Hybrid rotor and motor
By designing an annular limiting groove in the rotor body of the mixed rotor, the axial and radial displacement problems that are prone to occur in the manufacturing process of copper strips are solved, the balance of the magnetic circuit is ensured, and the starting performance of the motor is improved.
Patent Information
- Application Number
- CN202422115854.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-29
- Publication Date
- 2025-06-17
- Estimated Expiration
- 2034-08-29
AI Technical Summary
During the manufacturing process of a hybrid rotor, the displacement of the copper bar in the axial and radial directions causes different resistivity of copper and aluminum materials in the rotor, resulting in unbalanced magnetic circuits and affecting the starting performance of the motor.
A hybrid rotor is designed to ensure the stable position of the copper strip in the axial and radial directions by forming an annular limiting groove between the copper strip assembly and the aluminum strip assembly of the rotor body, thereby avoiding magnetic circuit imbalance.
It effectively prevents the displacement of the copper bars in the channel, improves the starting performance of the motor, and reduces the cost of manual intervention and post-adjustment.
Smart Images
Figure CN222996302U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to a hybrid rotor and a motor including the hybrid rotor. Background Art
[0002] In the manufacture of a hybrid rotor, a plurality of annular rotor laminations are usually stacked in the axial direction to a certain length to form a rotor body. A plurality of rotor slots arranged radially are formed on each rotor lamination. After these rotor laminations are stacked, these rotor slots constitute an internal channel extending in the axial direction. A copper bar is inserted into the channel and a gap is reserved at the top of the copper bar to facilitate the flow of aluminum liquid. Then it is placed in an aluminum die-casting mold to generate a copper-aluminum hybrid rotor by die-casting aluminum liquid.
[0003] In such a case, the copper bar inserted into the channel has no axial limit, resulting in easy axial displacement of the copper bar during the process of placing it into the aluminum die-casting mold. Moreover, these channels are evenly distributed radially, and the copper bar inserted into the channel has no radial limit. Therefore, due to the action of gravity, the copper bar located below the circumference is prone to radial displacement during the process of placing it into the aluminum die-casting mold. However, the displacement of the copper bar in the channel will cause the copper bar to be asymmetrically distributed in the rotor. Due to the different resistivity of copper and aluminum materials, it will cause the rotor magnetic circuit to be unbalanced. Considering the skin effect of the current during the motor starting process, it is easy to cause poor starting performance of the motor.
[0004] In the existing production, usually manual intervention is used to control the displacement of the copper bar. This method has high requirements for manual labor and limited limitation. In addition, the displacement of the copper bar can also not be controlled, but the starting performance of the motor is improved by adjusting electromagnetic parameters or changing the stator and rotor slot shapes in the later stage, but this will significantly increase the cost. Summary of the Utility Model
[0005] In order to overcome the above-mentioned defects existing in the prior art, the present application provides a hybrid rotor, which includes: a cylindrical rotor body including a plurality of channels arranged radially around the central axis of the rotor body and extending in the axial direction; a copper bar assembly including a plurality of copper bars, each copper bar being inserted into a corresponding one of the channels and occupying a part of the volume of the channel; an aluminum bar assembly including a plurality of aluminum bars, each aluminum bar being filled in a corresponding one of the channels and occupying the remaining part of the volume of the channel; and two cast aluminum end rings integrally cast with the aluminum bar assembly and surrounding the corresponding exposed ends of the copper bar assembly. Wherein, a circumferential limiting groove extending in the circumferential direction and recessed in the axial direction is formed on the axial outer end surface of the cast aluminum end ring, and the circumferential limiting groove is located within the radial extension range of the copper bar assembly in the radial direction. Accordingly, the displacement of the copper bar in the channel can be effectively prevented, thereby improving the starting performance of the motor.
[0006] Furthermore, the annular limiting groove is formed by an annular protrusion formed in the aluminum casting mold for casting the aluminum cast end ring. Accordingly, the axial displacement of the copper bar can be effectively prevented.
[0007] Furthermore, the annular limiting groove extends in a wavy shape in the circumferential direction. Accordingly, the conventional balance posts and the arrangement of the aluminum cast blades can be accommodated while effectively ensuring the prevention of the axial displacement of the copper bar.
[0008] Furthermore, the bottom of the annular limiting groove is axially spaced from the axial end face of the copper bar assembly by an axial distance of 0.5 mm. Accordingly, the axial limiting effect can be improved.
[0009] Furthermore, the recessed depth of the annular limiting groove in the axial direction is in the range of 2 mm to 3 mm. Accordingly, the convenience of casting and demolding can be achieved.
[0010] Furthermore, the annular limiting groove has a trapezoidal shape in a cross-section parallel to the radial direction and the axial direction. Accordingly, the demolding of the aluminum casting mold can be facilitated.
[0011] Furthermore, the hybrid rotor further includes a metal ring hoop-mounted on the exposed end of the copper bar assembly. Accordingly, the radial displacement of the copper bar can be effectively prevented.
[0012] Furthermore, the copper bar assembly includes a set of receiving grooves at its exposed end for receiving the metal ring, and each receiving groove in the set of receiving grooves is located at the end of a corresponding copper bar and radially recessed inward from the outer radial surface of the copper bar. Accordingly, the positioning of the metal ring can be facilitated.
[0013] Furthermore, the axial distances between each receiving groove and the axial end face of the copper bar where it is located are equal to each other and are in the range of 5 mm to 10 mm. Accordingly, the installation of the metal ring can be facilitated.
[0014] Furthermore, each receiving groove has a semi-circular shape in a cross-section parallel to the radial direction and the axial direction. Accordingly, the positioning of the metal ring can be facilitated.
[0015] Furthermore, each copper bar includes a joining groove radially recessed inward from the outer radial surface of the copper bar. Accordingly, the joining effect between the copper bar and the aluminum bar can be improved.
[0016] Furthermore, the length of the joining groove in the axial direction is equal to the length of the copper bar where the joining groove is located in the axial direction, and the width of the joining groove in the circumferential direction is smaller than the width of the receiving groove in the radial direction. Accordingly, the joining effect can be further improved.
[0017] Furthermore, at least one metal ring is provided on each exposed end of the copper bar assembly. Accordingly, the stability of the radial limit can be improved.
[0018] Furthermore, the metal ring can be made of galvanized steel wire with a diameter of 1.2 mm. Accordingly, it is convenient for manufacturing.
[0019] The present application also provides a motor, which includes: a stator fixed on the housing or base of the motor and configured to generate a magnetic field; and the aforementioned hybrid rotor that rotates in response to the magnetic field generated by the stator. Accordingly, the motor of the present application can have improved motor starting performance. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The drawings are used to provide a further understanding of the present application and form a part of the present application. The schematic embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation to the present application. In the drawings:
[0021] Figure 1 is a schematic perspective view showing the hybrid rotor of the present application;
[0022] Figure 2 is showing Figure 1 a schematic perspective view of a part of the hybrid rotor in
[0023] Figure 3 is showing Figure 1 a schematic perspective view of the hybrid rotor in
[0024] Figure 4 is showing Figure 3 a schematic enlarged view of area A of the hybrid rotor in
[0025] Figure 5 is showing Figure 1 a schematic cross-sectional view of the hybrid rotor in
[0026] Figure 6 is showing Figure 1 a schematic longitudinal sectional view of the hybrid rotor in
[0027] Figure 7 is showing Figure 6 a schematic enlarged view of area B of the hybrid rotor in
[0028] Figure 8 is a schematic perspective view showing the copper bar of the present application.
[0029] LIST OF REFERENCE NUMERALS
[0030] 100 Hybrid Rotor
[0031] 1 Rotor Body
[0032] 10 Metal Rings
[0033] 11 Central Through-Hole
[0034] 12 Channels
[0035] 2 Copper Bar Assemblies
[0036] 21 Copper Bars
[0037] 3 Aluminum Bar Assemblies
[0038] 31 Aluminum Bars
[0039] 4 Cast Aluminum End Rings
[0040] 5 Balance Columns
[0041] 6 Cast Aluminum Blades
[0042] C Central Axis
[0043] D1 Axial Distance
[0044] D2 Recessed Depth
[0045] G1 Annular Limiting Groove
[0046] GB Bottom
[0047] G2 Receiving Groove
[0048] G3 Joining Groove Detailed Implementation Manner
[0049] Next, the technical solutions in the embodiments of the present application will be described in detail in conjunction with the accompanying drawings in the embodiments of the present application. It should be noted that, without conflict, the embodiments in the present application and the features in the embodiments can be combined with each other.
[0050] In the following detailed description, reference is made to the accompanying drawings that form a part of this specification, in which specific embodiments in which the present application can be implemented are shown by way of illustration. Regarding the drawings, directional terms such as "top", "bottom", "inner", "outer", "upper", "lower", "front", "rear", etc. are used with reference to the directions of the described drawings. Since the components of the embodiments of the present application can be placed in many different directions, the directional terms are for illustration only and have no limiting meaning. It should be understood that other embodiments can be used and structural or logical changes can be made without departing from the scope of the present application. Therefore, the following detailed description should not be construed as having a limiting meaning, and the present application is defined by the appended claims.
[0051] The present application proposes a hybrid rotor 100.
[0052] The hybrid rotor 100 may generally include a cylindrical rotor body 1, a copper bar assembly 2, an aluminum bar assembly 3, and two cast aluminum end rings 4.
[0053] The rotor body 1 may include a plurality of channels 12 that are radially arranged around the central axis C of the rotor body 1 and extend in the axial direction. In addition, the rotor body 1 may further include a central through hole 11 arranged in the axial direction for connecting the rotor shaft.
[0054] The copper bar assembly 2 may include a plurality of copper bars 21, and each copper bar 21 is inserted into a corresponding channel 12 and occupies a part of the volume of the channel 12. In addition, both ends of each copper bar 21 in the axial direction may be located outside the rotor body 1, so that the copper bar assembly 2 has two exposed ends in the axial direction.
[0055] The aluminum bar assembly 3 may include a plurality of aluminum bars 31, and each aluminum bar 31 fills a corresponding channel 12 and occupies the remaining part of the volume of the channel 12. In addition, in each channel 12, the aluminum bar 31 may be located radially outside the copper bar 21.
[0056] The cast aluminum end ring 4 may be integrally cast with the aluminum bar assembly 3 and surround the corresponding exposed ends of the copper bar assembly 2. In particular, the cast aluminum end ring 4 is fixed on the corresponding axial end side of the rotor body 1.
[0057] A circumferential limiting groove G1 extending in the circumferential direction and recessed in the axial direction is formed on the axial outer end face of the cast aluminum end ring 4, and the circumferential limiting groove G1 is located within the radial extension range of the copper bar assembly 2 in the radial direction. Accordingly, during the casting of the cast aluminum end ring 4 and the aluminum bar assembly 3, the movement of the copper bar assembly 2 can be prevented, thereby avoiding the deterioration of the motor starting performance caused by magnetic circuit imbalance.
[0058] In particular, the circumferential limiting groove G1 may be formed by a circumferential protrusion formed in the cast aluminum mold for casting the cast aluminum end ring 4. The circumferential protrusion protrudes from the inner wall of the cast aluminum mold in the axial direction toward the axial end face of the copper bar assembly 2 and is axially spaced from the axial end face of the copper bar assembly 2 by an axial distance. Thus, a circumferential limiting groove G1 that is shape-matched with the circumferential protrusion can be formed on the axial end face of the cast aluminum end ring 4 after casting. The circumferential limiting groove G1 is not necessarily strictly circular, but both its radially maximum part and its radially minimum part are within the radial extension range of the copper bar assembly 2. Accordingly, during casting, the axial limiting of all the copper bars 21 can be achieved.
[0059] In particular, the circumferential limiting groove G1 may extend in a wavy shape in the circumferential direction, as Figure 1 shown, to bypass the balance column 5 and the cast aluminum blade 6 formed on the axial end face of the cast aluminum end ring 4.
[0060] In addition, the bottom GB of the annular limiting groove G1 (i.e., the farthest part recessed in the axial direction) may be axially spaced from the axial end face of the copper bar assembly 2 by an axial distance D1, and the axial distance D1 may be 0.5 mm. Of course, the present application is not limited thereto, and the size of the axial distance D1 can be selected according to actual needs.
[0061] In addition, the recessed depth D2 of the annular limiting groove G1 in the axial direction may be in the range of 2 mm to 3 mm. However, the present application is not limited thereto, and the size of the recessed depth D2 can be selected according to actual needs.
[0062] In addition, the annular limiting groove G1 may have a trapezoidal shape in a cross section parallel to the radial direction and the axial direction, as Figure 7 best shown.
[0063] In addition, the hybrid rotor may further include a metal ring 10 hoop-mounted on the exposed end of the copper bar assembly 2, whereby the resistance in the channel is symmetrically and uniformly distributed in the circumferential direction, thus avoiding the deterioration of the motor starting performance caused by magnetic circuit imbalance.
[0064] In particular, the copper bar assembly 2 may include a set of receiving grooves G2 at its exposed end for receiving the metal ring 10. Each receiving groove in this set of receiving grooves G2 is located at the end of the corresponding copper bar 21 and recessed radially inward from the radial outer side face of the copper bar 21.
[0065] In addition, the axial distance between each receiving groove G2 and the axial end face of the copper bar 21 where it is located may be equal to each other and in the range of 5 mm to 10 mm. Of course, the present application is not limited thereto, and the size of this axial distance can be selected according to actual needs.
[0066] In addition, the receiving groove G2 may have a semi-circular shape in a cross section parallel to the radial direction and the axial direction, as Figure 7 best shown.
[0067] In addition, each copper bar 21 may include a joining groove G3 recessed radially inward from the radial outer side face of the copper bar 21.
[0068] In particular, the length of the joining groove G3 in the axial direction may be equal to the length of the copper bar 21 where the joining groove G3 is located in the axial direction, and the width of the joining groove G3 in the circumferential direction may be smaller than the width of the receiving groove G2 in the radial direction.
[0069] In addition, at least one metal ring 10 may be provided on each exposed end of the copper bar assembly 2.
[0070] In addition, the metal ring 10 can be made of galvanized steel wire with a diameter of 1.2 mm. Of course, the material for manufacturing the metal ring is not limited to this, and any suitable metal or metal alloy can be used to manufacture it.
[0071] During the manufacturing process, the wire can first hoop all the copper bars, then tighten the wire at the gaps between two adjacent copper bars, and finally cut off the excess wire, whereby the above-mentioned metal ring can be obtained. Such a wire binding process is convenient to operate and easy to position, thus effectively preventing the wire from slipping on the surface of the copper bar.
[0072] This application also proposes a motor, which includes a stator and the aforementioned hybrid rotor 100. The stator can be fixed on the outer shell or base of the motor and configured to generate a magnetic field, and the hybrid rotor 100 can rotate in response to the magnetic field generated by the stator.
[0073] The above are only the preferred embodiments of this application and are not intended to limit this application. For those skilled in the art, this application can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of this application shall be included within the protection scope of this application.
Claims
1. A mixing rotor, characterized in that: The mixing rotor comprises: A cylindrical rotor body (1), the rotor body (1) comprising a plurality of channels (12) arranged radially around a central axis (C) of the rotor body (1) and extending in an axial direction; A copper bar assembly (2), the copper bar assembly (2) comprising a plurality of copper bars (21), each of the copper bars (21) being inserted into a corresponding channel (12) and occupying a portion of the volume of the channel (12); an aluminum bar assembly (3), the aluminum bar assembly (3) comprising a plurality of aluminum bars (31), each of the aluminum bars (31) filling a corresponding channel (12) and occupying the remainder of the volume of the channel (12); and two cast aluminum end rings (4), the cast aluminum end rings (4) being integrally cast with the aluminum bar assembly (3) and surrounding the corresponding exposed ends of the copper bar assembly (2), An annular limiting groove (G1) extending in the circumferential direction and recessed in the axial direction is formed on the axial outer end surface of the cast aluminum end ring (4), and the annular limiting groove (G1) is located in the radial direction within the extension range of the copper bar assembly (2) in the radial direction.
2. The mixing rotor according to claim 1, characterized in that The annular limiting groove (G1) is formed by an annular protrusion formed in an aluminum casting mold for casting the aluminum casting end ring (4).
3. The mixing rotor according to claim 1, characterized in that: The annular limiting groove (G1) extends in a wave shape in the circumferential direction.
4. The mixing rotor according to claim 1, characterized in that: The bottom (GB) of the annular limiting groove (G1) is spaced an axial distance (D1) from the axial end surface of the copper bar assembly (2), and the axial distance (D1) is 0.5 mm.
5. The mixing rotor according to claim 1, characterized in that The recessed depth (D2) of the annular limiting groove (G1) along the axial direction is in the range of 2 mm to 3 mm.
6. The mixing rotor according to claim 1, characterized in that The annular limiting groove (G1) has a trapezoidal shape in a cross section parallel to the radial direction and the axial direction.
7. The mixing rotor according to claim 1, characterized in that The mixing rotor further comprises a metal ring (10) clamped on the exposed end of the copper bar assembly (2).
8. The mixing rotor according to claim 7, characterized in that The copper bar assembly (2) comprises a group of receiving grooves (G2) at its exposed end for receiving the metal ring (10), each receiving groove in the group of receiving grooves (G2) being located at the end of the corresponding copper bar (21) and being recessed radially inward from the radial outer side of the copper bar (21).
9. The mixing rotor according to claim 8, characterized in that The axial distances between each receiving groove (G2) and the axial end surface of the copper strip (21) where it is located are equal to each other and are within the range of 5 mm to 10 mm.
10. The mixing rotor according to claim 8, characterized in that Each receiving groove (G2) has a semicircular shape in a cross section parallel to the radial direction and the axial direction.
11. The mixing rotor according to claim 8, characterized in that Each of the copper strips (21) comprises a joining groove (G3) recessed radially inward from a radially outer side surface of the copper strip (21).
12. The mixing rotor according to claim 11, characterized in that The length of the engagement groove (G3) in the axial direction is equal to the length of the copper bar (21) where the engagement groove (G3) is located in the axial direction, and the width of the engagement groove (G3) in the circumferential direction is smaller than the width of the receiving groove (G2) in the radial direction.
13. The mixing rotor according to claim 7, characterized in that At least one metal ring (10) is provided on each exposed end of the copper bar assembly (2).
14. The mixing rotor according to claim 7, characterized in that The metal ring (10) can be made of galvanized steel wire with a diameter of 1.2 mm.
15. A motor, characterized in that: The motor comprises: a stator fixed to a housing or a base of the motor and configured to generate a magnetic field; and A hybrid rotor according to any one of claims 1 to 14, wherein the hybrid rotor rotates in response to a magnetic field generated by the stator.