An end slotting anti-pullout cast aluminum rotor structure
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-03
- Publication Date
- 2026-08-11
AI Technical Summary
[0002]NEMA D设计电机为满足高堵转转矩需求，其铸铝转子需采用小槽型冲片与高阻合金铝，但该设计导致转子冲片与铝端环接触面积过小
[0013]有益效果：本实用新型通过加强型冲片的大槽型设计倍增铝端环与转子铁芯接触面积，扩大界面结合力，消除端环径向脱开风险；导条凸起与端环凹槽的互锁结构将传统平面接触转化为三维嵌合，将破坏性剪切力转化为结构压应力；沟槽与弧形过渡区共同优化应力分布，避免出现裂纹。从而使转子铁芯在极端启停、过载工况下仍保持端环与铁芯间的零位移，提高电机寿命。
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Figure CN224626501U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of motor rotor technology, and in particular relates to a cast aluminum rotor structure with end-grooved anti-breakage. Background Technology
[0002] To meet the high stall torque requirements, the NEMA D design motor requires a cast aluminum rotor with small-slot laminations and high-resistance aluminum alloy. However, this design results in an excessively small contact area between the rotor laminations and the aluminum end rings. Under frequent start-stop conditions, the aluminum end rings, with a thermal expansion coefficient much greater than that of the core, experience repeated thermal stress, causing micro-cracks at the interface between the end rings and laminations. Simultaneously, centrifugal force causes radial expansion of the aluminum end rings, further weakening the interfacial bonding force, occasionally leading to end ring detachment or even breakage. Summary of the Invention
[0003] Purpose of the invention: In order to overcome the shortcomings of the existing technology, this utility model provides an end-grooved anti-detachment cast aluminum rotor structure, which solves the problem of aluminum end ring detachment and breakage by structurally strengthening the interface between the aluminum end ring and the iron core.
[0004] Technical solution: To achieve the above objectives, this utility model provides an end-grooved anti-breakage cast aluminum rotor structure, including a rotor core, cast aluminum guide bars, and an aluminum end ring. The rotor core is formed by lamination, and at least one layer of lamination at both ends of the rotor core is a reinforcing lamination. The groove cross-sectional area of the reinforcing lamination is larger than that of the middle layer lamination, and the groove wall of the reinforcing lamination forms a radially extending contact surface with the axial inner side of the aluminum end ring.
[0005] Furthermore, the groove profile of the reinforcing lamination is geometrically similar to that of the intermediate layer lamination, and the groove wall surface is provided with at least one groove that runs through the axial direction.
[0006] Furthermore, the grooves are distributed on the groove wall surface of the reinforced lamination and are radially distributed on the groove wall, with the depth of the grooves decreasing from the end of the rotor core towards the middle.
[0007] Furthermore, the reinforced lamination has an arc-shaped transition zone at the connection between the groove bottom and the groove wall, and the radius of curvature of the arc-shaped transition zone is greater than the radius of curvature of the corresponding position of the intermediate layer lamination.
[0008] Furthermore, the cast aluminum guide bar forms a radially outward expanding protrusion structure in the axial section corresponding to the reinforcing lamination;
[0009] The aluminum end ring has an annular groove on its circumferential inner side, which fits into the protruding structure to form an axial limit.
[0010] Furthermore, the thickness of the reinforcing lamination is greater than the thickness of the intermediate lamination.
[0011] Furthermore, the groove of the reinforcing lamination is larger than that of the intermediate layer lamination in both circumferential width and radial depth.
[0012] Furthermore, the outer edge of the aluminum end ring is covered with a non-magnetic constraint ring, which is press-fitted onto the outside of the aluminum end ring by an interference fit.
[0013] Beneficial effects: This invention doubles the contact area between the aluminum end ring and the rotor core through the large groove design of the reinforced laminations, expanding the interfacial bonding force and eliminating the risk of radial separation of the end ring; the interlocking structure of the guide bar protrusions and the end ring grooves transforms the traditional planar contact into a three-dimensional fit, converting destructive shear force into structural compressive stress; the grooves and arc-shaped transition zone jointly optimize stress distribution, avoiding cracks. This ensures that the rotor core maintains zero displacement between the end ring and the core even under extreme start-stop and overload conditions, improving motor lifespan. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0015] Figure 2 for Figure 1 Enlarged structural diagram of region A in the middle;
[0016] Figure 3 This is a schematic diagram of the intermediate layer lamination structure;
[0017] Figure 4 This is a schematic diagram of the structure of a reinforced lamination;
[0018] Figure 5 A schematic diagram of the cross-sectional structure of the rotor exposing groove 6. Detailed Implementation
[0019] The present invention will be further described below with reference to the accompanying drawings.
[0020] like Figure 1 , Figure 2 , Figure 3 as well as Figure 4 As shown, an end-grooved anti-detachment cast aluminum rotor structure includes a rotor core 1, cast aluminum guide bars 2, and an aluminum end ring 3. The rotor core 1 is formed by laminations, and at least one layer of laminations at both ends of the rotor core 1 is a reinforcing lamination 4. The groove cross-sectional area of the reinforcing lamination 4 is larger than that of the middle layer laminations, and the groove wall of the reinforcing lamination 4 forms a radially extending contact surface 5 with the axial inner side of the aluminum end ring 3. By increasing the large groove cross-sectional area of the reinforcing lamination 4, the volume of aluminum liquid filling is increased, expanding the contact area with the aluminum end ring 3. The radially extending contact surface 5 forms a mechanical fit when the aluminum liquid cools and contracts, inhibiting the radial detachment of the aluminum end ring 3.
[0021] like Figure 2 , Figure 3 and Figure 4 As shown, the groove profile of the reinforcing lamination 4 is geometrically similar to that of the intermediate layer lamination, maintaining a consistent magnetic field distribution and avoiding magnetic reluctance torque fluctuations caused by abrupt changes in the groove profile. Furthermore, the groove wall surface is provided with at least one axially penetrating groove 6, increasing the flow path of the molten aluminum and eliminating casting porosity. After solidification, it forms an aluminum-like "anchor" to enhance the bonding force.
[0022] like Figure 2 As shown, the grooves 6 are distributed on the surface of the groove wall of the reinforced lamination 4, and are radially distributed on the groove wall, so that the centrifugal force is dispersed to multiple directions on the groove wall, such as... Figure 5 As shown, the depth of the groove 6 decreases from the end of the rotor core 1 to the middle. The deep groove at the end resists the impact of starting and stopping, while the shallow groove in the middle smoothly transitions the stress.
[0023] Figure 3 and Figure 4 As shown, the reinforced stamping 4 has an arc-shaped transition zone 7 at the connection between the groove bottom and the groove wall. The radius of curvature of the arc-shaped transition zone 7 is greater than the radius of curvature of the corresponding position of the intermediate layer stamping, which can eliminate the stress concentration point at the groove bottom and prevent the stamping from cracking during thermal cycling.
[0024] like Figure 2 As shown, the cast aluminum guide bar 2 forms a radially outward expanding protrusion structure 8 in the axial section corresponding to the reinforcing lamination 4; the circumferential inner side of the aluminum end ring 3 is provided with an annular groove 9, which interlocks with the protrusion structure 8 to form an axial limit. The axial shear force is converted into a radial clamping force, preventing relative displacement between the aluminum end ring 3 and the cast aluminum guide bar 2.
[0025] like Figure 1 or Figure 2 as well as Figure 3 and Figure 4 As shown, in this utility model, the reinforced lamination 4 has a more specific structure as follows: the thickness of the reinforced lamination 4 is greater than the thickness of the intermediate layer lamination, and the thickness of the reinforced lamination 4 is 20mm. Furthermore, the groove of the reinforced lamination 4 is larger than the groove of the intermediate layer lamination in both circumferential width and radial depth; the groove width of the reinforced lamination 4 is twice the groove width of the intermediate layer lamination, and the groove depth of the reinforced lamination 4 is three to four times the groove depth of the intermediate layer lamination.
[0026] like Figure 1 or Figure 2 As shown, as a further constraint and protection for the aluminum end ring 3, the outer edge of the aluminum end ring 3 is covered with a non-magnetic constraint ring 10. The non-magnetic constraint ring 10 is press-fitted to the outside of the aluminum end ring 3 by interference fit, so as to offset the centrifugal expansion of the aluminum end ring 3 through rigid constraint and prevent the aluminum end ring 3 from fatigue fracture.
[0027] In summary, this invention doubles the contact area between the aluminum end ring and the rotor core through the large groove design of the reinforced laminations, expanding the interfacial bonding force and eliminating the risk of radial separation of the end ring. The interlocking structure of the guide bar protrusions and the end ring grooves transforms the traditional planar contact into a three-dimensional fit, converting destructive shear force into structural compressive stress. The grooves and arc-shaped transition zone jointly optimize stress distribution, preventing cracks. This ensures that the rotor core maintains zero displacement between the end ring and the core even under extreme start-stop and overload conditions, thus improving motor lifespan.
[0028] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.
Claims
1. A type of end-grooved anti-breakage cast aluminum rotor structure, comprising a rotor core (1), cast aluminum guide bars (2), and aluminum end rings (3), wherein the rotor core (1) is formed by lamination, characterized in that: At least one lamination at both ends of the rotor core (1) is a reinforced lamination (4), the groove cross-sectional area of the reinforced lamination (4) is larger than the groove cross-sectional area of the intermediate lamination, and the groove wall of the reinforced lamination (4) forms a radially extending contact surface (5) with the axial inner side of the aluminum end ring (3).
2. The end-grooved anti-fracture cast aluminum rotor structure according to claim 1, characterized in that: The groove profile of the reinforced stamping (4) is geometrically similar to that of the groove profile of the intermediate layer stamping, and the groove wall surface is provided with at least one groove (6) that runs through the axial direction.
3. The end-grooved anti-fracture cast aluminum rotor structure according to claim 2, characterized in that: The grooves (6) are distributed on the groove wall surface of the reinforced lamination (4) and are radially distributed on the groove wall. The depth of the grooves (6) decreases from the end of the rotor core (1) to the middle.
4. The end-grooved anti-fracture cast aluminum rotor structure according to claim 1, characterized in that: The reinforced lamination (4) has an arc-shaped transition area (7) at the connection between the groove bottom and the groove wall. The radius of curvature of the arc-shaped transition area (7) is greater than the radius of curvature of the corresponding position of the intermediate layer lamination.
5. The end-grooved anti-fracture cast aluminum rotor structure according to claim 1, characterized in that: The cast aluminum guide bar (2) forms a radially outward expanding protrusion structure (8) in the axial section corresponding to the reinforcing punch (4). The aluminum end ring (3) has an annular groove (9) on its circumferential inner side, which is engaged with the protruding structure (8) to form an axial limit.
6. The end-grooved anti-fracture cast aluminum rotor structure according to claim 1, characterized in that: The thickness of the reinforced lamination (4) is greater than the thickness of the intermediate lamination.
7. The end-grooved anti-fracture cast aluminum rotor structure according to claim 1, characterized in that: The groove of the reinforced lamination (4) is larger than that of the intermediate layer lamination in both circumferential width and radial depth.
8. The end-grooved anti-fracture cast aluminum rotor structure according to claim 1, characterized in that: The outer edge of the aluminum end ring (3) is covered with a non-magnetic constraint ring (10), which is press-fitted to the outside of the aluminum end ring (3) by an interference fit.