Rotor structure and electric machine
By employing an annular sheath structure with a separator layer and a sheath layer in the rotor structure, and applying tension to form compressive stress, the problem of insufficient rotor material strength is solved, achieving stable operation at high speeds and cost control.
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
- 2026-06-02
AI Technical Summary
The rotor structure of existing electric vehicle drive motors has insufficient material strength at high speeds, which leads to increased iron loss and affects efficiency. In addition, high-strength silicon steel sheets are expensive, making it difficult to meet the requirements of both high speed and low cost at the same time.
The ring-shaped sheath structure with a separator layer and a sheath layer is adopted. Tension is applied during the wrapping process to form compressive stress, which increases the prestress of the rotor core. Combined with the layered design of fiber materials, the overall cost is reduced and the sheath layer is protected to avoid burr damage.
It increases the rotor's maximum operating speed, reduces radial deformation, ensures the functional stability and cost-effectiveness of the rotor structure, and achieves stable operation at high speeds.
Smart Images
Figure CN224319121U_ABST
Abstract
Description
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. Utility Model Content
[0005] The purpose of this invention is to provide a rotor structure and a motor. This rotor structure forms an annular sheath structure by wrapping a separator layer and a sheath layer. 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, giving the rotor core a certain prestress. This allows the core to resist greater centrifugal force and increases the rotor's maximum operating speed. At the same time, the separator layer can protect the outer sheath layer, preventing burrs on the rotor core from damaging the sheath layer, thereby ensuring the functional stability of the rotor structure.
[0006] This application discloses a rotor structure, which includes:
[0007] Rotor core;
[0008] A separator layer is wound around the rotor core and covers the outer circumferential surface of the rotor core;
[0009] A sheath layer, at least surrounding a portion of the separator layer, and at least covering the outer peripheral surface of a portion of the separator layer;
[0010] Both the separator layer and the sheath layer are made of fibrous material.
[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 completely covers the rotor core in the axial direction, the sheath layer is segmented in the axial direction, there is a sheath gap between two adjacent sheath layers, and each sheath layer covers the outer peripheral surface of the separator layer in the circumferential direction.
[0015] Furthermore, the separator layer completely covers the rotor core in the axial direction, and the sheath layer completely covers the separator layer in the axial direction.
[0016] Furthermore, the separator layer is segmented in the axial direction, with a separation gap between adjacent segments of the separator layer, and each separator layer covers the outer peripheral surface of the rotor core in the circumferential direction. The sheath layer is segmented in the axial direction, with a sheath gap between adjacent segments of the sheath layer, and each sheath layer covers the outer peripheral surface of the separator layer in the circumferential direction.
[0017] Furthermore, the separator layer and / or the sheath layer are made of carbon fiber, nylon fiber or glass fiber.
[0018] 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.
[0019] This application also discloses an electric motor that includes the rotor structure described above.
[0020] The rotor structure and motor provided by this utility model have at least the following beneficial effects, including but not limited to:
[0021] 1) The rotor structure forms an annular sheath structure through a wrapping separator layer and a sheath layer. 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, giving the rotor core a certain prestress. This enables the core to resist greater centrifugal force and increases the rotor's maximum operating speed. At the same time, the separator layer can protect the outer sheath layer, preventing burrs on the rotor core from damaging the sheath layer, thereby ensuring the functional stability of the rotor structure.
[0022] 2) The fiber sheath wrapped around the outer surface of the rotor core in this rotor structure can also limit the amount of deformation of the outer circle of the rotor core at high speed, thereby reducing the radial deformation of the rotor and increasing the maximum operating speed.
[0023] 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
[0024] 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:
[0025] Figure 1 This is a schematic diagram of the rotor structure provided in the embodiments of this application;
[0026] Figure 2 This is a schematic diagram of the end face of the rotor structure provided in an embodiment of this application;
[0027] Figure 3 A side view of a rotor structure provided in an embodiment of this application;
[0028] Figure 4 A cross-sectional schematic diagram of the rotor structure provided in an embodiment of this application;
[0029] Figure 5 This is another cross-sectional schematic diagram of the rotor structure provided in an embodiment of this application.
[0030] Icons: 100 - Rotor structure; 10 - Rotor core; 11 - Separator layer; 111 - Separator gap; 12 - Sheath layer; 121 - Sheath gap. Detailed Implementation
[0031] 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.
[0032] 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.
[0033] Please refer to Figures 1-5This application discloses a rotor structure 100, including a rotor core 10, a separator layer 11, and a sheath layer 12. The separator layer 11 is wound around the rotor core 10 and covers the outer peripheral surface of the rotor core 10. The sheath layer 12 is wound around at least a portion of the separator layer 11 and covers at least a portion of the outer peripheral surface of the separator layer 11; both the separator layer 11 and the sheath layer 12 are made of fibrous material. It is understood that the outer peripheral surface in this embodiment refers to the outer edge peripheral surface of the rotor core 10, that is, the annular plane of the rotor core 10 in the circumferential direction.
[0034] It is worth noting that the rotor structure 100 forms an annular sheath structure by wrapping multiple layers of separator layer 11 and sheath layer 12. During the wrapping process, tension control is applied to the fiber material, so that after the annular sheath structure is formed, compressive stress is formed on the surface of the rotor core 10, giving the rotor core 10 a certain prestress, thereby enabling the core to resist greater centrifugal force and increasing the maximum operating speed of the rotor. At the same time, the fiber sheath wrapped on the outer surface of the rotor core 10 can also limit the outward expansion deformation of the outer circle of the rotor core 10 at high speed, thereby reducing the radial deformation of the rotor and increasing the maximum operating speed.
[0035] 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.
[0036] In some embodiments, the tensile strength of the separator layer 11 is less than the tensile strength of the sheath layer 12.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] Optionally, the partition layer 11 has a multi-layer structure.
[0041] 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.
[0042] Please refer to this again. Figure 4 In one embodiment, the separator layer 11 completely covers the rotor core 10 in the axial direction, the sheath layer 12 is segmented in the axial direction, there is a sheath gap 121 between two adjacent sheath layers 12, and each sheath layer 12 covers the outer peripheral surface of the separator layer 11 in the circumferential direction.
[0043] 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 while improving 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 low cost, strong effect and flexible process.
[0044] Please refer to this again. Figure 5 In another embodiment, the separator layer 11 completely covers the rotor core 10 in the axial direction, and the sheath layer 12 completely covers the separator layer 11 in the axial direction.
[0045] It is worth noting that the double-layer continuous coating has the most complete structure, which can achieve full coverage protection of the rotor core 10. At the same time, it provides a uniform compressive stress distribution, improves structural strength and durability, and has the advantages of high strength, stable performance and suitability for extreme performance.
[0046] Please refer to this again. Figure 3In another embodiment, the partition layer 11 is segmented in the axial direction, with a partition gap 111 between adjacent partition layers 11, and each partition layer 11 covers the outer peripheral surface of the rotor core 10 in the circumferential direction. The sheath layer 12 is segmented in the axial direction, with a sheath gap 121 between adjacent sheath layers 12, and each sheath layer 12 covers the outer peripheral surface of the partition layer 11 in the circumferential direction.
[0047] It is worth noting that the double-layer spacer design is a relatively economical structural design, which can minimize the amount of material used. It is suitable for medium and low speed motors that require high local strength but have lower overall coverage requirements, and it has the advantages of being lightweight and low-cost. At this time, the sheath gap 121 and the partition gap 111 are located at different radial heights on the same plane.
[0048] In some embodiments, the separator layer 11 and / or sheath layer 12 are made of carbon fiber, nylon fiber or glass fiber.
[0049] It should be noted 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 applications 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] 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.
[0056] 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.
[0057] 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”.
[0058] 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.
[0059] 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; A separator layer is wound around the rotor core and covers the outer circumferential surface of the rotor core; A sheath layer, at least surrounding a portion of the separator layer, and at least covering the outer peripheral surface of a portion of the separator layer; Both the separator layer and the sheath layer are made of fibrous material.
2. The rotor structure according to claim 1, characterized in that, The tensile strength of the separator layer is less than the tensile strength of the sheath layer.
3. The rotor structure according to claim 1, 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.
4. The rotor structure according to claim 1, characterized in that, The separating layer has a multi-layer structure.
5. The rotor structure according to any one of claims 1-4, characterized in that, The separator layer completely covers the rotor core in the axial direction, the sheath layer is segmented in the axial direction, there is a sheath gap between two adjacent sheath layers, and each sheath layer covers the outer peripheral surface of the separator layer in the circumferential direction.
6. The rotor structure according to any one of claims 1-4, characterized in that, The separator layer completely covers the rotor core in the axial direction, and the sheath layer completely covers the separator layer in the axial direction.
7. The rotor structure according to any one of claims 1-4, 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. The sheath layer is segmented in the axial direction, with a sheath gap between adjacent segments, and each sheath layer covers the outer circumferential surface of the separator layer in the circumferential direction.
8. The rotor structure according to claim 1, characterized in that, The separator layer and / or the sheath layer are made of carbon fiber, nylon fiber or glass fiber.
9. The rotor structure according to claim 8, 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.
10. An electric motor, characterized in that, The rotor structure includes any one of claims 1-9.