Shapeable rotor structure

Abstract

The utility model relates to a reshapable rotor structure, comprising a rotor iron core, a plurality of tooth portions arranged on the rotor iron core along a circumferential direction, and winding grooves formed between adjacent tooth portions; the opening of the winding groove forms a flaring structure in an unshaped state; after plastic deformation is carried out on the two sides of the opening of the winding groove, the distance between the openings of the winding groove is reduced, and a folding structure is formed. The size of the opening of the winding groove can form a flaring structure and a folding structure, so that a large groove opening distance is kept during winding, and winding operation is facilitated; and after winding, the groove opening is closed through plastic deformation, and the groove fullness rate is increased by more than 5%.

Description

Technical Field

[0001] This utility model relates to the field of motor rotor technology, and in particular to a shapeable rotor structure. Background Technology

[0002] The rotor winding slot fill factor has a significant impact on motor winding. A slot fill factor that is too low results in poor space utilization, while a slot fill factor that is too high makes rotor winding difficult. For example... Figure 1 In existing rotor core structures, the rotor winding slot space and slot spacing are fixed. The slot fill factor is between 50% and 70%. When the slot fill factor reaches the upper limit, winding difficulties occur, reaching the winding adjustment limit. Summary of the Invention

[0003] To address the aforementioned problems, the purpose of this invention is to provide a shapeable rotor structure that can improve the slot fill factor of the rotor winding slots and enhance motor performance without increasing the difficulty of winding.

[0004] A shapeable rotor structure, comprising:

[0005] The rotor core has multiple teeth arranged circumferentially, and winding slots are formed between adjacent teeth.

[0006] The opening of the winding groove forms a flared structure in the unshaped state;

[0007] After plastic deformation, the gap between the openings of the winding grooves is reduced, forming a converging structure.

[0008] Preferably, each tooth of the rotor core is provided with a pre-punched groove on both sides. When the pre-punched groove is not shaped, the opening of the winding groove forms an flared structure. After the pre-punched groove is plastically deformed, the opening of the winding groove forms a constricted structure.

[0009] Preferably, the pre-punched grooves are symmetrically arranged on both sides of the tooth tip of each tooth.

[0010] Preferably, the depth of the pre-punched groove is 5%-24% of the tooth thickness, and the width is 0.15-0.5 mm.

[0011] Preferably, the rotor core includes multiple stacked rotor laminations, and a notch corresponding to the pre-punched groove 4 is machined in the circumferential direction of each rotor lamination. After the multiple rotor laminations are stacked, the notches on them form a pre-punched groove arranged along the axial direction of the rotor core.

[0012] Preferably, the winding slot is arc-shaped on the side near the radial outer end of the rotor core, with the arc protruding from the inner side to the outer side of the rotor core in the radial direction.

[0013] Preferably, the rotor core is plastically deformed using a high-frequency heating and shaping process.

[0014] Preferably, the winding groove is provided with an insulating coating layer.

[0015] Because of the above-mentioned scheme, the opening size of the winding slot can form an flared structure and a converging structure, thereby maintaining a large slot spacing during winding to facilitate winding operation; after winding, the slot opening is converging through plastic deformation, increasing the slot fill factor by more than 5%. In addition, plastic deformation ensures the final dimensional accuracy and maintains the overall structural strength of the rotor. Attached Figure Description

[0016] Figure 1 A schematic diagram of an electronic core structure in the prior art;

[0017] Figure 2 A schematic diagram of the rotor tooth structure in its unshaped state;

[0018] Figure 3 Figure 2 A structural diagram from another angle;

[0019] Figure 4 A schematic diagram of the reshaped tooth structure;

[0020] Figure 5 Figure 4 A structural diagram from another angle.

[0021] Figure label:

[0022] Rotor shaft 1, teeth 2, winding groove 3, opening 31 of winding groove, pre-punched groove 4. Detailed Implementation

[0023] The embodiments of this utility model are described in detail below.

[0024] like Figure 2-5As shown, this embodiment provides a formable rotor structure. The rotor core includes multiple stacked rotor laminations. A rotor shaft 1 is located at the center of the rotor core, and multiple teeth 2 are arranged circumferentially on the rotor core, forming winding slots 3 between adjacent teeth 2. In this embodiment, the opening 31 of the winding slot 3 has two states: an unformed state and a formed state. In the unformed state, the opening 31 of the winding slot forms a flared structure. Under the flared structure, the spacing between the openings 31 of the winding slot is large, and both ends of the openings 31 of the winding slot expand outward along the radial direction of the rotor core. At this time, the openings 31 of the winding slot are large, and the internal space of the winding slot 3 is large, which facilitates the winding operation. After winding is completed, the openings 31 of the winding slot undergo plastic deformation on both sides, and the spacing between the openings 31 of the winding slot decreases, forming a closed structure. At this time, the winding slot 3 maintains the closed structure state. With the above structure, the slot fill factor of the same size winding slot 3 under the closed structure can be increased by at least 5% compared with the prior art.

[0025] Preferably, the side of the winding slot 3 near the radial outer end of the rotor core is arc-shaped, with the arc protruding from the inner side to the outer side of the rotor core. On the one hand, the arc structure can increase the volume of the winding slot 3, and on the other hand, the arc structure can fit as closely as possible to the surface arc of the coil in the winding slot 3 after winding, thereby increasing the slot fill factor.

[0026] To achieve the specific shaping structure, in this embodiment, pre-punched grooves 4 are provided on both sides of each tooth 2 of the rotor core. By providing these pre-punched grooves 4, the outer edge of the pre-punched groove 4 on the tooth 2 can be rotated and shaped with the pre-punched groove 4 as the rotation reference, thereby realizing the switch between the flared structure and the contracted structure. In a specific embodiment, notches corresponding to the pre-punched grooves 4 are machined in the circumferential direction of each rotor lamination. After multiple rotor laminations are stacked, the notches on them form pre-punched grooves arranged along the axial direction of the rotor core. This scheme of pre-setting notches on the rotor laminations makes processing more convenient.

[0027] Preferably, the pre-punched grooves 4 are symmetrically arranged on both sides of the tooth tip of each tooth 2, which facilitates machining and control of dimensional accuracy. In one specific embodiment, the depth of the pre-punched grooves 4 is 5%-24% of the thickness of the tooth 2, and the width is 0.15-0.5mm. This arrangement balances the flaring radius of the winding groove 31 opening with the prevention that the pre-punched grooves 4 may affect the strength of the rotor core itself. In a specific embodiment, the cross-sectional shape of the pre-punched grooves 4 can be rectangular, trapezoidal, or arc-shaped, etc.

[0028] It should be further explained that the rotor core is plastically deformed using a high-frequency heating and shaping process. For example, after winding, a high-frequency induction coil is used to heat the pre-punched groove 4 area to a predetermined temperature, and then pressure is immediately applied for hot plastic deformation. After shaping, it is cooled to form a stable, closed structure, thereby ensuring the strength of the shapeable rotor core. The teeth 2 deform along a circular arc trajectory according to a set center point under the action of the shaping fixture, ensuring that the outer diameter of the deformed core is circular, thus guaranteeing its accuracy.

[0029] An insulating coating or insulating paper is attached to the winding slots of the rotor core to form an insulating layer. In a preferred embodiment, using an insulating coating is less expensive than using insulating paper, and during heat shaping, the insulating coating can soften and deform with the teeth simultaneously, without damaging the insulating coating during the shaping process.

[0030] Although embodiments of the present invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A shapable rotor structure, characterized by, The rotor core is provided with a plurality of tooth portions in the circumferential direction, and winding slots are formed between adjacent tooth portions. The opening of the winding slot forms a flared structure in the unshaped state. After plastic deformation of both sides of the opening of the winding slot, the opening distance of the winding slot is reduced, forming a gathered structure.

2. The shapable rotor structure according to claim 1, wherein Each tooth portion of the rotor core is provided with a pre-punched groove on both sides, and the opening of the winding slot forms a flared structure in the unshaped state; after plastic deformation of the pre-punched groove, the opening of the winding slot forms a gathered structure.

3. The shapable rotor structure according to claim 2, wherein The pre-punched grooves are symmetrically arranged on both sides of the tooth top of each tooth portion.

4. The shapable rotor structure according to claim 2, wherein The depth of the pre-punched groove is 5%-24% of the thickness of the tooth portion, and the width is 0.15-0.5mm.

5. The shapable rotor structure according to claim 2, wherein The rotor core includes a plurality of laminated rotor laminations, and a notch corresponding to the pre-punched groove is processed in the circumferential direction of each rotor lamination; after the plurality of rotor laminations are laminated, the notches thereon form a pre-punched groove arranged in the axial direction of the rotor core.

6. The shapable rotor structure according to claim 1 or 2, wherein The side of the winding slot close to the radial outer end of the rotor core is arc-shaped, and the arc is protruding from the inner side to the outer side of the rotor core in the radial direction.

7. The shapable rotor structure according to claim 1 or 2, wherein The rotor core is subjected to plastic deformation processing using a high-frequency heating and shaping process.

8. The shapable rotor structure according to claim 1, wherein An insulating coating layer is arranged in the winding slot. ​

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