Pole module, rotor, electric machine and wind turbine generator system

Abstract

This disclosure provides a magnetic pole module, a rotor, a motor, and a wind turbine generator set. The magnetic pole module is used to install in the iron core of the motor. The magnetic pole module includes a positioning member and a magnet assembly. The positioning member extends a predetermined length along the axial direction of the iron core. The magnet assembly includes at least two magnets, which are distributed along the axial direction of the iron core and respectively connected to the positioning member, so that at least two magnets can be inserted into the iron core as a whole, thereby improving the assembly efficiency of the rotor.

Description

Technical Field

[0001] This disclosure pertains to the field of wind power technology, and in particular relates to a magnetic pole module, rotor, motor, and wind turbine generator set. Background Technology

[0002] Generators generate heat when they are working. To ensure that the generator is not affected by the heat and can work normally, it is necessary to cool and dissipate heat from the generator.

[0003] As the generator speed increases, permanent magnet generators, due to their smaller diameter, result in an increase in generator power or, if the power remains the same, a decrease in the rotor's heat dissipation area. This can cause the magnets to overheat and lose performance, affecting the generator's reliability. Utility Model Content

[0004] The main purpose of this disclosure is to provide a magnetic pole module, rotor, motor, and wind turbine generator set to ensure heat dissipation requirements and prevent magnet overheating failure.

[0005] To achieve the above objectives, this disclosure provides the following technical solution:

[0006] One aspect of this disclosure provides a magnetic pole module for installation in the iron core of an electric motor. The magnetic pole module includes a positioning member and a magnet assembly. The positioning member extends a predetermined length along the axial direction of the iron core. The magnet assembly includes at least two magnets, which are distributed along the axial direction of the iron core and respectively connected to the positioning member, such that at least two magnets can be inserted integrally into the iron core.

[0007] According to an exemplary embodiment of this disclosure, at least two of the magnets are spaced apart along the axial direction of the core to form a ventilation gap between adjacent magnets.

[0008] According to an exemplary embodiment of this disclosure, the magnetic pole module further includes a first limiting block disposed between two adjacent magnets along the axial direction of the iron core, so as to form the ventilation gap between the two adjacent magnets.

[0009] According to an exemplary embodiment of the present disclosure, at least two first limiting blocks are provided between every two adjacent magnets, and the at least two first limiting blocks are distributed at intervals in the circumferential direction of the iron core.

[0010] According to an exemplary embodiment of this disclosure, the magnetic pole module further includes a plurality of second limiting blocks, which are respectively disposed on both sides of the magnet assembly along the axial direction of the iron core. Along the axial direction of the iron core, the thickness of the second limiting block is less than the thickness of the first limiting block.

[0011] According to an exemplary embodiment of the present disclosure, at least two second limiting blocks are provided on each of the two sides of the magnet assembly along the axial direction of the iron core. The at least two second limiting blocks are spaced apart in the circumferential direction of the iron core. In the axial direction of the iron core, the thickness of the first limiting block is equal to twice the thickness of the second limiting block.

[0012] According to an exemplary embodiment of this disclosure, the magnet is provided with positioning portions on both sides of the iron core along the axial direction, and the first limiting block and the second limiting block are respectively disposed in the positioning portions of the corresponding magnet.

[0013] According to an exemplary embodiment of this disclosure, the positioning member includes two edge portions. In the circumferential direction of the iron core, the two edge portions are respectively disposed on both sides of the magnet assembly. The edge portions have receiving cavities, and the magnet assembly is inserted into the receiving cavities at both ends in the circumferential direction of the iron core.

[0014] According to an exemplary embodiment of the present disclosure, each of the edging portions is a box-shaped structure and the two edging portions have openings at one end of the iron core facing each other in the circumferential direction. The magnet assembly is inserted into the receiving cavity through the openings at both ends in the circumferential direction and is fixedly connected to the edging portion.

[0015] According to an exemplary embodiment of the present disclosure, each of the edging portions includes an end plate, two first plates, and two second plates. The end plate faces the end face of the magnet assembly in the circumferential direction of the iron core. The first plates and the second plates extend from the end plate toward the side of the magnet assembly. The two first plates are spaced apart and opposite to each other in the radial direction of the iron core, and the two second plates are spaced apart and opposite to each other in the axial direction of the iron core. The end plate, the two first plates, and the two second plates enclose and form the receiving cavity.

[0016] According to an exemplary embodiment of this disclosure, the magnet is provided with clearance portions on both sides of the iron core in the radial direction, and the magnet is connected to the positioning member through the clearance portions.

[0017] According to an exemplary embodiment of this disclosure, the positioning member protrudes radially from the magnet in the iron core.

[0018] According to an exemplary embodiment of this disclosure, the positioning member includes two edge portions. In the circumferential direction of the iron core, the two edge portions are respectively disposed on both sides of the magnet group. The edge portions have receiving cavities. Two first limiting blocks are disposed between every two adjacent magnets. Two second limiting blocks are respectively disposed on both sides of the axial direction of each magnet group. The first limiting blocks and the second limiting blocks are both disposed on both sides of the magnet in the circumferential direction of the iron core and located in the receiving cavity.

[0019] According to an exemplary embodiment of this disclosure, at least two magnetic pole modules are provided in each mounting hole. The at least two magnetic pole modules are distributed along the axial direction of the iron core. Two adjacent magnetic pole modules are spaced apart from each other and form an inter-module ventilation gap, which is connected to the radial air duct.

[0020] According to another aspect of this disclosure, a rotor is provided, the rotor including an iron core and a magnetic pole module as described above, the iron core being provided with a mounting hole matching the magnetic pole module, the mounting hole extending along the axial direction of the rotor, and the magnetic pole module being disposed within the mounting hole.

[0021] According to an exemplary embodiment of the present disclosure, the iron core is provided with a radial air duct, the radial air duct is disposed through the iron core along the radial direction of the iron core, and the ventilation gap is disposed between at least two of the magnets, the radial air duct and the ventilation gap are connected.

[0022] According to another aspect of this disclosure, an electric motor is provided, the electric motor including the rotor as described above.

[0023] According to another aspect of this disclosure, a wind turbine generator set is provided, the wind turbine generator set including a motor as described above, the motor being a generator.

[0024] The magnetic pole module, rotor, motor, and wind turbine generator provided in this disclosure have at least the following beneficial effects: Since the magnetic pole module includes a positioning component and multiple magnets, the positioning component can be used to fix the relative positions of the multiple magnets, so that at least two magnets can be inserted into the iron core as a whole, thereby improving the assembly efficiency of the rotor. Attached Figure Description

[0025] The above and / or other objects and advantages of this disclosure will become clearer from the following description of embodiments taken in conjunction with the accompanying drawings, in which:

[0026] Figure 1 This is a schematic diagram of the structure of a wind turbine generator set according to an embodiment of the present disclosure;

[0027] Figure 2 This is a schematic diagram of the structure of a generator according to an embodiment of the present disclosure;

[0028] Figure 3 This is a schematic diagram of the rotor structure according to an embodiment of the present disclosure;

[0029] Figure 4 yes Figure 3 A magnified view of a section at point A in the middle;

[0030] Figure 5This is a side view of a rotor according to an embodiment of this disclosure;

[0031] Figure 6 yes Figure 5 A magnified view of a section at point B in the middle;

[0032] Figure 7 This is a longitudinal sectional view of a rotor according to an embodiment of this disclosure;

[0033] Figure 8 yes Figure 7 A magnified view of a section at point D;

[0034] Figure 9 This is a schematic diagram of the structure of a magnetic pole module according to an embodiment of the present disclosure;

[0035] Figure 10 This is an exploded view of a magnetic pole module according to an embodiment of the present disclosure;

[0036] Figure 11 This is a partial cross-sectional view of a magnetic pole module according to an embodiment of this disclosure;

[0037] Figure 12 yes Figure 11 Enlarged view of a section at point F in the middle;

[0038] Figure 13 yes Figure 8 Enlarged view of a section at point E in the middle;

[0039] Figure 14 yes Figure 6 Enlarged view of a section at point C;

[0040] Figure 15 This is a schematic diagram of the structure of the edge portion according to an embodiment of the present disclosure;

[0041] Figure 16 This is a schematic diagram of the structure of the edging portion according to another embodiment of the present disclosure;

[0042] Figure 17 This is a schematic flowchart of a rotor forming method according to an embodiment of the present disclosure.

[0043] Explanation of reference numerals in the attached figures:

[0044] 100. Generator;

[0045] 1. Rotor;

[0046] 10. Shaft;

[0047] 20. Iron core; 21. Radial air duct; 22. Mounting hole; 23. Axial air duct;

[0048] 30. Magnetic pole module; 31. Positioning component; 311. Edge banding; 311a. End plate; 311b. First plate; 311c. Second plate; 32. Magnet; 321. Positioning part; 322. Clearance part; 32a. Main body section; 32b. Mating section; 33. Ventilation gap; 34. First limiting block; 35. Second limiting block;

[0049] 2. Stator;

[0050] 200, Tower; 300, Nacelle; 400, Impeller; 410, Hub; 420, Blade;

[0051] X, axial direction; Y, circumferential direction; Z, radial direction.

[0052] In the accompanying drawings, the same parts use the same reference numerals. The drawings are not drawn to scale. Detailed Implementation

[0053] Features and exemplary embodiments of various aspects of this disclosure will now be described in detail. Numerous specific details are set forth in the following detailed description in order to provide a thorough understanding of this disclosure. However, it will be apparent to those skilled in the art that this disclosure may be practiced without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of this disclosure by illustrating examples. In the accompanying drawings and the following description, at least some well-known structures and techniques have not been shown in order to avoid unnecessarily obscuring this disclosure; and, for clarity, the dimensions of some structures may be exaggerated. Furthermore, the features, structures, or characteristics described below may be combined in any suitable manner in one or more embodiments.

[0054] The directional terms used in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of the rotor, generator, wind turbine generator set, and forming method of this disclosure. It should also be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly; for example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0055] like Figure 1 , Figure 2As shown, this embodiment of the present disclosure provides a wind turbine generator set, including a tower 200, a nacelle 300, a generator 100, and a rotor 400. The tower 200 is connected to a wind turbine foundation, the nacelle 300 is disposed at the top of the tower 200, and the generator 100 is disposed in the nacelle 300. In some examples, the generator 100 may be located outside the nacelle 300; of course, in some examples, the generator 100 may also be located inside the nacelle 300. The rotor 400 includes a hub 410 and a plurality of blades 420 connected to the hub 410. When wind power acts on the blades 420, it drives the entire rotor 400 to rotate, and further drives the rotor 1 of the generator 100 to rotate relative to the stator 2, so as to convert wind energy into electrical energy.

[0056] Generator 100 generates heat during operation. To ensure that generator 100 is not affected by heat and can operate normally, cooling and heat dissipation treatment is required. As the rotational speed of generator 100 increases, the power of permanent magnet generator 100 increases due to its small diameter, or the power remains the same but the heat dissipation area of ​​rotor 1 decreases. This causes magnet 32 ​​to overheat and lose performance, affecting the reliability of generator 100.

[0057] like Figure 2 As shown, based on this, one embodiment of the present disclosure also provides a new generator 100, including a rotor 1 and a stator 2. The rotor 1 and the stator 2 are coaxially arranged and rotate in cooperation. The generator 100 can adopt an inner rotor and outer stator structure. Of course, in some embodiments, the generator 100 can also adopt an outer rotor and inner stator structure.

[0058] The rotor 1 provided in one embodiment of this disclosure can be manufactured or sold as an independent product, or it can be used in the generator 100 and as a component of the generator 100.

[0059] In this embodiment, the motor is described using the generator of a wind turbine generator set as an example, but it is not limited thereto. The motor provided in this disclosure may also include an electric motor.

[0060] like Figures 3 to 9As shown, a rotor 1 provided in one embodiment of this disclosure includes a rotating shaft 10, an iron core 20, and a magnetic pole module 30. The iron core 20 is sleeved on the rotating shaft 10 and fixed in a relative position to the rotating shaft 10. The iron core 20 is provided with a radial air duct 21 and a mounting hole 22. The mounting hole 22 extends along the axial direction X of the rotating shaft 10, and the radial air duct 21 penetrates the iron core 20 along the radial direction Z of the rotating shaft 10. The magnetic pole module 30 is inserted into the mounting hole 22. The magnetic pole module 30 includes a positioning member 31 and a magnet assembly. The magnet assembly may include at least two magnets 32. The at least two magnets 32 are distributed along the axial direction X and are respectively connected to the positioning member 31. The at least two magnets 32 can be inserted into the mounting hole 22 as a whole, which can improve the assembly efficiency of the magnets 32, thereby improving the assembly efficiency of the rotor.

[0061] As an example, at least two magnets 32 are spaced apart along the axial direction X to form a ventilation gap 33 between two adjacent magnets 32. When the magnetic pole module 30 is inserted into the mounting hole 22, the radial air duct 21 is connected to the ventilation gap 33.

[0062] The iron core 20 is sleeved on the rotating shaft 10. The relative positions of the two can be fixed by key connection. Alternatively, the iron core 20 and the rotating shaft 10 can be connected by interference fit. Alternatively, the connection can be achieved by high temperature heat fitting.

[0063] In this embodiment, the iron core 20 and the rotating shaft 10 are coaxially arranged. For ease of description, in the accompanying drawings and the following description, the symbol X represents the axial direction of the rotating shaft 10 and the iron core 20, the symbol Z represents the radial direction of the rotating shaft 10 and the iron core 20, and the symbol Y represents the circumferential direction of the rotating shaft 10 and the iron core 20.

[0064] The iron core 20 is provided with multiple radial air channels 21, which can extend along the radial direction Z of the rotating shaft 10 and penetrate the iron core 20. Optionally, the multiple radial air channels 21 are distributed at intervals along the axial direction X of the rotating shaft 10. Optionally, the spacing between two adjacent radial air channels 21 can be equal to ensure uniform cooling and heat dissipation.

[0065] The number of mounting holes 22 provided on the iron core 20 can be multiple, and each mounting hole 22 extends along the axial direction X. When there are multiple mounting holes 22, the multiple mounting holes 22 can be distributed along the circumferential direction Y of the rotating shaft 10. Optionally, the multiple mounting holes 22 can be spaced apart and evenly distributed along the circumferential direction Y of the rotating shaft 10.

[0066] The number of magnetic pole modules 30 set in each mounting hole 22 can be one or more. When there are more than two, the two or more magnetic pole modules 30 can be distributed along the axial direction X.

[0067] The number of magnets 32 included in the magnet assembly can be two, three or more. Each magnet 32 ​​can be fixedly connected to the positioning member 31 by means of adhesive bonding or by means of snap-fit, so that the distance between two adjacent magnets 32 is fixed by the positioning member 31 to form a ventilation gap 33.

[0068] The positioning component 31 can take the form of a positioning box, positioning frame, or other structural forms.

[0069] The radial air ducts 21 and ventilation gaps 33 can be arranged opposite each other in the radial Z direction, or they can be partially offset. Optionally, they can be arranged opposite each other in the radial Z direction. The number of radial air ducts 21 and ventilation gaps 33 can be equal, or one can be less than the other. Optionally, the number of radial air ducts 21 and ventilation gaps 33 can be equal and arranged one-to-one in the radial Z direction.

[0070] The rotor 1 provided in one embodiment of this disclosure includes a rotating shaft 10, an iron core 20, and a magnetic pole module 30. The iron core 20 is sleeved on the rotating shaft 10 and its relative position is fixed. By providing mounting holes 22 on the iron core 20, the magnetic pole module 30 can be plugged in and installed through the mounting holes 22, thus ensuring the installation requirements of the magnetic pole module 30.

[0071] In this disclosure, the magnetic pole module 30 can be manufactured or sold as an independent product, or it can be used in the generator rotor as a component of the generator rotor.

[0072] Since the magnetic pole module 30 includes a positioning element 31 and a magnet assembly, and the magnet assembly includes at least two magnets 32, the positioning element 31 can fix the relative positions of the multiple magnets 32. Because a ventilation gap 33 is formed between two adjacent magnets 32, and the ventilation gap 33 is connected to the radial air duct 21, the cooling airflow can pass through the radial air duct 21 and the ventilation gap 33 to meet the cooling and heat dissipation requirements of the rotor 1, improving the reliability of the generator 100 where the rotor 1 is located. Furthermore, the structure of the rotor 1 allows for the first connection and fixation of the iron core 20 and the shaft 10 using a high-temperature heat-shrink fitting during assembly, and then the magnetic pole module 30 can be installed in the mounting hole 22, which facilitates meeting the assembly and usage requirements of the rotor 1 for a high-speed rotating motor.

[0073] like Figures 9 to 12 As shown, in some optional embodiments, the magnetic pole module 30 provided in one embodiment of this disclosure further includes a first limiting block 34. The first limiting block 34 is disposed between two adjacent magnets 32, such that the two adjacent magnets 32 are supported by the first limiting block 34 to form a ventilation gap 33 between the two adjacent magnets 32. Since the first limiting block 34 is supported between the two adjacent magnets 32, it is beneficial to form and maintain the ventilation gap 33.

[0074] As an example, along the axial direction X, the first limiting block 34 is clamped between two adjacent magnets 32.

[0075] Along the axial direction X of the iron core 20, a first limiting block 34 is clamped between each two adjacent magnets 32. Optionally, at least two first limiting blocks 34 are clamped between each two adjacent magnets 32, and each first limiting block 34 located between two adjacent magnets 32 can be distributed along the circumferential direction Y.

[0076] As an example, the first limiting block 34 is connected to the positioning element 31 and the magnet 32 ​​respectively, but this is not a limitation. It can be understood that the first limiting block 34 can directly contact and connect with the positioning element 31, or the first limiting block 34 can contact and connect with the magnet 32, and indirectly connect with the positioning element 31 through the magnet 32. That is, in this case, the first limiting block 34 and the positioning element 31 do not need to be in direct contact.

[0077] Furthermore, in this embodiment, the magnetic pole module 30 also includes a plurality of second limiting blocks 35, which are respectively disposed on both sides of the magnet assembly along the axial direction of the iron core 20.

[0078] As an example, at least two second limiting blocks 35 are provided on each side of the magnet assembly along the axial direction of the iron core 20, and the at least two second limiting blocks 35 are spaced apart on the circumferential Y direction of the iron core 20.

[0079] Along the axial direction X of the iron core 20, the two outermost magnets 32 of the magnetic pole module 30 are each provided with two or more second limiting blocks 35 at the ends opposite to each other. The second limiting blocks 35 located on the same side can be distributed along the circumferential direction Y. As an example, the two outermost magnets 32 of the magnetic pole module 30 are provided with second limiting blocks 35 at the ends opposite to each other, and the first limiting block 34 and the second limiting block 35 are respectively connected to the magnets 32.

[0080] The first limiting block 34 and the second limiting block 35 can have the same structure, or they can be different. For example, the thickness of the first limiting block 34 and the second limiting block 35 in the axial direction X can be different.

[0081] As an example, in the axial direction X of the core 20, the thickness of the second limiting block 35 is less than the thickness of the first limiting block 34. Alternatively, in the axial direction X of the core 20, the thickness of the first limiting block 34 is twice the thickness of the second limiting block 35.

[0082] The first limiting block 34 can be fixedly connected to the magnet 32 ​​and the positioning element 31 by means of adhesive bonding or other methods. The second limiting block 35 can also be connected to the magnet 32 ​​and the positioning element 31 by means of adhesive bonding or other methods.

[0083] One embodiment of this disclosure provides a magnetic pole module 30 including a first limiting block 34 and a second limiting block 35, which define the positional relationship between the first limiting block 34, the second limiting block 35 and the magnet 32. The first limiting block 34 can be used to support the relative position between two adjacent magnets 32, which is beneficial for the formation and maintenance of the ventilation gap 33. Furthermore, by providing the second limiting block 35, it is beneficial to ensure the formation and maintenance of the ventilation gap 33 between the magnets 32 of two adjacent magnetic pole modules 30 when there are two or more magnetic pole modules 30 in the same mounting hole 22.

[0084] In some optional embodiments, one embodiment of this disclosure provides a magnetic pole module 30, wherein a magnet 32 ​​is provided with positioning portions 321 on both sides of the axial direction X, and a first limiting block 34 and a second limiting block 35 are respectively engaged in the positioning portions 321 of the corresponding magnet 32. As an example, two first limiting blocks 34 are provided between two adjacent magnets 32, and the two first limiting blocks 34 can be provided on both sides of the magnet 32 ​​along the circumference of the iron core 20. Correspondingly, each of the two adjacent magnets 32 is provided with two positioning portions 321, and the two positioning portions 321 are respectively provided on both sides of the magnet 32, but this is not a limitation.

[0085] As an example, the positioning part 321 may be a groove or step provided on the magnet 32, but is not limited thereto.

[0086] This embodiment uses the example of two first limiting blocks 34 between two adjacent magnets 32 for illustration, but it is not limited to this, and the number of first limiting blocks 34 can be set as needed. As an example, along the axial direction of the iron core 20, two positioning parts 321 are arranged opposite each other on each of the two circumferential sides of the magnet 32, but it is not limited to this.

[0087] Two second limiting blocks 35 may be provided on each side of each group of magnets, and the two second limiting blocks 35 may be provided on both sides of the magnet 32 ​​along the circumferential direction, but are not limited thereto.

[0088] The shape of the positioning part 321 can match the shape of the corresponding first limiting block 34 or second limiting block 35, and parts of the first limiting block 34 and the second limiting block 35 can extend into the corresponding positioning part 321.

[0089] One embodiment of the magnetic pole module 30 disclosed herein provides a positioning part 321, in which a first limiting block 34 and a second limiting block 35 are respectively engaged with the positioning part 321 of the corresponding magnet 32. This positioning part 321 limits the position of the first limiting block 34 and the second limiting block 35, preventing positional movement of the first limiting block 34 and the second limiting block 35 relative to the magnet 32 ​​and ensuring the stability of the ventilation gap 33. Furthermore, this arrangement reduces the assembly difficulty between the first limiting block 34, the second limiting block 35, the magnet 32, and the positioning member 31, improving assembly efficiency.

[0090] In some optional embodiments, the magnetic pole module 30 provided in one embodiment of this disclosure, the first limiting block 34 and the second limiting block 35 are all arranged in pairs. The paired first limiting blocks 34 are spaced apart on the circumferential Y direction of the rotating shaft 10, and the paired second limiting blocks 35 are spaced apart on the circumferential Y direction.

[0091] Optionally, the magnet 32 ​​may be provided with positioning parts 321 on both sides of the circumferential Y direction of the rotating shaft 10, and the paired first limiting blocks 34 and the paired second limiting blocks 35 may be inserted into the corresponding positioning parts 321.

[0092] The magnetic pole module 30 provided in one embodiment of this disclosure, by having the first limiting block 34 and the second limiting block 35 arranged in pairs and spaced apart in the circumferential Y direction, can support the adjacent magnets 32 at both ends of the circumferential Y direction to ensure the formation of the ventilation gap 33 and the stability of the relative position between the two adjacent magnets 32, thereby ensuring the power generation performance and cooling function when applied to the generator 100.

[0093] Continue reading Figures 7 to 12 In some optional embodiments, one embodiment of the present disclosure provides a magnetic pole module 30, which has two or more magnetic pole modules 30 disposed in the mounting hole 22 along the axial direction X. The magnets 32 of two adjacent magnetic pole modules 30 are spaced apart and form a ventilation gap 33.

[0094] Along the axial direction X, the number of magnetic pole modules 30 arranged in the same mounting hole 22 can be two, three or more, and a ventilation gap is formed between each two adjacent magnetic pole modules 30, which is connected to the radial air duct 21.

[0095] In two adjacent magnetic pole modules located within the same mounting hole 22, two magnets 32 facing each other are spaced apart and form an inter-module ventilation gap, which can communicate with the radial air duct 21. As an example, the height of the inter-module ventilation gap and the height of the ventilation gap 33 can be the same along the axial direction of the core 20, but this is not a limitation. This embodiment is illustrated using the example of the inter-module ventilation gap and the ventilation gap 33 being the same.

[0096] Two adjacent magnetic pole modules located within the same mounting hole 22 can be fitted together or spaced apart. When the two magnetic pole modules are fitted together, the outer surfaces of the two edge portions 311 can be fitted together (e.g., Figure 13 As shown in the figure, since the end of the magnetic pole module is provided with a second limiting block 35, the two magnets 32 facing each other in two adjacent magnetic pole modules are spaced apart, forming a ventilation gap between the modules.

[0097] One embodiment of the rotor 1 disclosed herein provides that, by arranging two or more magnetic pole modules 30 within the mounting hole 22, while ensuring that the rotor 1 meets the power generation requirements of the generator 100, the length of a single magnetic pole module 30 along the axial direction X can be shortened, the strength of a single magnetic pole module 30 can be increased, and the impact of deformation of the magnetic pole modules 30 under gravity on the performance of the rotor 1 can be reduced. Furthermore, the ventilation gap 33 formed between two adjacent magnetic pole modules 30 can ensure the ventilation and heat dissipation requirements between the magnets 32 of the two adjacent magnetic pole modules 30, thereby improving the reliability of the rotor 1.

[0098] like Figures 9 to 13 As shown, in some optional embodiments, in one embodiment of the present disclosure, the magnetic pole module 30 has a first limiting block 34 with a thickness d1 greater than the second limiting block 35 with a thickness d2 along the axial direction X, and two adjacent magnetic pole modules 30 have a second limiting block 35 at their ends facing each other.

[0099] In one embodiment of this disclosure, a magnetic pole module 30 is provided. By making the thickness d1 of the first limiting block 34 greater than the thickness d2 of the second limiting block 35, the ventilation gap 33 formed by the docking of two adjacent magnetic pole modules 30 is similar in size to the ventilation gap 33 formed between two adjacent magnets 32 of the same magnetic pole module 30, so as to ensure the uniformity of cooling and heat dissipation requirements of the rotor 1.

[0100] Along the axial direction X, the thickness d1 of the first limiting block 34 can be twice the thickness d2 of the second limiting block 35. This arrangement ensures that the ventilation gap 33 formed by the docking of two adjacent magnetic pole modules 30 is approximately the same size as the ventilation gap 33 formed between two adjacent magnets 32 of the same magnetic pole module 30, reliably guaranteeing the uniformity of cooling and heat dissipation requirements throughout the rotor 1.

[0101] like Figures 9 to 13As shown, in some optional embodiments, the magnetic pole module 30 provided in one embodiment of this disclosure includes a positioning member 31 comprising two edging portions 311. The two edging portions 311 are symmetrically distributed on both sides of the magnet 32 ​​in the circumferential Y direction of the rotating shaft 10. The edging portions 311 may have receiving cavities, and the magnet 32 ​​is respectively inserted and fixed in the corresponding receiving cavities at both ends in the circumferential Y direction.

[0102] The two edging portions 311 can have the same structure. Each magnet 32 ​​can be inserted into the receiving cavity of one edging portion 311 at one end in the circumferential Y direction and into the receiving cavity of the other edging portion 311 at the other end in the circumferential Y direction. When the magnetic pole module 30 includes a first limiting block 34 and a second limiting block 35, the first limiting block 34 and the second limiting block 35 can also be inserted into the receiving cavity of the edging portion 311 on the corresponding side.

[0103] The magnetic pole module 30 provided in one embodiment of this disclosure, by having the positioning member 31 include two edge portions 311 and defining their distribution position and their cooperation relationship with the magnets 32, facilitates the limiting of the position of each magnet 32 ​​by the two edge portions 311, ensuring the stability of the gap value of the ventilation gap 33. Furthermore, the above configuration allows for modularization of the magnetic pole module 30, reducing production costs. As an example, the two edge portions 311 can have identical structures and be symmetrically arranged on both sides of the magnets 32.

[0104] Optionally, the magnet 32, the first limiting block 34, the second limiting block 35, and the edge banding 311 can be connected and fixed to each other by adhesive bonding.

[0105] As an example, the first limiting block 34 and the second limiting block 35 are respectively disposed in the receiving cavity of the edge portion 311 to prevent the first limiting block 34 or the second limiting block 35 from being exposed, thereby protecting the edge portion 311. On the other hand, the first limiting block 34 and the second limiting block 35 are respectively disposed in the receiving cavity to avoid affecting the ventilation gap 33.

[0106] like Figures 9 to 13 As shown, in some optional embodiments, the clearance portion 322 is described in this embodiment as a groove formed by recessing relative to the surface of the magnet 32. The magnet 32 ​​has clearance portions 322 on both sides of the radial direction Z of the rotating shaft 10. The positioning member 31 extends into the clearance portion 322 and is fixedly connected to the magnet 32. As an example, the clearance portion 322 can be a groove or step provided on the magnet 32, but is not limited thereto.

[0107] The clearance portion 322 can extend a predetermined length along the circumferential Y direction starting from the end face of the magnet 32 ​​on the circumferential Y direction. The extension length can be equal to the extension length of the positioning member 31 on the circumferential Y direction. Optionally, the extension length of the clearance portion 322 on each side on the circumferential Y direction can be equal to the extension length of the edge portion 311 on the same side.

[0108] Optionally, the clearance portion 322 is disposed through the magnet 32 ​​in the axial direction X.

[0109] Optionally, the positioning member 31 can extend into the clearance portion 322 in the radial Z direction and be fixedly connected to the magnet 32, which can be fixedly connected by adhesive.

[0110] In one embodiment of this disclosure, a magnetic pole module 30 is provided, in which a clearance portion 322 is provided on both sides of the radial Z of the rotating shaft 10 via a magnet 32. The magnet 32 ​​can be connected to the positioning member 31 through the clearance portion 322, which can not only ensure the positional limitation requirements of each magnet 32, but also reduce the size of the positioning member 31 protruding from the magnet 32 ​​in the radial Z, thereby reducing the distance between the magnet surface and the iron core 20, resulting in less magnetic field damage and optimizing the electrical performance of the rotor 1.

[0111] This embodiment uses the example of the recessed groove formed by the relief portion 322 relative to the surface of the magnet 32 ​​to illustrate the concept. In some optional embodiments, when the positioning member 31 includes a pair of edge portions 311, the two ends of one edge portion 311 in the radial Z direction can respectively extend into the corresponding relief portion 322 and be fixedly connected to the magnet 32.

[0112] In some optional embodiments, the magnetic pole module 30 provided in one embodiment of this disclosure may include a main body segment 32a and a mating segment 32b. There are two mating segments 32b, which are respectively disposed at both ends of the main body segment 32a in the circumferential direction Y. Along the circumferential direction Y, the cross-sectional area of ​​the mating segment 32b is smaller than the cross-sectional area of ​​the main body segment 32a. The clearance part 322 and the positioning part 321 are both located in the mating segment 32b.

[0113] Optionally, both the clearance portion 322 and the positioning portion 321 extend along the circumferential Y direction of the iron core 20. The clearance portion 322 is disposed through the magnet 32 ​​in the axial X direction, and the positioning portion 321 is disposed through the magnet 32 ​​in the radial Z direction. By providing the clearance portion 322 and the positioning portion 321, the cross-sectional dimension of the mating section 32b is smaller than the cross-sectional dimension of the main body section 32a. The clearance portion 322 is recessed in the radial Z direction, and the positioning portion 321 is recessed in the axial X direction. The clearance portion 322 and the positioning portion 321 are connected.

[0114] The magnetic pole module 30 provided in one embodiment of this disclosure, through the above-described configuration, facilitates the cooperation between the first limiting block 34, the second limiting block 35, the magnet 32, and the positioning member 31.

[0115] like Figures 9 to 14 As shown, in some optional embodiments, in one embodiment of the present disclosure, the magnetic pole module 30 has a positioning member 31 that protrudes from the magnet 32, and the magnet 32 ​​is spaced apart from the iron core 20.

[0116] Optionally, when the positioning member 31 includes two edge portions 311, the two edge portions 311 can be arranged such that their ends protrude from the magnet 32 ​​in the radial Z direction.

[0117] Because there is a strong magnetic field between the magnet 32 ​​and the iron core 20, they will attract each other. In one embodiment of the present disclosure, the magnetic pole module 30 is configured such that, during assembly, the edge portion 311 is closer to the iron core 20 than the surface of the magnet 32. This ensures that the attraction will not damage the coating on the surface of the magnet 32, thus reducing the risk of corrosion.

[0118] like Figure 15 as well as Figure 16 As shown, in some optional embodiments, the magnetic pole module 30 provided in one embodiment of this disclosure has two edging portions 311 that are respectively box-shaped structures and have openings at one end facing each other in the circumferential Y direction. Multiple magnets 32 are respectively inserted into the receiving cavity of the corresponding edging portion 311 through the openings at both ends in the circumferential Y direction and are fixedly connected to the edging portion 311.

[0119] Optionally, the edging portion 311 may be in the shape of a rectangular box and have an opening at one end facing the magnet 32 ​​in the circumferential Y direction.

[0120] The magnetic pole module 30 provided in one embodiment of this disclosure, through the above-described configuration, makes the structure of the edging portion 311 simple, and can limit the multiple magnets 32 in the circumferential Y, axial X and radial Z directions of the rotating shaft 10, ensuring that the multiple magnets 32 are connected as a whole and their relative positions are stable. Furthermore, the edging portion 311 adopts the above-described structure, making its wall thickness relatively thin, which ensures that magnetic field damage can be reduced when the multiple magnets 32 are installed and fixed.

[0121] Optionally, when the first limiting block 34 and the second limiting block 35 are included, both the first limiting block 34 and the second limiting block 35 are inserted into the edge portion 311 on their respective sides along the axial direction X. The second limiting blocks 35 at both ends of the axial direction X can be clamped between the positioning member 31 and the magnet 32, or optionally between the corresponding edge portion 311 and the magnet 32.

[0122] In some optional embodiments, the magnetic pole module 30 provided in one embodiment of this disclosure may include an end plate 311a, a pair of first plates 311b arranged in the radial direction Z, and a pair of second plates 311c arranged in the axial direction X. Each first plate 311b and second plate 311c is connected to the end plate 311a at one end in the circumferential direction Y. The paired first plates 311b are partially inserted into the corresponding clearance portion 322. The second plate 311c abuts against the second limiting block 35 in the axial direction X.

[0123] The magnetic pole module 30 provided in one embodiment of this disclosure has an edge portion 311 with the above-described structure, which facilitates the installation and position limitation of the magnet 32, the first limiting block 34 and the second limiting block 35.

[0124] like Figure 15 As shown, in some optional embodiments, the magnetic pole module 30 provided in one embodiment of this disclosure can be formed by stamping, thus allowing its surrounding edges to be closed. Of course, this is one optional implementation method. Figure 16 As shown, in some embodiments, bending can also be used for forming, and if bending is used, the edges can be stacked.

[0125] Optionally, in one embodiment of the magnetic pole module 30 provided in this disclosure, each edge portion 311 of the positioning member 31 may be made of non-magnetic stainless steel, or may be made of other non-magnetic structures, such as plastic.

[0126] In some optional embodiments, one embodiment of this disclosure also provides a rotor 1, including an iron core 20 and the aforementioned magnetic pole module 30. The iron core 20 is provided with a mounting hole 22, and the magnetic pole module 30 is mounted in the mounting hole 22. An axial air duct 23 is provided on the iron core 20, extending along the axial direction X, and the axial air duct 23 communicates with a radial air duct 21 and a ventilation gap 33.

[0127] The number of axial air ducts 23 can be multiple, and the multiple axial air ducts 23 are distributed at intervals in the circumferential Y direction of the rotating shaft 10, and can be spaced out and evenly distributed.

[0128] The rotor 1 provided in one embodiment of this disclosure has an axial air duct 23, which facilitates the entry of cooling airflow. The axial air duct 23 is connected to the radial air duct 21 and the ventilation gap 33, so that the cooling airflow entering through the axial air duct 23 can flow through the radial air duct 21 and the ventilation gap 33, carrying away the heat generated by the iron core 20 and the magnet 32, ensuring the cooling and heat dissipation requirements of the rotor 1 and improving its reliability.

[0129] One embodiment of this disclosure also provides a generator 100, including the rotor 1 provided in the above embodiments. According to this embodiment, the generator 100, while ensuring power generation requirements, enables cooling airflow to pass through the radial air duct 21 and ventilation gap 33 to meet the cooling and heat dissipation requirements of the rotor 1, thereby improving the reliability of the generator 100 containing the rotor 1.

[0130] like Figure 17 As shown, in another aspect, one embodiment of this disclosure also provides a method for forming a rotor 1, which can be used to form the rotor 1 provided in the above embodiments. The forming method includes:

[0131] S100 provides a rotating shaft 10 and an iron core 20, the iron core 20 being provided with a radial air duct 21 and a mounting hole 22.

[0132] S200, heat the iron core 20 to a preset temperature, and then fit the heated iron core 20 onto the rotating shaft 10 and cool it so that the iron core 20 is connected to the rotating shaft 10, and the mounting hole 22 extends along the axial direction X of the rotating shaft 10, and the radial air duct 21 passes through the iron core 20 along the radial direction Z of the rotating shaft 10.

[0133] S300, a magnetic pole module 30 is provided. The magnetic pole module 30 includes a positioning element 31 and a plurality of magnets 32. The plurality of magnets 32 are distributed at intervals along the axial direction of the iron core 20 and are respectively connected to the positioning element 31. A ventilation gap 33 is formed between two adjacent magnets 32.

[0134] S400, Insert the magnetic pole module 30 into the mounting hole 22 so that multiple magnetic pole modules 30 are distributed at intervals along the axial direction X of the rotating shaft 10 and the radial air duct 21 is connected to the ventilation gap 33.

[0135] In step S100, the mounting holes 22 and radial air ducts 21 provided on the iron core 20 include multiple mounting holes 22, which can be spaced apart from each other in the circumferential Y direction, and the radial air ducts 21 can be spaced apart from each other in the axial X direction.

[0136] In step S200, before the magnetic pole module 30 is installed, the iron core 20 is first press-fitted with the rotating shaft 10 by a high-temperature heat fitting to achieve a fixed connection between the two.

[0137] In step S300, optionally, the provided magnetic pole module 30 may further include a first limiting block 34 and a second limiting block 35. A first limiting block 34 is clamped between two adjacent magnets 32, and a second limiting block 35 is provided at the ends of the two outermost magnets 32 of the magnetic pole module 30 that are away from each other. The first limiting block 34 and the second limiting block 35 are respectively connected to the positioning member 31 and the magnets 32. Optionally, the first limiting block 34 and the second limiting block 35 are both arranged in pairs. The paired first limiting blocks 34 can be spaced apart in the circumference of the iron core 20, and the paired second limiting blocks 35 can be spaced apart in the circumference of the iron core 20. Optionally, the thickness of the first limiting block 34 is greater than the thickness of the second limiting block 35. Two adjacent magnetic pole modules 30 each have a second limiting block 35 at their ends facing each other. Optionally, the magnet 32 ​​has clearance portions 322 on both sides of the radial direction Z of the rotating shaft 10, and the positioning member 31 partially extends into the clearance portion 322 and is fixedly connected to the magnet 32. Optionally, the positioning member 31 partially protrudes from the magnet 32. Optionally, the positioning member 31 may include two edge portions 311, which are respectively disposed on both sides of the magnet 32 ​​in the circumferential direction of the iron core 20. Optionally, the paired edge portions 311 are box-shaped structures with openings at their ends facing each other in the circumferential direction Y. Multiple magnets 32 are inserted into the corresponding edge portions 311 through the openings at both ends of the circumferential direction Y and are fixedly connected to the edge portions 311. Optionally, the magnetic pole module 30 can adopt the structural forms in the rotor 1 of the above embodiments, which will not be described in detail here.

[0138] In step S400, optionally, two or more magnetic pole modules 30 are provided in the mounting hole 22 along the axial direction X. Adjacent magnetic pole modules 30 are spaced apart from each other by their respective magnets 32, forming a ventilation gap 33. Optionally, the magnets 32 are spaced apart from the iron core 20.

[0139] The molding method provided in one embodiment of this disclosure can meet the molding requirements of the rotor 1 provided in the above embodiments. Furthermore, this molding method is applicable to high-speed rotating motors. The iron core 20 is manufactured separately, and the iron core 20 is first connected and fixed to the rotating shaft 10 by means of high-temperature heat sleeve, etc., and then the magnetic pole module 30 is installed and a ventilation gap 33 is formed. This can not only ensure its cooling and heat dissipation requirements, but also avoid the magnet 32 ​​from being affected by high temperature, thereby improving the reliability of the molded rotor 1.

[0140] In the description of this disclosure, it should be understood that the terms “center,” “upper,” “lower,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer,” etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this disclosure and simplifying the description, and are not intended to 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 disclosure.

[0141] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this disclosure, unless otherwise stated, "a plurality of" means two or more.

[0142] In the description of this disclosure, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0143] The features, structures, or characteristics described in this disclosure can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the foregoing description to give a full understanding of embodiments of this disclosure. However, those skilled in the art will recognize that the technical solutions of this disclosure can be practiced without one or more of the specific details described, or other methods, components, materials, etc., can be employed. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring various aspects of this disclosure.

Claims

1. A pole module characterized by, The magnetic pole module is designed for installation in the iron core (20) of a motor and includes: The positioning element (31) extends a predetermined length along the axial direction of the iron core (20); The magnet assembly includes at least two magnets (32), which are distributed along the axial direction (X) of the iron core (20) and connected to the positioning member (31) respectively, so that at least two magnets (32) can be inserted into the iron core (20) as a whole.

2. The pole module of claim 1, wherein, At least two of the magnets (32) are spaced apart along the axial (X) direction of the core (20) to form a ventilation gap (33) between two adjacent magnets (32).

3. The pole piece module of claim 2, wherein, The magnetic pole module (30) further includes a first limiting block (34) on the axial (X) direction of the iron core (20). The first limiting block (34) is disposed between two adjacent magnets (32) to form the ventilation gap (33) between the two adjacent magnets (32).

4. The pole piece module of claim 3, wherein, At least two first limiting blocks (34) are provided between every two adjacent magnets (32), and the at least two first limiting blocks (34) are spaced apart on the circumferential (Y) direction of the iron core (20).

5. The pole piece module of claim 4, wherein, The magnetic pole module (30) further includes at least two second limiting blocks (35), which are respectively disposed on both sides of the magnet assembly along the axial direction (X) of the iron core (20). Along the axial direction (X) of the iron core (20), the thickness of the second limiting block (35) is less than the thickness of the first limiting block (34).

6. The pole piece module of claim 5, wherein, At least two second limiting blocks (35) are provided on each side of the magnet assembly along the axial direction of the iron core (20). The at least two second limiting blocks (35) are spaced apart on the circumferential (Y) direction of the iron core (20). On the axial (X) direction of the iron core (20), the thickness of the first limiting block (34) is equal to twice the thickness of the second limiting block (35).

7. The pole piece module of claim 6, wherein, The magnet (32) has a positioning part (321) on both sides of the iron core (20) along the axial direction (X), and the first limiting block (34) and the second limiting block (35) are respectively disposed in the positioning part (321) of the corresponding magnet (32).

8. The pole module of any one of claims 1-7, wherein, The positioning member (31) includes two edge portions (311). In the circumferential direction of the iron core (20), the two edge portions (311) are respectively disposed on both sides of the magnet assembly. The edge portion (311) has a receiving cavity. The two ends of the magnet assembly in the circumferential direction (Y) of the iron core (20) are respectively inserted into the receiving cavity.

9. The pole piece module of claim 8, wherein, Each of the edging portions (311) includes an end plate (311a), two first plates (311b) and two second plates (311c). The end plate (311a) faces the end face of the magnet assembly in the circumferential direction of the iron core (20). The first plates (311b) and the second plates (311c) extend from the end plate (311a) toward the side of the magnet assembly. The two first plates (311b) are spaced apart and opposite to each other in the radial direction of the iron core (20). The two second plates (311c) are spaced apart and opposite to each other in the axial direction of the iron core (20). The end plate (311a), the two first plates (311b) and the two second plates (311c) enclose the receiving cavity.

10. The pole piece module of any of claims 1-7, wherein, The magnet (32) has clearance portions (322) on both sides of the radial (Z) direction of the iron core (20), and the magnet (32) is connected to the positioning member through the clearance portions (322).

11. The pole piece module of claim 10, wherein, The positioning element (31) is provided to protrude from the magnet (32) in the radial upper part of the iron core (20).

12. The pole piece module of any of claims 1-7, wherein, The positioning member (31) includes two edge portions (311). In the circumferential direction of the iron core (20), the two edge portions (311) are respectively disposed on both sides of the magnet group. The edge portion (311) has a receiving cavity. Two first limiting blocks (34) are disposed between every two adjacent magnets (32). Two second limiting blocks (35) are respectively disposed on both sides of the axial direction of each magnet group. The first limiting blocks (34) and the second limiting blocks (35) are both disposed on both sides of the magnet (32) in the circumferential direction of the iron core (20) and located in the receiving cavity.

13. A rotor characterized by, The rotor includes an iron core (20) and a magnetic pole module according to any one of claims 1-12, wherein the iron core (20) is provided with a mounting hole (22) matching the magnetic pole module, the mounting hole (22) extends along the axial direction of the rotor, and the magnetic pole module is disposed in the mounting hole (22).

14. The rotor of claim 13, wherein The iron core (20) is provided with a radial air duct (21), which runs through the iron core (20) radially. A ventilation gap (33) is provided between at least two magnets (32), and the radial air duct (21) and the ventilation gap (33) are connected.

15. The rotor of claim 14, wherein At least two magnetic pole modules are provided in each of the mounting holes (22). The at least two magnetic pole modules are distributed along the axial direction of the iron core (20). Two adjacent magnetic pole modules are spaced apart from each other and form a ventilation gap between the modules. The ventilation gap between the modules is connected to the radial air duct (21).

16. An electric machine characterized by The motor includes a rotor according to any one of claims 13 to 15.

17. A wind power unit, characterized in that The wind turbine generator set includes the motor according to claim 16, wherein the motor is a generator.

Images