the rotor structure while maintaining the connection between the rotor support 1 and the rotor shaft 3.

[0043] In the rotor structure of the axial flux motor, multiple magnet assemblies 2 are respectively arranged in magnet mounting positions 14 formed by adjacent support parts 13. The circumferential sides of the magnet assembly 2 are matched with the support parts 13 and the radially outer side is matched with the continuously closed outer ring part 12. The inner ring part 11 forms a discontinuous structure through multiple openings 11a. The end of each support part 13 near the rotor shaft 3 is fixedly connected to the rotor shaft 3 through the connecting hole 13a. An insulating isolator is arranged between the rotor shaft 3 and the rotor support 1. Through the cooperation between the various structures, while ensuring the installation of the magnet assembly 2 and the fixed connection between the rotor support 1 and the rotor shaft 3, the outer ring part 12 is kept continuously closed to improve the structural integrity and mechanical strength of the outer peripheral area of ​​the rotor support 1. At the same time, the conductive path is configured through the discontinuous structure of the inner ring part 11 and the insulating isolator between the rotor shaft 3 and the rotor support 1, thereby taking into account both the mechanical load-bearing capacity and eddy current loss of the rotor support 1.

[0044] like Figure 4 As shown, multiple openings 11a are spaced apart circumferentially along the inner ring 11. Each opening 11a corresponds to a magnet mounting position 14, meaning that each magnet mounting position 14 corresponds to one opening 11a. The inner ring 11 forms a discontinuous region at the position corresponding to each magnet mounting position 14. By arranging multiple openings 11a according to the circumferential arrangement of the magnet mounting positions 14, the discontinuous structure on the radially inner side of the rotor support 1 is distributed circumferentially. This allows the conductive path of the rotor support 1 to be configured while the outer ring 12 remains continuously closed. The arrangement of the openings 11a on the inner ring 11 also takes into account the mechanical load-bearing capacity and eddy current loss of the rotor support 1.

[0045] like Figure 4 , Figure 5As shown, a gap 11b extending circumferentially along the rotor support 1 is formed between the opposite sides of each opening 11a, so that the inner ring portions 11 on both sides of the opening 11a are spaced apart from each other in the circumferential direction, and the opening 11a positions do not form a continuous connection. This keeps the inner ring portions 11 in a discontinuous state at the corresponding positions, thereby separating the continuous conductive path on the radially inner side of the rotor support 1 and forming a different structural continuity state from the continuously closed outer ring portion 12.

[0046] like Figure 2 As shown, multiple connecting holes 13a are spaced apart along the circumference of the rotor support 1. The rotor shaft 3 is provided with multiple mounting holes 31 corresponding to the multiple connecting holes 13a. The rotor shaft 3 and the rotor support 1 are fixedly connected by fasteners passing through the connecting holes 13a and mounting holes 31. During installation, the fasteners pass through the corresponding connecting holes 13a and mounting holes 31, so that the rotor shaft 3 and the rotor support 1 form a circumferentially distributed connection relationship, and the rotor support 1 can be fixed to the rotor shaft 3 through the connecting holes 13a.

[0047] Continue to refer to Figure 2 The insulating isolator is an insulating gasket 4, which is sandwiched between the surfaces of the rotor shaft 3 and the rotor support 1. The insulating gasket 4 has multiple through holes 41 corresponding to multiple connection holes 13a. Fasteners are inserted through the through holes 41. The rotor shaft 3 and the rotor support 1 are isolated from each other by the insulating gasket 4 while maintaining a fixed connection, thereby reducing the possibility of forming a continuous conductive path between the rotor shaft 3 and the rotor support 1, so as to further take into account the eddy current loss in the rotor structure.

[0048] In some embodiments of the present invention, such as Figure 6 As shown, each magnet assembly 2 includes a first magnet 21 and a second magnet 22. The first magnet 21 and the second magnet 22 are respectively disposed on both sides of the rotor support 1. The opposite sides of the first magnet 21 and the second magnet 22 are fixedly connected, so that the first magnet 21 and the second magnet 22 located on both sides of the rotor support 1 form a magnet assembly 2 that is interconnected. Thus, the first magnet 21 and the second magnet 22 are jointly installed in the corresponding magnet mounting positions 14, and an overall installation relationship is formed between the magnet assembly 2 and the rotor support 1.

[0049] In some embodiments of the present invention, an adhesive layer is provided between the opposite sides of the first magnet 21 and the second magnet 22, and the first magnet 21 and the second magnet 22 are fixedly connected by the adhesive layer, so that the first magnet 21 and the second magnet 22 form an integrally connected magnet assembly 2, thereby maintaining the relative position between the first magnet 21 and the second magnet 22 and forming a fixed connection structure of the magnet assembly 2.

[0050] like Figure 5As shown, each support portion 13 has a first mating surface 13b and a second mating surface 13c on its axial sides. The first mating surface 13b and the second mating surface 13c are both inclined relative to the axial direction of the rotor support 1. The first magnet 21 mates with the first mating surface 13b, and the second magnet 22 mates with the second mating surface 13c. The support portion 13 forms inclined mating areas on its axial sides that mate with the first magnet 21 and the second magnet 22. The structural mating between the support portion 13 and the first magnet 21 and the second magnet 22 forms a positional constraint on the magnet assembly 2, thereby improving the installation stability of the magnet assembly 2 in the magnet mounting position 14.

[0051] Continue to refer to Figure 5 Both the first magnet 21 and the second magnet 22 have chamfered portions 21a on their circumferential sides. The chamfered portion 21a of the first magnet 21 forms an inclined surface that mates with the corresponding first mating surface 13b, and the chamfered portion 21a of the second magnet 22 forms an inclined surface that mates with the corresponding second mating surface 13c. This allows the circumferential sides of the first magnet 21 and the second magnet 22 to mate with the adjacent support portion 13 through the inclined surfaces. Thus, the structural fit between the chamfered portion 21a and the corresponding mating surface constrains the circumferential position of the first magnet 21 and the second magnet 22, improving the stability of the fit between the magnet assembly 2 and the support portion 13.

[0052] like Figure 1 As shown, the first magnet 21 and the second magnet 22 in the same magnet assembly 2 have the same axial magnetization direction, and the axial magnetization directions of two adjacent magnet assemblies 2 along the circumference of the rotor support 1 are opposite. Multiple magnet assemblies 2 are arranged at intervals along the circumference of the rotor support 1. The first magnet 21 and the second magnet 22 in the same magnet assembly 2 form the same axial magnetization direction, and the axial magnet assemblies 2 that are adjacent along the circumference form opposite axial magnetization directions. Thus, multiple magnet assemblies 2 form an alternating magnetic pole arrangement relationship along the circumference of the rotor support 1.

[0053] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A rotor structure for an axial flux motor, characterized in that, include: Rotor support, multiple magnet assemblies, rotor shaft, and insulating components; The rotor support includes an inner ring portion, an outer ring portion, and a plurality of support portions connected between the inner ring portion and the outer ring portion. The plurality of support portions are arranged at intervals along the circumference of the rotor support, and a magnet mounting position is formed between two adjacent support portions. Multiple magnet assemblies are respectively disposed in multiple magnet mounting positions, and the two circumferential sides of each magnet assembly are respectively engaged with two adjacent support portions, and the radial outer side of each magnet assembly is engaged with the outer ring portion; The outer ring portion is continuously closed along the circumference of the rotor support; The inner ring portion is provided with multiple openings, which extend radially from the inner circumference of the inner ring portion to the corresponding magnet mounting position, and the openings are spaced apart on opposite sides. Each of the support portions has a connecting hole at one end near the rotor shaft, and the rotor shaft is fixedly connected to the rotor bracket through the connecting hole; The insulating isolator is disposed between the rotor shaft and the rotor support.

2. The axial flux motor rotor structure according to claim 1, characterized in that, The plurality of openings are spaced apart circumferentially along the inner ring portion, and each of the plurality of openings corresponds one-to-one with a plurality of magnet mounting positions.

3. The axial flux motor rotor structure according to claim 2, characterized in that, A gap extending circumferentially along the rotor support is formed between the opposite sides of each of the openings.

4. The axial flux motor rotor structure according to claim 1, characterized in that, The plurality of connecting holes are spaced apart along the circumference of the rotor support, and the rotor shaft is provided with a plurality of mounting holes corresponding to the plurality of connecting holes. The rotor shaft and the rotor support are fixedly connected by fasteners passing through the connecting holes and the mounting holes.

5. The axial flux motor rotor structure according to claim 1, characterized in that, The insulating insulating component is an insulating gasket, which is sandwiched between the surfaces of the rotor shaft and the rotor support. The insulating gasket has multiple through holes corresponding to the multiple connection holes, and the fastener passes through the through holes.

6. The axial flux motor rotor structure according to claim 1, characterized in that, Each of the magnet assemblies includes a first magnet and a second magnet, which are respectively disposed on opposite sides of the rotor support, and the opposite sides of the first magnet and the second magnet are fixedly connected.

7. The axial flux motor rotor structure according to claim 6, characterized in that, An adhesive layer is provided between the opposite sides of the first magnet and the second magnet, and the first magnet and the second magnet are fixedly connected by the adhesive layer.

8. The axial flux motor rotor structure according to claim 7, characterized in that, Each of the support portions has a first mating surface and a second mating surface on its axial sides. Both the first mating surface and the second mating surface are inclined relative to the axial direction of the rotor bracket. The first magnet mates with the first mating surface, and the second magnet mates with the second mating surface.

9. The axial flux motor rotor structure according to claim 8, characterized in that, Both the first magnet and the second magnet have chamfered portions on their circumferential sides. The chamfered portion of the first magnet forms an inclined surface that mates with the corresponding first mating surface, and the chamfered portion of the second magnet forms an inclined surface that mates with the corresponding second mating surface.

10. The axial flux motor rotor structure according to claim 9, characterized in that, The first and second magnets in the same magnet assembly have the same axial magnetization direction, and the axial magnetization directions of two adjacent magnet assemblies along the circumference of the rotor support are opposite. Multiple magnet assemblies are arranged at intervals along the circumference of the rotor support.

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