Amorphous stator core, electric machine, and vehicle

Abstract

The application relates to an amorphous stator core, a motor and a vehicle. The amorphous stator core comprises a plurality of silicon steel sheets and a plurality of amorphous sheets. The plurality of silicon steel sheets and the plurality of amorphous sheets are alternately stacked along the axial direction of the amorphous stator core. The silicon steel sheet comprises a protruding piece located at the outer edge of the silicon steel sheet and extending outward along the radial direction of the silicon steel sheet, and used for connecting the shell of the motor. The axial direction is perpendicular to the radial direction. The scheme can improve the overall strength and safety of the amorphous stator core, and reduce the maintenance frequency of the motor during use. At the same time, the scheme can ensure better insulation effect between the stacked amorphous sheets, thereby further reducing the eddy current loss of the amorphous stator core, and further reducing the energy loss of the core during operation. Furthermore, the scheme can further reduce the radial stress of the amorphous sheet, and reduce the eddy current loss of the amorphous stator core.

Description

Technical Field

[0001] This application relates to the field of vehicles, and more particularly to an amorphous stator core, an electric motor, and a vehicle. Background Technology

[0002] In vehicle motors (especially AC motors, such as asynchronous motors and permanent magnet synchronous motors), the stator core is the core magnetic conductive component of the stator and a key component of the motor's magnetic circuit. Its core function is to provide a low magnetic resistance path for magnetic flux, while supporting the stator windings and isolating electromagnetic losses from the mechanical structure. It is the basic carrier for the motor to realize the conversion of "electrical energy to mechanical energy".

[0003] When an alternating magnetic field passes through a conductive iron core, closed currents (called "eddy currents") resembling vortices are induced inside the core. These eddy currents generate heat loss across the core's resistance, known as eddy current losses. In existing iron core designs, amorphous alloys are typically used to reduce eddy current losses. However, amorphous crystals are prone to conduction, leading to a significant increase in eddy current losses. Furthermore, amorphous alloys exhibit greater magnetostriction, and their iron losses are directly proportional to radial stress. Therefore, in motor iron core applications, the losses after assembling an amorphous iron core are significantly higher than those of a single iron core. Utility Model Content

[0004] This application provides an amorphous stator core, a motor, and a vehicle to address some or all of the shortcomings in the related technologies.

[0005] The amorphous stator core of this application is used in an electric motor. The amorphous stator core includes multiple layers of silicon steel sheets and multiple layers of amorphous wafers. The multiple layers of silicon steel sheets and multiple layers of amorphous wafers are alternately stacked along the axial direction of the amorphous stator core. The silicon steel sheets include protrusions located at the outer edge of the silicon steel sheets and extending radially outward for connection to the motor housing. The orthogonal projection area of ​​the protrusions along the axial direction is located outside the orthogonal projection area of ​​the amorphous wafers along the axial direction, and the axial direction is perpendicular to the radial direction.

[0006] Optionally, any layer of the silicon steel sheet includes at least two protrusions, which are respectively disposed at opposite ends of the silicon steel sheet along the radial direction.

[0007] Optionally, the outer diameter of the silicon steel sheet is larger than the outer diameter of the non-wafer.

[0008] Optionally, two layers of non-wafer sheets are sandwiched between any two adjacent silicon steel sheets.

[0009] Optionally, the thickness of the silicon steel sheet is 0.2 mm; and / or, the thickness of the non-wafer is 0.1 mm.

[0010] Optionally, the amorphous wafer comprises four layers of amorphous units, each amorphous unit having a thickness of 0.025 mm.

[0011] Optionally, the amorphous stator core further includes an insulating coating sprayed onto the surface of the silicon steel sheet.

[0012] Optionally, any one of the silicon steel sheets is bonded to the adjacent non-wafer.

[0013] The motor of this application includes a housing and an amorphous stator core as described above, the amorphous stator core being installed within the housing. The amorphous stator core is spaced apart from the inner wall of the housing, and the housing includes a keyway into which the protrusion is inserted. When the motor is in operation, the torque of the amorphous stator core is transmitted through the protrusion.

[0014] The vehicle described in this application includes an electric motor as described above.

[0015] The technical solutions provided by the embodiments of this application may include the following beneficial effects: As can be seen from the above embodiments, the amorphous stator core of this application can improve the overall strength and safety of the amorphous stator core by relying on the high hardness and high corrosion resistance of silicon steel sheets, thereby reducing the maintenance frequency of the motor during use. Simultaneously, due to the low iron loss and high magnetic permeability of silicon steel sheets, better insulation between the stacked amorphous wafers is ensured, further reducing eddy current losses in the amorphous stator core and thus reducing energy loss during operation. Furthermore, because the outer edge of the silicon steel sheets is designed with protrusions, they can connect with the motor housing through these protrusions. This ensures that after the amorphous stator core is installed in the motor, there is a certain distance between the amorphous wafers and the motor housing. The interaction force between the housing and the core is only transmitted to the silicon steel sheets through the protrusions, and does not directly act on the amorphous wafers, further reducing the radial force on the amorphous wafers and lowering the eddy current losses of the amorphous stator core.

[0016] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this application. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a partial structural diagram of the motor in one embodiment of this application; Figure 2 This is a schematic diagram of the overall structure of an amorphous stator core in one embodiment of this application; Figure 3 This is a partially exploded view of the amorphous stator core structure in one embodiment of this application; Figure 4 This is a simplified cross-sectional view of an amorphous stator core according to one embodiment of this application; Figure 5 This is a schematic diagram of the structure of a silicon steel sheet in one embodiment of this application; Figure 6 This is a schematic diagram of a non-chip structure in one embodiment of this application.

[0019] Explanation of reference numerals in the attached figures: 100. Motor; 1. Amorphous stator core; 11. Silicon steel sheet; 111. Protrusion; 12. Non-crystalline; 2. Housing; 21. Keyway; X, Axial; Y, Radial. Detailed Implementation

[0020] The technical solutions in the embodiments (or "implementations") of this application will be clearly and completely described herein with reference to the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements.

[0021] If the embodiments of this application contain terms relating to directional indications or positional relationships (such as up, down, left, right, front, back, inside, outside, top, bottom, center, vertical, horizontal, longitudinal, transverse, length, width, counterclockwise, clockwise, axial, radial, circumferential, etc.), such terms are only used to explain the relative positional relationships and movement of the components in a specific posture (as shown in the attached figures); if the specific posture changes, the directional indications or positional relationships will also change accordingly. Furthermore, the terms "first" and "second" used in the embodiments of this application are only for descriptive convenience and should not be construed as indicating or implying relative importance.

[0022] In the design of current new energy vehicles, the motor is a core component, and its output efficiency and energy loss are key research areas. During the operation of the motor, iron losses are generated inside the stator core. Among these, eddy current losses are a significant component of iron losses. Simply put, when an alternating magnetic field passes through the conductive iron core, eddy currents, similar to vortices, are induced inside the core. These eddy currents generate heat loss across the iron core's resistance, hence the term eddy current loss.

[0023] In existing iron core designs, amorphous alloys are typically used to reduce eddy current losses. However, after stacking amorphous wafers, interlayer conductivity can easily occur, leading to an increase in eddy current losses. Furthermore, due to the significant magnetostrictive effect of amorphous alloys, and the fact that the iron loss of amorphous alloys is directly proportional to the radial force, the amorphous alloy may undergo dimensional changes during motor operation due to the magnetostrictive effect. This can cause the amorphous alloy to interact with the internal components of the motor, increasing the radial force on the amorphous alloy and resulting in a significantly higher loss after assembling an amorphous iron core compared to a single iron core.

[0024] In view of this, this application provides a vehicle including an electric motor 100.

[0025] The vehicle described in this application specifically refers to a new energy vehicle. In a new energy vehicle, the motor 100, as a core component, converts electrical energy into mechanical energy, thereby driving the vehicle forward. During vehicle operation, the motor 100 not only provides a power source for the vehicle's operation but also supplies power to various electronic modules of the vehicle.

[0026] Combination Figure 1 and Figure 2 As shown, the motor 100 of this application includes an amorphous stator core 1 and a housing 2, with the amorphous stator core 1 installed inside the housing 2. The amorphous stator core 1 includes silicon steel sheets 11 and amorphous wafers 12. The amorphous wafers 12 are spaced apart from the inner wall of the housing 2. The housing 2 includes a keyway 21, and the protrusions 111 of the silicon steel sheets 11 are inserted into the keyway 21. When the motor 100 is in operation, the torque of the amorphous stator core 1 is transmitted through the protrusions 111.

[0027] In the scheme described in this application, the non-crystalline core 12 and the inner wall of the housing 2 are spaced apart. This design ensures that the non-crystalline cores 12 are mutually insulated, thereby effectively reducing the eddy current loss of the motor 100. Furthermore, the non-crystalline core 12 is not subjected to radial Y-pressure or torsional force from the housing 2, thus improving the safety and stability of the non-crystalline core 12 and effectively reducing the core loss of the amorphous stator core 1. This design not only maximizes the advantages of the non-crystalline core 12, such as high saturation magnetic induction intensity, high permeability, and low loss, but also significantly reduces the production and maintenance costs of the amorphous stator core 1.

[0028] Combination Figure 3 and Figure 4As shown, the amorphous stator core 1 of this application includes multilayer silicon steel sheets 11 and multilayer amorphous wafers 12. The multilayer silicon steel sheets 11 and multilayer amorphous wafers 12 are alternately stacked along the axial direction X of the amorphous stator core 1. The silicon steel sheets 11 include protrusions 111, which are located at the outer edge of the silicon steel sheets 11 and extend outward along the radial direction Y of the silicon steel sheets 11 for connecting to the housing 2 of the motor 100. The orthogonal projection area of ​​the protrusions 111 along the axial direction X is located outside the orthogonal projection area of ​​the amorphous wafers 12 along the axial direction X, and the axial direction X is perpendicular to the radial direction Y.

[0029] The solution proposed in this application employs a design that interlayers silicon steel sheets 11 and amorphous steel sheets 12. This design leverages the high hardness and corrosion resistance of the silicon steel sheets 11 to improve the overall strength and safety of the amorphous stator core 1, reducing the maintenance frequency of the motor 100 during use. Simultaneously, the low iron loss and high magnetic permeability of the silicon steel sheets 11 ensure better insulation between the interlayered amorphous steel sheets 12, further reducing eddy current losses in the amorphous stator core 1 and consequently minimizing energy loss during operation. Furthermore, since the outer edge of the silicon steel sheet 11 is designed with a protrusion 111, it can be connected to the housing 2 of the motor 100 through the protrusion 111. This ensures that after the amorphous stator core 1 is installed in the motor 100, there is a certain distance between the amorphous wafer 12 and the housing 2 of the motor 100. The interaction force between the housing 2 and the core will only be transmitted to the silicon steel sheet 11 through the protrusion 111, and will not directly act on the amorphous wafer 12. This further reduces the magnitude of the radial Y force on the amorphous wafer 12 and reduces the eddy current loss of the amorphous stator core 1.

[0030] In an optional embodiment, any layer of silicon steel sheet 11 includes at least two protrusions 111, which are respectively disposed at opposite ends of the silicon steel sheet 11 along the radial Y direction.

[0031] Combination Figure 5 and Figure 6 As shown, the single silicon steel sheet 11 includes two protrusions 111, which are arranged at opposite ends along the radial direction Y of the silicon steel sheet 11. During the operation of the motor 100, this design makes the silicon steel sheet 11 more uniformly stressed, and can better transmit the interaction force between the housing 2 and the amorphous stator core 1. This not only improves the safety of the silicon steel sheet 11, but also better protects the amorphous core 12 from external forces, thereby reducing the eddy current loss of the core and ensuring the working efficiency and safety of the motor 100 during operation.

[0032] Of course, it should be noted that in some other optional embodiments, the number of protrusions 111 can be adjusted according to the specific working scenario, core structure and user needs. For example, only a single protrusion 111 can be designed, or 3, 4, 5, 6 or even more protrusions 111 can be designed. This application does not impose any restrictions on this.

[0033] In an optional embodiment, the outer diameter of the silicon steel sheet 11 is larger than the outer diameter of the non-wafer 12.

[0034] Because amorphous alloy materials have a high magnetostrictive effect, the dimensions of the amorphous wafers 12 may change during the operation of the motor 100, potentially causing the burrs of adjacent amorphous wafers 12 to conduct to each other. Therefore, this application designs the outer diameter of the silicon steel sheet 11 to be larger than the outer diameter of the amorphous wafers 12, and combines this with the design of the protrusion 111. This not only prevents the burrs of adjacent amorphous wafers 12 from conducting to each other, but also ensures that the amorphous wafers 12 do not directly contact the housing 2 of the motor 100. This effectively improves the safety of the amorphous wafers 12, reduces the overall eddy current loss of the iron core, and ensures the output efficiency of the motor 100.

[0035] In an optional embodiment, two non-wafer layers 12 are sandwiched between any two adjacent silicon steel sheets 11.

[0036] This application significantly reduces the overall iron loss of the core by sandwiching two non-crystal layers 12 between two layers of silicon steel sheets 11, thereby utilizing the low-loss characteristics of the non-crystal layers 12 to block the conduction and diffusion of eddy currents between the silicon steel sheets 11. This design not only reduces energy waste during the operation of the motor 100, but also reduces heat generation in the core, thus ensuring the long-term stable operation of the motor 100.

[0037] In an optional embodiment, the thickness of the silicon steel sheet 11 is 0.2 mm, and the thickness of the non-wafer 12 is 0.1 mm.

[0038] As described above, the scheme of sandwiching two layers of non-crystalline silicon steel sheets 11 between any two layers of silicon steel sheets 11 shows that the thickness of the two non-crystalline silicon steel sheets 12 can reach 0.2 mm, the same as the thickness of a single silicon steel sheet 11. This design, while relying on the silicon steel sheets 11 to provide rigid support, also allows for a larger proportion of the low-loss non-crystalline silicon steel sheets 12 in the core, thereby further reducing the overall eddy current loss of the amorphous stator core 1. Therefore, the design scheme of this application can improve the overall structural strength of the amorphous stator core 1, reduce iron loss, and avoid the high cost problem caused by excessive ultra-thin materials. It combines the economic advantages of silicon steel sheets 11 and the low-loss advantages of non-crystalline silicon steel sheets 12, making it more suitable for mass production.

[0039] In an optional embodiment, the amorphous 12 includes four layers of amorphous units, each with a thickness of 0.025 mm.

[0040] In this application, the single-layer amorphous core 12 is composed of four layers of amorphous units stacked together. Since the thin layer more easily blocks eddy current diffusion, this design makes the amorphous core 12 more effective at suppressing high-frequency magnetic flux, thereby further suppressing eddy current losses during the operation of the motor 100. Furthermore, the multi-layer amorphous unit design also improves heat dissipation performance, enabling the amorphous stator core 1 to have more balanced operating performance and heat dissipation during the operation of the motor 100, thus resulting in higher output efficiency of the motor 100.

[0041] Of course, it should be noted that the specific structure, thickness, and stacking scheme of the silicon steel sheet 11 and the non-wafer 12 in this application are specific embodiments proposed for specific working scenarios. In other optional embodiments, the specific design scheme of the core can be adjusted accordingly based on the actual application scenario, core structure, and user requirements. For example, the silicon steel sheet 11 and the non-wafer 12 can be modified into a square structure; or only a single layer of non-wafer 12, or 3, 4, or even more layers of non-wafer 12 can be designed between any two adjacent silicon steel sheets 11; or the thickness of the single layer of non-wafer 12 can be designed to be the same as the thickness of the silicon steel sheet 11, etc. Therefore, this application does not limit the design of the specific structure, thickness, and stacking scheme of the silicon steel sheet 11 and the non-wafer 12.

[0042] In an optional embodiment, the amorphous stator core 1 further includes an insulating coating sprayed onto the surface of the silicon steel sheet 11.

[0043] The design of the insulating coating in this scheme can further ensure the insulation effect between the silicon steel sheet 11 and the non-wafer 12, and avoid the situation of eddy current diffusion across layers due to interlayer conductivity. This can further suppress the generation of eddy currents and reduce the overall eddy current loss of the iron core.

[0044] In an optional embodiment, any layer of silicon steel sheet 11 is bonded to an adjacent non-wafer 12.

[0045] This application connects the silicon steel sheet 11 and the non-crystal sheet 12 by adhesive bonding. This design not only offers high convenience and reliability, but also utilizes the insulating properties of the adhesive itself to further prevent interlayer eddy current coupling between the silicon steel sheet 11 and the non-crystal sheet 12. Furthermore, the adhesive bonding method reduces friction and resonance between the layers, resulting in less noise and vibration generated by the motor 100 during actual operation, thus improving the user's driving experience.

[0046] It should be noted that the technical solutions or features described in the above embodiments can be combined or supplemented with each other without conflict. The scope of protection of this application is not limited to the precise structures described in the above embodiments and shown in the accompanying drawings; all modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. An amorphous stator core, characterized in that, The amorphous stator core, used in motors, comprises: Multilayer silicon steel sheets and multilayer non-crystalline silicon sheets; The multilayer silicon steel sheets and the multilayer amorphous sheets are alternately stacked along the axial direction of the amorphous stator core; the silicon steel sheets include protrusions located at the outer edge of the silicon steel sheets and extending outward along the radial direction of the silicon steel sheets for connection to the housing of the motor. Wherein, the orthogonal projection area of ​​the protrusion along the axial direction is located outside the orthogonal projection area of ​​the non-wafer along the axial direction; the axial direction is perpendicular to the radial direction.

2. The amorphous stator core according to claim 1, characterized in that, Each layer of the silicon steel sheet includes at least two protrusions, which are respectively disposed at opposite ends of the silicon steel sheet along the radial direction.

3. The amorphous stator core according to claim 1, characterized in that, The outer diameter of the silicon steel sheet is larger than the outer diameter of the non-wafer.

4. The amorphous stator core according to claim 1, characterized in that, Between any two adjacent silicon steel sheets, two layers of non-crystal sheets are sandwiched.

5. The amorphous stator core according to claim 4, characterized in that, The thickness of the silicon steel sheet is 0.2 mm; and / or the thickness of the non-crystal sheet is 0.1 mm.

6. The amorphous stator core according to claim 5, characterized in that, The amorphous wafer comprises four layers of amorphous units, each with a thickness of 0.025 mm.

7. The amorphous stator core according to claim 1, characterized in that, The amorphous stator core also includes an insulating coating sprayed onto the surface of the silicon steel sheet.

8. The amorphous stator core according to claim 1, characterized in that, Any layer of the silicon steel sheet is bonded to the adjacent non-wafer.

9. An electric motor, characterized in that, It includes a housing and an amorphous stator core as described in any one of claims 1 to 8, wherein the amorphous stator core is installed within the housing; The non-wafer is spaced apart from the inner wall of the housing; the housing includes a keyway, and the protrusion is inserted into the keyway; When the motor is in operation, the torque of the amorphous stator core is transmitted through the protrusion.

10. A vehicle, characterized in that, Includes the motor as described in claim 9.

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