Rotor and motor

Abstract

The rotor is characterized in that the rotor comprises a rotor framework, the rotor framework is of an annular structure which is made of a plastic magnetic material and is symmetrical about the central axis, the rotor framework is provided with a plurality of permanent magnet containing holes which are symmetrically arranged about the central axis, and each permanent magnet containing hole extends in the axial direction; the plurality of permanent magnets are respectively accommodated in the corresponding permanent magnet accommodating holes; and the plastic package structure comprises two plastic package cover parts which cover two opposite end surfaces of the rotor framework in the axial direction, and each permanent magnet is fixed relative to the permanent magnet accommodating hole. According to the structure, the rotor made of the plastic magnetic material does not comprise an iron core, the dead weight of the rotor is small, centrifugal force and tensile stress borne by the rotor during rotation are reduced, the rotor is particularly suitable for the high-rotating-speed condition, and the process is simple due to the fact that the rotor is integrally formed through the injection molding method. In addition, the rotor is plastically packaged, and the rotor framework and the permanent magnet are coated with the high polymer material, so that certain mechanical strength is provided for the rotor.

Description

Technical Field

[0001] The present disclosure relates to the field of motors, and in particular to a rotor and a motor comprising the rotor. Background Art

[0002] The industrial motor rotors currently on the market consist of a rotor core and permanent magnets. The rotor core is made of stamped and stacked silicon steel sheets. Depending on the placement of the permanent magnets on the rotor core, it is divided into surface-mounted permanent magnet rotors and embedded permanent magnet rotors. Industrial motors generally require higher power, and the matching rotors are large in size and heavy in weight. When the motor rotates at a higher speed, conventional laminated rotors and permanent magnets cannot withstand the huge centrifugal force and tensile stress generated by the high-speed rotation of the rotor, causing the rotor core to crack or the permanent magnets to be thrown away, ultimately reducing the efficiency of the motor or even causing it to get stuck or burn out.

[0003] In order to improve the strength of the rotor, the conventional practice is to cover the rotor with a high-strength stainless steel or other non-magnetic material fastening sleeve, or to stack the silicon steel sheets in a high-strength manner. The use of a fastening sleeve will inevitably reduce the magnetic permeability, thereby reducing the efficiency of the motor. In order to improve efficiency, the rotor core must use thinner silicon steel sheets to reduce eddy currents, but the mechanical strength of thinner silicon steel sheets cannot meet the requirements of higher speeds of industrial motors, and it will also increase costs. If the silicon steel sheets are stacked in a high-strength manner, the process will become complicated and the processing cost will increase.

[0004] Therefore, a high-strength and high-efficiency rotor structure is required. Utility Model Content

[0005] The purpose of the present disclosure is to at least solve the shortcomings existing in the prior art. The present disclosure proposes a rotor, including a rotor frame, which is an annular structure made of plastic magnetic material and symmetrical about the central axis, and has a plurality of permanent magnet accommodating holes arranged symmetrically about the central axis, each permanent magnet accommodating hole extending in the axial direction; a plurality of permanent magnets are respectively accommodated in corresponding permanent magnet accommodating holes; a plastic sealing structure, including two plastic sealing cover parts covering two end faces of the rotor frame opposite to each other in the axial direction, and each permanent magnet is fixed relative to the permanent magnet accommodating hole.

[0006] For example, according to some embodiments of the present disclosure, a first through hole is provided on the rotor skeleton and penetrates the two end faces in the axial direction. The plastic packaging structure is an integrated component and includes a first filling portion that fills the first through hole. The two plastic packaging cover portions are connected via the first filling portion.

[0007] For example, according to some embodiments of the present disclosure, the rotor includes a plurality of first through holes, and each first through hole is disposed between each pair of two adjacent permanent magnet accommodating holes.

[0008] For example, according to some embodiments of the present disclosure, the permanent magnet has an edge groove extending in the axial direction, so that a second through hole penetrating the two end faces is provided between the hole wall of each permanent magnet accommodating hole and the corresponding edge groove of the permanent magnet, and the plastic packaging structure includes a second filling portion filling the second through hole, and the two plastic packaging cover portions are connected via the second filling portion.

[0009] For example, according to some embodiments of the present disclosure, the shapes of the permanent magnet accommodating hole and the permanent magnet are configured so that a third through hole penetrating the two end faces is provided between the hole wall of each permanent magnet accommodating hole and the corresponding permanent magnet, the plastic packaging structure includes a third filling portion filling the third through hole, and the two plastic packaging cover portions are connected via the third filling portion.

[0010] For example, according to some embodiments of the present disclosure, the second through hole and the third through hole are positioned at two ends of the permanent magnet accommodating hole in the radial direction of the rotor skeleton.

[0011] For example, according to some embodiments of the present disclosure, the rotor skeleton also includes a plurality of first grooves extending circumferentially along the rotor skeleton on the two end faces, each first groove is located between each pair of adjacent two permanent magnet accommodating holes, and the plastic encapsulation structure also includes a first rib portion filling the first groove.

[0012] For example, according to some embodiments of the present disclosure, the permanent magnet includes two permanent magnet faces opposite to each other in the axial direction, the permanent magnet faces include a second groove extending circumferentially along the rotor frame, and the plastic packaging structure also includes a second rib filling the second groove.

[0013] For example, according to some embodiments of the present disclosure, the first groove and the second groove are staggered in the radial direction of the rotor skeleton, so that the first ribs at both ends of the circumferential direction of the rotor skeleton respectively abut against the permanent magnet, and the second ribs at both ends of the circumferential direction of the rotor skeleton respectively abut against the rotor skeleton.

[0014] For example, according to some embodiments of the present disclosure, the plastic cover is provided with a rib protruding in the axial direction on the side facing away from the rotor frame.

[0015] For example, according to some embodiments of the present disclosure, each of the two end faces includes a first sub-end face, a second sub-end face and a third sub-end face, the first sub-end face is located at the outermost side of the rotor skeleton along the axial direction, and the second sub-end face is between the first sub-end face and the third sub-end face along the axial direction; the first sub-end face is farther away from the center axis than the third sub-end face in the radial direction, and the second sub-end face is between the first sub-end face and the third sub-end face in the radial direction.

[0016] The present disclosure also provides an electric motor, comprising any one of the above-described rotors.

[0017] For example, according to some embodiments of the present disclosure, the motor is a permanent magnet brushless DC motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A three-dimensional schematic diagram of a rotor before plastic packaging according to an embodiment of the present disclosure is shown;

[0019] Figure 2 Show according to Figure 1 A schematic plan view of a rotor;

[0020] Figure 3 Show according to Figure 1 An exploded schematic diagram of the rotor;

[0021] Figure 4 A partial cross-sectional perspective schematic diagram of a rotor after plastic sealing according to an embodiment of the present disclosure is shown;

[0022] Figure 5 Show Figure 4 A plan view of a cross-sectional view of a rotor;

[0023] Figure 6 A three-dimensional schematic diagram of a rotor after plastic sealing according to an embodiment of the present disclosure is shown.

[0024] Reference numerals

[0025] 1 rotor frame, 11 permanent magnet receiving hole, 121 first sub-end surface, 122 second sub-end surface, 123 third sub-end surface,

[0026] 2 permanent magnets, 21 edge slots,

[0027] 3 plastic sealing structure, 30 plastic sealing end cover, 31 first filling part, 32 second filling part, 33 third filling part, 34 first rib part, 35 second rib part, 36 rib part

[0028] 41 first through hole, 42 second through hole, 43 third through hole

[0029] 51 first groove, 52 second groove

[0030] 6 Rotor sleeve

[0031] 7 reels DETAILED DESCRIPTION

[0032] In order to make the purpose, scheme and advantages of the technical solution of the present disclosure clearer, the technical solution of the embodiment of the present disclosure will be clearly and completely described in conjunction with the drawings of the specific embodiments of the present disclosure. Unless otherwise specified, the terms used herein have the usual meanings in the art. The same reference numerals in the drawings represent the same components.

[0033] In the description of the present disclosure, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present disclosure can be understood according to specific circumstances.

[0034] For ease of explanation, in the present disclosure, since the rotor skeleton is not a ring-shaped structure symmetrical about the central axis, the direction along the central axis of the rotor skeleton is designated as the axial direction, the radial direction is the direction of the diameter of the ring-shaped structure of the rotor skeleton perpendicular to the central axis, and the circumferential direction is the circumferential direction that circles around the central axis.

[0035] Figures 1 to 3 The structure of the rotor before plastic packaging according to the embodiment of the present disclosure is shown in a three-dimensional schematic diagram, a plan schematic diagram and an exploded schematic diagram. Figures 1 to 3 The rotor according to the present disclosure includes a rotor frame 1 and a permanent magnet 2. Specifically, a plurality of permanent magnet receiving holes 11 are provided on the rotor frame 1 to receive the permanent magnet 2 in the corresponding permanent magnet receiving holes 11, so as to realize the embedded arrangement of the permanent magnet. The number of the permanent magnet receiving holes 11 can be 4, 6, 8, 10, 12, etc., and 10 are shown in the figure.

[0036] Furthermore, the rotor frame is made of integral injection molding of plastic magnetic material, and has a ring structure symmetrical about the central axis. The plurality of permanent magnet receiving holes 11 are symmetrically arranged about the central axis, and are arranged at equal intervals in the circumferential direction, and each permanent magnet receiving hole 11 extends in the axial direction and can penetrate the rotor frame 1 in the axial direction.

[0037] In order to fix the permanent magnet 2 relative to the rotor frame 1, the rotor according to the present disclosure is plastic-encapsulated with a polymer material to seal the permanent magnet 2, in particular, to seal the two end faces of the rotor frame 1 opposite to each other in the axial direction. Figure 4-6As shown, the rotor may include a molded structure 3, which includes two molded cover portions 30 covering two end surfaces of the rotor frame that are opposite to each other in the axial direction. The molded structure 3 is formed by injection molding and is directly bonded to the rotor frame 1 and the permanent magnet 2, thereby the two molded cover portions 30 fix each permanent magnet 2 relative to the permanent magnet accommodating hole 11.

[0038] According to the structure disclosed in the present invention, the rotor made of plastic magnetic material does not include an iron core, and the rotor has a small deadweight, which reduces the centrifugal force and tensile stress on the rotor when it rotates, so it is particularly suitable for high-speed situations, and is integrally formed by injection molding, with a simple process and no need to stack silicon steel sheets. In addition, the rotor is plastic-sealed, and the polymer material covers the rotor frame and permanent magnets, providing a certain mechanical strength for the rotor, preventing the permanent magnets from being thrown away and the plastic magnetic rotor frame from being damaged and cracked when the rotor rotates at high speed.

[0039] In addition, if Figure 4-6 As shown, the plastic cover 30 is provided with ribs 36 protruding in the axial direction on the side facing away from the rotor frame 1 , and the ribs 36 have a structure staggered in the circumferential direction and in the radial direction, thereby further improving the strength of the plastic cover 30 .

[0040] In order to further increase the strength of the rotor, according to the present disclosure, the rotor is also provided with a hole structure and a groove structure for allowing a polymer material to be filled therein to form a part of the plastic packaging structure, thereby increasing the strength of the rotor.

[0041] Specifically, combined Figure 1-Figure 3 According to the present invention, the rotor may include a first through hole 41, a second through hole 42, and a third through hole 43, as well as a first groove 51 and a second groove 52. Thus, when the fluid polymer material is injected, the polymer material fills the above holes and grooves. When solidified, the corresponding first filling part 31, the second filling part 32, and the third filling part 33, as well as the first rib part 34 and the second rib part 35 are formed. Figure 4-6 As shown, the above components 31-35 can all be part of the plastic package structure 3, because the plastic package structure 3 is integrally formed by injection molding, and the above components 31-35 are interconnected through two plastic package covers 30. Because of the structure in which multiple components are interconnected, the "second skeleton" of the rotor is formed, providing strong support strength for the rotor skeleton 1 and the permanent magnet 2.

[0042] Furthermore, the first through hole 41 is provided on the rotor frame 1 and penetrates the two end surfaces of the rotor frame 1 in the axial direction. Thus, the plastic packaging structure may include a first filling portion 31 that fills the first through hole 41. Since the first through hole 31 completely penetrates the rotor frame 1, the first filling portion 31 may be connected to the plastic packaging cover 30 at both ends, such as Figure 4-6As shown, the two plastic cover parts 30 can interact with each other, further increasing the strength of the rotor in the axial direction.

[0043] In addition, the rotor includes a plurality of first through holes 41, each of which is disposed between each pair of two adjacent permanent magnet receiving holes 11. Figure 1-3 As shown. Therefore, when the rotor rotates, the strength of the rotor skeleton in the circumferential direction can be enhanced to reduce the strength reduction caused by setting a plurality of permanent magnet accommodating holes 11.

[0044] As for the second through hole 42, it also penetrates the two end surfaces of the rotor frame 1 in the axial direction. In particular, the permanent magnet 2 has an edge groove 21 extending in the axial direction, such as Figure 3 As shown, the second through hole is formed between the hole wall of each permanent magnet receiving hole 11 and the edge groove 21 of the corresponding permanent magnet 2, as shown in FIG. Figure 1-Figure 2 As shown. Thus, the plastic packaging structure 3 may include a second filling portion 32 that fills the second through hole 42. Since the second through hole 31 completely penetrates the rotor frame 1, the second filling portion 32 may be connected to the plastic packaging cover 30 at both ends, as shown. Figure 4-6 The second through hole 42 is provided so that the second filling portion 32 can be located in the edge groove 21 of the permanent magnet 2, so that when the rotor rotates, the second filling portion 32 can directly interact with the permanent magnet 2 in the circumferential direction, thereby reducing the load on the rotor frame 1, thereby improving the overall strength of the rotor.

[0045] The rotor may further include a third through hole 42, which also penetrates the two end surfaces of the rotor frame 1 in the axial direction. Figure 1-3 As shown. Thus, the plastic packaging structure 3 may include a third filling portion 33 that fills the third through hole 43. Since the third through hole 33 completely penetrates the rotor frame 1, the third filling portion 33 may be connected to the plastic packaging cover 30 at both ends, as shown. Figure 4-6 The third through hole 42 is arranged between the hole wall of each permanent magnet receiving hole 11 and the edge groove 21 of the corresponding permanent magnet 2, so that the third filling part 33 further increases the strength of the rotor.

[0046] In particular, the second through hole 42 and the third through hole 43 are located at both ends of the permanent magnet receiving hole 11 in the radial direction, for example, Figure 1-3As shown, the second through hole 42 is located at one end away from the central axis, and the third through hole 43 is located at one end close to the central axis. Through this arrangement, the second filling portion 32 and the third filling portion 33 can provide strength support for the permanent magnet 2 and the rotor frame 1 in the radial direction, in particular, to resist the centrifugal force and tensile stress generated by the rotation, and prevent the permanent magnet from being thrown away and the rotor frame from being damaged and cracked when the rotor rotates at high speed. In addition, since the second filling portion 32 and the third filling portion 33 are respectively located at the two ends of the permanent magnet accommodating hole 11 in the radial direction, the interference with the magnetic field lines of the permanent magnet 2 is minimal, which is beneficial to the rotor efficiency.

[0047] Furthermore, the rotor may further include a plurality of first grooves 51 disposed on the rotor frame, wherein the plurality of first grooves 51 extend along the circumferential direction on the two end surfaces of the rotor frame. Figure 1-3 As shown. Therefore, the plastic packaging structure 3 may include a first rib 34 that fills the first groove 51 to provide additional strength support for the rotor, especially the rotor frame, at two end surfaces.

[0048] The rotor may further include a plurality of second grooves 52 disposed on each permanent magnet 2, wherein the plurality of second grooves 52 extend in the circumferential direction on two permanent magnet surfaces opposite to each other in the axial direction. Figure 1-3 As shown, the plastic package structure 3 may include a second rib 35 filling the second groove 52 to provide additional strength support for the rotor, especially the permanent magnet, at the permanent magnet surfaces at both ends.

[0049] Each first groove 51 may be located between each pair of two adjacent permanent magnet accommodating holes 11, and the first groove 51 and the second groove 52 are staggered in the radial direction. Figure 2 As shown. The two ends of the first rib 34 in the circumferential direction respectively abut against the permanent magnet 2, and the two ends of the second rib 35 in the circumferential direction respectively abut against the rotor frame 1. Therefore, when the rotor rotates, the first rib 34 directly interacts with the permanent magnet 2 in the circumferential direction, and the second rib directly interacts with the rotor frame 1 in the circumferential direction, further increasing the support for the rotor frame 1 and the permanent magnet 2 in the circumferential direction, and strengthening the strength of the rotor.

[0050] Further, each of the two end faces of the rotor skeleton includes a first sub-end face 121, a second sub-end face 122 and a third sub-end face 123. The first sub-end face 121 is located at the outermost side of the rotor skeleton 1 in the axial direction, and the second sub-end face 122 is between the first sub-end face 121 and the third sub-end face 123 in the axial direction. The first sub-end face 121 is farther away from the central axis than the third sub-end face 123 in the radial direction, and the second sub-end face 122 is between the first sub-end face 121 and the third sub-end face 123 in the radial direction. This arrangement can save plastic magnetic materials during injection molding, increase the volume of the coated polymer material, and increase the mechanical strength.

[0051] like Figure 3 As shown, the rotor according to the present disclosure may also include a Figure 6 The rotor sleeve 6 is provided with a matching rotor sleeve 6 (as shown in FIG. 1 ), and the rotor sleeve is located on the inner side of the annular rotor frame 1. The rotor frame 1 and the rotor sleeve 6 may respectively have a matching portion for abutting against each other in the axial direction to transmit torque, which will not be elaborated in detail here.

[0052] The present disclosure also proposes a motor comprising the above rotor, in particular a permanent magnet brushless DC motor.

[0053] It should be understood that the above description is intended to illustrate rather than limit. For example, the above embodiments (and / or aspects thereof) can be used in combination with each other. In addition, without departing from the scope of the present disclosure, many modifications can be made to adapt specific situations or materials to the teachings of the present disclosure. The functions or performances of the various elements or modules described herein are only for illustration and are by no means restrictive, but are merely exemplary embodiments. After reading the above description, many other embodiments and modifications within the spirit and scope of the claims will be apparent to those skilled in the art. Therefore, the scope of the present disclosure should be determined with reference to the full scope of the equivalents given by the attached claims and these claims.

[0054] In the following claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

Claims

1. A rotor, characterized in that: include The rotor frame is a ring-shaped structure made of plastic magnetic material and symmetrical about the central axis, and has a plurality of permanent magnet accommodating holes arranged symmetrically about the central axis, each permanent magnet accommodating hole extending in the axial direction, A plurality of permanent magnets are respectively accommodated in corresponding permanent magnet accommodating holes, The plastic packaging structure comprises two plastic packaging cover parts covering two end surfaces of the rotor frame which are opposite to each other in the axial direction, and fixes each permanent magnet relative to the permanent magnet accommodating hole.

2. The rotor according to claim 1, characterized in that The rotor frame is provided with a first through hole penetrating through the two end surfaces in the axial direction. The plastic packaging structure is an integrated component and includes a first filling portion that fills the first through hole, and the two plastic packaging cover portions are connected via the first filling portion.

3. The rotor according to claim 2, characterized in that The rotor comprises a plurality of first through holes, each of which is arranged between each pair of two adjacent permanent magnet accommodating holes.

4. The rotor according to claim 3, characterized in that The permanent magnet has an edge groove extending in the axial direction, so that a second through hole penetrating the two end faces is provided between the hole wall of each permanent magnet receiving hole and the corresponding edge groove of the permanent magnet. The plastic packaging structure includes a second filling portion that fills the second through hole, and the two plastic packaging cover portions are connected via the second filling portion.

5. The rotor according to claim 4, characterized in that The shapes of the permanent magnet accommodating holes and the permanent magnets are configured such that a third through hole penetrating the two end faces is provided between the hole wall of each permanent magnet accommodating hole and the corresponding permanent magnet. The plastic packaging structure includes a third filling portion that fills the third through hole, and the two plastic packaging cover portions are connected via the third filling portion.

6. The rotor according to claim 5, characterized in that The second through hole and the third through hole are positioned at two ends of the permanent magnet accommodating hole in the radial direction of the rotor frame.

7. The rotor according to claim 1, characterized in that The rotor frame further comprises a plurality of first grooves extending along the circumferential direction of the rotor frame on the two end surfaces, each first groove being located between each pair of two adjacent permanent magnet accommodating holes. The plastic packaging structure further includes a first rib portion filling the first groove.

8. The rotor according to claim 7, characterized in that The permanent magnet includes two permanent magnet surfaces facing each other in the axial direction, and the permanent magnet surfaces include second grooves extending along the circumferential direction of the rotor frame. The plastic packaging structure also includes a second rib portion filling the second groove.

9. The rotor according to claim 8, characterized in that The first groove and the second groove are staggered in the radial direction of the rotor frame, so that the first rib portion abuts against the permanent magnet at both ends of the circumferential direction of the rotor frame, and the second rib portion abuts against the rotor frame at both ends of the circumferential direction of the rotor frame.

10. The rotor according to claim 1, characterized in that The plastic cover is provided with a rib protruding in the axial direction on the side facing away from the rotor frame.

11. The rotor according to claim 1, characterized in that Each of the two end surfaces includes a first sub-end surface, a second sub-end surface and a third sub-end surface, The first sub-end surface is located at the outermost side of the rotor frame along the axial direction, and the second sub-end surface is located between the first sub-end surface and the third sub-end surface along the axial direction; The first sub-end surface is farther away from the central axis than the third sub-end surface in the radial direction, and the second sub-end surface is between the first sub-end surface and the third sub-end surface in the radial direction.

12. A motor, characterized in that: Comprising a rotor according to any one of claims 1-11.

13. The motor according to claim 12, characterized in that The motor is a permanent magnet brushless DC motor.

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