Motor system

Abstract

The utility model discloses a motor system, which is used for reducing ripple torque related to an inner bridge arranged in one or more partition plates of a rotor stack and improving mechanical strength when the rotor stack is configured to have no inner bridge. In one example, the rotor stack (302) includes at least one interlocking element (309a, 315a, 321a) disposed in one or more bulkheads (305a, 311a, 317a). In another example, at least one interlocking element (309a, 315a, 321a) may be manufactured separately, independently of the rotor stack, or using the rotor stack as a mold.

Description

Technical Field

[0001] The present disclosure relates generally to electric machine systems and, more particularly, to synchronous reluctance machines and permanent magnet assisted synchronous reluctance machines. Background Art

[0002] The magnetic design of synchronous reluctance motor (SynRM) and permanent magnet assisted synchronous reluctance motor (PMASynRM) rotors can include structural magnetic anisotropy and can be configured with high and low reluctance regions. More specifically, the rotor can be composed of magnetic disks called laminations that are adjacent along the rotor's axis of rotation. Each lamination can be made of a magnetically conductive material (such as iron or steel) and has a magnetic structure that is divided into pole sectors that define the number of magnetic poles. Each sector has a direction of minimum reluctance (such as the "d" or orthogonal axis) and a direction of maximum reluctance (such as the "q" or orthogonal axis).

[0003] The rotor's reluctance depends on the presence of empty regions within the laminations, which are made of magnetically insulating material (e.g., air). These empty regions (hereafter referred to as "magnetic grids") can create magnetic barriers where the magnetic flux encounters high resistance (i.e., high reluctance), potentially hindering the flow of the magnetic field. One or more internal bridges can be placed in the center of the magnetic grids to reduce the mechanical stress induced by the magnetic grids in existing motor systems. Each rotor lamination has one or more internal bridges, and because the laminations are manufactured from high-permeability electrical steel, the one or more internal bridges create a closed, low-reluctance path for the magnetic flux to flow, where the magnetic field lines are highly concentrated.

[0004] When current is supplied to the stator windings, a magnetic field is generated. In response, the rotor aligns its d-axis (i.e., magnetic axis) with the magnetic field to minimize the magnetic resistance through the magnetic path and reduce the permeability of the motor circuit. However, due to the presence of the internal bridge, the performance of synchronous reluctance motors (SynRMs) and permanent magnet-assisted synchronous reluctance motors (PMASynRMs) can be degraded by high ripple torque at both high and low speeds.

[0005] In U.S. Patent No. 4,916,346, Kilman et al. disclose a rotor system configuration that improves rotor strength, speed capability, and specific torque. The system includes a stacked structure in which a magnetic portion comprises a plurality of pole pieces extending radially outward from a core portion of the rotor system to form a plurality of interpole spaces; and a nonmagnetic portion comprises nonmagnetic segments between the pole pieces. Furthermore, the nonmagnetic segments can be wedge-shaped, with gaps between the nonmagnetic segments and the inner core. Nonmagnetic segments of varying sizes and shapes can be used in other rotor system configurations, where the nonmagnetic segments are bonded to adjacent edges of the pole pieces to replace bridges and ligaments that increase rotor strength. The arrangement of the nonmagnetic segments can reduce complex welding paths during rotor manufacturing.

[0006] The disclosures discussed above rely on a configuration of the rotor and rotor magnets designed to reduce complex weld paths. However, this simple rotor design may result in reduced torque output compared to a more complex design that strategically utilizes high and low reluctance areas to achieve the desired torque output. Utility Model Content

[0007] The inventors herein have recognized the aforementioned issues and have provided an electric machine system that at least partially addresses these issues, including a rotor stack comprising at least one interlocking element disposed within one or more barriers, the at least one interlocking element being non-metallic and non-magnetic. In this manner, the present disclosure can utilize regions of high and low reluctance to achieve a desired torque output without the torque ripple associated with rotor stacks with bridges and the mechanical impairments associated with rotor stacks without bridges.

[0008] The above advantages and other advantages and features of this specification will be readily apparent when read alone or in conjunction with the accompanying drawings in the following detailed description. It should be understood that the above summary is intended to introduce concepts further described in the detailed description in a simplified form. It is not intended to identify key or essential features of the claimed subject matter, the scope of which is determined solely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure may be better understood by reading the following description of non-limiting embodiments and referring to the accompanying drawings:

[0010] Figure 1 A schematic diagram of the vehicle including the motor is shown;

[0011] Figure 2 The rotor lamination with bridges is shown;

[0012] Figure 3A 、 Figure 3B and Figure 3C is a schematic diagram of a motor rotor stack with interlocking elements;

[0013] Figure 4 is a flow chart of a first method of manufacturing interlocking elements independent of rotor laminations;

[0014] Figure 5 is a flow chart of a second method of manufacturing interlocking elements, which method depends on rotor lamination;

[0015] Figure 6 a schematic diagram showing a rotor stack-up including a cross-sectional view of interlocking elements manufactured according to the first method; and

[0016] Figure 7 A schematic diagram of the rotor stack-up is shown, along with a cross-sectional view of the interlocking elements manufactured according to the second method. DETAILED DESCRIPTION

[0017] Methods and systems described herein relate to a rotor structure for reducing ripple torque in vehicle electric motors, particularly synchronous reluctance machines (SynRMs) and permanent magnet-assisted synchronous reluctance machines (PMASynRMs), by eliminating rotor bridges and including interlocking elements. In particular, systems and methods are provided for manufacturing interlocking elements and configuring rotor stacks with interlocking elements. As a result, the efficiency of the electric motor can be improved due to the reduced ripple torque of the disclosed rotor stack configuration.

[0018] Figure 1 A vehicle system including an electric machine is shown that communicatively couples various components of the vehicle system. Figure 2 A rotor stackup configured with multiple bridges is shown. Figure 3A-3C Various embodiments of rotor stacks configured with multiple interlocking elements are shown. Figure 4 A first method of manufacturing a single interlocking element independent of the rotor lamination is described. Figure 5 A second method for manufacturing interlocking elements based on a rotor laminate structure is described. Figure 6 An example of a rotor stack configured with interlocking elements manufactured according to the first method is shown. Figure 7 is an example of a rotor stack manufactured according to the second method. Figure 2 、 Figure 3A 、 Figure 3B 、 Figure 3C 、 Figure 6 and Figure 7 Drawn to scale, but other relative dimensions may be used.

[0019] Figure 1 A schematic diagram of a vehicle system 100 is shown. Vehicle system 100 may include rear wheels 104, front wheels 106, a traction battery 108, and an electric drive system 120. Electric drive system 120 may include a motor 102 and an electric drive 118 electrically coupled to motor 102. Electric drive 118 may include an inverter in communication with control system 110 for controlling the speed and torque of motor 102. An inverter may be electrically coupled to a power source, wherein executable instructions are configured, stored, and executed by at least one processor of the inverter in at least one memory.

[0020] The control system 110 may include a controller 112, one of a plurality of controllers, communicatively coupled to a plurality of sensors 114 and a plurality of actuators 116. The control system 110 may receive information from the plurality of sensors 114, for example, via the controller 112, and send control signals to the plurality of actuators 116 based on the received information. For example, the plurality of sensors 114 may include a plurality of position sensors, a plurality of motor phase current sensors, etc. As another example, the plurality of actuators 116 may include electric actuators for adjusting the speed and torque of the motor 102. The controller 112 may receive input data from the various sensors, process the input data, and control the actuators in response to the processed input data according to executable instructions or code programmed therein corresponding to one or more routines.

[0021] The vehicle system 100 can obtain propulsion power from the motor 102. For example, the motor 102 can be a synchronous reluctance motor (SynRM), a permanent magnet assisted synchronous reluctance motor (PMASynRM), etc. In some embodiments, the laminates of the rotor of the motor 102 may not be configured with an inner bridge for reducing mechanical stress associated with obstacles. Instead, the laminates can be configured with interlocking elements that reduce mechanical stress associated with obstacles. In the present disclosure, the motor 102 is installed in a rear-wheel drive configuration. Other embodiments of the present disclosure may adopt other configurations, such as installing the motor 102 in a front-wheel configuration, or adopting a configuration in which the motor 102 is installed on both the rear wheel 104 and the front wheel 106. The motor 102 can receive electrical energy from the traction battery 108 to provide torque to the rear wheel 104. In some embodiments, such as during braking operation, the motor 102 can operate as a generator to provide electricity for charging the traction battery 108.

[0022] The motor 102 may include a transmission integrated therein. Furthermore, the motor 102 may be connected to the exterior of the transmission / gearbox housing. The integrated transmission may include a differential gear set and a planetary gear set for transmitting power from the motor 102 to the rear wheels 104. The motor 102 may also include at least one clutch. A controller in a designated control system of the vehicle system 100 (e.g., excluding the control system 110) may send a signal to an actuator of the clutch to engage or disengage the clutch, thereby coupling or decoupling power transmission from the motor 102 to the rear wheels 104 or from the motor 102 to the front wheels 106. Furthermore, multiple traction batteries may be configured to power different driven wheels, where the power to each wheel may be determined based on the traction of the wheel, driver demand, and other conditions. In one example, the vehicle system 100 includes an all-wheel drive vehicle system.

[0023] Similar to control system 110, the aforementioned designated control system may receive information from multiple sensors and send control signals to multiple actuators based on the received information. For example, the multiple sensors may include a battery charge sensor, a clutch activation sensor, and the like. Another example is that the multiple actuators may include a clutch. The controller in the designated control system may receive input data from the various sensors, process the input data, and control the actuators in response to the processed input data according to executable instructions or code programmed therein corresponding to one or more routines.

[0024] Figure 1 An axis system 122 is provided for reference. In one example, the Z axis can be a vertical axis (e.g., parallel to the gravity axis), the X axis can be a transverse axis (e.g., a horizontal axis), and / or the Y axis can be a longitudinal axis. However, in other examples, these axes can have other orientations.

[0025] Now let's see Figure 2 , Figure 2 A rotor 200 is shown, which can be integrated into an existing electric machine, e.g. Figure 1 The motor 102 in FIG. The motor may include a rotor 200 (which may be implemented in existing motor systems) and a stator (not shown). The rotor 200 may include a magnetic portion 212 (including a plurality of internal bridges 208 and a plurality of segments 210) and a non-magnetic portion (including a plurality of separators 206). The plurality of internal bridges 208 may include a first internal bridge 208a, a second internal bridge 208b, and a third internal bridge 208c, and the plurality of segments 210 may include a first segment 210a, a second segment 210b, and a third segment 210c. The plurality of separators 206 may include a first separator 206a, a second separator 206b, a third separator 206c, and a fourth separator 206d. Each separator may be generally arc-shaped and spaced apart from each other. In addition, one or more internal bridges may extend through each separator. The internal bridges are manufactured in the rotor laminate and stamped together with the rotor laminate itself, introducing a design constraint where the thickness of the internal bridges and the thickness of the rotor laminate are strategically chosen.

[0026] For example, the first separator 206a may be separated from the second separator 206b by a first segment 210a, with the first internal bridge 208a extending through the first separator 206a, or vice versa. The second separator 206b may be separated from the third separator 206c by a second segment 210b, with the second internal bridge 208b extending from the first segment 210a, through the second separator 206b, to the second segment 210b, or vice versa. The third separator 206c may be separated from the fourth separator 206d by a third segment 210c, with the third internal bridge 208c extending from the second segment 210b, through the third separator 206c, to the third segment 210c. The rotor 200 may be configured with multiple internal bridges, including the first internal bridge 208a, the second internal bridge 208b, and the third internal bridge 208c, to reduce mechanical stress associated with the presence of multiple obstacles.

[0027] The rotor with the above configuration includes high reluctance regions and low reluctance regions. Arrow 202 indicates the high reluctance region, and arrow 204 indicates the low reluctance region. The high reluctance region may include areas where the magnetic flux encounters greater flow resistance and reduced magnetic flux. The low reluctance region may include areas where the magnetic flux encounters less flow resistance and greater magnetic flux.

[0028] A set of reference axes may include a d-axis 214 and a q-axis 216. When referring to directions, positive may refer to the direction of the arrows of the d-axis 214 and the q-axis 216, and negative may refer to the opposite direction of the arrows of the d-axis 214 and the q-axis 216. During operation of the motor 102, direct current may be negative along the d-axis 214, and quadrature current may be positive along the q-axis 216.

[0029] A current control scheme may be applied to the motor 102 based on at least one of maximum torque per ampere (MTPA), flux weakening, and maximum torque per volt (MTPV). In current control schemes utilizing flux weakening and MTPV, the d-axis current may be negative to offset and reduce the rotor flux of the rotor 200. Because the plurality of internal bridges are fabricated from electrical steel having high magnetic permeability, one or more internal bridges form a narrow path between the partitions, generating high leakage flux through the internal bridges. Consequently, the interaction between the high leakage flux and the rotating magnetic field of the stator generates radial forces. Consequently, the motor generates high ripple torque at both high and low speeds, thereby degrading the motor's performance and reducing the ride quality for the vehicle operator.

[0030] For example, in embodiments where the motor is a traction motor, high ripple torque at low speeds and high loads may cause noticeable wheel wobble, thereby impacting the driving experience for the vehicle operator and / or passengers. The ripple torque may be reduced by removing multiple inner bridges and increasing the thickness of the outer bridges or crowns around the rotor baffles. However, removing multiple inner bridges reduces the mechanical strength of the rotor stack, thereby preventing the motor from operating at high torque and / or high speed. To achieve comparable mechanical strength for the rotor stack, multiple interlocking elements may be disposed within one or more of the multiple baffles. Various embodiments of rotor stacks with integrated interlocking elements are as follows Figures 3A-3C shown.

[0031] Figures 3A-3C Various embodiments of an electric motor without multiple internal bridges are shown, which can be one embodiment of electric motor 102. The electric motor can include a rotor and a stator 314. The rotor can include a generally cylindrical rotor body including an outer surface 332 and an inner surface 334. The stator 314 can include a hollow cylinder, surrounding the rotor outer surface 332 and coupled to a rotor shaft and a plurality of stator windings 318. The stator windings 318 are electrically coupled to control circuitry of a plurality of circuits including at least one transistor. In some embodiments, a gap can be provided between the stator 314 and the rotor.

[0032] A set of reference axes may include a d-axis 336 and a q-axis 338. When referring to directions, positive may refer to the direction of the arrows of the d-axis 336 and the q-axis 338, and negative may refer to the opposite direction of the arrows of the d-axis 336 and the q-axis 338. During operation of the motor 102, direct current may be negative along the d-axis 336, and quadrature current may be positive along the q-axis 338.

[0033] The current control scheme may be applied to the motor 102 based on at least one of maximum torque per ampere (MTPA), flux weakening, and maximum torque per volt (MTPV). In current control schemes utilizing flux weakening and MTPV, the d-axis current may be negative to counteract and reduce the rotor flux.

[0034] The rotor and stator 314 may be concentric about a central axis 340. The rotor shaft may extend in a direction parallel to the central axis 340. When the stator 314 remains stationary, the rotor may rotate about the central axis 340. The rotor may be a rotor stack including a magnetic portion 304 (including a plurality of segments) and a non-magnetic portion (including a plurality of partitions and a plurality of interlocking elements). Figure 2Compared to a conventional rotor, the thickness of the outer baffles or baffle crowns may be increased to compensate for the loss of mechanical strength associated with the internal bridge. The stator 314 may include stator windings 318 extending from its body. The stator 314 may include a plurality of slots 316 extending through the stator core of the stator 314. The plurality of slots 316 may receive one or more wires of the plurality of stator windings 318. In certain embodiments, the plurality of stator windings 318 may be I-shaped windings or U-shaped windings. The plurality of stator windings 318 may be electrically connected to a control circuit in a plurality of circuits. The control circuit may include at least one transistor for applying current to the plurality of stator windings 318 to generate a magnetic field, with the rotor's d-axis 336 aligned therewith. The plurality of stator windings 318 may extend through the plurality of slots 316. In one example, the axial direction may be parallel to the central axis 340.

[0035] In one example, stator 314 includes an inner surface 328 closest to the rotor and an outer surface 326 distal to the rotor. A plurality of slots 316 may be arranged between inner surface 328 and outer surface 326 toward an end face of stator 314. Slots 316 may be arranged in the stator core using additive manufacturing, injection molding, or other manufacturing techniques (e.g., stamping or cutting stacks of electrical steel sheets). A plurality of stator windings 318 may extend in a direction parallel to the slots, with winding ends interconnected by welding or other connection methods. Slots 316 may include electrical wires (e.g., windings) arranged therein.

[0036] Each slot in plurality of slots 316 may include two or more distinct portions characterized by different widths. The widths may be measured in both the axial and radial directions. Slots 316 may be arranged adjacent to inner surface 328. Inner surface 328 may include a circular cross-section and may be concentric with the rotor about central axis 340 of the rotor shaft. Inner surface 328 may be sealed except for a plurality of openings corresponding to the slot openings of slots 316.

[0037] and Figure 2 Similar to the rotor 200 in FIG. 1 , due to the presence of multiple reluctances, the rotor can be configured as a high reluctance region and a low reluctance region. The high reluctance region may include a region where the magnetic flux encounters greater flow resistance and a reduced magnetic flux. The low reluctance region may include a region where the magnetic flux encounters less flow resistance and a greater magnetic flux.

[0038] Figure 3AA first embodiment of an electric machine 300 with interlocking elements is shown. The rotor may be a rotor stack 302, comprising a magnetic portion 304 (comprising a plurality of segments) and a non-magnetic portion (comprising a plurality of partitions and a plurality of interlocking elements). The plurality of segments may include a first segment 304a and a second segment 304b in a first quadrant 320 of the rotor stack 302, and a third segment 304c and a fourth segment 304d in a second quadrant 324 of the rotor. The first quadrant 320 and the second quadrant 324 may be divided by a dashed line 330. The plurality of partitions may include a first partition 305a, a second partition 305b, and a third partition 305c in the first quadrant 320 of the rotor stack 302, and a fourth partition 305d, a fifth partition 305e, and a sixth partition 305f in the second quadrant 324 of the rotor.

[0039] At least one interlocking element may be arranged in one or more partitions, wherein the shape of the at least one interlocking element matches the curves and edges of the partitions, thereby enabling the at least one interlocking element to be positioned within the partitions. Each partition may be generally arc-shaped and spaced apart by a segment. For example, in the first quadrant 320, the first partition 305a and the second partition 305b may be separated by the first segment 304a, and the second partition 305b and the third partition 305c may be separated by the second segment 304b. In the second quadrant 324, the fourth partition 305d may be separated from the fifth partition 305e by the third segment 304c, and the fifth partition 305e may be separated from the sixth partition 305f by the fourth segment 304d.

[0040] Furthermore, each separator may include two peripheral ends extending toward the outer surface 332 of the rotor lamination 302 and a middle portion spaced between the two peripheral ends. The middle portion may enclose one of the plurality of permanent magnets in the rotor lamination 302. For example, the first separator 305a may include a first peripheral end 307a, a second peripheral end 307b, and a first middle portion 307c, while the second separator 305b may include a third peripheral end 307d, a fourth peripheral end 307e, and a second middle portion 307f. The first peripheral end 307a and the second peripheral end 307b extend toward the outer surface 332 of the rotor lamination 302, while the third peripheral end 307d and the fourth peripheral end 307e may extend toward the outer surface 332.

[0041] The first middle portion 307c is located between the first peripheral end 307a and the second peripheral end 307b, and the second middle portion 307f is located between the third peripheral end 307d and the fourth peripheral end 307e. The first middle portion 307c and the second middle portion 307f can both surround one permanent magnet among the plurality of magnets.

[0042] In one embodiment, the curvature and width of the barrier layer can vary depending on the radial distance between the barrier layer and the outer surface of rotor lamination 302. More specifically, the curvature and width of the barrier layer decrease as the radial distance between the barrier layer and outer surface 332 decreases. In other words, the curvature and width of the barrier layer increase as the radial distance between the barrier layer and inner surface 334 decreases. For example, when comparing first barrier layer 305a and second barrier layer 305b, first barrier layer 305a is positioned closer to inner surface 334 of rotor lamination 302 than second barrier layer 305b. Therefore, the radial distance between second barrier layer 305b and outer surface 332 is less than the radial distance between first barrier layer 305a and outer surface 332. Consequently, first barrier layer 305a has a greater curvature and width than second barrier layer 305b.

[0043] In another embodiment, the curvature and width of the barrier layer's peripheral end portion may vary depending on the radial distance between a point on the peripheral end portion and the rotor lamination outer surface 332. Thus, as the radial distance between the peripheral end portion and the outer surface 332 decreases, the curvature of the peripheral end portion may increase, and the width of the peripheral end portion may decrease. For example, a first point 342 on the first peripheral end 307a is closer to the outer surface 332 than a second point 344 on the first peripheral end 307a. Therefore, the radial distance R1 between the first point 342 and the outer surface 332 is smaller than the radial distance R2 between the second point 344 and the outer surface 332. Due to the smaller radial distance R1 between the first point 342 and the first peripheral end 307a, the curvature of the first peripheral end 307a at the first point 342 is greater than the curvature at the second point 344. Furthermore, the width of the first peripheral end 307a at the first point 342 is smaller than the width at the second point 344.

[0044] like Figure 3A As shown, a cross-section of the middle portion of a separator may include two protruding rounded rectangular edges located at the center of the middle portion. In one example, a cross-section of the first middle portion 307c of the first separator 305a and a cross-section of the second middle portion 307f of the second separator 305b include two protruding rounded rectangular edges located at the center of the first middle portion 307c and the second middle portion 307f, respectively. Similarly, a cross-section of the fourth separator 305d and the fifth separator 305e includes two protruding rounded rectangular edges located at the center of the middle portion, respectively. Because the shapes of the interlocking elements match the curves and edges of the separators in which they are located, the shapes of the first interlocking element 309a, the second interlocking element 309b, the third interlocking element 309c, and the fourth interlocking element 309d are configured to enable insertion of multiple interlocking elements into their respective separators.

[0045] At least one interlocking element disposed in one or more separators of rotor stack 302 may include a central interlocking element. A central interlocking element may include a first interlocking component having a rectangular cross-section and two parallel convex surfaces. First interlocking element 309a, second interlocking element 309b, third interlocking element 309c, and fourth interlocking element 309d may be central interlocking elements and may be disposed within the middle portions of first separator 305a, second separator 305b, fourth separator 305d, and fifth separator 305e, respectively.

[0046] Figure 3B A second embodiment of an electric machine 301 is shown. The rotor may be a rotor stack 312, including a magnetic portion 306 (including a plurality of segments) and a non-magnetic portion (including a plurality of partitions and a plurality of interlocking elements). The plurality of segments may include a first segment 306a and a second segment 306b in a first quadrant 320 of the rotor stack 312, and a third segment 306c and a fourth segment 306d in a second quadrant 324 of the rotor. The first quadrant 320 and the second quadrant 324 may be divided by a dashed line 330. The plurality of partitions may include a first partition 311a, a second partition 311b, and a third partition 311c in the first quadrant 320 of the rotor stack 312, and a fourth partition 311d, a fifth partition 311e, and a sixth partition 311f in the second quadrant 324 of the rotor stack.

[0047] At least one interlocking element may be arranged in one or more separators, wherein the shape of the at least one interlocking element matches the curves and edges of the separators, thereby enabling the at least one interlocking element to be positioned within the separators. Each separator may be generally arc-shaped and spaced apart by a segment. For example, in the first quadrant 320, the first separator 311a and the second separator 311b may be separated by the first segment 306a, and the second separator 311b and the third separator 311c may be separated by the second segment 306b. In the second quadrant 324, the fourth barrier layer 311d may be separated from the fifth barrier layer 311e by the third segment 306c, and the fifth barrier layer 311e may be separated from the sixth barrier layer 311f by the fourth segment 306d.

[0048] Furthermore, each separator may include two peripheral ends extending toward the outer surface 332 of the rotor stack 312 and a middle portion spaced between the two peripheral ends. The middle portion may enclose one of the plurality of permanent magnets in the rotor stack 312. For example, the first separator 311a may include a first peripheral end 313a, a second peripheral end 313b, and a first middle portion 313c, while the second separator 311b may include a third peripheral end 313d, a fourth peripheral end 313e, and a second middle portion 313f. The first peripheral end 313a and the second peripheral end 313b extend toward the outer surface 332 of the rotor stack 312, while the third peripheral end 313d and the fourth peripheral end 313e may extend toward the outer surface 332.

[0049] The first middle portion 313c is located between the first peripheral end 313a and the second peripheral end 313b, and the second middle portion 313f is located between the third peripheral end 313d and the fourth peripheral end 313e. Both the first middle portion 313c and the second middle portion 313f can surround one permanent magnet among the plurality of magnets.

[0050] In one embodiment, the curvature and width of the barrier layer can vary depending on the radial distance between the barrier layer and the outer surface of rotor lamination 312. More specifically, the curvature and width of the barrier layer decrease as the radial distance between the barrier layer and outer surface 332 decreases. In other words, the curvature and width of the barrier layer increase as the radial distance between the barrier layer and inner surface 334 decreases. For example, when comparing first barrier layer 311a and second barrier layer 311b, first barrier layer 311a is positioned closer to inner surface 334 of rotor lamination 312 than second barrier layer 311b. Therefore, the radial distance between second barrier layer 311b and outer surface 332 is smaller than the radial distance between first barrier layer 311a and outer surface 332. Consequently, first barrier layer 311a has a greater curvature and width than second barrier layer 311b.

[0051] In another embodiment, the curvature and width of the barrier layer's peripheral end portion may vary depending on the radial distance between a point on the peripheral end portion and the rotor lamination outer surface 332. Thus, as the radial distance between the peripheral end portion and the outer surface 332 decreases, the curvature of the peripheral end portion may increase, and the width of the peripheral end portion may decrease. For example, third point 346 on the first peripheral end 313a is closer to the outer surface 332 than fourth point 348 on the first peripheral end 313a. Therefore, the radial distance R3 between third point 346 and the outer surface 332 is smaller than the radial distance R4 between fourth point 348 and the outer surface 332. Due to the smaller radial distance R3 between third point 346 and the outer surface 332, the curvature of the first peripheral end 313a at third point 346 is greater than the curvature at fourth point 348. Furthermore, the width of the first peripheral end 313a at third point 346 is smaller than the width at fourth point 348.

[0052] like Figure 3B As shown, the cross-sections of the two outer ends of the separator can be generally circularly swept wings, with two protruding rounded rectangular edges arranged toward one end relative to the other end of each outer end, while the cross-sections of the middle portions of the separators can be rectangular. For example, the cross-sections of the two outer ends of the first separator 311a, the second separator 311b, the fourth separator 311d, and the fifth separator 311e can be generally circularly swept wings, with two protruding rounded rectangular edges arranged toward one end relative to the other end of each outer end. The cross-sections of the middle portions of the first separator 311a, the second separator 311b, the fourth separator 311d, and the fifth separator 311e can be rectangular.

[0053] Because the shapes of the interlocking elements match the curves and edges of the partitions, the positions of the interlocking elements, the shapes of the first interlocking element 315a and the second interlocking element 315b of the first partition 311a, the shapes of the third interlocking element 315c and the fourth interlocking element 315d of the second partition 311b, and the shapes of the fifth interlocking element 315e and the sixth interlocking element 315f of the fourth partition 311d, as well as the shapes of the seventh interlocking element 315g and the eighth interlocking element 315g, the shape of the fifth interlocking element 315e and the shape of the sixth interlocking element 315f of the fourth partition 311d, and the shape of the seventh interlocking element 315g and the shape of the eighth interlocking element 315h of the fifth partition 311e, are all configured to enable multiple interlocking elements to be inserted into their respective partitions.

[0054] The peripheral interlocking elements disposed in one or more partitions of rotor stack 312 may include two lateral interlocking elements. The two lateral interlocking elements may include a first lateral interlocking element disposed at a first peripheral end of the partition and a second lateral interlocking element disposed at a second peripheral end of the partition. The lateral interlocking elements may include a second interlocking member having a generally circular swept wing-like cross-section and having two protruding rounded rectangular edges at one end, relative to the other end of the second interlocking member. The two protruding rounded rectangular edges may be disposed on different sides of the cross-section.

[0055] The first interlocking element 315a and the second interlocking element 315b of the first separator 311a, the third interlocking element 315c and the fourth interlocking element 315d of the second separator 311b, the fifth interlocking element 315e and the sixth interlocking element 315f of the fourth separator 311d, and the seventh interlocking element 315g and the eighth interlocking element 315h of the fifth separator 311e can be lateral interlocking elements. In one example, the first interlocking element 315a can be provided at the first peripheral end 313a of the first separator 311a, and the second interlocking element 315b can be provided at the second peripheral end 313b. Similarly, the third interlocking element 315c can be provided at the third peripheral end 313d, and the fourth interlocking element 315d can be provided at the fourth peripheral end 313e of the second separator 311b. The first, second, third, fourth, and fifth interlocking elements 315a, 315b, 315c, 315d, 315e, 315f, 315g, and 315h interlocking elements can have a generally circular, swept-wing cross-section with two protruding, rounded rectangular edges disposed toward one end relative to the other end of each interlocking element. Thus, the first and second interlocking elements 315a, 315b can be inserted into the first separator 311a, the third and fourth interlocking elements 315c, 315d can be inserted into the second separator 311b, the fifth and sixth interlocking elements 315e, 315f can be inserted into the fourth separator 311d, and the seventh and eighth interlocking elements 315g, 315h can be inserted into the fifth separator 311e.

[0056] Figure 3C A third embodiment of an electric machine 303 is shown. The rotor may be a rotor stack 322 comprising a magnetic portion 308 (comprising a plurality of segments) and a non-magnetic portion (comprising a plurality of separators and a plurality of interlocking elements). The plurality of segments may include a first segment 308a and a second segment 308b in a first quadrant 320 of the rotor stack 322, and a third segment 308c and a fourth segment 308d in a second quadrant 324 of the rotor. The first quadrant 320 and the second quadrant 324 may be divided by a dashed line 330. The plurality of separators may include a first separator 317a, a second separator 317b, and a third separator 317c in the first quadrant 320 of the rotor stack 322, and a fourth separator 317d, a fifth separator 317e, and a sixth separator 317f in the second quadrant 324 of the rotor stack.

[0057] At least one interlocking element may be arranged in one or more partitions, wherein the shape of the at least one interlocking element matches the curves and edges of the partitions, thereby enabling the at least one interlocking element to be positioned within the partitions. Each partition may be generally arc-shaped and spaced apart from each other by a segment. For example, in the first quadrant 320, the first partition 317a may be separated from the second partition 317b by a first segment 308a, and the second partition 317b may be separated from the third partition 317c by a second segment 308b. In the second quadrant 324, the fourth partition 317d may be separated from the fifth partition 317e by a third segment 308c, and the fifth partition 317e may be separated from the sixth partition 317f by a fourth segment 308d.

[0058] Furthermore, each separator may include two peripheral ends extending toward the outer surface 332 of the rotor stack 322 and a middle portion spaced between the two peripheral ends. The middle portion may enclose one of the plurality of permanent magnets in the rotor stack 322. For example, the first separator 317a may include a first peripheral end 319a, a second peripheral end 319b, and a first middle portion 319c, while the second separator 317b may include a third peripheral end 319d, a fourth peripheral end 319e, and a second middle portion 319f. The first and second peripheral ends 319a, 319b extend toward the outer surface 332 of the rotor stack 322, while the third and fourth peripheral ends 319d, 319e may extend toward the outer surface 332.

[0059] The first middle portion 319c is located between the first peripheral end 319a and the second peripheral end 319b, and the second middle portion 319f is located between the third peripheral end 319d and the fourth peripheral end 319e. The first middle portion 319c and the second middle portion 319f can both surround a permanent magnet among the plurality of magnets.

[0060] In one embodiment, the curvature and width of the barrier layer can vary depending on the radial distance between the barrier layer and the outer surface of rotor lamination 322. More specifically, the curvature and width of the barrier layer decrease as the radial distance between the barrier layer and outer surface 332 decreases. In other words, the curvature and width of the barrier layer increase as the radial distance between the barrier layer and inner surface 334 decreases. For example, when comparing first barrier layer 317a and second barrier layer 317b, first barrier layer 317a is positioned closer to inner surface 334 of rotor lamination 322 than second barrier layer 317b. Therefore, the radial distance between second barrier layer 317b and outer surface 332 is smaller than the radial distance between first barrier layer 317a and outer surface 332. Consequently, first barrier layer 317a has a greater curvature and width than second barrier layer 317b.

[0061] In another embodiment, the curvature and width of the barrier layer's peripheral end portion may vary depending on the radial distance between a point on the peripheral end portion and the rotor lamination outer surface 332. Thus, as the radial distance between the peripheral end portion and the outer surface 332 decreases, the curvature of the peripheral end portion may increase, and the width of the peripheral end portion may decrease. For example, the fifth point 350 on the first peripheral end 319a is closer to the outer surface 332 than the sixth point 352 on the first peripheral end 319a. Therefore, the radial distance R5 between the fifth point 350 and the outer surface 332 is less than the radial distance R6 between the sixth point 352 and the outer surface 332. Due to the smaller radial distance R5 between the fifth point 350 and the first peripheral end 319a, the curvature of the first peripheral end 319a at the fifth point 350 is greater than the curvature at the sixth point 352. Furthermore, the width of the first peripheral end 319a at the fifth point 350 is less than the width at the sixth point 352.

[0062] like Figure 3C As shown, the cross-sections of the two peripheral ends of the separator may be generally circularly swept, with two protruding rounded rectangular edges arranged toward one end of each peripheral end relative to the other end of each peripheral end. The middle portion of the separator may have a rectangular cross-section, with the two protruding rounded rectangular edges arranged at the center of the middle portion. The two protruding rounded rectangular edges arranged toward one end of each peripheral end relative to the other end of each peripheral end may be arranged on different sides of the cross-section. As an example, the two peripheral ends of the first separator 317a, the second separator 317b, the fourth separator 317d, and the fifth separator 317e may have generally circularly swept cross-sections, with the two protruding rounded rectangular edges arranged toward one end of each peripheral end relative to the other end of each peripheral end. The middle portion of the first separator 317a, the second separator 317b, the fourth separator 317d, and the fifth separator 317e may have a rectangular cross-section, with two protruding rounded rectangular edges arranged toward one end of each peripheral end relative to the other end of each peripheral end.

[0063] Because the interlocking shapes match the curves and edges of the partitions, the positions of the interlocking elements are: the shapes of the first interlocking element 321a, the second interlocking element 321b and the third interlocking element 321c of the first partition 317a, the shapes of the fourth interlocking element 321d, the fifth interlocking element 321e and the sixth interlocking element 321f of the second partition 317b, the shapes of the seventh interlocking element 321g, the eighth interlocking element 321h and the ninth interlocking element 321i of the fourth layer of partition 317d, and the shapes of the tenth interlocking element 321j, the eleventh interlocking element 321k and the twelfth interlocking element 321l of the fifth layer of partition 317e, are all configured to enable multiple interlocking elements to be inserted into their respective partitions.

[0064] The peripheral interlocking elements arranged in one or more partitions of the rotor stack 322 may include three interlocking elements, including two lateral interlocking elements and an intermediate interlocking element, the intermediate interlocking element including a third interlocking component, the cross-section of the third interlocking component being rectangular, and two protruding rounded rectangular edges being arranged at a central position of the third interlocking component, and the two protruding rounded rectangular edges may be arranged on different sides of the cross-section.

[0065] The first interlocking element 321a and the second interlocking element 321b of the first partition 317a, the fourth interlocking element 321d and the fifth interlocking element 321e of the second partition 317b, the seventh interlocking element 321g and the eighth interlocking element 321h of the fourth partition 317d, and the tenth interlocking element 321j and the eleventh interlocking element 321k of the fifth partition 317e can be lateral interlocking elements. The third interlocking element 321c, the sixth interlocking element 321f, the ninth interlocking element 321i, and the twelfth interlocking element 321l can be intermediate interlocking elements.

[0066] In one example, the first interlocking element 321a can be disposed at the first peripheral end 319a of the first separator 317a, and the second interlocking element 321b can be disposed at the second peripheral end 319b of the first separator 317a. The third interlocking element 321c can be disposed at the first intermediate portion 319c. Similarly, the fourth interlocking element 321d can be disposed at the third peripheral end 319d, and the fifth interlocking element 321e can be disposed at the fourth peripheral end 319e of the second separator 317b.

[0067] The sixth interlocking element 321f can be disposed in the second intermediate portion 319f. The first interlocking element 321a, the second interlocking element 321b, the fourth interlocking element 321d, the fifth interlocking element 321e, the seventh interlocking element 321g, the eighth interlocking element 321h, the tenth interlocking element 321j, and the eleventh interlocking element 321k can have a generally circular, swept-wing cross-section with two protruding, rounded rectangular edges disposed toward one end of each interlocking element relative to the other end. The third interlocking element 321c, the sixth interlocking element 321f, the ninth interlocking element 321i, and the twelfth interlocking element 321l can have a generally rectangular cross-section with two protruding, rounded rectangular edges located at the center of each interlocking element.

[0068] In this way, the first interlocking element 321a, the second interlocking element 321b and the third interlocking element 321c can be inserted into the first partition plate 317a, the fourth interlocking element 321d, the fifth interlocking element 321e and the sixth interlocking element 321f can be inserted into the second partition plate 317b, the seventh interlocking element 321g, the eighth interlocking element 321h and the ninth interlocking element 321i can be inserted into the fourth partition plate 317d, and the tenth interlocking element 321j, the eleventh interlocking element 321k and the twelfth interlocking element 321l can be inserted into the fifth partition plate 317e.

[0069] It is understandable that the above discussion Figures 3A-3B The rotor stacking described is exemplary and may be deviated from without departing from the scope of the present disclosure. As one example, other embodiments of the present disclosure may include additional or fewer spacers, as well as different positioning of the spacers depending on design constraints (e.g., size, required operating specifications, permanent magnet embedding of the permanent magnet synchronous motor, etc.). As another example, other embodiments of the present disclosure may include additional or fewer interlocking elements, as well as different positioning of the interlocking elements.

[0070] By Figures 3A-3C Incorporating interlocking elements into the rotor stack reduces torque ripple, pulsating radial forces, jerky motion, and motor speed ripple across various operating speeds without compromising the mechanical strength of the rotor stack. Furthermore, the rotor stack configuration with interlocking elements reduces the costs associated with manufacturing the rotor stack. In particular, because the rotor stack configuration does not include an inner bridge, the rotor stack does not need to be manufactured using specialized molds and stacks, which incur additional costs during manufacturing and are more difficult to manufacture due to the presence of the inner bridge.

[0071] Figure 4 A method 400 for manufacturing a plurality of interlocking elements is shown. The plurality of interlocking elements may be Figures 3A-3C The interlocking elements included in the various embodiments of the rotor stack shown may also be another suitable rotor stack. Method 400 can be implemented by one or more machines, such as machines configured for molding or three-dimensional (3D) printing. The machine may include instructions stored in a memory that can be executed by a processor to implement the various steps. In detail, at least some of the method steps can be implemented as an automated machine process. However, in other examples, at least some of the steps can be executed based on user input or manually by manufacturing personnel.

[0072] At 402, method 400 includes selecting a material for the interlocking elements based on the maximum motor speed and load. The material of the interlocking elements can be selected based on the material's ability to support the motor operating at a predetermined maximum motor speed and load. The rotor stack relies on multiple interlocking elements rather than internal bridges to reduce the mechanical stress associated with multiple obstacles. Therefore, the material is strong enough to reduce mechanical weakening due to the lack of internal obstacles and does not interfere with the magnetic flux inside the rotor stack. In particular, non-magnetic, non-metallic materials with properties similar to air may be suitable candidates and have high magnetic resistance (e.g., low magnetic permeability). For example, the material can be rubber, plastic, carbon fiber, composite materials, etc.

[0073] At 404, method 400 includes manufacturing interlocking elements independent of the rotor lamination. In some embodiments, the interlocking elements can be manufactured using three-dimensional (3D) printing or additive manufacturing. In particular, separate models can be created for the central interlocking element, the lateral interlocking elements (e.g., one at each peripheral end), and the intermediate interlocking elements. Accordingly, additive manufacturing techniques can be used to construct the central interlocking element, the lateral interlocking elements, and the intermediate interlocking elements based on the models for each type of interlocking element.

[0074] In other embodiments, the interlocking elements can be manufactured using a mold separate from the rotor stack. An automated system can mechanically pour liquid material into interlocking element molds, which can include molds for a central interlocking element, lateral interlocking elements (e.g., one at each peripheral end), and a middle interlocking element. While in the mold, the material can be cured and formed into a solid, single interlocking element by exposing it to ultraviolet (UV) light and / or heating it to a predetermined temperature. In this way, a solid, single interlocking element can be constructed in the shape of the first interlocking element, the side interlocking elements, and the middle interlocking element.

[0075] At 406, method 400 includes inserting one or more interlocking elements into the spacers of the rotor stack. In some embodiments, a machine can assemble the rotor stack and insert the one or more interlocking elements into the one or more spacers of the rotor stack. In other embodiments, an assembly line worker can manually insert the interlocking elements into the rotor stack. Thus, lateral interlocking elements can be inserted into the outer ends of the spacers, while intermediate or central interlocking elements can be inserted into the middle of the spacers. Method 400 then ends.

[0076] Figure 5 A method 500 of manufacturing a plurality of interlocking elements is shown. The plurality of interlocking elements may be Figures 3A-3CThe interlocking elements included in the various embodiments of the rotor stack shown in or another suitable rotor stack. Method 500 can be implemented by one or more machines, such as machines configured for molding, three-dimensional (3D) printing or additive manufacturing, and assembly. These machines may include instructions stored in a memory, which can be executed by a processor to implement different steps. In detail, at least some of the method steps can be implemented as an automated machine process. However, in other examples, at least some of the steps can be executed based on user input or manually by manufacturing personnel.

[0077] At 502, method 500 includes selecting a material for an interlocking element based on a maximum motor speed and load. The material for the interlocking element may be selected based on the material's ability to support the motor operating at a predetermined maximum motor speed and load, similar to Figure 4 The method described. Therefore, the material should be strong enough to reduce mechanical weakening due to the absence of internal barriers and not interfere with the magnetic flux inside the rotor stack. In particular, non-magnetic, non-metallic composite materials that behave like air and have high magnetic resistance (for example, low magnetic permeability) may be suitable candidates. For example, the composite material can be polycarbonate resin, epoxy resin, etc.

[0078] At 504, method 500 includes pouring a material in liquid form into the separators of the rotor stack. The barrier layer of the rotor stack can serve as a mold for the interlocking elements. In some embodiments, the material can be poured into specific areas of the separators, such as at the outer ends or in the middle. In other embodiments, the material can be poured into the entire barrier layer, forming a single interlocking element that fills the entire barrier layer. More specifically, an automated system can mechanically pour the liquid material into the separators of the rotor stack, with each separator being individually filled, allowing the entire separator or specific areas of the separator to be filled with the liquid material.

[0079] At 506, method 500 includes curing the material in the partitions by ultraviolet light and / or heat. While in the rotor stack, the material can be cured by exposing the material to ultraviolet light (UV) and / or heating the material to a predetermined temperature, thereby forming interlocking elements in the partitions of the rotor stack. In this way, interlocking elements in the shape of first interlocking elements, side interlocking elements, and intermediate interlocking elements can be constructed. By utilizing specific areas of the partitions or the entire partition, the time to assemble the motor can be reduced because the assembly process does not include the step of inserting the interlocking elements into the partitions. As a result, the efficiency of the motor assembly process is improved. Method 500 then ends.

[0080] Figure 6 and Figure 7 Shown respectively according to Figure 4 and Figure 5The rotor stacks 600 and 700 manufactured by the method can be the rotor stacks 600 and 700 described above. Figures 3A-3C The rotor stack of one embodiment may share at least some structural and functional features. Therefore, for the sake of brevity, redundant descriptions of these overlapping features are omitted.

[0081] Rotor laminations 600 and 700 may include a magnetic portion 602 including a plurality of segments, and a non-magnetic portion including a plurality of spacers and a plurality of interlocking elements, wherein at least one interlocking element is disposed in one or more of the spacers. Figure 6 and Figure 7 A cross-sectional view of a plurality of interlocking elements is included. The plurality of separators may include a first separator 604a, a second separator 604b, a third separator 604c, a fourth separator 604d, a fifth separator 604e, and a sixth separator 604f.

[0082] Go to Figure 6 , the first partition 604a includes a first peripheral end 606a and a second peripheral end 606b, the second partition 604b includes a third peripheral end 606c and a fourth peripheral end 606d, the fourth partition 604d includes a fifth peripheral end 606e and a sixth peripheral end 606f, and the fifth partition 604e includes a seventh peripheral end 606g and an eighth peripheral end 606h. In addition, the plurality of interlocking elements may include a first interlocking element 608a, a second interlocking element 608b, a third interlocking element 608c, a fourth interlocking element 608d, a fifth interlocking element 608e, a sixth interlocking element 608f, a seventh interlocking element 608g, and an eighth interlocking element 608h. Each of the plurality of interlocking elements is a lateral interlocking element of various shapes and sizes. As described above, it is possible to Figure 4 Method 400 is provided for manufacturing a plurality of interlocking elements, wherein the solid interlocking elements are individually manufactured. In particular, the lateral interlocking elements can be manufactured using various molds or additive manufacturing. Thus, during the manufacturing process, the plurality of interlocking elements can be positioned within both peripheral ends of each separator.

[0083] For example, the first interlocking element 608a can be set in the first peripheral end 606a of the first partition 604a, the second interlocking element 608b can be set in the second peripheral end 606b, the third interlocking element 608c can be set in the third peripheral end 606c, the fourth interlocking element 608d can be set in the fourth peripheral end 606d of the second partition 604b, the fifth interlocking element 608e can be set in the fifth peripheral end 606e of the fourth partition 604d, the sixth interlocking element 608f can be set in the sixth peripheral end 606f of the fourth partition 604d, the seventh interlocking element 608g can be set in the seventh peripheral end 606g, and the eighth interlocking element 608h can be set in the eighth peripheral end 606h of the fifth partition 604e.

[0084] Back to Figure 7 , the plurality of interlocking elements may include a first interlocking element 702a, a second interlocking element 702b, a third interlocking element 702c, and a fourth interlocking element 702d. Each interlocking element in the plurality of interlocking elements occupies the entire partition where the interlocking element is located. As described above, the plurality of interlocking elements may be arranged according to the embodiment of the present invention. Figure 5 Method 500 for manufacturing a plurality of interlocking elements involves pouring a liquid compound material into a barrier layer to fill a region or the entire barrier layer, and then curing the material to solidify the compound material within the barrier layer. Thus, the barrier layer of rotor stack 700 serves as a mold for the plurality of interlocking elements. For example, the liquid compound material may be poured into the first separator 604a and cured to form a first interlocking element 702a; the liquid compound material may be poured into the second separator 604b and cured to form a second interlocking element 702b; the liquid compound material may be poured into the fourth separator 604d and cured to form a third interlocking element 702c; and the liquid compound material may be poured into the fifth separator 604e and cured to form a fourth interlocking element 702d.

[0085] The technical benefit of configuring multiple interlocking elements on the rotor stack is that the mechanical strength of the rotor stack is maintained while reducing torque ripple generated by the motor at both high and low speeds. Furthermore, the simplified rotor stack configuration reduces the costs of stamping dies and stacking.

[0086] The present disclosure also provides a support for a motor system, comprising: a rotor stack, the stack including at least one interlocking element, the interlocking element being arranged in one or more partitions, the at least one interlocking element being non-metallic and non-magnetic. In a first example of the system, each of the one or more partitions is roughly arc-shaped. In a second example of the system, optionally including the first example, each partition includes two peripheral ends extending toward the outer surface of the rotor and a middle portion spaced between the two peripheral ends. In a third example of the system, optionally including one or both of the first and second examples, the middle portion includes one of a plurality of permanent magnets. In a fourth example of the system, optionally including one or more or each of the first to third examples, the curvature and width of the barrier layer vary according to the radial distance between the barrier layer and the outer surface of the rotor stack, and the curvature and width of the barrier layer decrease as the radial distance between the barrier layer and the outer surface decreases.

[0087] In a fifth example of the system, optionally including one or more or each of the first through fourth examples, the curvature and width of the peripheral end portion of the partition vary based on the radial distance between a point on the peripheral end portion and the outer surface of the rotor stack, such that as the radial distance between the point on the peripheral end portion and the outer surface decreases, the curvature of the peripheral end portion increases and the width of the peripheral end portion decreases. In a sixth example of the system, optionally including one or more or each of the first through fifth examples, the shape of at least one interlocking element matches the curve and edge of the barrier layer, enabling the at least one interlocking element to be positioned within the barrier layer. In a seventh example of the system, optionally including one or more or each of the first through sixth examples, the at least one interlocking element includes a central interlocking element, the central interlocking element including a first interlocking component having a rectangular cross-section and two parallel concave surfaces.

[0088] In an eighth example of the system, optionally including one or more or each of the first to seventh examples, the at least one interlocking element comprises two lateral interlocking elements, the two lateral interlocking elements comprising a first lateral interlocking element disposed at a first peripheral end of the partition and a second lateral interlocking element disposed at a second peripheral end of the partition. In a ninth embodiment of the system, optionally including one or more or each of the first to eighth embodiments, the lateral interlocking element comprises a second interlocking member having a generally circular swept wing-shaped cross-section having two protruding rounded rectangular edges disposed toward one end relative to the other end of the second interlocking member, the two protruding rounded rectangular edges disposed on different sides of the cross-section.

[0089] In a tenth example of the system, optionally including one or more or each of the first to ninth examples, the at least one interlocking element includes three interlocking elements, the three interlocking elements include two lateral interlocking elements, and an intermediate interlocking element, the intermediate interlocking element includes a third interlocking component, the third interlocking component has a rectangular cross-section, two protruding rounded rectangular edges are set at the center of the third interlocking component, and the two protruding rounded rectangular edges are set on different sides of the cross-section.

[0090] The present disclosure also provides support for a method for manufacturing interlocking elements of a rotor laminate, the method comprising inserting an interlocking element into a barrier layer of the rotor laminate, the interlocking element being manufactured independently of the rotor laminate or using the rotor laminate as a mold to manufacture and position the interlocking element within the barrier layer, wherein the material of the interlocking element is non-magnetic and non-metallic. In a first example of the method, manufacturing the interlocking element independently of the rotor laminate comprises separately manufacturing an interlocking element using a three-dimensional (3D) printer or one of a plurality of interlocking element molds, each interlocking element mold being separate from the rotor laminate and having a shape used to manufacture one of the center interlocking element, the side interlocking elements, and the middle interlocking element. In a second example of the method, optionally including the first example, the material has high magnetic reluctance. In a third example of the method, optionally including one or both of the first and second examples, the rotor laminate is used as a mold to manufacture the interlocking element and position it within the barrier layer, comprising: pouring a liquid material into the barrier layer of the rotor laminate, and curing the material in the barrier layer by applying ultraviolet light or heating the material to a predetermined temperature.

[0091] The present disclosure also provides support for an electric machine system including a rotor comprising a generally cylindrical rotor body having an inner surface and an outer surface, the rotor being arranged in a rotor lamination stack, the rotor lamination stack comprising a magnetic portion comprising a plurality of segments and a non-magnetic portion comprising a plurality of baffles and a plurality of interlocking elements, wherein at least one interlocking element is arranged in one or more baffles, a stator having a plurality of stator windings, the stator being electrically coupled to a control circuit comprising a plurality of circuits including at least one transistor, and an inverter being electrically coupled to a power source, wherein executable instructions are configured, stored, and executed by at least one processor of the inverter in at least one memory to apply current to the plurality of stator windings. In a first example of the system, each baffle is generally arcuate and includes two peripheral ends and a middle portion, the two peripheral ends extending toward the outer surface of the rotor.

[0092] In a second example of a system, optionally including the first example, the plurality of interlocking elements include at least one central interlocking element, one lateral interlocking element, or one intermediate interlocking element, which are disposed within one or more of the plurality of obstacles. In a third example of a system, optionally including one or both of the first and second examples, a lateral interlocking element is disposed at a peripheral end portion of the obstacle. In a fourth example of a system, optionally including one or more or each of the first to third examples, one of the central interlocking element and the intermediate interlocking element is disposed within a central portion of the partition.

[0093] While various embodiments have been described above, it should be understood that these embodiments are intended to be illustrative rather than restrictive. It will be apparent to those skilled in the art that the disclosed subject matter may be embodied in other specific forms without departing from the spirit of the subject matter. Therefore, the above embodiments are to be considered in all respects as illustrative rather than restrictive.

[0094] Figure 1-7 Configuration examples of various components positioned relative to each other are shown. If elements shown in a figure are in direct contact or directly coupled to each other, then, in at least one example, these elements may be referred to as being in direct contact or directly coupled, respectively. Similarly, in at least one example, elements shown as being adjacent or adjacent to each other may be adjacent or adjacent to each other, respectively. For example, elements in face-to-face contact may be referred to as face-to-face contact elements. As another example, in at least one example, elements placed apart from each other, with only space between them and no other elements, may be referred to as being placed apart from each other. As another example, elements displayed above / below, to the sides of, or to the left / right of each other relative to each other may be referred to as such elements. Furthermore, as shown in the figure, in at least one example, the topmost element or element point may be referred to as the "top" of the element, and the bottommost element or element point may be referred to as the "bottom" of the element. As used herein, the terms top / bottom, upper / lower, and above / below may be used relative to the vertical axis in the figure to describe the positioning of elements in the figure relative to each other. Thus, in one example, an element displayed above other elements is positioned vertically above the other elements. For another example, the shapes of elements depicted in the figures may be referred to as having those shapes (e.g., circular, straight, flat, curved, rounded, chamfered, beveled, or the like). Furthermore, in at least one example, elements depicted as intersecting one another may be referred to as intersecting elements or as intersecting one another. Furthermore, in one example, elements that appear within or outside another element may also be referred to as intersecting elements.

[0095] Note that the control and estimation routine examples included herein can be used with various powertrain and / or vehicle system configurations. The control methods and routines disclosed herein can be stored as executable instructions in non-transitory memory and executed by a control system, including a controller, in conjunction with various sensors, actuators, and other transmission and / or vehicle hardware. Furthermore, portions of the methods may represent physical actions taken in the real world to change device states. The specific routines described herein may represent one or more of any number of processing strategies, such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. Therefore, the various actions, operations, and / or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Similarly, the order of processing is not necessarily required to achieve the features and advantages of the examples described herein and is provided for ease of illustration and description. Depending on the specific strategy employed, one or more of the illustrated actions, operations, and / or functions may be repeated. Furthermore, the described actions, operations, and / or functions may graphically represent code to be programmed into the non-transitory memory of a computer-readable storage medium in a vehicle and / or transmission control system, where the described actions are implemented by executing the instructions in a system comprising various hardware components in conjunction with an electronic controller. If desired, one or more of the method steps described herein may be omitted.

[0096] It will be appreciated that the configurations and routines disclosed herein are exemplary in nature, and that these specific examples are not intended to be limiting, as many variations are possible. For example, the above-described techniques can be applied to power systems that include different types of propulsion sources, including different types of electric motors, internal combustion engines, and / or transmissions. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and / or properties disclosed herein.

[0097] The following claims particularly point out certain combinations and subcombinations regarded as novel and non-obvious. These claims may refer to "an" element or a "first" element or its equivalent. These claims should be understood to include one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amendment of the present claims or by presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, are also deemed included within the subject matter of the present disclosure.

[0098] The terms "approximately" and "substantially" as used herein, unless otherwise indicated, should be understood to mean a range of plus or minus 5%.

Claims

1. A motor system, characterized in that: include: a rotor stack comprising at least one interlocking element disposed in one or more spacers, the at least one interlocking element being non-metallic and non-magnetic; wherein each of the one or more baffles is generally arc-shaped; Each of the partitions includes two peripheral ends extending toward the outer surface of the rotor and a middle portion spaced between the two peripheral ends; wherein the middle portion encloses one of the plurality of permanent magnets; The shape of the at least one interlocking element matches the curves and edges of the partition, thereby enabling the at least one interlocking element to be positioned within the partition.

2. The electric machine system of claim 1 , wherein the curvature and width of the partition vary according to the radial distance between the partition and the outer surface of the rotor lamination, and the curvature and width of the partition decrease as the radial distance between the partition and the outer surface decreases.

3. The electric motor system of claim 2 , wherein the curvature and width of the peripheral end of the diaphragm vary according to the radial distance between a point on the peripheral end and the outer surface of the rotor lamination, and as the radial distance between the point on the peripheral end and the outer surface decreases, the curvature of the peripheral end increases and the width of the peripheral end decreases.

4. The electric machine system of claim 1, wherein the at least one interlocking element comprises a central interlocking element comprising a first interlocking member having a rectangular cross-section and two parallel concave surfaces.

5. The motor system of claim 4, wherein the at least one interlocking element comprises two lateral interlocking elements, the two lateral interlocking elements comprising a first lateral interlocking element disposed at a first peripheral end of the partition and a second lateral interlocking element disposed at a second peripheral end of the partition.

6. The motor system of claim 5 , wherein the lateral interlocking element comprises a second interlocking component having a generally circular swept-wing cross-section, two protruding rounded rectangular edges disposed toward one end of the second interlocking component relative to the other end, the two protruding rounded rectangular edges disposed on different sides of the cross-section.

7. The motor system of claim 6 , wherein the at least one interlocking element comprises three interlocking elements, the three interlocking elements comprising two lateral interlocking elements and one intermediate interlocking element, the intermediate interlocking element comprising a third interlocking component, the third interlocking component having a rectangular cross-section, two protruding rounded rectangular edges disposed at a center of the third interlocking component, and the two protruding rounded rectangular edges disposed on different sides of the cross-section.

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