A non-metallic flux disk rotor assembly with a metal collar

Abstract

The application discloses a non-metal magnetic flux disc rotor assembly with a metal ring for fastening, a plurality of magnetic steel mounting grooves are formed in the non-metal magnetic flux disc, a magnetic steel is arranged at each magnetic steel mounting groove, and each magnetic steel is provided with a sawtooth structure formed in the inner wall of each magnetic steel mounting groove; a metal ring is sleeved on the non-metal magnetic flux disc, the metal ring is in interference fit with the non-metal magnetic flux disc, and the metal ring is used for fastening the non-metal magnetic flux disc to prevent the non-metal magnetic flux disc from being deformed by a magnetic force; a plurality of fastening bolts are arranged on the metal ring, each fastening bolt is arranged in one-to-one correspondence with each magnetic steel mounting groove, and is connected with the non-metal magnetic flux disc, and is used for fixing the metal ring on the outer ring of the non-metal magnetic flux disc. The application improves the overall mechanical strength and operation stability of the rotor assembly, improves the reliability of the magnetic steel fixation, reduces the dependence on special equipment, reduces the manufacturing cost, guarantees the form and position tolerances and surface precision of the rotor assembly, and improves the smoothness of the motor during operation.

Description

Technical Field

[0001] This invention relates to the field of motor rotor technology, and more specifically, to a non-metallic flux disk rotor assembly clamped by a metal ring. Background Technology

[0002] In the field of motor rotor technology, flux disk rotor assemblies are one of the core components of motors. With technological advancements, non-metallic flux disks have been increasingly adopted due to their specific advantages. However, existing non-metallic flux disks still have some shortcomings in practical applications. First, the non-metallic magnetic flux disk itself is not strong enough. During the installation and operation of the magnets, it is easily deformed due to the strong magnetic force, which affects the operating stability and service life of the rotor assembly. Secondly, traditional non-metallic structures have poor reliability when fixing magnets. The inner wall of existing magnet mounting slots usually adopts a flat straight wall structure (i.e., a straight up and down plane). When installing magnets, although the adhesion between the glue and the magnet is good, the flat contact surface is prone to slippage, resulting in a high risk of the magnet falling off under the action of strong magnetic attraction. In addition, in order to solve the problems of insufficient strength and easy deformation of non-metallic magnetic flux disks, carbon fiber tape winding process is often used to reinforce the rotor in the existing technology; however, this process has disadvantages such as high cost, reliance on special equipment, and difficulty in mass production.

[0003] Therefore, there is an urgent need for a rotor assembly that can improve the mechanical strength of non-metallic magnetic flux disks, prevent deformation during operation, enhance the reliability of magnet fixing, and is easy to mass-produce, in order to solve the problems existing in the above-mentioned prior art. Summary of the Invention

[0004] To achieve the above objectives, the present invention provides a non-metallic flux disk rotor assembly with a metal ring clamp, comprising a non-metallic flux disk, wherein a plurality of magnet mounting slots are provided on the non-metallic flux disk, and a magnet is provided at each of the magnet mounting slots. Each magnet increases the contact area with the magnet mounting slot through a serrated structure formed on the inner wall of each magnet mounting slot to prevent the magnet from falling off. A metal ring is fitted onto the non-metallic magnetic flux disk, and the metal ring is interference-fitted with the non-metallic magnetic flux disk to tighten the non-metallic magnetic flux disk and prevent the non-metallic magnetic flux disk from deforming under magnetic force. The metal ring is provided with a number of fastening bolts, each of which is respectively provided with a corresponding magnetic steel mounting groove and connected to the non-metallic magnetic flux disk, for fixing the metal ring to the outer ring of the non-metallic magnetic flux disk.

[0005] Furthermore, the overall outer diameter of the non-metallic flux disk is within 350mm, and the interference fit tolerance between the metal ring and the non-metallic flux disk is H7 / s6 or H7 / r6.

[0006] Furthermore, the serrated structure encircles the inner wall of each mounting position of the magnet mounting groove, and the serrated structure is filled with structural adhesive. After the structural adhesive cures, it forms a mechanical interlock with the serrated structure, which is used to reinforce the magnet without affecting the strength of the non-metallic magnetic flux disk body.

[0007] Furthermore, the structural adhesive is EP1249 high-temperature resistant epoxy structural adhesive, the curing conditions of the EP1249 high-temperature resistant epoxy structural adhesive are 40 minutes at 100°C, the thermal strength of the EP1249 high-temperature resistant epoxy structural adhesive at 25°C is 26 MPa, and the thermal strength of the EP1249 high-temperature resistant epoxy structural adhesive at 180°C is 5 MPa.

[0008] Furthermore, the sawtooth structure is provided in three rows, which are arranged sequentially at intervals along the rotor axis, and each sawtooth structure extends circumferentially along the inner wall of the magnet mounting groove.

[0009] Furthermore, the inner wall of the magnet mounting groove is provided with several side grooves; the serrated structure continuously penetrates each side groove in the circumferential direction, so that the groove wall of the side groove is correspondingly formed with serrated segments that connect with the serrations of the inner wall.

[0010] Furthermore, a motor shaft is provided at the center of the non-metallic flux disk, the motor shaft passes through the non-metallic flux disk, a flat key is provided on the motor shaft, the flat key is used to transmit torque, and the metal ring is fixedly connected to the motor shaft by a through-lock bolt.

[0011] Furthermore, the non-metallic flux disk includes an inner ring and an outer ring, the motor shaft passes through the inner ring, and the outer wall of the inner ring is connected to the inner wall of the outer ring by a number of connectors, the connectors being integrally formed with the inner ring and the outer ring; There are magnet mounting slots between two adjacent connectors, the outer wall of the inner ring is provided with one side groove, and the inner wall of the outer ring is provided with two side grooves.

[0012] Furthermore, after the metal ring and the non-metallic magnetic flux disk are assembled with an interference fit, the metal ring and the non-metallic magnetic flux disk are machined as a whole to ensure dimensional and positional tolerances and surface accuracy.

[0013] Furthermore, the metal ring is an aluminum ring or a stainless steel ring.

[0014] The present invention has the following beneficial effects: 1. This invention involves placing a metal ring around the outer ring of a non-metallic flux disk and using an interference fit between the metal ring and the non-metallic flux disk. Simultaneously, fastening bolts are used to fix the metal ring to the outer ring of the non-metallic flux disk. The fastening force generated by the interference fit tightens the non-metallic flux disk, thereby constraining the deformation tendency of the non-metallic material under strong magnetic environment and improving the overall mechanical strength and operational stability of the rotor assembly. 2. This invention creates a serrated structure on the inner wall of the magnet mounting groove and fills the serrated structure with structural adhesive. After the adhesive cures, it forms a mechanical interlock with the serrated structure, increasing the contact area and interlocking force between the adhesive and the substrate. This prevents the magnet from falling off along the normal direction of the contact surface due to magnetic attraction and improves the reliability of magnet fixing. 3. This invention uses a metal ring interference fit clamping method to reinforce the non-metallic magnetic flux disk, replacing the traditional carbon fiber tape winding process, reducing dependence on special equipment, reducing manufacturing costs, and making it easier to achieve mass production; 4. This invention creates side grooves on the inner wall of the magnet mounting groove, allowing the serrated structure to continuously penetrate each side groove in the circumferential direction. Corresponding serrated segments are formed on the groove wall of the side grooves to connect with the serrated teeth on the inner wall, which further increases the filling space and interlocking area of ​​the structural adhesive and enhances the connection between the magnet and the magnet mounting groove. 5. The present invention sets a motor shaft at the center of a non-metallic flux disk and sets a flat key on the motor shaft for transmitting torque. At the same time, a metal ring is fixedly connected to the motor shaft by a through-locking bolt, and a serrated structure is also set on the inner wall of the mounting hole through which the through-locking bolt passes, so that the connection at the mounting hole also has a mechanical interlocking effect, thereby improving the overall stability of the rotor assembly. 6. This invention eliminates the microscopic deformation of non-metallic materials caused by magnetic force or assembly stress by machining the entire assembly after the metal ring and non-metallic flux disk are assembled with an interference fit. This ensures the form and position tolerances and surface accuracy of the rotor assembly and improves the stability of the motor during operation. Attached Figure Description

[0015] Figure 1 This is a structural schematic diagram of a specific embodiment of the present invention.

[0016] Figure 2 This is another three-dimensional structural schematic diagram of the present invention.

[0017] Figure 3 This is a schematic diagram of the structure of the present invention without components such as a motor shaft.

[0018] Figure 4 yes Figure 3 A magnified schematic diagram of the structure at point A in the middle.

[0019] Figure 5 This is a three-dimensional structural diagram of the magnet in this invention.

[0020] Figure 6 This is a schematic diagram of the connection structure between a non-metallic flux disk and components such as a metal ring.

[0021] Figure 7 This is a schematic diagram of the three-dimensional structure of a metal ring.

[0022] Figure 8 This is a schematic diagram of the three-dimensional structure of a non-metallic magnetic flux disk.

[0023] The attached diagram lists the components represented by each number as follows: 1. Non-metallic flux disk; 1a. Inner ring; 1b. Outer ring; 1c. Connector; 2. Magnet mounting slot; 3. Magnet; 5. Metal ring; 6. Fastening bolt; 7. Serrated structure; 7a. Serrated section; 10. Side groove; 11. Motor shaft; 12. Flat key; 13. Through-lock bolt. Detailed Implementation

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments: In the description of this invention, it should be noted that the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not 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 the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0025] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "setting," and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0026] like Figures 1 to 8 As shown, this embodiment provides a non-metallic flux disk rotor assembly with a metal ring clamp, which mainly solves the problem of structural deformation caused by strong magnetic force during the installation and operation of non-metallic flux disks and the defect of poor reliability of traditional non-metallic structures for fixing magnets; by adopting a structural design that combines metal ring interference fit clamping with inner wall serration reinforcement, the mechanical strength and operational stability of the rotor assembly are improved.

[0027] The non-metallic magnetic flux disk rotor assembly with metal ring clamping in this embodiment mainly includes a non-metallic magnetic flux disk 1, a metal ring 5, a magnet mounting groove 2, and fastening bolts.

[0028] Specifically, the non-metallic magnetic flux disk 1 has several magnet mounting slots 2, and the magnet mounting slots 2 are all non-metallic, so the product as a whole is a non-metallic magnetic flux disk.

[0029] Each magnet mounting slot 2 is equipped with a magnet 3. Each magnet 3 has a serrated structure 7 on the inner wall of each magnet mounting slot 2 to increase the contact area with the magnet mounting slot 2 and prevent the magnet 3 from falling off.

[0030] A metal ring 5 is fitted onto the non-metallic magnetic flux disk 1. The metal ring 5 is interference-fitted with the non-metallic magnetic flux disk 1 to tighten it and prevent deformation under magnetic force. Specifically, the non-metallic magnetic flux disk 1 is prone to deformation under strong magnetic force during operation. The metal ring 5 tightens the non-metallic magnetic flux disk 1 through interference fit, thus constraining the deformation tendency of the non-metallic material under strong magnetic environment, thereby solving the problems of insufficient strength and easy deformation of the non-metallic magnetic flux disk 1 under strong magnetic force during operation.

[0031] A number of fastening bolts 6 are provided on the metal ring 5, each corresponding to a magnet mounting slot 2 and connected to the non-metallic magnetic disk 1 to fix the metal ring 5 to the outer ring of the non-metallic magnetic disk 1. After the metal ring 5 is assembled in place, it is fixed to the outer ring position of the magnet mounting slot 2 by the fastening bolts 6, so that the metal ring 5, the magnet mounting slot 2 and the non-metallic magnetic disk 1 form an integrated structure.

[0032] As an example, in this embodiment, the metal ring 5 structure is mainly used to replace the carbon fiber tape winding process commonly used in the prior art, and has the advantages of low cost, no need for special equipment, and easy mass production.

[0033] In this embodiment or other embodiments, the overall outer diameter of the non-metallic flux disk 1 is within 350mm, and the interference fit tolerance grade between the metal ring 5 and the non-metallic flux disk 1 is H7 / s6 or H7 / r6.

[0034] In this embodiment or other embodiments, the metal ring 5 is an aluminum ring or a stainless steel ring.

[0035] According to the above description, in an exemplary embodiment, the serrated structure 7 encircles the inner wall of each mounting position of the magnet mounting groove 2, that is, a serrated structure 7 is provided on the inner wall of each mounting position of the magnet mounting groove 2. The serrated structure 7 is filled with structural adhesive, which, after curing, forms a mechanical interlock with the serrated structure 7, thereby reinforcing the magnet 3 without affecting the strength of the non-metallic magnetic flux disk 1, and effectively preventing the magnet 3 from falling off along the normal direction of the contact surface due to magnetic attraction.

[0036] The main function of the serrated structure 7 is to form a mechanical interlock after the adhesive has cured. Compared with the traditional flat straight-wall structure (i.e., the original straight-up-down plane of the inner wall), the serrated structure 7 can significantly increase the contact area and interlocking force between the adhesive and the substrate, solving the risk that although the adhesive and the magnet 3 have good adhesion, the flat surface is prone to slippage; if it is the original straight-up-down plane of the inner wall, the magnet 3 is more likely to fall off.

[0037] According to the above description, in an exemplary embodiment, the structural adhesive is EP1249 high-temperature resistant epoxy structural adhesive. The curing conditions of EP1249 high-temperature resistant epoxy structural adhesive are 40 minutes at 100°C, the thermal strength of EP1249 high-temperature resistant epoxy structural adhesive at 25°C is 26 MPa, and the thermal strength of EP1249 high-temperature resistant epoxy structural adhesive at 180°C is 5 MPa.

[0038] According to the above description, in an exemplary embodiment, the sawtooth structure 7 is provided with three sawtooth structures 7, which are arranged sequentially at intervals along the rotor axis, and each sawtooth structure 7 extends circumferentially along the inner wall of the magnet mounting groove 2.

[0039] According to the above description, in an exemplary embodiment, the inner wall of the magnet mounting groove 2 is provided with a plurality of side grooves 10; the serrated structure 7 continuously penetrates each side groove 10 in the circumferential direction, so that the groove wall of the side groove 10 is correspondingly formed with serrated segments 7a that connect with the serrations of the inner wall.

[0040] According to the above description, in an exemplary embodiment, a motor shaft 11 is provided at the center of the non-metallic magnetic flux disk 1, the motor shaft 11 passes through the non-metallic magnetic flux disk 1, a flat key 12 is provided on the motor shaft 11, the flat key 12 is used to transmit torque, and the metal ring 5 is fixedly connected to the motor shaft 11 by a through-locking bolt 13.

[0041] According to the above description, in an exemplary embodiment, the non-metallic flux disk 1 includes an inner ring 1a and an outer ring 1b, the motor shaft 11 passes through the inner ring 1a, and the outer wall of the inner ring 1a and the inner wall of the outer ring 1b are connected by a plurality of connectors 1c, wherein the connectors 1c, the inner ring 1a and the outer ring 1b are integrally formed. There is a magnet mounting groove 2 between each of the two adjacent connectors 1c. The outer wall of the inner ring 1a is provided with a side groove 10, and the inner wall of the outer ring 1b is provided with two side grooves 10.

[0042] According to the above description, in an exemplary embodiment, after the metal ring 5 and the non-metallic magnetic flux disk 1 are assembled with an interference fit, the metal ring 5 and the non-metallic magnetic flux disk 1 are machined as a whole to ensure the form and position tolerances and surface accuracy, and to solve the problem of deformation of non-metallic materials caused by magnetic force.

[0043] The specific assembly process of the rotor assembly in this embodiment is as follows: Metal ring assembly: The metal ring 5 (aluminum ring or stainless steel ring) is interference-fitted with the outer ring of the magnet mounting groove 2 on the non-metallic magnetic flux disk 1 (H7 / s6 or H7 / r6 grade), and then the metal ring 5 is firmly fixed with the fastening bolts 6 to complete the overall reinforcement of the non-metallic magnetic flux disk 1.

[0044] Overall machining: The non-metallic magnetic flux disk 1 assembly with assembled metal ring 5 is machined as a whole to ensure its dimensional and positional tolerances and surface accuracy, and to solve the problem of deformation of non-metallic materials caused by magnetic force.

[0045] Magnet fixing: Apply structural adhesive evenly to the serrated structure 7 of the magnet mounting groove 2, and precisely embed the magnet 3 into the magnet mounting groove 2; after the adhesive has completely cured, the serrated structure 7 will lock the magnet 3 to prevent it from falling off.

[0046] This embodiment, by adding a metal clamping ring to the outer ring of the non-metallic magnetic flux disk 1, and using a combination of interference fit and fastening bolts 6 for fixation, constrains the deformation tendency of the non-metallic material in a strong magnetic environment; at the same time, the serrated structure 7 on the inner wall improves the reliability of the fixation of the magnets 3. Specifically, the metal ring 5 is assembled with the non-metallic magnetic flux disk 1 by interference fit, and the fastening force generated by the interference fit clamps the non-metallic magnetic flux disk 1 to prevent it from deforming under the action of strong magnetic force during operation; each magnet 3 is fixed in the magnet mounting groove 2 by the mechanical interlocking action of the serrated structure 7 and the structural adhesive. Compared with the traditional planar straight wall structure, the serrated structure 7 can significantly increase the contact area and interlocking force between the adhesive and the substrate, effectively preventing the magnets 3 from falling off along the normal direction of the contact surface due to magnetic attraction.

[0047] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

[0048] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A non-metallic flux disk rotor assembly clamped by a metal ring, characterized in that, The non-metallic magnetic flux disk (1) is provided with a plurality of magnet mounting slots (2), and each magnet mounting slot (2) is provided with a magnet (3). Each magnet (3) is provided with a serrated structure (7) on the inner wall of each magnet mounting slot (2) to increase the contact area between the magnet (3) and the magnet mounting slot (2) to prevent the magnet (3) from falling off. A metal ring (5) is fitted on the non-metallic magnetic flux disk (1). The metal ring (5) is interference-fitted with the non-metallic magnetic flux disk (1) to tighten the non-metallic magnetic flux disk (1) and prevent the non-metallic magnetic flux disk (1) from being deformed by magnetic force. The metal ring (5) is provided with a number of fastening bolts (6), each of the fastening bolts (6) is respectively provided with a corresponding magnetic steel mounting groove (2) and connected to the non-metallic magnetic flux disk (1) to fix the metal ring (5) on the outer ring of the non-metallic magnetic flux disk (1).

2. The non-metallic flux disk rotor assembly with metal ring clamping according to claim 1, characterized in that: The outer diameter of the non-metallic magnetic flux disk (1) is within 350 mm, and the interference fit tolerance grade between the metal ring (5) and the non-metallic magnetic flux disk (1) is H7 / s6 or H7 / r6.

3. The non-metallic flux disk rotor assembly with metal ring clamping according to claim 1, characterized in that: The serrated structure (7) surrounds the inner wall of each mounting position of the magnet mounting groove (2) in a complete circle. The serrated structure (7) is filled with structural adhesive. After the structural adhesive is cured, it forms a mechanical interlock with the serrated structure (7) to reinforce the magnet (3) without affecting the strength of the non-metallic magnetic flux disk (1).

4. The non-metallic flux disk rotor assembly with metal ring clamping according to claim 3, characterized in that: The structural adhesive is EP1249 high-temperature resistant epoxy structural adhesive. The curing conditions of the EP1249 high-temperature resistant epoxy structural adhesive are 40 minutes at 100°C, the thermal strength of the EP1249 high-temperature resistant epoxy structural adhesive at 25°C is 26 MPa, and the thermal strength of the EP1249 high-temperature resistant epoxy structural adhesive at 180°C is 5 MPa.

5. A non-metallic flux disk rotor assembly with a metal ring clamp according to claim 4, characterized in that: The sawtooth structure (7) is provided in three places. The three sawtooth structures (7) are arranged in sequence along the rotor axis at intervals, and each sawtooth structure (7) extends circumferentially along the inner wall of the magnet mounting groove (2).

6. A non-metallic flux disk rotor assembly with a metal ring clamp according to claim 5, characterized in that: The inner wall of the magnet mounting groove (2) is provided with several side grooves (10); the sawtooth structure (7) continuously penetrates each side groove (10) in the circumferential direction, so that the groove wall of the side groove (10) is correspondingly formed with sawtooth segments (7a) that connect with the sawtooth of the inner wall.

7. A non-metallic flux disk rotor assembly with a metal ring clamp according to claim 1, characterized in that: The non-metallic magnetic flux disk (1) has a motor shaft (11) at its center, the motor shaft (11) passes through the non-metallic magnetic flux disk (1), and a flat key (12) is provided on the motor shaft (11). The flat key (12) is used to transmit torque, and the metal ring (5) is fixedly connected to the motor shaft (11) by a through bolt (13).

8. A non-metallic flux disk rotor assembly with a metal ring clamp according to claim 7, characterized in that: The non-metallic flux disk (1) includes an inner ring (1a) and an outer ring (1b). The motor shaft (11) passes through the inner ring (1a). The outer wall of the inner ring (1a) and the inner wall of the outer ring (1b) are connected by a number of connectors (1c). The connectors (1c) are integrally formed with the inner ring (1a) and the outer ring (1b). There is a magnet mounting groove (2) between each of the two adjacent connectors (1c), the outer wall of the inner ring (1a) is provided with a side groove (10), and the inner wall of the outer ring (1b) is provided with two side grooves (10).

9. A non-metallic flux disk rotor assembly with a metal ring clamp according to claim 1, characterized in that: After the metal ring (5) and the non-metallic magnetic flux disk (1) are assembled with an interference fit, the metal ring (5) and the non-metallic magnetic flux disk (1) are machined as a whole to ensure the form and position tolerances and surface accuracy.

10. A non-metallic flux disk rotor assembly with a metal ring clamp according to claim 1, characterized in that: The metal ring (5) is an aluminum ring or a stainless steel ring.

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