Rotor structure and motor
By wrapping segmental sheathing and separator layers around the rotor core, compressive stress is formed to improve the rotor's resistance to centrifugal force, thus solving the problem of insufficient rotor material strength and achieving efficient operation and cost control of the motor at high speeds.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- UNITED AUTOMOTIVE ELECTRONICS SYST
- Filing Date
- 2025-04-22
- Publication Date
- 2026-05-01
AI Technical Summary
The existing motor rotor material has insufficient strength, which leads to increased iron loss at high speeds, affecting efficiency. In addition, high-strength silicon steel sheet material is expensive.
The segmented annular sheath structure is adopted, and compressive stress is formed by wrapping fiber material. Combined with the separator layer, it reduces costs and improves the rotor core's resistance to centrifugal force.
It increases the rotor's maximum operating speed, reduces production costs, and at the same time limits rotor radial deformation, thereby increasing the motor's power density.
Smart Images
Figure CN224191704U_ABST
Abstract
Description
A rotor structure and motor Technical Field
[0001] This utility model relates to the field of motor technology, and in particular to a rotor structure and a motor. Background Technology
[0002] In order to increase the power density of electric vehicle drive motors and make the drive system more compact, the market demands increasingly higher maximum operating speeds for motors.
[0003] However, as the operating speed increases, the rotor laminations require materials with higher strength. Currently, the yield strength of most silicon steel sheets on the market is between 400MPa and 500MPa. Only a very small number of high-strength silicon steel sheets exist, but their iron loss is significantly higher than that of conventional silicon steel sheets, severely impacting efficiency.
[0004] Therefore, a new solution is urgently needed to improve the maximum operating speed of the rotor structure. Summary of the Invention
[0005] The purpose of this invention is to provide a rotor structure and a motor. This rotor structure forms a segmented annular sheath structure by wrapping a sheath layer. During the wrapping process, tension control is applied to the fiber material, causing compressive stress to be generated on the surface of the rotor core after the annular sheath structure is formed. This gives the rotor core a certain prestress, thereby enabling the core to resist greater centrifugal force and increasing the rotor's maximum operating speed. Furthermore, compared to a sleeve-shaped structure, the segmented sheath layer, while ensuring compressive stress on the rotor core surface, can save on production costs.
[0006] This application discloses a rotor structure, which includes:
[0007] Rotor core;
[0008] A sheath layer is wound around the rotor core and covers the outer circumferential surface of the rotor core in the circumferential direction. The sheath layer is segmented in the axial direction, and there is a sheath gap on the side of a single segment of the sheath layer or between two adjacent segments of the sheath layer.
[0009] The sheath layer is made of fibrous material.
[0010] Furthermore, it also includes a separator layer, which is wound around the rotor core and is in contact with the outer peripheral surface of the rotor core; wherein, through the separator layer, the sheath layer covers the outer peripheral surface of the rotor core in the circumferential direction.
[0011] Furthermore, the tensile strength of the separator layer is less than the tensile strength of the sheath layer.
[0012] Furthermore, the thickness of the separator layer in the radial direction is less than the thickness of the sheath layer in the radial direction.
[0013] Furthermore, the separating layer has a multi-layer structure.
[0014] Furthermore, the separator layer is continuously distributed in the axial direction and completely covers the rotor core.
[0015] Furthermore, the partition layer is segmented in the axial direction, with a separation gap between adjacent partition layers, and each partition layer covers the outer circumferential surface of the rotor core in the circumferential direction.
[0016] Furthermore, both the separator layer and the sheath layer are multi-segmented, with each segment of the separator layer corresponding to one of the segments of the sheath layer, and their projections in the circumferential direction overlap.
[0017] Furthermore, the sheath layer is made of carbon fiber, nylon fiber, or glass fiber.
[0018] Furthermore, the separator layer is made of carbon fiber, nylon fiber, or glass fiber.
[0019] Furthermore, the rotor core is formed by stacking silicon steel sheets, and the magnetic permeability of the separator layer and the sheath layer is less than the magnetic permeability of the silicon steel sheets.
[0020] This application also discloses an electric motor that includes the rotor structure described above.
[0021] The rotor structure and motor provided by this utility model have at least the following beneficial effects, including but not limited to:
[0022] 1) This rotor structure forms a segmented annular sheath structure through a wrapping sheath layer. During the wrapping process, tension control is applied to the fiber material, causing compressive stress to form on the rotor core surface after the annular sheath structure is formed. This also gives the rotor core a certain prestress, enabling it to resist greater centrifugal force and increasing the rotor's maximum operating speed. Furthermore, compared to a sleeve-shaped structure, the segmented sheath layer saves on production costs while ensuring compressive stress on the rotor core surface.
[0023] 2) In this rotor structure, the fiber rings wrapped around the outer surface of the rotor core can also limit the outward expansion of the outer circle of the rotor core at high speeds, thereby reducing the radial deformation of the rotor and increasing the maximum operating speed.
[0024] 3) In this rotor structure, the tensile strength of the separator layer is lower than that of the sheath layer. Generally, high-strength fiber materials are more expensive. Therefore, during the wrapping process, materials with lower cost and lower strength are preferred as separator layers, and then a sheath layer with higher strength and relatively higher cost is wrapped on the outside. This achieves good compressive stress effect while effectively reducing the overall cost. Attached Figure Description
[0025] This specification will be further described by way of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These embodiments are not limiting; in these embodiments, the same reference numerals denote the same structures, wherein:
[0026] Figure 1 is a schematic diagram of the end face of the rotor structure provided in Embodiment 1 of this application;
[0027] Figure 2 is a side view of one embodiment of the rotor structure provided in Embodiment 1 of this application;
[0028] Figure 3 is a side view of another embodiment of the rotor structure provided in Embodiment 1 of this application;
[0029] Figure 4 is a side view of another embodiment of the rotor structure provided in Embodiment 1 of this application.
[0030] Figure 5 is a schematic diagram of the rotor structure provided in Embodiment 2 of this application;
[0031] Figure 6 is a schematic diagram of the end face of the rotor structure provided in Embodiment 2 of this application;
[0032] Figure 7 is a side view of the rotor structure provided in Embodiment 2 of this application;
[0033] Figure 8 is a cross-sectional schematic diagram of the rotor structure provided in Embodiment 3 of this application.
[0034] Icons: 100 - Rotor structure; 10 - Rotor core; 11 - Separator layer; 111 - Separator gap; 12 - Sheath layer; 121 - Sheath gap. Detailed Implementation
[0035] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.
[0036] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the illustrations only show the components related to the present invention and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.
[0037] Example 1
[0038] Referring to Figures 1-4, this application discloses a rotor structure 100, including a rotor core 10 and a sheath layer 12. The sheath layer 12 is wound around the rotor core 10 and covers the outer circumferential surface of the rotor core 10 in the circumferential direction. The sheath layer 12 is segmented in the axial direction, and a sheath gap 121 is formed between the side of a single segment of the sheath layer 12 or between two adjacent segments of the sheath layer 12. The sheath layer 12 is made of fibrous material. It is understood that the circumferential direction in this embodiment refers to the circumferential direction of the rotor core 10 as shown in Figure 1.
[0039] In one embodiment, as shown in FIG2, the sheath layer 12 can be a single-segment structure, which is itself an annular sheath. When this single-segment sheath layer 12 is arranged at the end face of the rotor core 10 in the axial direction, the side opposite to the end face is the sheath gap 121. In another embodiment, as shown in FIG3, when the single-segment sheath layer 12 is arranged at the middle position in the axial direction of the rotor core 10, both sides are sheath gaps 121. In yet another embodiment, as shown in FIG4, the sheath layer 12 can also be a multi-segment structure, with sheath gaps 121 between adjacent sheath layers 12. It is understood that, regardless of whether the sheath layer 12 is a single-segment or multi-segment structure, in this embodiment it does not completely cover the rotor core 10 in the axial direction, thereby saving sheath layers and reducing production costs.
[0040] Therefore, as described above, the rotor structure 100 forms a segmented annular sheath structure by wrapping the sheath layer 12. During the wrapping process, tension control is applied to the fiber material, so that the annular sheath structure forms compressive stress on the surface of the rotor core 10, thus giving the rotor core 10 a certain prestress. This enables the core to resist greater centrifugal force and increases the rotor's maximum operating speed. Furthermore, compared to a sleeve-shaped structure, the segmented sheath layer 12 saves production costs while ensuring compressive stress on the rotor core surface.
[0041] In this embodiment, the sheath layer is made of carbon fiber, nylon fiber, or glass fiber.
[0042] It is worth noting that the rotor structure 100 offers a wide range of material options, allowing for adaptation to different application requirements by using various materials. Specifically, carbon fiber possesses extremely high tensile strength and rigidity, making it suitable for motor scenarios requiring high strength in the sheath layer 12 and high-speed operation; glass fiber offers good overall strength and is less expensive than carbon fiber, making it suitable for cost-sensitive applications that still require good mechanical properties; nylon fiber offers better flexibility, making it suitable for structures with higher requirements for fit and cushioning performance, and it also boasts excellent processability.
[0043] Example 2
[0044] Referring to Figures 5-7, the rotor structure 100 further includes a partition layer 11, which is wound around the rotor core 10 and is in close contact with the outer peripheral surface of the rotor core 10; wherein, through the partition layer 11, the sheath layer 12 covers the outer peripheral surface of the rotor core 10 in the circumferential direction.
[0045] It is worth noting that the distribution of the sheath layer 12 in this embodiment is the same as that in Embodiment 1, and will not be described again here.
[0046] It is also worth noting that, because the outer diameter surface of the rotor core 10 is a punched edge with sharp punched burrs, if it is directly connected to the sheath layer 12, the inner surface of the sheath layer 12 will be under high tensile stress when the rotor is rotating at high speed. This can easily damage the fibers on the inner surface of the sheath layer 12, leading to cracking and failure of the sheath. Therefore, when winding the main structure of the sheath layer 12, a separator layer 11 can be wrapped around the outer surface of the rotor core 10 first to protect the outer sheath layer 12, thereby increasing the maximum operating speed of the rotor structure 100.
[0047] In some embodiments, the tensile strength of the separator layer 11 is less than the tensile strength of the sheath layer 12.
[0048] It is worth noting that, under normal circumstances, high-strength fiber materials are expensive. Therefore, in the wrapping process, materials with lower cost and lower strength are preferred as the separator layer 11, and then a sheath layer 12 with higher strength and relatively higher price is wrapped on the outside. This achieves good compressive stress effect while effectively reducing the overall cost.
[0049] In some embodiments, the thickness of the separator layer 11 in the radial direction is less than the thickness of the sheath layer 12 in the radial direction.
[0050] It is worth noting that the thicker sheath layer 12 provides stronger radial compressive stress during the wrapping process. Meanwhile, the thinner separator layer 11 acts as an intermediate buffer layer. Introducing the thin separator layer 11 can evenly distribute tension, slow down stress transmission, and protect the integrity of the core surface. Furthermore, adding a thinner, less expensive separator layer 11 within the high-strength sheath layer 12 can significantly reduce costs without compromising overall performance.
[0051] Optionally, the partition layer 11 has a multi-layer structure.
[0052] Specifically, the multi-layer structure has a better graded buffering capacity than the single-layer structure. The stress and strain caused by burrs in the rotor core 10 can be gradually attenuated in the multi-layer structure, avoiding stress concentration. In addition, compared with the single-layer structure, the partition layer 11 of the multi-layer design can make each layer thinner, making it easier to accurately cover the small geometric features of the core and improve the consistency and integrity of the covering.
[0053] Please refer to Figures 5-7 again. In this embodiment, the partition layer 11 is segmented in the axial direction, and there is a partition gap 111 between two adjacent partition layers 11. Each partition layer 11 covers the outer circumferential surface of the rotor core 10 in the circumferential direction.
[0054] It is worth noting that in this embodiment, both the separator layer 11 and the sheath layer 12 adopt an intermittent wrapping arrangement, which can minimize the amount of material used. This is suitable for medium and low speed motors that require high local strength but have low overall coverage requirements, and has the advantages of being lightweight and low cost.
[0055] In this embodiment, both the separator layer 11 and the sheath layer 12 are multi-segmented, with each segment of the separator layer 11 corresponding to one segment of the sheath layer 12, and their projections in the circumferential direction coincide. That is, the sheath gap 121 and the separator gap 111 are located at different radial heights on the same plane. In this case, the separator layer 11 not only protects the sheath layer 12 (preventing burrs from affecting the sheath layer), but also improves the utilization rate of the separator layer 11.
[0056] In this embodiment, the separator layer 11 is made of carbon fiber, nylon fiber or glass fiber.
[0057] It is worth noting that the separator layer 11 can also be made of fiber material, so that it can also play a certain radial support role during the wrapping process.
[0058] In some embodiments, the rotor core 10 is formed by stacking silicon steel sheets, and the permeability of both the separator layer 11 and the sheath layer 12 is less than the permeability of the silicon steel sheets.
[0059] Example 3
[0060] Please refer to Figure 8. Except for the arrangement of the partition layer 11, the rotor structure is the same as that in Embodiment 2. The same features will not be described again here.
[0061] Specifically, in embodiment 3, the partition layer 11 of the rotor structure 100 is continuously distributed in the axial direction and completely covers the rotor core.
[0062] It is worth noting that since high-strength fiber materials are generally expensive, when wrapping, the sheath layer 12 can be wrapped at intervals to form an axially distributed sheath strip on the outer circumference of the rotor, which reduces the amount of fiber material used and improves strength. The continuous wrapping of the separator layer 11 can achieve full axial coverage and protection of the rotor core 10. This arrangement has the advantages of strong effect and flexible process.
[0063] This application further discloses an electric motor that includes the rotor structure 100 described above. This electric motor possesses all the beneficial effects of the rotor structure 100.
[0064] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.
[0065] Throughout this description, numerous specific details, such as examples of components and / or methods, are provided to provide a complete understanding of embodiments of this application. However, those skilled in the art will recognize that embodiments of this invention may be practiced without one or more of these specific details or by other devices, systems, components, methods, parts, materials, components, etc. In other instances, well-known structures, materials, or operations have not been specifically shown or described in detail to avoid obscuring aspects of embodiments of this application.
[0066] Throughout this specification, references to "an embodiment," "an embodiment," or "a specific embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention, but not necessarily in all embodiments. Therefore, the various representations of the phrases "in one embodiment," "in an embodiment," or "in a specific embodiment" in different places throughout the specification do not necessarily refer to the same embodiment. Furthermore, a particular feature, structure, or characteristic of any specific embodiment of the present invention can be combined with one or more other embodiments in any suitable manner. It should be understood that other variations and modifications of the embodiments described herein may be based on the teachings herein and will be considered part of the spirit and scope of the present invention.
[0067] It should also be understood that one or more of the elements shown in the figures may be implemented in a more separate or more integrated manner, or may even be removed because they are inoperable in certain circumstances or provided because they may be useful for a particular application.
[0068] Furthermore, unless otherwise expressly stated, any arrows in the accompanying drawings should be considered illustrative only and not limiting. Additionally, unless otherwise stated, the term "or" as used herein is generally intended to mean "and / or". Where a term is anticipated to provide a separation or combination capability that is unclear, a combination of components or steps will also be considered as indicated.
[0069] As used herein and throughout the claims below, unless otherwise specified, “a” and “the” include the plural references. Similarly, as used herein and throughout the claims below, unless otherwise specified, “in” means “in” and “on”.
[0070] The above description of the embodiments shown in this utility model (including the content in the abstract of the specification) is not intended to be an exhaustive enumeration or to limit the utility model to the precise forms disclosed herein. Although specific embodiments and examples of the utility model have been described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the utility model, as will be recognized and understood by those skilled in the art. As indicated, these modifications can be made to the utility model in accordance with the above description of the embodiments of this application, and such modifications will be within the spirit and scope of the utility model.
[0071] This document has generally described the systems and methods in detail to aid in understanding the present invention. Furthermore, various specific details have been set forth to provide a general understanding of the embodiments of this application. However, those skilled in the art will recognize that embodiments of the present invention can be practiced without one or more specific details, or using other devices, systems, accessories, methods, components, materials, parts, etc. In other instances, well-known structures, materials, and / or operations have not been specifically shown or described in detail to avoid obscuring various aspects of the embodiments of this application.
Claims
1. A rotor structure, characterized in that, include: Rotor core; sheath layer, wound around the rotor core and covering the outer circumferential surface of the rotor core in the circumferential direction, the sheath layer is segmented in the axial direction, and there is a sheath gap on the side of a single segment of the sheath layer or between two adjacent segments of the sheath layer; wherein, the sheath layer is made of fiber material.
2. The rotor structure according to claim 1, characterized in that, It also includes a separator layer, which is wound around the rotor core and is in contact with the outer peripheral surface of the rotor core; wherein, through the separator layer, the sheath layer covers the outer peripheral surface of the rotor core in the circumferential direction.
3. The rotor structure according to claim 2, characterized in that, The tensile strength of the separator layer is less than the tensile strength of the sheath layer.
4. The rotor structure according to claim 2, characterized in that, The thickness of the separator layer in the radial direction is less than the thickness of the sheath layer in the radial direction.
5. The rotor structure according to claim 2, characterized in that, The separating layer has a multi-layer structure.
6. The rotor structure according to any one of claims 2-5, characterized in that, The separator layers are continuously distributed in the axial direction and completely cover the rotor core.
7. The rotor structure according to any one of claims 2-5, characterized in that, The separator layer is segmented in the axial direction, with a separation gap between adjacent segments, and each separator layer covers the outer circumferential surface of the rotor core in the circumferential direction.
8. The rotor structure according to claim 7, wherein both the partition layer and the sheath layer are multi-segmented, the multi-segmented partition layer and the multi-segmented sheath layer correspond one-to-one, and their projections in the circumferential direction coincide with each other.
9. The rotor structure according to claim 1, characterized in that, The sheath layer is made of carbon fiber, nylon fiber or glass fiber.
10. The rotor structure according to claim 2, characterized in that, The separator layer is made of carbon fiber, nylon fiber or glass fiber.
11. The rotor structure according to claim 2, characterized in that, The rotor core is formed by stacking silicon steel sheets, and the magnetic permeability of the separator layer and the sheath layer is less than that of the silicon steel sheets.
12. An electric motor, characterized in that, Includes the rotor structure as described in any one of claims 1-11.