Lightweight rotor assembly and generator

Abstract

The embodiment of the utility model provides a kind of lightweight rotor assembly and generator, it is related to motor technical field.Lightweight rotor assembly of generator includes iron core magnetic steel component, motor mandrel, hub and rotor end plate.Rotor end plate is circular annular plastic plate.Hub is sleeved and fixed on motor mandrel.Iron core magnetic steel component is embedded in the outside of hub.A pair of rotor end plate is sleeved in the outer periphery of hub and respectively adheres in the two sides of iron core magnetic steel component.Keyway is provided on hub.Positioning key is provided on rotor end plate and projects radially inward.Positioning key is matched with keyway.The utility model can reduce the overall weight and rotational inertia of rotor assembly, improve the energy conversion efficiency and response speed of motor.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and more specifically, to a lightweight rotor assembly and generator. Background Technology

[0002] In related technologies, the rotor assembly of an automotive generator or other rotating electric machine typically includes a rotor core, magnets, a spindle, and a pair of metal rotor end plates. After the metal rotor end plates are made into blanks through stamping or casting, they need to undergo multiple machining processes, such as turning the inner holes, end faces, and drilling balance holes and oil holes, before they are finally formed.

[0003] The inventors discovered that metal end plates, due to their high material density and the need for sufficient thickness (typically greater than 8mm) to meet dynamic balance requirements during weight reduction processing, are inherently heavy. This directly increases the rotational inertia of the rotor assembly, reducing the motor's starting response speed and energy conversion efficiency. Utility Model Content

[0004] The purpose of this invention is to provide a lightweight rotor assembly and generator, which can reduce the overall weight and moment of inertia of the rotor assembly and improve the energy conversion efficiency and response speed of the motor.

[0005] The embodiments of this utility model can be implemented as follows: In a first aspect, this utility model provides a lightweight rotor assembly, including an iron core magnet assembly, a motor spindle, a hub, a rotor end plate, and a fixing component. The rotor end plate is a circular plastic plate. The hub is sleeved and fixed on the motor spindle. The iron core magnet assembly is embedded on the outer side of the hub. A pair of rotor end plates are sleeved on the outer circumference of the hub and respectively attached to both sides of the iron core magnet assembly. A keyway is provided on the hub, and a radially inwardly protruding positioning key is provided on the rotor end plate. The positioning key cooperates with the keyway.

[0006] In an optional embodiment, a fixing component is also included, which includes a fixing ring and a fastening bolt. The fixing ring and the hub are respectively provided with axially penetrating fixing holes. The hub is also provided with a radially protruding positioning shoulder. The fastening bolt passes through the fixing holes of the fixing ring and the hub in sequence, so as to press and fix the fixing ring, the rotor end plate on one side, the iron core magnet assembly, the rotor end plate on the other side, and the positioning shoulder.

[0007] In an optional embodiment, a first cooling chamber is provided inside the motor spindle, a second cooling chamber is provided inside the hub, a through hole is provided on the motor spindle connecting the first cooling chamber and the second cooling chamber, an annular groove flow channel communicating with the second cooling chamber is provided on the inner end face of the rotor end plate, a flow gap is provided between the groove flow channel and the iron core magnet assembly, and a flow groove communicating with the annular groove flow channel is also provided on the plate surface of the rotor end plate.

[0008] In an optional embodiment, the extension direction of the flow groove is set at an angle to the radial direction of the rotor end plate.

[0009] In an optional embodiment, the rotor end plate is clearance-fitted with the hub to form the annular groove flow channel.

[0010] In an optional embodiment, the first cooling chamber is arranged along the axial direction of the motor spindle, and a plurality of through holes are formed in the inner wall of the first cooling chamber and arranged circumferentially around the motor spindle.

[0011] In an optional embodiment, one end of the motor spindle is further provided with a liquid injection hole that communicates with the first cooling chamber.

[0012] In an optional embodiment, the hub is provided with a weight-reducing groove or a weight-reducing hole.

[0013] In an optional embodiment, the rotor end plate is provided with reinforcing ribs.

[0014] Secondly, this utility model provides a generator, including the lightweight rotor assembly described in any of the foregoing embodiments.

[0015] The beneficial effects of the lightweight rotor assembly and generator provided by this embodiment of the invention include: This utility model discloses a lightweight rotor assembly comprising an iron core magnet assembly, a motor spindle, a hub, and rotor end plates. The rotor end plates are annular plastic plates. The hub is fitted and fixed to the motor spindle. The iron core magnet assembly is embedded on the outer side of the hub. A pair of rotor end plates are fitted onto the outer circumference of the hub and respectively attached to both sides of the iron core magnet assembly. A keyway is provided on the hub. Radially inwardly protruding positioning keys are provided on the rotor end plates. The positioning keys mate with the keyways. By using annular plastic plates as rotor end plates, the overall weight and moment of inertia of the rotor assembly can be significantly reduced, thereby effectively improving the energy conversion efficiency and dynamic response performance of the motor. Simultaneously, by mates between the positioning keys on the rotor end plates and the keyways on the hub, the rotor end plates can be integrally molded using injection molding while ensuring reliable circumferential positioning and power transmission. This eliminates the need for multiple machining processes required for traditional metal end plates, significantly reducing the manufacturing cost of the rotor end plates and the entire assembly. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the lightweight rotor assembly provided in this embodiment; Figure 2 This is a cross-sectional view of the lightweight rotor assembly provided in this embodiment; Figure 3 This is a schematic diagram of the rotor end plate provided in this embodiment.

[0018] Icons: 100-Rotor assembly; 10-Iron core magnet assembly; 20-Motor spindle; 21-First cooling chamber; 22-Through hole; 23-Injection hole; 30-Hub; 31-Positioning shoulder; 40-Rotor end plate; 41-Flow groove; 50-Fixing component; 51-Fixing ring; 52-Fastening bolt. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0021] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0022] In the description of this utility model, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the utility model product is usually placed during use, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0023] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0024] It should be noted that, where there is no conflict, the features in the embodiments of this utility model can be combined with each other.

[0025] The following detailed description of the overall structure, working principle, and technical effects of the lightweight rotor assembly provided by this utility model, through embodiments and in conjunction with the accompanying drawings, is a practical example.

[0026] Please refer to Figures 1-3 The lightweight rotor assembly 100 for an engine provided by this utility model is applicable to the automotive field, and is particularly suitable for automotive generators or starters where weight, efficiency, and cost are critical. Through its unique lightweight and integrated structural design, the lightweight rotor assembly 100 can effectively improve the power density and energy efficiency of the motor.

[0027] This lightweight rotor assembly 100 includes a core magnet assembly 10, a motor spindle 20, a hub 30, and rotor end plates 40. The rotor end plate 40 is a circular plastic plate. The hub 30 is fitted onto and fixed to the motor spindle 20. The core magnet assembly 10 is embedded on the outer side of the hub 30. A pair of rotor end plates 40 are fitted onto the outer periphery of the hub 30 and respectively abut against both sides of the core magnet assembly 10. A keyway is provided on the hub 30. A radially inwardly protruding locating key is provided on the rotor end plate 40. The locating key mates with the keyway.

[0028] The motor spindle 20 and hub 30 are fixedly mounted, and the iron core magnet assembly 10 is embedded in the periphery of the hub 30. The motor spindle 20 is used to transmit torque and support the rotation of the hub 30 and the iron core magnet assembly 10. The iron core magnet assembly 10 is used to establish a magnetic field during rotation to achieve electromechanical energy conversion. The rotor end plate 40 is used to cover and fix the iron core magnet assembly 10 on both axial sides to prevent axial movement or breakage during high-speed rotation. At the same time, its thin-walled plastic structure effectively reduces the overall weight and rotational inertia of the rotor assembly 100.

[0029] By setting a structure in which the positioning protrusion on the rotor end plate 40 mates with the keyway on the hub 30, reliable circumferential positioning can be provided for the injection-molded plastic rotor end plate 40, thereby effectively transmitting torque and ensuring the relative positional accuracy between the rotor end plate 40 and the hub 30. By setting the annular plastic rotor end plate 40 structure, the weight of components and material costs can be significantly reduced, thereby effectively reducing the overall weight and moment of inertia of the rotor assembly 100 and improving the energy conversion efficiency of the motor.

[0030] Specifically, the rotor assembly 100 also includes a fixing member 50. The fixing member 50 includes a fixing ring 51 and fastening bolts 52. Both the fixing ring 51 and the hub 30 have axially penetrating fixing holes. The hub 30 is also provided with a radially protruding positioning shoulder 31. The fastening bolts 52 pass through the fixing holes of the fixing ring 51 and the hub 30 in sequence, so as to press and fix the fixing ring 51, the rotor end plate 40 on one side, the iron core magnet assembly 10, the rotor end plate 40 on the other side, and the positioning shoulder 31.

[0031] By setting an axial clamping structure in which the fixing ring 51, the fastening bolt 52 and the positioning shoulder 31 on the hub 30 cooperate, a clamping force can be formed from one rotor end plate 40 through the iron core magnet assembly 10 to the other rotor end plate 40. This can reliably fix all rotating parts into a compact whole, effectively preventing axial movement of each part under high-speed rotation and impact load, and ensuring the structural integrity and operational reliability of the rotor assembly 100.

[0032] Specifically, the iron core magnet assembly 10 includes a rotor iron core and permanent magnets. The rotor iron core is made of multiple stacked silicon steel sheets, with multiple slots evenly formed along its circumference. The permanent magnets are correspondingly embedded in these slots. By setting up a structure consisting of a stacked rotor iron core and embedded permanent magnets, a high-intensity and uniformly distributed alternating magnetic field can be established when the rotor rotates, thereby effectively improving the torque density and energy conversion efficiency of the motor. This structure also facilitates the assembly and fixing of the magnets, which is beneficial for improving production efficiency. It can be understood that the rotor iron core provides a supporting structure for the permanent magnets. The inner periphery of the rotor iron core is interference-fitted with the hub 30. This interference fit ensures a reliable connection between the iron core and the hub 30, thereby enabling effective torque transmission. By setting rotor end plates 40 at both ends of the rotor iron core, the axial displacement of the permanent magnets and the rotor iron core stacks can be limited, preventing the magnets from falling off due to centrifugal force during high-speed rotation and ensuring the safe and reliable operation of the motor.

[0033] Furthermore, the lightweight rotor assembly 100 in this embodiment also includes a cooling system. Specifically, a first cooling chamber 21 is provided inside the motor spindle 20. A second cooling chamber is provided inside the hub 30. A through hole 22 is provided on the motor spindle 20, connecting the first cooling chamber 21 and the second cooling chamber. An annular groove flow channel communicating with the second cooling chamber is provided on the inner end face of the rotor end plate 40. A flow gap is provided between the groove flow channel and the iron core magnet assembly 10. A flow groove 41 communicating with the annular groove flow channel is also provided on the plate surface of the rotor end plate 40. It can be understood that the cooling oil in the first cooling chamber 21 inside the motor spindle 20 enters the second cooling chamber of the hub 30 through the through hole 22. As the motor spindle 20 and the hub 30 rotate, the cooling oil flows into the rotor end plates 40 on both sides and into the annular groove flow channel of the rotor end plate 40. By setting up a structure in which the annular groove flow channel is connected to the flow groove 41, the cooling oil can be evenly distributed along the annular flow channel under the action of centrifugal force, and then thrown out through the flow groove 41, thereby achieving uniform spray cooling of the inner side of the stator winding located on the outside of the rotor assembly 100. This integrated cooling channel design can effectively reduce the motor operating temperature, thereby improving the motor's power density and service life.

[0034] Furthermore, the extension direction of the flow groove 41 is set at an angle to the radial direction of the rotor end plate 40. By setting this inclined angle of the flow groove 41 structure, the cooling oil can obtain a velocity component perpendicular to the motor axis when flowing out, thereby achieving precise jet cooling of the inner side of the stator winding. This non-radial flow groove 41 guiding structure can effectively enhance the penetration and coverage of the cooling oil, thereby significantly improving the cooling efficiency of key heat-generating areas.

[0035] Specifically, the rotor end plate 40 is fitted with the hub 30 with a clearance to form an annular groove flow channel. By adopting a structure in which the flow channel is naturally formed by the fit between the rotor end plate 40 and the hub 30, complex deep groove machining on the rotor end plate 40 can be avoided, thereby significantly reducing machining difficulty and manufacturing costs.

[0036] In this embodiment, the first cooling chamber 21 is arranged along the axial direction of the motor spindle 20. A plurality of through holes 22 are formed in the inner wall of the first cooling chamber 21 and arranged circumferentially around the motor spindle 20. By adopting a structure of multiple through holes 22 distributed circumferentially, the cooling oil can be evenly distributed from the first cooling chamber 21 to various parts of the second cooling chamber, thereby ensuring the uniform distribution of cooling oil within the rotor assembly 100.

[0037] Furthermore, one end of the motor spindle 20 is provided with a liquid injection hole 23 that communicates with the first cooling chamber 21. By providing a liquid injection hole 23 at the end of the motor spindle 20, a cooling medium inlet can be provided for the cooling system, thereby facilitating connection with an external oil supply line and enabling a continuous supply of cooling oil.

[0038] To further reduce the weight of the rotor assembly 100, in this embodiment, the hub 30 is provided with a weight-removing groove or a weight-removing hole. By setting the dynamic balancing weight-removing structure on the hub 30, the machining characteristics of the metal hub 30 can be utilized to achieve precise dynamic balance adjustment without adding extra parts. This weight-removing structure set on the hub 30 avoids weight-removing processing on the thin-walled plastic end plate, thus effectively solving the dynamic balancing process difficulties caused by the thin walls and material characteristics of plastic parts, while ensuring that the rotor assembly 100 meets the high-precision dynamic balance requirements.

[0039] To improve the strength and rigidity of the rotor end plate 40, in this embodiment, reinforcing ribs are provided on the rotor end plate 40. Specifically, the reinforcing ribs are irregularly shaped radial rib structures provided on the rotor end plate 40, extending radially from the inner ring region of the rotor end plate 40 to the outer periphery. This significantly improves the bending stiffness and structural stability of the thin-walled rotor end plate 40 while minimizing the increase in material usage, thereby suppressing the deformation of the rotor end plate 40 caused by centrifugal force during high-speed rotation.

[0040] The beneficial effects of the lightweight rotor assembly 100 and generator provided by this embodiment of the invention include: The lightweight rotor assembly 100 of this utility model includes a core magnet assembly 10, a motor spindle 20, a hub 30, rotor end plates 40, and a fixing member 50. The rotor end plate 40 is a circular plastic plate. The hub 30 is sleeved and fixed on the motor spindle 20. The core magnet assembly 10 is embedded on the outside of the hub 30. A pair of rotor end plates 40 are sleeved on the outside of the hub 30 and pressed onto both sides of the core magnet assembly 10 by the fixing member 50. A keyway is provided on the hub 30. A radially inwardly protruding positioning key is provided on the rotor end plate 40. The positioning key mates with the keyway. By using a circular plastic plate as the rotor end plate 40, the overall weight and moment of inertia of the rotor assembly 100 can be significantly reduced, thereby effectively improving the energy conversion efficiency and dynamic response performance of the motor. Meanwhile, by using the positioning protrusion on the rotor end plate 40 to cooperate with the keyway on the hub 30, the rotor end plate 40 can be integrally molded by injection molding while ensuring reliable circumferential positioning and power transmission. This eliminates the need for multiple machining processes of traditional metal end plates and significantly reduces the manufacturing cost of the rotor end plate 40 and the assembly.

[0041] The above description is only a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model.

Claims

1. A lightweight rotor assembly, characterized in that, The device includes an iron core magnet assembly, a motor spindle, a hub, and rotor end plates. The rotor end plates are annular plastic plates. The hub is fitted and fixed to the motor spindle. The iron core magnet assembly is embedded on the outside of the hub. A pair of rotor end plates are fitted on the outer circumference of the hub and respectively attached to both sides of the iron core magnet assembly. The hub is provided with a keyway, and the rotor end plates are provided with radially protruding positioning protrusions that cooperate with the keyway.

2. The lightweight rotor assembly according to claim 1, characterized in that, It also includes a fixing component, which includes a fixing ring and a fastening bolt. The fixing ring and the hub are respectively provided with axially penetrating fixing holes. The hub is also provided with a radially protruding positioning shoulder. The fastening bolt passes through the fixing holes of the fixing ring and the hub in sequence, so as to press and fix the fixing ring, the rotor end plate on one side, the magnet, the rotor end plate on the other side, and the positioning shoulder.

3. The lightweight rotor assembly according to claim 1, characterized in that, The motor spindle is provided with a first cooling chamber, the hub is provided with a second cooling chamber, the motor spindle is provided with a through hole connecting the first cooling chamber and the second cooling chamber, the inner end face of the rotor end plate is provided with an annular groove flow channel communicating with the second cooling chamber, a flow gap is provided between the groove flow channel and the iron core magnet assembly, and a flow groove communicating with the annular groove flow channel is also provided on the surface of the rotor end plate.

4. The lightweight rotor assembly according to claim 3, characterized in that, The extension direction of the flow groove is set at an angle to the radial direction of the rotor end plate.

5. The lightweight rotor assembly according to claim 3, characterized in that, The rotor end plate is fitted with the hub with a clearance to form the annular groove flow channel.

6. The lightweight rotor assembly according to claim 3, characterized in that, The first cooling chamber is arranged along the axial direction of the motor spindle, and a plurality of through holes are opened in the inner wall of the first cooling chamber and arranged around the circumference of the motor spindle.

7. The lightweight rotor assembly according to claim 3, characterized in that, One end of the motor spindle is also provided with a liquid injection hole that communicates with the first cooling chamber.

8. The lightweight rotor assembly according to claim 1, characterized in that, The hub is provided with a weight-reducing groove or a weight-reducing hole.

9. The lightweight rotor assembly according to claim 1, characterized in that, The rotor end plate is provided with reinforcing ribs.

10. A generator, characterized in that, Includes the lightweight rotor assembly as described in any one of claims 1-9.

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