A rotor assembly and power generation system

Abstract

This utility model provides a rotor assembly and a power generation system, relating to the field of electric motors. The rotor assembly includes a support ring, a core support, and a connector. The first end of the core support has an opening, the support ring is disposed inside the opening, and the connector is connected to the second end of the core support. The first end of the core support also has an outwardly facing flanged ring. In this embodiment, the rotor assembly uses the flanged ring to limit the core, eliminating the need for end plates and retaining rings, saving materials, reducing the number of parts in the rotor assembly, simplifying the assembly process, reducing manufacturing costs, and lowering the overall weight and moment of inertia of the rotor assembly, thus improving the energy conversion efficiency of the motor. The connector at the second end of the core support allows direct connection to the engine crankshaft, reducing the overall axial dimension. This utility model also provides a power generation system, including the rotor assembly.

Description

Technical Field

[0001] This utility model relates to the field of electric motors, and more specifically, to a rotor assembly and a power generation system. Background Technology

[0002] The rotor assembly is an important component of the generator. The rotor generally includes a rotor support, iron core, end plates, and retaining rings. The iron core and end plates are sleeved on the shaft. The end plates are set on the two end faces of the iron core for axial positioning of the iron core. The retaining rings are installed on the end plates to fix the end plates and the iron core, thereby fixing the iron core on the shaft.

[0003] Currently, rotor assemblies have a large number of parts, many assembly processes, consume a lot of materials, and have high manufacturing costs. They are also relatively heavy and have a large moment of inertia, resulting in low energy conversion efficiency of the motor. Furthermore, the rotor and the generator crankshaft need to be connected by components such as drive shafts, which makes the overall axial dimension of the rotor assembly large. Utility Model Content

[0004] This invention provides a rotor assembly and a power generation system that can solve the aforementioned problems existing in existing rotor assemblies.

[0005] The embodiments of this utility model can be implemented as follows:

[0006] An embodiment of this utility model provides a rotor assembly comprising:

[0007] Support ring;

[0008] The iron core support has an opening at its first end, and a support ring is set inside the opening. The first end of the iron core support is also provided with an outward flange ring, which is used to limit the iron core.

[0009] The connector is attached to the second end of the iron core bracket and can be used to connect to the crankshaft of the engine.

[0010] Optionally, the connector includes a cylindrical part and a disc part, the disc part is fixed to the end of the cylindrical part, the cylindrical part is coaxially arranged with the core support, and the disc part is connected to the connector.

[0011] Optionally, the second end of the iron core support is provided with a plurality of first screw holes, and the disc part is provided with a plurality of second screw holes, the plurality of second screw holes corresponding to the plurality of first screw holes respectively.

[0012] Optionally, the opening of the second screw hole is provided with a guide surface.

[0013] Optionally, the second end of the iron core bracket is provided with a first positioning pin hole, and the disc part is provided with a second positioning pin hole. The first positioning pin hole and the second positioning pin hole are adapted to each other. When the first positioning pin hole and the second positioning pin hole are aligned, the multiple second screw holes are aligned with the multiple first screw holes respectively.

[0014] Optionally, there are four first positioning pin holes and four second positioning pin holes. The four first positioning pin holes are equally spaced at the second end of the iron core bracket, and the four second positioning pin holes are equally spaced at the disc portion.

[0015] Optionally, a limiting groove is provided at one end of the opening of the iron core bracket, and the support ring is set in the limiting groove.

[0016] Optionally, the open end of the iron core support is provided with a guide ramp.

[0017] Optionally, the iron core support is provided with a weight reduction zone.

[0018] An embodiment of this utility model also provides a power generation system, including an engine and the rotor assembly, the engine having a crankshaft, and the crankshaft being connected to a connecting member by bolts.

[0019] The beneficial effects of this utility model embodiment:

[0020] The rotor assembly includes a support ring, a core bracket, and a connector. The first end of the core bracket has an opening, and the support ring is disposed inside the opening. The connector is connected to the second end of the core bracket. The first end of the core bracket also has an outwardly flanged ring. In this embodiment, the rotor assembly uses the flanged ring to limit the core, eliminating the need for end plates and retaining rings, saving materials, reducing the number of parts in the rotor assembly, simplifying the assembly process, and reducing manufacturing costs. Furthermore, due to the reduced number of parts, the overall weight of the rotor assembly is lowered, and the moment of inertia is reduced, which helps improve the energy conversion efficiency of the motor. In addition, the second end of the core bracket is connected to the connector, which allows direct connection to the engine crankshaft, resulting in high transmission efficiency and reducing the overall axial dimension of the rotor assembly.

[0021] The power generation system includes a rotor assembly, which has all the functions of a rotor assembly. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1This is a first-view schematic diagram of the rotor assembly structure provided in an embodiment of the present invention;

[0024] Figure 2 This is a second-view schematic diagram of the rotor assembly structure provided in an embodiment of the present invention;

[0025] Figure 3 This is a cross-sectional schematic diagram of the rotor assembly (after hiding the iron core) provided in an embodiment of the present invention;

[0026] Figure 4 This is a first-view schematic diagram of the iron core support provided in an embodiment of the present utility model;

[0027] Figure 5 This is a second-view schematic diagram of the iron core support provided in an embodiment of the present utility model;

[0028] Figure 6 This is a structural schematic diagram of the connector provided in an embodiment of the present utility model.

[0029] Icons: 1-Support ring; 2-Iron core bracket; 20-Opening; 21-Flanged ring; 22-First screw hole; 23-First locating pin hole; 24-Limiting groove; 25-Guide slope; 26-Weight reduction area; 3-Connector; 30-Cylindrical part; 31-Disc part; 311-Second screw hole; 312-Second locating pin hole; 4-Iron core. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0031] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0032] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0033] In the description of this utility model, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the utility model product is usually placed during use, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0034] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0035] The terms “comprising,” “including,” or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase “comprising one…” does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0036] Unless otherwise explicitly specified and limited, terms such as "setup" and "connection" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0037] It should be noted that, where there is no conflict, the features in the embodiments of this utility model can be combined with each other.

[0038] The rotor assembly is a crucial component of a generator, responsible for rotation and torque transmission. Its weight significantly impacts energy conversion efficiency. A rotor typically includes a shaft, rotor support, core, end plates, and retaining rings. The core and end plates are fitted onto the shaft, with the end plates positioned at both ends of the core. The retaining rings abut against the end plates to prevent axial movement of the end plates and core on the shaft. Therefore, current rotor assemblies typically include at least two end plates, retaining rings, a rotor support, a shaft, and a core. The large number of components leads to numerous assembly steps, high material consumption, and high manufacturing costs. Furthermore, the large overall weight of the rotor assembly results in a high moment of inertia, leading to lower energy conversion efficiency. Additionally, when the rotor is connected to the generator crankshaft, a drive shaft and other components are required between the rotor and crankshaft, resulting in a large overall axial dimension and hindering its placement within the vehicle compartment.

[0039] In view of this, an embodiment of the present invention provides a rotor assembly and a power generation system that can solve the above problems, and will be described in detail below.

[0040] Please refer to Figures 1 to 3 The rotor assembly includes a support ring 1, a core bracket 2, and a connector 3. The first end of the core bracket 2 has an opening 20, and the support ring 1 is disposed inside the opening 20. The connector 3 is connected to the second end of the core bracket 2. The first end of the core bracket 2 is also provided with an outwardly flanged ring 21, which can be used to limit the core 4. The core 4 is sleeved on the core bracket 2, and the core 4 and the core bracket 2 can be interference-fitted.

[0041] The rotor assembly of this utility model embodiment is provided with a core support 2. A flange ring 21 is provided at one end of the core support 2. The flange ring 21 can limit the core 4, thereby eliminating the need for an end plate and a retaining ring. This not only saves production costs but also reduces the number of parts in the rotor assembly, simplifies the assembly process, and reduces the weight of the rotor assembly. When the weight of the rotor assembly is reduced, the moment of inertia of the rotor assembly is reduced, which can improve the energy conversion efficiency of the motor. The support ring 1 is provided inside the opening 20 of the core support 2. On the one hand, it provides radial support for the core support 2 and improves the support strength of the core support 2. On the other hand, placing the support ring 1 inside the opening 20 of the core support 2 can reduce the axial dimension of the rotor assembly, which is beneficial for arrangement in areas with limited space, such as the car cabin. Moreover, the second end of the core support 2 is connected to a connector 3, which can be directly connected to the crankshaft of the engine. This not only has high transmission efficiency but also further reduces the overall axial dimension of the rotor assembly.

[0042] It should be noted that the core support 2 of this embodiment is integrally formed by sheet metal bending. Compared with the traditional rotor support which is formed by casting, the core support 2 of this embodiment has thinner walls and lighter weight. The support ring 1 strengthens the support strength and rigidity of the core support 2. The support ring 1 is formed by sheet metal stamping. Although the rotor assembly is equipped with the support ring 1, the mass of the support ring 1 is much less than the sum of the weights of the end plate and the retaining ring. Therefore, the overall weight of the rotor assembly of this embodiment is reduced compared with the existing rotor assemblies.

[0043] refer to Figure 4 and Figure 5 The core support 2 has a cylindrical shape. The first end of the core support 2 is open 20, and the second end is bent. A shaft hole is provided in the middle of the bent portion, with the center of the shaft hole located on the axis of the core support 2. Because the core support 2 is formed by sheet metal bending, a weight-reducing zone 26 can be arranged in the transition area between the core 4 and the bent portion to reduce the weight of the core support 2. Figure 3As shown, the weight reduction zone 26 is inclined relative to the bent portion, and is directly connected at a right angle to the area where the iron core 4 is sleeved compared to the bent portion. Figure 3 (As shown by the dashed line in the middle), the inclined weight reduction zone 26 can reduce the weight of the iron core support 2, which is beneficial to reduce the rotational inertia of the rotor assembly and improve the energy conversion efficiency of the motor.

[0044] The opening 20 of the iron core support 2 is provided with a guide slope 25, which can play a guiding role when the support ring 1 is assembled into the iron core support 2, reducing the difficulty of assembly.

[0045] Optionally, a limiting groove 24 is provided at one end of the opening 20 of the core support 2. The support ring 1 is disposed within the limiting groove 24. The limiting groove 24 limits the support ring 1, bringing it closer to the first end of the core support 2, thereby increasing the support strength of the core support 2 and preventing deformation. The depth of the limiting groove 24 is adapted to the support ring 1. Generally, the depth of the limiting groove 24 is less than the thickness of the support ring 1, while the width of the limiting groove 24 is not less than the width of the support ring 1.

[0046] The support ring 1 and the iron core bracket 2 can be connected by welding or by interference fit. When welding is used, the outer wall of the support ring 1 and the inner wall of the iron core bracket 2 are in clearance fit, and then spot welding is used to fix them at the circumferential gap. When interference fit is used, the iron core bracket 2 is first fixed by tooling, then the iron core bracket 2 is heated or the support ring 1 is frozen, and then the support ring 1 is assembled onto the iron core bracket 2.

[0047] refer to Figure 6 The connector 3 is located at the second end of the iron core support 2. The connector 3 includes a cylindrical part 30 and a disc part 31. The disc part 31 is fixed at the end of the cylindrical part 30. The cylindrical part 30 is coaxially arranged with the iron core support. The disc part 31 is clearance-fitted with the bent part of the connector 3. Then, the connector 3 and the iron core support 2 are fixed by welding.

[0048] The bent portion at the second end of the core support 2 is provided with multiple first screw holes 22, which are located on the same circumference and are evenly distributed. The disc portion 31 is provided with multiple second screw holes 311, which are also located on the same circumference and are evenly distributed. The multiple second screw holes 311 correspond to the multiple first screw holes 22, so that the multiple first screw holes 22 and the multiple second screw holes 311 can be aligned. When the multiple first screw holes 22 and the multiple second screw holes 311 are aligned, and the engine crankshaft is also provided with screw holes corresponding to the second screw holes 311, bolts can be inserted into the first screw holes 22, the second screw holes 311, and the screw holes on the crankshaft and screwed in to connect the rotor assembly to the engine crankshaft. This eliminates the need for components such as the drive shaft, which helps to reduce the axial dimension of the overall structure. The direct connection between the crankshaft and the core support 2 also reduces the amount of oscillation of the rotor assembly.

[0049] Optionally, the opening of the second screw hole 311 is provided with a guide surface. The guide surface can be a sloping plane or an arc-shaped surface. The guide surface is beneficial for guiding the bolt during installation and facilitates assembly and connection.

[0050] To quickly align the multiple second screw holes 311 with the multiple first screw holes 22, a first positioning pin hole 23 is provided at the bent portion at the second end of the core support 2, and a second positioning pin hole 312 is provided at the disc portion 31. The first positioning pin hole 23 and the second positioning pin hole 312 are adapted to each other. When the first positioning pin hole 23 and the second positioning pin hole 312 are aligned, a pin can be inserted into the first positioning pin hole 23 and the second positioning pin hole 312, thereby rotatably connecting the connector 3 to the core support 2. At this time, it is only necessary to rotate the connector 3 to align the second screw hole 311 and the first screw hole 22 for welding.

[0051] Optionally, there are four first positioning pin holes 23 and four second positioning pin holes 312. The four first positioning pin holes 23 are equally spaced at the second end of the iron core support 2, and the four second positioning pin holes 312 are equally spaced at the disc portion 31. This arrangement allows the iron core support 2 and the connecting piece 3 to rotate smoothly during high-speed rotation, preventing swaying due to uneven weight distribution.

[0052] The rotor assembly of this utility model eliminates the need for components such as drive shaft, bearing, and resolver assembly mounting base when connected to the engine crankshaft, shortening the overall axial dimension, increasing the overall connection rigidity, and reducing the overall weight and rotor assembly sway.

[0053] Compared to existing rotor assembly configurations, the rotor assembly of this invention has at least the following advantages:

[0054] (1) The number of parts is small. With fewer parts, less material is consumed, resulting in lower production costs. At the same time, it can reduce assembly steps and improve production and assembly efficiency.

[0055] (2) The overall weight is light. The weight reduction can reduce the rotational inertia of the rotor assembly, thereby improving the energy conversion efficiency of the motor.

[0056] (3) The overall axial dimension is small, which can be arranged in the cabin of a compact car and has a wide range of applications;

[0057] (4) Both the iron core bracket 2 and the support ring 1 are stamped parts, which are simple to manufacture and have low cost.

[0058] An embodiment of this utility model also provides a power generation system, including an engine and the aforementioned rotor assembly. The engine has a crankshaft with multiple threaded holes. These threaded holes on the crankshaft are adapted to multiple second threaded holes 311 on the connector 3. Bolts are inserted into the first threaded hole 22, the second threaded hole 311, and the threaded holes on the crankshaft to connect the crankshaft and the rotor assembly together. Other parts of the generator and engine are not described in detail here and can be understood as prior art.

[0059] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the protection scope of the claims.

Claims

1. A rotor assembly, characterized in that, include: Support ring (1); The iron core support (2) has an opening (20) at its first end, and the support ring (1) is disposed inside the opening (20). The first end of the iron core support (2) is also provided with an outward flange ring (21), which is used to limit the iron core (4). Connector (3), which is connected to the second end of the iron core bracket (2), can be used to connect with the crankshaft of the engine.

2. The rotor assembly according to claim 1, characterized in that, The connector (3) includes a cylindrical part (30) and a disc part (31). The disc part (31) is fixed to the end of the cylindrical part (30). The cylindrical part (30) is coaxially arranged with the iron core support (2). The disc part (31) is connected to the connector (3).

3. The rotor assembly according to claim 2, characterized in that, The second end of the iron core support (2) is provided with a plurality of first screw holes (22), and the disc part (31) is provided with a plurality of second screw holes (311), with the plurality of second screw holes (311) corresponding to the plurality of first screw holes (22).

4. The rotor assembly according to claim 3, characterized in that, The opening of the second screw hole (311) is provided with a guide surface.

5. The rotor assembly according to claim 3, characterized in that, The second end of the iron core bracket (2) is provided with a first positioning pin hole (23), and the disc part (31) is provided with a second positioning pin hole (312). The first positioning pin hole (23) and the second positioning pin hole (312) are adapted to each other. When the first positioning pin hole (23) and the second positioning pin hole (312) are aligned, the plurality of second screw holes (311) are aligned with the plurality of first screw holes (22) respectively.

6. The rotor assembly according to claim 5, characterized in that, The number of the first positioning pin hole (23) and the second positioning pin hole (312) are both four. The four first positioning pin holes (23) are equally spaced at the second end of the iron core bracket (2), and the four second positioning pin holes (312) are equally spaced at the disc part (31).

7. The rotor assembly according to claim 1, characterized in that, The iron core support (2) has a limiting groove (24) at one end of the opening (20), and the support ring (1) is located in the limiting groove (24).

8. The rotor assembly according to claim 1, characterized in that, The opening (20) end of the iron core support (2) is provided with a guide slope (25).

9. The rotor assembly according to any one of claims 1-8, characterized in that, The iron core support (2) is provided with a weight reduction zone (26).

10. A power generation system, characterized in that, include: The engine and the rotor assembly according to any one of claims 1-9, the engine having a crankshaft, the crankshaft being bolted to the connecting member (3).

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