Rotor assembly, electric machine and electric appliance

Abstract

The utility model discloses a rotor assembly, motor and electrical equipment relates to motor technical field, rotor assembly includes: axle sleeve, the axle sleeve includes a plurality of connecting pieces of laminated arrangement, the quality of connecting piece is non -magnetic material, and the outer periphery interval of connecting piece is equipped with a plurality of first splicing units, and rotor core, the rotor core includes a plurality of core units, a plurality of core units are along the circumferential arrangement of connecting piece, and the quality of rotor core is magnetic material, and every core unit is equipped with a second splicing unit to the first splicing unit, and the first splicing unit and second splicing unit splice and interference fit to fix core unit and connecting piece. The utility model discloses a technical scheme, has reduced motor vibration and noise.

Description

Technical Field

[0001] This utility model relates to the field of motors, and more particularly to a rotor assembly, a motor, and electrical equipment. Background Technology

[0002] With the continuous development of motor technology, especially the widespread application of high-efficiency, high-power-density motors in new energy vehicles, industrial drives, and home appliances, higher requirements have been placed on the reliability, magnetic properties, and operational stability of motor rotor structures. As one of the core components of a motor, the rotor's structural design directly affects the motor's electromagnetic performance, mechanical strength, and vibration and noise levels.

[0003] Currently, common motor rotors typically employ a rotor core structure formed by stacking several rotor laminations. The rotor core has shaft holes for mounting the shaft, multiple magnet slots for embedding magnets, and a yoke bridge (or magnetic bridge) connecting the yoke to the shaft hole area. To improve manufacturing efficiency and structural consistency, the shaft hole, yoke, magnet slots, and magnetic bridge are usually designed on the same rotor lamination, forming an integrated structure. Because the shaft hole is made of a magnetically conductive material, this area participates in magnetization during motor operation. Some magnetic flux passes through the shaft hole, forming a leakage magnetic path, reducing the magnetic flux and lowering the motor's magnetic performance and efficiency.

[0004] To address the magnetic leakage problem, one approach is to separate the bushing from the rotor yoke. This involves machining the bushing and yoke separately before assembling them together. However, the connection between the bushing and yoke is not secure, resulting in significant motor vibration and noise when the rotor is running at high speed. Utility Model Content

[0005] The main objective of this invention is to provide a rotor assembly, a motor, and an electrical device, aiming to solve at least one of the aforementioned technical problems.

[0006] To achieve the above objectives, this utility model provides a rotor assembly, which includes:

[0007] A bushing, comprising a plurality of stacked connectors, the connectors being made of a non-magnetic material, and the outer periphery of each connector having a plurality of first splicing portions spaced apart; and

[0008] The rotor core includes multiple core units, which are arranged circumferentially along the connector. The rotor core is made of a magnetically conductive material. Each core unit has a second splicing part corresponding to a first splicing part. The first splicing part and the second splicing part are spliced ​​together and interference-fitted to fix the core unit and the connector.

[0009] In one embodiment, the first splicing part and the second splicing part are spliced ​​and fixed in a stamping die.

[0010] In one embodiment, one of the first splicing portion and the second splicing portion is configured as a splicing groove, and the other of the first splicing portion and the second splicing portion is configured as a splicing protrusion, wherein the splicing groove and the splicing protrusion are interference-fitted.

[0011] In one embodiment, the splicing protrusion includes a connecting portion and a positioning portion disposed at one end of the connecting portion, wherein the outer diameter of the positioning portion is larger than the outer diameter of the connecting portion, and the connecting portion extends radially along the connector.

[0012] In one embodiment, the end face of the positioning portion away from the connecting portion is an arc surface.

[0013] In one embodiment, the outer periphery of the connector is provided with a recessed clearance portion, which is located between two adjacent core units.

[0014] In one embodiment, the recessed clearance portion includes a first recess and a second recess connected together, the recess depth of the first recess is greater than the recess depth of the second recess, and the first recess and the second recess are arranged circumferentially along the connector.

[0015] In one embodiment, the rotor assembly further includes a snap-fit ​​structure, through which two adjacent connectors are fixed.

[0016] In one embodiment, the rotor assembly further includes a rotating shaft that passes through the connector, and the rotating shaft and the connector rotate synchronously.

[0017] To achieve the above objectives, this utility model provides an electric motor, which includes the rotor assembly described above.

[0018] To achieve the above objectives, this utility model provides an electrical device, which includes the motor described above.

[0019] The technical solution of this application, by setting a first splicing part on the connector and a corresponding second splicing part on the iron core unit, and mechanically fixing the first and second splicing parts by snap-fitting, forms a stable and firm connection between the connector and the rotor iron core. This enhances the resistance to centrifugal force, effectively reduces the loosening, deformation, or detachment of the motor due to centrifugal force during high-speed operation, improves the mechanical strength and operational reliability of the rotor assembly, reduces vibration and noise during motor operation, and prevents stator-rotor rubbing or jamming. Furthermore, the first and second splicing parts can be quickly assembled by axial pushing or radial pressing, eliminating the need for additional screws, rivets, or adhesives, simplifying the process, improving assembly efficiency and product consistency, and facilitating modular design and automated mass production of the rotor assembly. Moreover, the separate design of the connector and the rotor iron core allows for the selection of non-magnetic materials for the connector, reducing magnetic loss and increasing the effective magnetic flux density of the rotor, depending on the actual application. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0021] Figure 1 This is a structural schematic diagram of an embodiment of the rotor assembly of this utility model;

[0022] Figure 2 This is another structural schematic diagram of an embodiment of the rotor assembly of this utility model;

[0023] Figure 3 for Figure 1 Schematic diagram of the middle connector;

[0024] Figure 4 for Figure 1 Schematic diagram of the rotor core structure;

[0025] Figure 5 This is a schematic diagram of stamping layout for an embodiment of the rotor assembly manufacturing method of this utility model.

[0026] Explanation of icon numbers:

[0027] 1. Connector; 11. Recessed relief part; 111. First recess; 112. Second recess; 12. Shaft hole; 2. Rotor core; 21. Core unit; 31. First splicing part; 32. Second splicing part; 33. Connecting part; 34. Positioning part; 41. First strip; 42. Second strip.

[0028] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the embodiments of the present utility model.

[0030] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0031] Furthermore, in the embodiments of this utility model, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of the embodiments of this utility model, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0032] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0033] Furthermore, the technical solutions of the various embodiments of this utility model can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the protection scope claimed by the embodiments of this utility model.

[0034] Common motor rotors typically employ a rotor core structure formed by stacking several rotor laminations. The shaft hole, yoke, magnet slots, and magnetic bridges are usually designed on the same rotor lamination, forming an integrated structure. Because the shaft hole is made of a magnetically conductive material, this area participates in magnetic conduction during motor operation. Some magnetic flux forms a leakage path through the shaft hole, reducing the magnetic flux and lowering the motor's magnetic performance and efficiency.

[0035] To address the magnetic leakage problem, one approach is to separate the bushing from the rotor yoke. This involves machining the bushing and yoke separately before assembling them together. However, the connection between the bushing and yoke is not secure, resulting in significant motor vibration and noise when the rotor is running at high speed.

[0036] In view of this, the present invention provides a rotor assembly, a motor, and electrical equipment. By providing a first splicing part on the connector and a corresponding second splicing part on the core unit, and mechanically fixing the first and second splicing parts by snap-fitting, a stable and firm connection is formed between the connector and the rotor core. This enhances the resistance to centrifugal force, effectively reduces the loosening, deformation, or detachment of the motor due to centrifugal force during high-speed operation, improves the mechanical strength and operational reliability of the rotor assembly, reduces vibration and noise during motor operation, and prevents stator-rotor rubbing or jamming. Moreover, the separate design of the core unit and the connector allows for the selection of the same or different materials for processing, depending on the actual situation, to meet the requirement of reducing magnetic leakage.

[0037] To better understand the above technical solution, the following detailed explanation is provided in conjunction with the accompanying drawings.

[0038] like Figure 1 As shown, this utility model embodiment proposes a rotor assembly, the rotor assembly comprising:

[0039] The bushing includes multiple stacked connectors 1 for mounting a rotating shaft. The connectors 1 can be stamped and have high mechanical strength. It is understood that multiple connectors 1 are stacked and fixed together to form the bushing, which is fitted onto the outside of the rotating shaft. Compared to a conventional one-piece bushing structure, the bushing is easier to process and can make more efficient use of materials. The material of the connectors 1 can be selected according to actual application requirements; in this embodiment, the material of the connectors is a non-magnetic material. Optionally, the outer contour of the connector 1 is circular. In one embodiment, the outer periphery of the connector 1 is provided with multiple first splicing portions 31 spaced apart.

[0040] The rotor core 2 comprises multiple independently arranged core units 21, which are arranged circumferentially along the connector 1. It is understood that the core units 21 are arranged in a circular array along the circumferential direction of the connector 1. Optionally, the rotor core 2 may comprise multiple layers stacked along the axial direction of the shaft, each layer comprising multiple core units 21. Adjacent core units 21 in two layers can be connected and fixed using a protrusion structure or an adhesive structure. Simultaneously, each layer corresponds to a connector 1, i.e., the connector 1 has multiple bushings arranged along the axial direction of the shaft. Adjacent connectors 1 can also be connected and fixed using an adhesive structure, which is not limited here. In one embodiment, the rotor core is made of a magnetically conductive material, and each core unit 21 corresponds to a first splicing portion 31 with a second splicing portion 32, the first splicing portion 31 and the second splicing portion 32 forming a splicing structure 3. It is understood that the first splicing part 31 is disposed on the connector 1, and the second splicing part 32 is disposed on the core unit 21, with each second splicing part 32 corresponding to one first splicing part 31; wherein, the first splicing part 31 and the second splicing part 32 are spliced ​​and fixed. That is to say, the splicing structure is used to connect and fix the rotor core 2 and the connector 1. In other words, the core unit 21 and the connector 1 are assembled and fixed by the cooperation of the first splicing part 31 and the second splicing part 32, and the first splicing part 31 and the second splicing part 32 are connected by splicing, which can achieve a tight and reliable fixation of the two, thereby reducing vibration and noise during motor operation.

[0041] In this embodiment, the rotor core 2 is made of a magnetically conductive material, while the connector 1 is made of a non-magnetically conductive material. It is understood that the rotor core 2, made of highly magnetically conductive materials such as electrical steel or silicon steel sheets, ensures efficient magnetic flux transmission; while the connector 1, made of non-magnetically conductive materials such as stainless steel, aluminum alloy, titanium alloy, or high-strength engineering plastics, blocks magnetic leakage paths, reduces magnetic losses, and thus improves the motor's efficiency, power density, and output torque.

[0042] In this embodiment, the technical solution employs a first splicing part 31 on the connector 1 and a corresponding second splicing part 32 on the core unit 21. The first and second splicing parts 31 are mechanically fixed by snap-fitting, creating a stable and robust connection between the connector 1 and the rotor core 2. This enhances resistance to centrifugal force, effectively reducing loosening, deformation, or detachment of the motor due to centrifugal force during high-speed operation. It also improves the mechanical strength and operational reliability of the rotor assembly, reducing vibration and noise during motor operation and preventing stator-rotor rubbing or jamming. Furthermore, the first and second splicing parts 31 and 32 can be quickly assembled via axial pushing or radial pressing, eliminating the need for screws, rivets, or adhesives. This simplifies the process, improves assembly efficiency and product consistency, and facilitates modular design and automated mass production of the rotor assembly. Moreover, the separate design of the connector 1 and the rotor core 2 allows for the selection of non-magnetic materials for the connector 1, reducing magnetic loss and increasing the effective magnetic flux density of the rotor.

[0043] In one embodiment, the first splicing part 31 and the second splicing part 32 are interference-fitted, so that a preload can be generated after assembly, the connecting surfaces can fit more closely, and a tight, gapless mechanical connection is formed between the first splicing part 31 and the second splicing part 32. When the motor rotates at high speed, it can effectively resist centrifugal force, reduce or avoid displacement of the iron core unit 21, improve the dynamic stability of the rotor assembly, and thus reduce vibration and noise during motor operation.

[0044] In one embodiment, the first splicing part and the second splicing part are spliced ​​and fixed in the stamping die. This replaces the manual direct assembly method, which is simpler and more convenient, improves assembly efficiency and consistency, and makes the splicing and fixing more reliable.

[0045] It is understood that the rotor assembly in this embodiment is manufactured using a double-strip rotor in-mold splicing process. Specifically, the double-strip rotor in-mold splicing process involves feeding two strips of two different materials or two strips of the same material simultaneously from the X and Y directions, stamping them in the same mold, and finally stamping and splicing the two workpieces at the cross intersection of the two strips to achieve the process of forming the two workpieces in the mold.

[0046] Specifically, the stamping die has two rows of dies arranged in a cross pattern at the center of the stamping force.

[0047] Reference Figure 5The first strip 41 serves as the main strip for stamping the core units. The first strip 41 is made of silicon steel. The first strip 41 is fed into the mold along the first direction, i.e., direction A. Through the punch and die in the stamping mold, the contours of each core unit and the second splicing part are stamped on the first strip 41. This mainly includes the gradual punching of the rotor positioning holes, channel steel channels, the second splicing part, and the inner hole. The reserved area enters the splicing position with the first strip 41.

[0048] The second strip 42, as a secondary strip, is made of non-magnetic material, such as 304 stainless steel, and is mainly used for stamping bushings. The second strip 42 is fed into the stamping die along the second direction, i.e., direction B. Through the corresponding punch and die of the stamping die, the second strip 42 is stamped to form the contours of the connecting parts and the first splicing part. This mainly includes the outer shape of the shaft connecting parts, the rivet points, the first splicing part, and the assembly of the shaft hole, and then it enters the splicing position.

[0049] After the first strip 41 and the second strip 42 enter the splicing position, the two strips cross each other, with the first strip 41 on top and the second strip 42 on the bottom. The punch A of the stamping die presses down on the splicing position of the first strip 41, and as the press presses down, the first splicing part and the second splicing part are spliced ​​and fixed together. Then, the punch B of the stamping die punches the second strip 42 and the connecting piece. After punching, the connecting piece detaches from the second strip 42 and is successfully nested on the first strip 41, proceeding with the subsequent steps along with the first strip 41. The second strip 42 then enters the scrap cutting step in the subsequent process, completing the cutting of the second strip 42.

[0050] After the connector is embedded into the first strip 41, the first strip 41 undergoes stamping processes such as snapping the iron core unit, rotating and dropping the material, and cutting the first strip 41.

[0051] In one embodiment of this utility model, one of the first splicing part 31 and the second splicing part 32 is configured as a splicing groove, and the other of the first splicing part 31 and the second splicing part 32 is configured as a splicing protrusion. The splicing groove and the splicing protrusion are interference-fitted. Thus, the splicing protrusion can be pressed into the splicing groove under the pressure of the mold, thereby achieving an interference fit. Moreover, the structure of the splicing protrusion and the splicing groove is simple and easy to process. Optionally, the splicing groove can be a T-slot or other irregular shape, and the shape of the splicing protrusion matches the shape of the splicing groove. In this way, while snapping and fixing, self-locking can also be achieved, further improving the connection's firmness and thus reducing motor vibration and noise.

[0052] In one embodiment of this utility model, the splicing protrusion includes a connecting portion 33 and a positioning portion 34 disposed at one end of the connecting portion 33. The outer diameter of the positioning portion 34 is larger than the outer diameter of the connecting portion 33, and the connecting portion 33 extends radially along the connector 1. Thus, a limiting step is formed at the connection between the positioning portion 34 and the connecting portion 33, which can prevent the connecting portion 33 or the positioning portion 34 from disengaging from the limiting groove, thereby improving the firmness of the connection.

[0053] In one embodiment of this utility model, the end face of the positioning part 34 away from the connecting part 33 is an arc surface. In this way, the arc surface can guide the splicing protrusion to be smoothly pressed into the splicing groove, reducing scratches or jamming during the pressing process, and reducing damage to the core unit 21 or the connecting piece by edge burrs or sharp edges.

[0054] In one embodiment of this utility model, the outer periphery of the connector 1 is provided with a recessed clearance portion 11, which is located between two adjacent iron core units 21. This increases the installation space for the magnet, making magnet installation more convenient. It is understood that the recessed clearance portion 11 is recessed towards the geometric center of the connector 1, thereby increasing the space between the connector 1 and the yoke, and thus facilitating magnet installation.

[0055] In one embodiment of this utility model, the recessed clearance portion 11 includes a first recess 111 and a second recess 112 connected together. The recess depth of the first recess 111 is greater than the recess depth of the second recess 112, and the first recess 111 and the second recess 112 are arranged circumferentially along the connector 1. Thus, the greater depth of the first recess 111 provides a larger space for magnet installation; the shallower depth of the second recess 112 reduces the adverse impact on the structural strength of the connector 1. It is understood that by combining the first recess 111 and the second recess 112 with different depths, the installation space for magnets can be increased as much as possible while ensuring the structural strength of the connector 1.

[0056] In one embodiment of this utility model, the rotor assembly further includes a snap-fit ​​structure, through which two adjacent connecting parts 1 are fixed. It is understood that when stamping the connecting parts 1, the snap-fit ​​structure can be formed using a stamping die, eliminating the need for other tools to create a fixed structure on the connecting parts 1, thus simplifying the process and making operation more convenient.

[0057] In one embodiment of this utility model, the rotor assembly further includes a rotating shaft, which passes through the connecting member 1, and the rotating shaft and the connecting member 1 rotate synchronously. Thus, the rotating shaft can rotate synchronously with the rotor core 2 to output torque. Optionally, the connecting member 1 is provided with a shaft hole 12, through which the rotating shaft passes, and can be connected by a spline, flat key, etc., for synchronous rotation.

[0058] To achieve the above objectives, this utility model provides an electric motor, which includes the rotor assembly described above. Specifically, the specific structure of the rotor assembly is the same as described in the above embodiments. Since this motor adopts all the technical solutions of the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, and will not be repeated here.

[0059] To achieve the above objectives, this utility model provides an electrical device, which includes the motor described above. Specifically, the specific structure of the motor refers to the above embodiments. Since this electrical device adopts all the technical solutions of the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0060] The above description is merely an exemplary embodiment of the present utility model and does not limit the scope of protection of the present utility model embodiments. Any equivalent structural transformations made under the technical concept of the present utility model using the description and drawings of the present utility model embodiments, or direct / indirect applications in other related technical fields, are included within the scope of protection of the present utility model embodiments.

Claims

1. A rotor assembly, characterized in that, The rotor assembly includes: A bushing, comprising a plurality of stacked connectors, the connectors being made of a non-magnetic material, and the outer periphery of each connector having a plurality of first splicing portions spaced apart; and The rotor core includes multiple core units, which are arranged circumferentially along the connector. The rotor core is made of a magnetically conductive material, and each core unit has a second splicing part corresponding to a first splicing part. The first splicing part and the second splicing part are spliced ​​together with an interference fit to fix the iron core unit and the connector.

2. The rotor assembly as claimed in claim 1, characterized in that, The first splicing part and the second splicing part are spliced ​​and fixed inside the stamping die.

3. The rotor assembly as described in claim 1 or 2, characterized in that, One of the first splicing part and the second splicing part is configured as a splicing groove, and the other of the first splicing part and the second splicing part is configured as a splicing protrusion, wherein the splicing groove and the splicing protrusion are interference-fitted.

4. The rotor assembly as claimed in claim 3, characterized in that, The splicing protrusion includes a connecting portion and a positioning portion located at one end of the connecting portion. The outer diameter of the positioning portion is larger than the outer diameter of the connecting portion, and the connecting portion extends radially along the connector.

5. The rotor assembly as claimed in claim 4, characterized in that, The end face of the positioning part away from the connecting part is an arc surface.

6. The rotor assembly as claimed in claim 1, characterized in that, The connector has a recessed clearance portion on its outer periphery, and the recessed clearance portion is located between two adjacent core units.

7. The rotor assembly as claimed in claim 6, characterized in that, The recessed clearance portion includes a first recess and a second recess connected together. The recessed depth of the first recess is greater than the recessed depth of the second recess. The first recess and the second recess are arranged circumferentially along the connector.

8. The rotor assembly as claimed in claim 1, characterized in that, The rotor assembly also includes a snap-fit ​​structure, through which two adjacent connectors are fixed.

9. The rotor assembly as claimed in claim 1, characterized in that, The rotor assembly also includes a rotating shaft that passes through the connector, and the rotating shaft and the connector rotate synchronously.

10. An electric motor, characterized in that, The motor includes a rotor assembly as described in any one of claims 1 to 9.

11. An electrical appliance, characterized in that, The electrical equipment includes the motor as described in claim 10.

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