ROTOR, RELUCTANCE MACHINE, SYSTEM AND METHOD FOR MANUFACTURING ROTOR

Abstract

The present application provides a rotor assembly, a system assembly, and a method of manufacturing a rotor assembly for a radial / axial synchronous reluctance machine. The rotor assembly (100) includes an elongated body (110) having a cross-section including at least a pair of first and second rotor pole segments (112). The rotor assembly (100) is arranged such that, when exposed to magnetic flux, the free end (referred to as the first free end (1122a)) of the first rotor pole segment (112) and the free end (referred to as the second free end (1123a)) of the second rotor pole segment (112) face each other, and the first free ends (1122a, 1123a) have no surface contact with each other or have minimal surface contact (1125) with each other, thereby forming a magnetic flux barrier that prevents magnetic flux from flowing between the first free ends (1122a, 1123a).

Description

[Technical field]

[0001] The present application relates to a rotor assembly for a radial / axial synchronous reluctance machine, a system assembly, and a method for manufacturing the rotor assembly.

[0002] Similar devices are described in EP 1 786 088 B1, EP 2 406 870 B1 or EP 3 128 647 B1. [Background technology]

[0003] Known rotors for synchronous reluctance machines are typically formed by a substantially cylindrical body having a plurality of high permeability soft magnetic material sections and a plurality of flux barrier sections, thereby forming one or more pole pairs. The high permeability soft magnetic material sections and the flux barrier sections differ from one another in degree of magnetic permeability, with the section having the high permeability generally designated as the d-axis of the rotor and the section having the relatively low magnetic permeability generally designated as the q-axis of the rotor. Optimum torque output is achieved when the d-axis permeability is as high as possible and the q-axis permeability is as low as possible.

[0004] In practice, this is achieved by creating a notch of an appropriate shape in the cylinder and filling the notch with air, which suppresses the magnetic flux in the q-axis direction (i.e., increases the magnetic reluctance) and reduces the magnetic permeability. Summary of the Invention [Problem to be solved by the invention]

[0005] However, the inventors have discovered that applying this method to current rotor topologies results in the use of more high permeability, soft magnetic material than is necessary, resulting in waste of a relatively large amount of high permeability, soft magnetic material and environmental pollution.

[0006] It is an object of the present invention to provide a novel rotor topology designed to overcome shortcomings typically associated with known rotor topologies. [Means for solving the problem]

[0007] The present application provides a rotor assembly for a radial / axial synchronous reluctance machine, a system assembly, and a method for manufacturing the rotor assembly, as recited in the accompanying claims.

[0008] The dependent claims describe particular embodiments of the present application.

[0009] These and other aspects of the present application will become apparent from and elucidated with reference to the embodiments described hereinafter.

[0010] Further details, aspects and embodiments of the present application are described, by way of example only, with reference to the drawings, in which like reference numbers are used to identify like or functionally similar elements, and in which elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 shows an elongated body of a rotor assembly according to the present application. [Diagram 2] FIG. 2 shows a cross section of a four pole rotor assembly according to the present application. [Diagram 3] FIG. 3 shows a cross section of a pole of a rotor assembly according to the present application. [Figure 4] FIG. 4 shows another cross section of a pole of a rotor assembly according to the present application. [Diagram 5] FIG. 5 shows a cross section of a four pole rotor assembly according to the present application. [Figure 6] FIG. 6 shows a cross section of a two pole rotor assembly according to the present application. [Figure 7] FIG. 7 shows another cross section of a four pole rotor assembly according to the present application. [Figure 8] FIG. 8 shows a system assembly according to the present application. [Figure 9]FIG. 9 shows a detailed view of the system assembly of FIG. [Figure 10] FIG. 10 shows an exploded view of the system assembly of FIG. [Figure 11] FIG. 11 shows a cross section of the system assembly of FIG. [Figure 12] FIG. 12 illustrates another system assembly according to the present application. [Figure 13] FIG. 13 shows an exploded view of the system assembly of FIG. [Figure 14] FIG. 14 shows a cross section of the system assembly of FIG. [Figure 15] FIG. 15 shows a cross section of a system assembly according to the present application. [Figure 16] FIG. 16 shows a cross section of another system assembly according to the present application. [Figure 17] FIG. 17 shows a schematic flow diagram according to the present application. [Figure 18] FIG. 18 shows another schematic flow diagram according to the present application. [Figure 19] FIG. 19 shows a diagram of at least one step of the schematic flow diagram of FIG. [Figure 20] FIG. 20 shows a diagram of at least one step of the schematic flow diagram of FIG. [Figure 21] FIG. 21 shows a diagram of at least one step of the schematic flow diagram of FIG. [Figure 22] FIG. 22 illustrates the result of at least one step of the schematic flow diagram of FIG. [Figure 23] FIG. 23 shows a diagram of at least one step of the schematic flow diagram of FIG. 18, where the rotor system is positioned relative to the stator yoke. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Because the illustrated embodiments of the present application are largely composed of components known to those skilled in the art, they will not be described in any more detail than is deemed necessary to understand and appreciate the concepts underlying the present application, so as not to obscure or distract from the teachings of the present application.

[0013] The inventors have discovered that the rotor assembly of the present application requires less conductive raw material than prior art rotors.

[0014] Surprisingly, the applicants have also discovered that a synchronous reluctance machine including the rotor assembly of the present application may provide improved performance compared to current synchronous reluctance machines, particularly with respect to torque, but also with respect to torque ripple.

[0015] Rotor Assembly

[0016] This application relates to a rotor assembly for a radial synchronous reluctance machine.

[0017] Radial synchronous reluctance machines are of a known type and will not be described in further detail.

[0018] Referring to FIG. 1, the rotor assembly 100 includes 1. It includes an elongated body 110 .

[0019] -Elongated body of rotor assembly

[0020] In one embodiment, 1. The elongated body 110 has a substantially cylindrical shape having desired dimensions.

[0021] In one example, 1. The elongate body 110 is a tubular body.

[0022] In another example, 1. The elongated body 110 is a hollow cylinder.

[0023] Further, in this application, 1. Elongate body 110 has a central longitudinal axis of rotation 111, a circumference, and a cross-section.

[0024] As used herein, the term "circumference" means 1. It is defined as the circumferential surface of the elongate body 110.

[0025] Also, the cross section is taken in a plane perpendicular to the central longitudinal axis of rotation 111 .

[0026] In particular, the cross section is Circumference Dimensions and Circumference The radial dimension perpendicular to the dimension is shown.

[0027] -Rotor pole segments

[0028] In this application, as shown in FIG. 1. A cross-section of the elongated body 110 includes at least one pair of rotor pole segments 112 including a first rotor pole segment 112 and a second rotor pole segment 112 .

[0029] In other words, 1. It should be understood that the cross-section of the elongated body 110 may include one or more pairs of rotor pole segments 112 .

[0030] As used herein, the term "segment" is defined as a rotor pole that can be considered separate from other rotor poles.

[0031] In one embodiment, at least one rotor pole segment 112 is made from a soft magnetic material having a relatively high magnetic permeability.

[0032] In the present implementation, the relatively high magnetic permeability soft magnetic material is a ferromagnetic-based material.

[0033] In one example of this implementation of the present embodiment, the ferromagnetic based material is selected from the group including ferrite, iron powder, and bulk iron.

[0034] However, other materials having a magnetic permeability higher than air may be considered without significant alteration to the application of this application.

[0035] Also as shown, each rotor pole segment 112 is a monoblock segment with no internal flux barriers.

[0036] -Rotor pole segment positioning

[0037] In the present application, first and second rotor pole segments 112 are disposed circumferentially adjacent to one another relative to one another about a central longitudinal axis of rotation 111 .

[0038] With this arrangement, as the rotor assembly 100 rotates, the rotor pole segments 112 rotate relative to one another simultaneously while the relative positions of the rotor pole segments 112 remain the same.

[0039] In one example, the first and second rotor pole segments 112 are evenly spaced around the circumference.

[0040] -Rotor pole segment structure

[0041] As shown in FIG. 1. When viewed in cross-section through the elongated body 110 in either a clockwise or counterclockwise direction, each rotor pole segment 112 includes a central region 1121 , a first outer region 1122 , and a second outer region 1123 .

[0042] In particular, as shown, each rotor pole segment 112 has an asymmetric Batman-like shape with a wider central region 1121 .

[0043] Any desired percentage of different areas of each rotor pole segment 112 may be contemplated in this application without requiring substantial modification of the application.

[0044] Further, in the present application, each rotor pole segment is provided with a first outer region 1122 and a second outer region 1123 on either side of the central region 1121, with the first outer region 1122 and the second outer region 1123 each extending from the central region 1121.

[0045] In other words, it should be understood that the first outer region 1122 and the second outer region 1123 of each rotor pole segment 112 are adjacent to respective sides of the central region 1121 .

[0046] In one embodiment, the first outer region 1122 and the second outer region 1123 of each rotor pole segment 112 are attached to respective sides of the central region 1121 .

[0047] The present invention In at least one rotor pole segment 112, the first outer region 1122 and / or the second outer region 1123 have a tapered shape that gradually narrows from the central region 1121 towards the respective free ends.

[0048] As used herein, the term "tapered shape" is defined as a shape in which a first tangent to the upper surface of the rotor pole segment 112 and a second tangent to the lower surface of the rotor pole segment 112 converge toward a single point at or beyond their respective free ends.

[0049] In the implementation of this embodiment, the tapered shape is such that it forms an acute angle with a coincident apex at each free end.

[0050] In another embodiment of this embodiment, the tapered shape is a tapered rounded shape.

[0051] From the above, it should be understood that only the first outer region 1122, only the second outer region 1123, or both the first outer region 1122 and the second outer region 1123 may have a tapered shape.

[0052] In one example, both the first outer region 1122 and the second outer region 1123 have a tapered shape towards their respective free ends.

[0053] In another example, as shown in Figures 2 and 3, the first outer region 1122 has a tapered shape toward its free end and the second outer region 1123 has a relatively larger surface shape toward its respective free end relative to the tapered surface shape of the first outer region 1122.

[0054] For example, the large surface feature may include an outwardly bulging region extending toward the free end.

[0055] In another example, the second outer region 1123 has a tapered shape toward its free end and the first outer region 1122 has a relatively larger surface profile toward its free end compared to the tapered surface profile of the second outer region 1123.

[0056] For example, the large surface feature may include an outwardly bulging region extending toward the free end.

[0057] In yet another embodiment, as shown in FIG. 4, for at least one rotor pole segment 112, the angular expansion α of the first outer region 1122 is 1122 is the angular expansion α of the second outer region 1123 1123 is different.

[0058] In particular, the angular expansion α of the first outer region 1122 1122 is measured from the side of the recess 1126 to the first free end 1122a, and the angular expansion α of the second outer region 1123 1123 is measured from another side of the recess 1126 to the second free end.

[0059] In one example, the angular expansion α of the first outer region 1122 1122 is the angular expansion α of the second outer region 1123 1123 Greater than.

[0060] In another example, the angular expansion α of the second outer region 1123 1123 is the angular expansion α of the first outer region 1122 1122 Greater than.

[0061] -Asymmetric characteristics of rotor pole segments

[0062] Further, in the present application, as shown in Figures 2, 3, 4, 5, 6, 7, 11, 14, 15, and 16, the cross section of each rotor pole segment 112 is asymmetric with respect to at least the bisector 10 of the pole sector that includes the rotor pole segment 112.

[0063] In one example, at least one rotor pole segment 112 is further asymmetric with respect to the bisector 11 of the central region 1121 of the rotor pole segment 112 .

[0064] In another example, at least one rotor pole segment 112 is further asymmetric with respect to the bisector of the first exterior region 1122 of the rotor pole segment 112 .

[0065] In yet another example, at least one rotor pole segment 112 is further asymmetric with respect to the bisector of the second exterior region 1123 of the rotor pole segment 112 .

[0066] In yet another example, the free ends of at least one rotor pole segment 112 are asymmetric with respect to one another.

[0067] In one embodiment, all of the rotor pole segments 112 have the same asymmetry.

[0068] In another embodiment, none of the rotor pole segments 112 have the same asymmetry.

[0069] In yet another embodiment, at least two rotor pole segments 112 are similarly asymmetric.

[0070] -Rotor pole segment arrangement

[0071] Further, in the present application, rotor assembly 100 is arranged to behave in a predetermined manner when exposed to magnetic flux.

[0072] In fact, the free end of the first outer region 1122 of the first rotor pole segment 112 (called the first free end 1122a) and the free end of the second outer region 1123 of the second rotor pole segment 112 (called the second free end 1123a) are In the circumferential direction They are facing each other.

[0073] Further, the first free end 1122a and the second free end 1123a have no surface contact with each other or a minimum contact length 1125 extending along a radial direction; It is designed to behave magnetically as a non-magnetic material when exposed to magnetic flux, This prevents magnetic flux from flowing between the first free end 1122a and the second free end 1123a. , between the first free end 1122a and the second free end 1123a A magnetic flux barrier is formed, The flux barrier is positioned to nullify the q-axis flux when the d-axis flux is at a maximum; The magnetic reluctance at the surface or minimum contact length 1125 separating the first free end 1122a and the second free end 1123a increases.

[0074] In particular, if a minimum contact length 1125 exists, the minimum contact length 1125 is designed to be very thin so that it behaves magnetically as a non-magnetic material when exposed to magnetic flux.

[0075] First embodiment of the present application: Accuracy of placement of free ends of adjacent rotor pole segments

[0076] The inventors have discovered that a particular arrangement of the first free end 1122a and the second free end 1123a exhibits improvements with respect to torque.

[0077] - When there is no surface contact between the free ends

[0078] As shown in FIG. 2, in one embodiment, when there is no surface contact between the first free end 1122a and the second free end 1123a, the angular distance that exists between the first free end 1122a and the second free end 1123a is a predetermined angular distance 1124.

[0079] Furthermore, the rotor assembly 100 is positioned such that the ratio of the predetermined angular distance 1124 to the radius of the rotor assembly 100 is between 0.1% and 20%.

[0080] In this embodiment implementation, the ratio of the predetermined angular distance 1124 to the radius of the rotor assembly 100 is between 2% and 15%.

[0081] In another embodiment of this embodiment, the ratio of the predetermined angular distance 1124 to the radius of the rotor assembly 100 is between 5% and 10%.

[0082] - When the contact length between the free ends is minimum

[0083] In another embodiment, in which a minimum contact length 1125 exists between the first free end 1122a and the second free end 1123a, as shown in FIG. 6, the rotor assembly 100 is further positioned such that the ratio of the radial dimension of the minimum contact length 1125 to the radius of the rotor assembly 100 is less than or equal to 10%.

[0084] In this implementation, the ratio of the radial dimension of the minimum contact length 1125 to the radius of the rotor assembly 100 is less than or equal to 5%.

[0085] In another embodiment of this embodiment, the ratio of the radial dimension of the minimum contact length 1125 to the radius of the rotor assembly 100 is less than or equal to 2%.

[0086] Second embodiment of the present application: Recess

[0087] The inventors have discovered that forming recesses in specific locations on the rotor pole segments 112 provides improvements with respect to torque ripple.

[0088] As shown in Figures 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13, 15, and 16, in one embodiment of the present application, the rotor assembly 100 further includes, for at least one rotor pole segment 112, the central region 1121 including at least one inwardly facing recess 1126.

[0089] Preferably, the inward recess 1126 is provided on the outer circumferential surface of the central region 1121 .

[0090] In one example, the inwardly facing recess 1126 is U-shaped.

[0091] In another example, the inwardly facing recess 1126 is V-shaped.

[0092] However, other shapes of the inwardly facing recess 1126 are contemplated without requiring a substantial modification of the present application.

[0093] -The recess is shifted

[0094] In this implementation, the recess 1126 is provided with a bisector 11 that is angularly offset relative to the bisector 10 of the rotor pole segment 112, as shown in FIG.

[0095] In another embodiment of this embodiment, 1. Along the radial direction of the cross-section of the elongate body 110 , the maximum depth of the recess 1126 is angularly offset relative to the bisector 11 of the recess 1126 .

[0096] -island area

[0097] In another variation of this embodiment, at least one rotor pole segment 112 further includes an island region 113 facing and spaced apart from the recess 1126, as shown in FIG.

[0098] In one aspect of this implementation of the present embodiment, at least one rotor pole segment 112 further includes a bridge (not shown) between the island region 113 and the recess 1126 and is configured to connect the island region 113 and the recess 1126.

[0099] In particular, the bridge is designed to be very thin so that when exposed to magnetic flux, it behaves magnetically as a non-magnetic material.

[0100] Third embodiment of the present application: Accuracy for different regions of the cross section of a rotor pole segment

[0101] The inventors have discovered that by adjusting the radii of different sections of the rotor pole segments 112, improvements can be seen in terms of torque and torque ripple.

[0102] In one embodiment, as shown in FIG. 1. The cross-section of the elongated body 110 further includes a specific arrangement for the at least one rotor pole segment 112 .

[0103] In particular, the first outer region 1122 has at least first and second outer arcuate sections (referred to as first and second sections 1122b, 1122c).

[0104] In particular, the first section 1122b is closer to the central region 1121 than the second section 1122c.

[0105] The second outer region 1123 also has at least one outer arcuate section referred to as the third section 1123b.

[0106] Additionally, the first section 1122b, the second section 1122c, and the third section 1123b each have a substantially constant radius of curvature.

[0107] Additionally, the first section 1122b and the second section 1122c have a first radius r1 and a second radius r2, respectively.

[0108] In particular, the second radius r2 is equal to or greater than the first radius r1.

[0109] Finally, the third section 1123b has a third radius r3 that is different from the second radius r2.

[0110] In one example of this embodiment, the first radius r1 is substantially equal to the rotor radius of the central longitudinal axis of rotation 111.

[0111] In another example of this embodiment, the second radius r2 is substantially equal to the third radius r3.

[0112] In yet another example of this embodiment, the second radius r2 is substantially smaller than the third radius r3.

[0113] In yet another example of this embodiment, the second radius r2 is substantially longer than the third radius r3.

[0114] In this implementation, the first section 1122b and the second section 1122c are connected in series via a transition portion.

[0115] In this example implementation of this embodiment, the transition portion is curved.

[0116] In another example of this implementation of the present embodiment, the transition portion is angled.

[0117] In yet another example of this implementation of the present embodiment, the transition portion is a square.

[0118] However, other shapes of the transition portion are contemplated without requiring substantial modification of the present application.

[0119] -teeth

[0120] The inventors have discovered that forming teeth at specific locations on the rotor pole segments 112 provides improvements with respect to torque ripple.

[0121] In the implementation of this embodiment, as shown in Figures 5, 6, 7, 11, 14, 15 and 16, the first section and / or the second section and / or the third section 1122b, 1122c, 1123b each include at least one cutout portion forming a tooth 1127, thereby locally adjusting the gap between the rotor assembly 100 and the stator, smoothing the torque and reducing torque ripple.

[0122] In other words, it should be understood that the first section 1122b and / or the second section 1122c and / or the third section 1123b may each include a number of cut-out portions that form the teeth 1127.

[0123] In one implementation of this embodiment, the number of cutout portions forming the teeth 1127 of the first section 1122b and / or the second section 1122c and / or the third section 1123b is different from each other.

[0124] In this implementation of the present embodiment, the first section 1122b includes two cutout portions that form the teeth 1127, and the third section 1223b includes one cutout portion that forms the teeth 1127.

[0125] In another implementation of this embodiment, the first section 1122b includes one cutout portion forming the teeth 1127 and the third section 1223b includes two cutout portions forming the teeth 1127.

[0126] Fourth embodiment of the present application: solidifying the rotor assembly

[0127] The inventors have discovered that by surrounding the rotor pole segments 112 with a hollow frame 1128, the robustness of the rotor assembly 100 is improved.

[0128] In one embodiment, as shown in FIG. 1. The cross section of the elongate body 110 further includes at least a pair of continuous hollow frames 1128 .

[0129] In particular, there are as many pairs of consecutive hollow frames 1128 as there are pairs of rotor pole segments 112 .

[0130] Each rotor pole segment 112 is also surrounded by a respective hollow frame 1128 .

[0131] In the implementation of this embodiment, the material of the hollow frame 1128 is made of a non-magnetic material.

[0132] In one example, the non-magnetic material is made from aluminum.

[0133] In another example, the non-magnetic material is made from plastic.

[0134] In another example, the non-magnetic material is made from a resin.

[0135] In yet another example, the non-magnetic material is made from a polymer.

[0136] However, other materials having non-magnetic electrical conductivity may be contemplated without requiring significant modification of the present application.

[0137] In another implementation of this embodiment, the material of the hollow frame 1128 is a ferromagnetic material that is thin enough that it behaves as a non-magnetic material when exposed to magnetic flux.

[0138] Systems including rotor assemblies

[0139] The present application also relates to a system assembly for a radial synchronous reluctance machine.

[0140] -First system

[0141] In an embodiment of the system assembly, as shown in FIGS. 8, 9, 10 and 11, a first system assembly 200 includes the rotor assembly 100 described above, a rotor shaft 210, and a first shaft connection assembly 220.

[0142] In particular, the rotor shaft 210 is of a known type and will not be described in further detail.

[0143] Preferably, the rotor shaft 210 is made of a non-magnetic material.

[0144] In the first system assembly 200 , the first shaft connection assembly 220 is configured to connect the rotor assembly 100 to the rotor shaft 210 .

[0145] In one example, the first shaft connection assembly 220 is removable from the rotor assembly 100 and / or the rotor shaft 210 .

[0146] In another example, the first shaft connection assembly 220 is made from a non-magnetic material.

[0147] Further, in the first system assembly 200, the first shaft connection assembly 220 is a cylindrical Second It includes an elongated body.

[0148] Additionally, the rotor assembly 100 is configured to surround the first shaft connection assembly 220 .

[0149] In one example, the rotor assembly 100 is glued to the first shaft connection assembly 220 .

[0150] However, the rotor assembly 100 may be secured to the first shaft connection assembly 220 in any other suitable manner without requiring significant modification of this application.

[0151] Furthermore, the rotor shaft 210 is Second and configured to protrude longitudinally from the distal end of the elongated body of the rotor shaft 210 by rotation of the rotor shaft 210. Second The long, thin bodies of the rotors rotate simultaneously and in sync.

[0152] In one example, the rotor shaft 210 is Second The elongated body of the stent is further configured to extend longitudinally therethrough.

[0153] In this implementation of the system assembly, the first shaft connection assembly 220 further includes a first flange, a second flange, and a plurality of longitudinal rods.

[0154] Further, in this embodiment of the system assembly implementation, the rotor assembly 100 is configured to be sandwiched between a first flange and a second flange.

[0155] Furthermore, in this implementation of the system assembly, the longitudinal rod is configured to extend through the rotor assembly 100 between the first flange and the second flange.

[0156] In another embodiment of the current embodiment of the system assembly, each rotor pole segment of the rotor assembly includes a plurality of grooves extending longitudinally along all or a portion of the outer surface of the cylinder.

[0157] Further, in the current embodiment of the system assembly, the shaft connection assembly includes a plurality of external teeth extending longitudinally, continuously and / or discontinuously, and protruding from an outer surface of the cylindrical body.

[0158] In particular, each tooth is shaped to slidably engage and mate with a corresponding groove.

[0159] In one example, the external teeth are made of a non-magnetic material.

[0160] In another example, the external teeth are made of a magnetic material, in fact a magnetic material can be used for the external teeth in the central area of ​​the system assembly since the central area has a low susceptibility to magnetism.

[0161] As shown in Figures 9, 10 and 11, in a current implementation of the current embodiment of the system assembly, at least one groove is a dovetail groove and at least one outer engagement arm is a dovetail member.

[0162] In yet another implementation of the current embodiment of the system assembly, each rotor pole segment of the rotor assembly includes a plurality of teeth extending longitudinally, continuously and / or discontinuously along all or a portion of the outer surface of the cylinder.

[0163] Additionally, in the current implementation of the current embodiment of the system assembly, the shaft connection assembly includes a plurality of exterior grooves extending longitudinally and protruding from the exterior surface of the cylindrical body.

[0164] In particular, each tooth is shaped to slidably engage and fit into a corresponding groove.

[0165] For example, the outer teeth are made of a non-magnetic material.

[0166] In a current example implementation of the current embodiment of the system assembly, the at least one groove is a dovetail groove and the at least one outer engagement arm is a dovetail member.

[0167] -Second system

[0168] In a system assembly embodiment, as shown in Figures 12, 13 and 14, a second system assembly 300 includes the rotor assembly 100 described above, a rotor shaft 310, and a second shaft connection assembly.

[0169] In particular, the rotor shaft 310 is of a known type and will not be described in further detail.

[0170] Preferably, the rotor shaft 310 is made of a non-magnetic material.

[0171] In the second system assembly 300 , a second shaft connection assembly is configured to connect the rotor assembly 100 to a rotor shaft 310 .

[0172] In one example, the second shaft connection assembly is removable from the rotor assembly 100 and / or the rotor shaft 310 .

[0173] In another example, the second shaft connection assembly is made from a non-magnetic material.

[0174] Furthermore, in the second system assembly 300 , the second shaft connection assembly includes a first flange 321 , a second flange 322 , and a plurality of longitudinal rods 323 .

[0175] Furthermore, the rotor assembly 100 is configured to be sandwiched between a first flange 321 and a second flange 322 .

[0176] Additionally, the longitudinal rod 323 is configured to extend through the rotor assembly 100 between the first flange 321 and the second flange 322 .

[0177] Furthermore, the rotor shaft 310 is configured to protrude longitudinally from the distal ends of the first flange 321 and the second flange 322, and rotation of the rotor shaft 310 causes the first flange 321, the second flange 322, and the rotor assembly 100 to rotate simultaneously and synchronously.

[0178] In one example, the rotor shaft 310 is Second The elongated body 110 is further configured to extend longitudinally therethrough.

[0179] -Adding permanent magnets to the system

[0180] In an embodiment of the system assembly, as shown in FIGS. 14 and 15, the system assembly further includes at least one permanent magnet 20.

[0181] In other words, it should be understood that in that embodiment, the system assembly may include multiple permanent magnets 20 arranged on the d-axis.

[0182] In particular, the permanent magnet 20 is disposed above and / or below at least one rotor pole segment 112 , thereby cooperating with the respective rotor pole segment 112 .

[0183] In one example, the system assembly of this embodiment includes one or more permanent magnets 20 disposed beneath at least one rotor pole segment 112 .

[0184] In another example, if the system assembly includes at least one inwardly facing recess 1126 of the rotor pole segment 112, the system assembly in this embodiment includes one permanent magnet 20 disposed on top of the inwardly facing recess 1126.

[0185] In this embodiment, the permanent magnets 20 are separated from the associated rotor pole segments 112 .

[0186] In another embodiment of this embodiment, at least a portion of the permanent magnet 20 is at least partially embedded within the associated rotor pole segment 112 .

[0187] In yet another embodiment of this embodiment, each of the one or more permanent magnets 20 has a magnetization direction and is further arranged such that the magnetization direction of the one or more permanent magnets 20 is substantially oriented toward a focal axis located near the q-axis.

[0188] In this embodiment of the present invention, the focal axis is the q axis.

[0189] In this embodiment of the present invention, the focal axis is angularly offset with respect to the q axis by a predetermined offset angle.

[0190] For example, the predetermined offset angle can be obtained according to the following formula: α=±(90°) / p where α is the predetermined offset angle and p is the number of pole pairs in the rotor assembly 100.

[0191] However, other values ​​of the predetermined offset angle may be considered without requiring significant modification of this application.

[0192] Synchronous reluctance machine including the rotor assembly of the present application

[0193] The present application also relates to a synchronous reluctance machine including at least one rotor assembly 100 as described above.

[0194] In one example, the synchronous reluctance machine is a motor in a drive or assembly.

[0195] In another example, the synchronous reluctance machine is part of a motor in a drive or assembly.

[0196] For example, the motor may be either a single phase motor or a polyphase motor.

[0197] In yet another example, the synchronous reluctance machine is a generator in a drive or assembly.

[0198] In yet another example, the synchronous reluctance machine is part of a generator in a drive or assembly.

[0199] A working machine including a synchronous reluctance machine according to the present application.

[0200] The present application also relates to a work machine including a synchronous reluctance machine as described above.

[0201] In one embodiment, the work machine is in the form of a vehicle.

[0202] In one example, the vehicle is a land vehicle such as a car, a taxi, a bus, or a train.

[0203] In another example, the vehicle is a water vehicle, such as a boat, ferry, or cruiser.

[0204] In yet another example, the vehicle is an aircraft, such as a plane, helicopter, glider, aerostat, or airship.

[0205] However, the work machine may be any suitable electric machine, such as a machine tool.

[0206] Manufacturing method of rotor assembly of the present application

[0207] The present application also relates to a method of manufacturing a rotor assembly for a radial / axial synchronous reluctance machine.

[0208] -First manufacturing method

[0209] In a first embodiment of the manufacturing method, as shown in FIG. 17, a method 400 is designed for manufacturing a rotor assembly 100 for a radial synchronous reluctance machine.

[0210] In step 410, a 3D shape having a central longitudinal axis of rotation 111, a circumference and a cross section is 1. An elongate body 110 is provided.

[0211] In step 420, 1. A cross-section of the elongated body 110 is defined to include at least one pair of rotor pole segments 112 including a first rotor pole segment 112 and a second rotor pole segment 112 .

[0212] In step 430, first and second rotor pole segments 112 are positioned circumferentially adjacent to one another relative to one another about the central longitudinal axis of rotation 111. , where each rotor pole segment (112) is a monoblock segment with no internal flux barriers. .

[0213] In step 440, 1. When viewed in a clockwise or counterclockwise direction in a cross-section of the elongated body 110, each rotor pole segment 112 is defined to include a central region 1121 and, on either side thereof, a first outer region 1122 and a second outer region 1123, each extending from the central region 1121.

[0214] In step 450, each rotor pole segment 112 is defined to be asymmetric with respect to at least the bisector 10 of the pole sector that contains the rotor pole segment 112. Each rotor pole segment (112) has an asymmetric Batman-like shape with a wider central region (1121), and for at least one rotor pole segment (112), the first outer region (1122) and / or the second outer region (1123) have a tapered shape that narrows from the central region (1121) toward their respective free ends. .

[0215] In step 460, a free end of the first outer region 1122 of the first rotor pole segment 112 (referred to as the first free end 1122a) and a free end of the second outer region 1123 of the second rotor pole segment 112 (referred to as the second free end 1123a) are In the circumferential direction are placed opposite each other.

[0216] Then, in step 470, the first free end 1122a and the second free end 1123a are not in surface contact with each other when exposed to a magnetic flux. Along the radial dimension the first free end 1122a and the second free end 1123a are arranged to have a minimum contact length 1125 with respect to each other; It is designed to behave magnetically as a non-magnetic material when exposed to magnetic flux, This prevents magnetic flux from flowing between the first free end 1122a and the second free end 1123a. , between the first free end 1122a and the second free end 1123a A magnetic flux barrier is formed , the flux barrier is positioned to nullify the q-axis flux when the d-axis flux is at a maximum; The magnetic reluctance between the first free end 1122a and the second free end 1123a increases.

[0217] -Second manufacturing method

[0218] In a second embodiment of the manufacturing method, a method (not shown) is designed for manufacturing a rotor assembly 100 for a radial synchronous reluctance machine.

[0219] In the first step, the central longitudinal axis of rotation, the circumference and Dimensions in a plane perpendicular to the central longitudinal axis of rotation, specifically, the circumferential dimension and the radial dimension perpendicular to the circumferential dimension An elongated hollow cylinder having a

[0220] In particular, an elongated hollow cylinder is made of a ferromagnetic-based material.

[0221] In a second step, the rotor assembly 100 is cut into an elongated hollow cylindrical shape according to the pattern defined by the cross section of the rotor assembly 100 as described above. Circumference is dug into.

[0222] In an embodiment of the second step, an elongated hollow cylinder Circumference A punching means is used to make holes in the substrate.

[0223] In particular, the punching means are of a known type and will not be described in further detail.

[0224] In an embodiment of the second step, an elongated hollow cylinder Circumference A cutting means is used to cut the

[0225] In particular, the cutting means are of a known type and will not be described in further detail.

[0226] -Third manufacturing method

[0227] In an embodiment of a manufacturing method, as shown in FIG. 18, a method 500 for manufacturing a rotor assembly of an axial synchronous reluctance machine is designed.

[0228] In step 510, at least one elongated hollow cylinder is provided having a central longitudinal axis of rotation, a circumference, an interior surface, and a width, as shown in Figure 19. In particular, the elongated hollow cylinder is made of a soft magnetic material with high magnetic permeability.

[0229] In step 520, a cross section of the rotor assembly 100 described above is provided, as shown in FIG.

[0230] In step 530, a cross section of the rotor assembly 100 is projected onto the inner surface of the elongated hollow cylinder, forming a projected pattern on the inner surface of the elongated hollow cylinder, as shown in FIG.

[0231] In step 540, the projection pattern is extended along the circular cross section of the elongated hollow cylinder in a radial direction relative to the circular cross section to form an extended projection pattern, as shown in FIGS.

[0232] In step 550, the width of the elongated hollow cylinder is drilled according to an extended projection pattern to extract a first rotor pole segment for the axial synchronous reluctance machine, as shown in FIG.

[0233] In step 560, steps 330 through 350 are repeated to extract at least a second rotor pole segment for the axial synchronous reluctance machine.

[0234] In step 570, the first and second rotor pole segments are positioned circumferentially adjacent to each other relative to one another about the central longitudinal axis of rotation, as shown in FIG.

[0235] In step 580, a free end of a first outer region of a first rotor pole segment (referred to as the first free end) and a free end of a second outer region of a second rotor pole segment (referred to as the second free end) are positioned facing each other, as shown in FIG.

[0236] Then, in step 590, the first free end and the second free end are positioned such that when exposed to magnetic flux, the first free end and the second free end do not come into surface contact with each other or have a minimum contact length 1125 with each other, as shown in FIG. 23, thereby preventing magnetic flux from flowing between the first free end and the second free end. Between the first free end 1122a and the second free end 1123a A magnetic flux barrier is formed, increasing the magnetic reluctance between the first free end and the second free end.

[0237] The description of the present application has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the application in the form disclosed. The embodiments have been chosen and described to better explain the principles and practical applications of the present application, and to enable those skilled in the art to understand the present application in various embodiments with various modifications suited to the specific uses contemplated.

[0238] Various other embodiments

[0239] For example, the rotor assembly is described as a cylindrical inner rotor.

[0240] However, one skilled in the art can easily adapt the teachings of the present application to create a rotor assembly in the form of an annular outer rotor.

[0241] Also, one skilled in the art can easily adapt the teachings of the present application to create a rotor assembly for a transverse synchronous reluctance machine or a mover assembly for a linear synchronous reluctance machine.

Claims

1. A rotor assembly (100) for a radial synchronous reluctance machine, comprising: - an elongated body (110) having a central longitudinal axis of rotation (111), a circumference and a cross section, A cross-section of the elongated body (110) defines a width dimension and a radial dimension perpendicular to the width dimension, the cross-section of the elongated body (110) defining: at least one pair of rotor pole segments (112) arranged relative to one another around said central longitudinal axis of rotation (111) and comprising a first rotor pole segment (112) and a second rotor pole segment (112) circumferentially adjacent to one another; When viewed in a clockwise or counterclockwise direction in cross section of the elongated body (110), each rotor pole segment (112) includes a central region (1121) bounded by a first outer region (1122) and a second outer region (1123), each of the first outer region (1122) and the second outer region (1123) extending from the central region (1121), each rotor pole segment (112) being asymmetric with respect to at least a bisector (10) of a pole sector that includes the rotor pole segment (112); The rotor assembly (100), when exposed to a magnetic flux, - a free end (called first free end (1122a)) of the first external region (1122) of the first rotor pole segment (112) and a free end (called second free end (1123a)) of the second external region (1123) of the second rotor pole segment (112) face each other, the first free end (1122a) and the second free end (1123a) having no surface contact with each other or a minimum contact length (1125) extending along a radial direction, whereby a magnetic flux barrier is formed that prevents magnetic flux from flowing between the first free end (1122a) and the second free end (1123a) and thus increasing the magnetic reluctance between the first free end (1122a) and the second free end (1123a); The rotor assembly (100) is arranged as follows.

2. The rotor assembly (100) of claim 1, wherein when there is no surface contact between the first free end (1122a) and the second free end (1123a), an angular distance existing between the first free end (1122a) and the second free end (1123a) is a predetermined angular distance (1124), and the rotor assembly (100) is further positioned such that a ratio of the predetermined angular distance (1124) to a radius of the rotor assembly (100) is between 0.1% and 20%.

3. The rotor assembly (100) of claim 1, wherein when a minimum contact length (1125) exists between the first free end (1122a) and the second free end (1123a), the rotor assembly (100) is further positioned such that a ratio of the minimum contact length (1125) to a radius of the rotor assembly (100) is 10% or less.

4. A rotor assembly (100) as described in any one of claims 1 to 3, wherein for at least one rotor pole segment (112), the first external region (1122) and / or the second external region (1123) have a tapered shape that gradually narrows from the central region (1121) toward their respective free ends.

5. A rotor assembly (100) according to any one of claims 1 to 4, wherein for at least one rotor pole segment (112), the central region (1121) includes at least one inwardly facing recess (1126), the recess (1126) having a bisector (11) that is angularly offset with respect to the bisector (10) of the pole sector that includes the rotor pole segment (112).

6. 6. The rotor assembly (100) of claim 5, wherein along the radial dimension, a deepest point of the depth of the recess (1126) is referenced to the bisector (11) of the recess (1126).

7. For at least one rotor pole segment (112), an angular expansion α of the first outer region (1122) measured from a side of the recess (1126) to the first free end (1122a) 1122 is the angular expansion α of the second outer region (1123) measured from another side of the recess (1126) to the second free end (1123a). 1123 A rotor assembly (100) according to claim 5 or 6, which is different from

8. The cross section of the elongated body (110) has, for at least one rotor pole segment (112), - said first outer region (1122) has at least a first and a second outwardly arcing portion (referred to as first and second sections (1122b, 1122c)), said first section (1122b) being closer to said central region (1121) than said second section (1122c); - said second outer region (1123) has at least one outwardly arched portion (called the third section (1123b)); - said first, second and third sections (1122b, 1122c, 1123b) each have a substantially constant radius of curvature; - said first and second sections (1122b, 1122c) each have a first radius r 1 and a second radius r 2 and said second radius r 2 is the first radius r 1 Longer than - said third section (1123b) has said second radius r 2 A third radius r different from 3 The rotor assembly (100) of any one of claims 1 to 7, comprising:

9. A rotor assembly (100) as described in claim 8, wherein the first section and / or the second section and / or the third section (1122b, 1122c, 1123b) each include a cutout portion forming at least one tooth (1127), thereby locally adjusting the gap between the rotor assembly (100) and a stator to smooth torque and reduce torque ripple.

10. A rotor assembly (100) according to any one of claims 1 to 9, wherein the cross section of the elongated body (110) further includes a number of pairs of consecutive hollow frames (1128) equal to the number of pairs of rotor pole segments (112), each rotor pole segment (112) being surrounded by a respective hollow frame (1128).

11. A system assembly (200) for a radial synchronous reluctance machine, comprising: A rotor assembly (100) according to any one of claims 1 to 10, - rotor shaft (210), and a first shaft connection assembly (220) configured to connect said rotor assembly (100) to said rotor shaft (210); Including, - said first shaft connection assembly (220) comprises a cylindrical elongated body; - said rotor assembly (100) is configured to surround said first shaft connection assembly (220); - a system assembly (200) wherein the rotor shaft (210) is configured to protrude longitudinally from a distal end of the cylindrical elongate body, and rotation of the rotor shaft (210) causes simultaneous synchronous rotation of the cylindrical elongate body.

12. A system assembly (300) for a radial synchronous reluctance machine, comprising: A rotor assembly (100) according to any one of claims 1 to 10, - rotor shaft (310), and a second shaft connection assembly configured to connect said rotor assembly (100) to said rotor shaft (310), said second shaft connection assembly comprising a first flange (321), a second flange (322), and a number of longitudinal rods (323); Including, - the rotor assembly (100) is configured to be sandwiched between the first flange (321) and the second flange (322); - said longitudinal rod (323) is configured to extend through said rotor assembly (100) between said first flange (321) and said second flange (322); - A system assembly (300) configured such that the rotor shaft (310) protrudes longitudinally from distal ends of the first flange (321) and the second flange (322), and rotation of the rotor shaft (310) causes the first flange (321), the second flange (322) and the rotor assembly (100) to rotate simultaneously and synchronously.

13. 13. The system assembly (200, 300) of claim 11 or 12, further comprising at least one permanent magnet (20) disposed on top and / or bottom of at least one rotor pole segment (112) thereby cooperating with the respective rotor pole segment (112), the permanent magnet (20) having a magnetization direction and disposed such that the magnetization direction is substantially oriented toward a focal axis located in the vicinity of the q-axis.

14. A method (400) for manufacturing a rotor assembly (100) for a radial synchronous reluctance machine, comprising the steps of: - providing (410) an elongate body (110) having a central longitudinal axis of rotation (111), a circumference and a cross-section; - defining (420) a cross-section of the elongated body (110) exhibiting a width dimension and a radial dimension perpendicular to the width dimension, the cross-section including at least one pair of rotor pole segments (112) including a first rotor pole segment (112) and a second rotor pole segment (112); - positioning (430) the first and second rotor pole segments (112) circumferentially adjacent to each other relative to each other about the central longitudinal axis of rotation (111); - defining (440) each rotor pole segment (112) as comprising, when viewed in a clockwise or counterclockwise direction in a cross-section of said elongated body (110), a central region (1121) bounded by a first outer region (1122) and a second outer region (1123), said first outer region (1122) and said second outer region (1123) each extending from said central region (1121); - defining (450) each rotor pole segment (112) as asymmetric with respect to at least the bisector (10) of the pole that includes said rotor pole segment (112); - positioning (460) a free end (called first free end (1122a)) of the first external region (1122) of the first rotor pole segment (112) and a free end (called second free end (1123a)) of the second external region (1123) of the second rotor pole segment (112) facing each other; - positioning the first free end (1122a) and the second free end (1123a) such that when exposed to magnetic flux, the first free end (1122a) and the second free end (1123a) have no surface contact with each other or a minimum contact length (1125) extending along a radial direction, thereby forming a magnetic flux barrier that prevents magnetic flux from flowing between the first free end (1122a) and the second free end (1123a) and increasing magnetic reluctance between the first free end (1122a) and the second free end (1123a); The method (400).

15. A method (500) for manufacturing a rotor assembly for an axial synchronous reluctance machine, comprising the steps of: - providing (510) at least one elongated hollow cylinder having a central longitudinal axis of rotation, a circumference, an inner surface and a width, the elongated hollow cylinder being made of a ferromagnetic-based material; - providing (520) a cross-section of a rotor assembly (100) according to any one of claims 1 to 10, - projecting (530) a cross section of the rotor assembly (100) onto an inner surface of an elongated hollow cylinder, thereby forming a projected pattern on the inner surface of the elongated hollow cylinder; - extending (540) the projection pattern along a circular cross-section of the elongated hollow cylinder in a radial direction relative to the circular cross-section, thereby forming an extended projection pattern; - drilling (550) the width of said elongated hollow cylinder according to said extended projection pattern in order to extract a first rotor pole segment of an axial synchronous reluctance machine; - repeating (560) the steps of projecting (530) through drilling (550) to extract at least a second rotor pole segment for an axial synchronous reluctance machine; - disposing the first and second rotor pole segments relative to and circumferentially adjacent to one another about the central longitudinal axis of rotation (570); - positioning (580) a free end of the first external region of the first rotor pole segment (called the first free end) and a free end of the second external region of the second rotor pole segment (called the second free end) facing each other; - positioning the first free end and the second free end such that when exposed to a magnetic flux, the first free end and the second free end have no surface contact with each other or a minimum contact length extending along a radial direction, thereby forming a magnetic flux barrier that prevents magnetic flux from flowing between the first free end and the second free end and increasing the magnetic reluctance between the first free end and the second free end (590); The method (500).

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