Motors, compressors, and cooling equipment

Abstract

We propose a motor, a compressor, and a cooling device. The motor comprises a stator perforated sheet (100) and a rotor perforated sheet (200), the rotor perforated sheet (200) being rotatably mounted inside the stator perforated sheet (100), the outer annular surface of the stator perforated sheet (100) being provided with n outwardly protruding contact protrusions (110), and the rotor perforated sheet (200) being provided with 2P magnet slots (210) for mounting permanent magnets, the relationship between n and P being n=P±2.

Description

Technical Field

[0001] This application claims the priority of a Chinese patent application with the application number 202311311689.5, filed on October 10, 2023, and all of its content is incorporated herein by reference.

[0002] This application relates to the field of motor technology, and particularly to motors, compressors, and cooling devices.

Background Art

[0003] As people's pursuit of environmental comfort increases, the requirements for the noise levels of motors and electrical devices are becoming increasingly stringent.

[0004] The main source of motor vibration noise in a compressor is electromagnetic noise. Electromagnetic noise is closely related to electromagnetic excitation force, stator, and the mode of the compressor. In particular, when the electromagnetic excitation force is close to the natural vibration frequency of the motor and the compressor, it will cause system resonance and generate large high-frequency carrier noise.

Summary of the Invention

Problems to be Solved by the Invention

[0005] The main object of this application is to provide a motor, a compressor, and a cooling device aimed at reducing the high-frequency carrier noise of the motor.

Means for Solving the Problems

[0006] To achieve the above object, this application presents a motor, which includes a stator punching sheet and a rotor punching sheet. The rotor punching sheet is rotatably provided inside the stator punching sheet. On the outer annular surface of the stator punching sheet, n contact convex portions protruding outward are provided. On the rotor punching sheet, 2P magnet slots for attaching permanent magnets are provided, and the relationship between n and P is n = P ± 2.

[0007] In one embodiment, the stator punching sheet includes an annular stator yoke and a plurality of stator teeth provided on the inner annular surface of the stator yoke, wherein the plurality of stator teeth are spaced apart along the circumferential direction of the annular stator yoke to form stator lots between any two adjacent stator teeth, the number of stator lots is Q, the width of the stator teeth is W, and the arc length of the contact protrusion is L, with the range of L being 2P+4(Q / W)≦L≦2P+6(Q / W).

[0008] In one embodiment, the number of status lots is Q=15, and the number of magnet slots is 2P=10.

[0009] In one embodiment, the height of the protrusion of the contact protrusion is h, and the range of h is 0.5 mm ≤ h ≤ 1 mm.

[0010] In one embodiment, the arc length of the contact protrusion gradually decreases in the direction away from the outer annular surface of the stator punching sheet.

[0011] In one embodiment, the contact protrusions are installed at equal intervals.

[0012] In one embodiment, the contact protrusion and the stator punching sheet are integrally molded.

[0013] In one embodiment, the magnet slot is configured as a V-shaped slot, a U-shaped slot, a W-shaped slot, a straight-line slot, or an I-shaped slot.

[0014] In one embodiment, the material of the stator punching sheet and / or the rotor punching sheet is configured as a soft magnetic material.

[0015] In one embodiment, the thickness of the stator punching sheet and / or the rotor punching sheet is d, and the range of d is 0.2 mm ≤ d ≤ 0.35 mm.

[0016] This application further provides a compressor including the above-mentioned motor.

[0017] This application further provides a cooling device including the above-mentioned compressor. [Brief explanation of the drawing]

[0018] To more clearly illustrate the embodiments of this application or the technical solutions of the prior art, the following drawings, which may be used in the description of the embodiments or the prior art, are briefly introduced below. Clearly, the drawings described below represent only a few embodiments of this application, and further drawings can be obtained based on the structures shown in these drawings, assuming that a person skilled in the art does not require any creative work.

[0019] [Figure 1] This is a schematic diagram of the structure of one embodiment of the stator housing, stator punching sheet, and rotor punching sheet of the motor according to this application. [Figure 2] This is a schematic diagram illustrating the structure of the stator punching sheet and rotor punching sheet of the motor according to this application. [Figure 3] This is a comparative diagram of a 60rps high-frequency carrier test of the motor described in this application and a conventional motor. [Figure 4] This is a comparative diagram of a 90rps high-frequency carrier test of the motor described in this application and a prior art motor. [Modes for carrying out the invention]

[0020] The achievement of the objectives of this application, its functional features, and advantages will be further described with reference to the drawings, along with the examples provided.

[0021] The technical solutions of the embodiments of this application are described clearly and completely below, together with the drawings of the embodiments of this application. Clearly, the embodiments described are only a selection of embodiments of this application, not all embodiments. All other embodiments obtained by a person skilled in the art without any creative work based on the embodiments of this application are within the scope of protection of this application.

[0022] In addition, all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship, movement status, etc. between various components in a specific posture (as shown in the drawings). When the specific posture changes, the directional indications will also change accordingly.

[0023] In this application, unless specifically specified or limited otherwise, the terms "connection" and "fixation" should be understood in a broad sense. For example, "fixation" may be a fixed connection, a detachable connection, or an integral connection, a mechanical connection, an electrical connection, a direct connection, or an indirect connection through an intermediate medium, an internal communication between two elements, or an interaction between two elements, unless specifically limited otherwise. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific situation.

[0024] Also, in the embodiments of this application, if there are descriptions related to "first", "second", etc., the descriptions such as "first", "second", etc. are only for the purpose of description and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, the features limited by "first" and "second" can explicitly or implicitly include at least one such feature. Also, "and / or" appearing throughout the specification includes three parallel schemes. Taking "A and / or B" as an example, it means including scheme A, or scheme B, or a scheme where A and B are satisfied simultaneously. Also, the technical solutions between the embodiments can be combined with each other, but it must be based on what those skilled in the art can achieve. If contradictions occur or it cannot be achieved in the combination of technical solutions, such a combination of technical solutions does not exist and should not be considered within the protection scope required by this application.

[0025] This application proposes a motor.

[0026] Referring to Figures 1 to 4, in one embodiment of the present application, the motor comprises a stator punching sheet 100 and a rotor punching sheet 200, the rotor punching sheet 200 being rotatably mounted inside the stator punching sheet 100, the outer annular surface of the stator punching sheet 100 being provided with n outwardly projecting contact protrusions 110, the rotor punching sheet 200 being provided with 2P magnet slots 210 for mounting permanent magnets, and the relationship between n and P being n = P ± 2.

[0027] In one embodiment, the contact protrusions 110 contact the stator housing 300, thereby improving the overall rigidity of the stator housing 300 and stator core after shrink-fitting. Furthermore, the appropriate fitting area improves motor efficiency and ensures a reliable holding force between the stator and stator housing 300 in the compressor, thereby reducing compressor vibration. Moreover, this solution limits the number of contact protrusions 110 to P±2, improving the stator's natural frequency. This avoids resonance caused by the motor and compressor's natural frequencies being close to the electromagnetic excitation frequency, thus reducing high-frequency carrier noise and further improving the performance of the motor and compressor.

[0028] Furthermore, in this embodiment, the stator core and the stator housing 300 can be assembled by shrink-fitting, which is a method that utilizes the principle of thermal expansion and contraction to achieve the purpose of interference fit. Specifically, the temperature of the stator core itself is maintained at room temperature, then the stator housing 300 is heated to expand it and increase the diameter of the stator housing 300, then the stator core is assembled into the stator housing 300, and then the temperature of the stator housing 300 is lowered to return it to room temperature. During the temperature decrease process, the diameter of the stator housing 300 continues to decrease and tighten until the inner wall of the stator housing 300 contacts the contact protrusion 110, thereby fixing the stator core inside the stator housing 300.

[0029] In one embodiment, the stator punching sheet 100 includes an annular stator yoke 120 and a plurality of stator teeth 130 provided on the inner annular surface of the stator yoke 120, wherein the plurality of stator teeth 130 are spaced apart along the circumference of the annular stator yoke 120, thereby forming a stator lot 140 between any two adjacent stator teeth 130, where Q is the number of the stator lot 140, W is the width of the stator teeth 130, and L is the arc length of the contact protrusion 110, with the range of L being 2P+4(Q / W)≦L≦2P+6(Q / W). The contact protrusion 110 corresponds to the order of forces generated by the stator and rotor, improving the rigidity of the stator, improving the natural frequency of the stator, and reducing high-frequency noise. Furthermore, if the length of the arc segments of the stator punching sheet 100 and the contact protrusion 110 meets the requirements for laser welding of the stator, the flow path area of ​​the compressor can be increased.

[0030] It is important to note that the unit of the width W of the stator teeth 130 is mm, and the unit of the arc length L of the contact protrusion 110 is mm.

[0031] In one embodiment, the conductor is wound around the stator teeth 130 along the axial direction to form a winding. The conductor may be an enameled wire such as acetal enameled wire, polyester enameled wire, polyurethane enameled wire, modified polyester enameled wire, or polyesterimide enameled wire. Enameled wire is the main type of winding and consists of a conductor and an insulating layer. Bare wire is softened by annealing and then formed by multiple coatings and firings, and has four main properties: mechanical properties, chemical properties, electrical properties, and thermal properties. Among these, the most widely used is polyesterimide / polyamideimide composite layer enameled wire, which has high heat resistance, excellent resistance to freezing, extreme cold, and radiation, high mechanical strength, stable electrical properties, excellent chemical resistance and refrigerant resistance, and strong overload capacity. Therefore, it is widely used in refrigerator compressors, air conditioner compressors, power tools, explosion-proof motors, and motors and electrical equipment used under conditions of high temperature, extreme cold, radiation resistance, and overload.

[0032] In one embodiment, each stator tooth 130 includes a first tooth shoe and a second tooth shoe, both of which extend along the circumferential direction of an annular stator yoke 120, with the first tooth shoe positioned on the first side of the centerline of the stator tooth 130 and the second tooth shoe positioned on the second side of the centerline. The installation of the first and second tooth shoes prevents the windings from gradually moving toward the rotor core due to the magnetic force generated during motor operation, and prevents the windings from detaching from the stator teeth 130, thereby improving the operational stability of the windings and extending the service life of the motor.

[0033] In one embodiment, the first tooth shoe of one of two adjacent stator teeth 130 does not contact the second tooth shoe of the other stator tooth 130. That is, the stator rod 140 formed between the two adjacent stator teeth 130 has one notch, and this notch also opens to the rotor opening, i.e., the gap between the adjacent first tooth shoe and second tooth shoe. If the notch of the stator rod 140 is too small, it may cause difficulties when winding the wire. At the same time, all four corners of the stator rod 140 are set in an arc shape. This setting ensures the mechanical strength of the connection end between the stator teeth 130 and the stator yoke 120, while also improving the slot area utilization rate of the stator rod 140.

[0034] In one embodiment, the tooth tips of the stator teeth 130 include an inwardly curved arc portion, that is, one end of the stator teeth 130 that is separated from the stator yoke 120 includes an inwardly curved arc portion, and in this solution, "inward" refers to the direction toward the center of the stator punching sheet 100.

[0035] In one embodiment, the radii of the arc portions of multiple stator teeth 130 are the same and concentric with the center of the stator punching sheet 100. By doing so, when injection molding the stator, the outer diameter of the inner mold can be set to match the radius of the arc portion, thereby enabling the inner mold to be positioned on the arc portion for injection molding.

[0036] In one embodiment, the bottom of the stator rod 140 is set in the shape of an arc, and this arc overlaps with the inner circumference of the stator yoke 120. This setting is beneficial for the magnetic force distribution during motor operation.

[0037] In one embodiment, the first and second tooth shoes are positioned symmetrically with respect to the center line of the stator teeth 130, which facilitates manufacturing. The purpose of adopting a symmetrical structure for the stator teeth 130 is twofold: (1) to meet the need for bidirectional rotation of the motor, and (2) to avoid the generation of excessive magnetic field harmonics. Of course, the arrangement is not limited to symmetrical configuration.

[0038] In one embodiment, the number of status lots 140 is Q=15 and the number of magnet slots 210 is 2P=10. By limiting the number of status lots 140 to 15 and the number of magnet slots 210 to 10, the manufacturing cost of the motor can be reduced and the cost performance of the motor can be improved.

[0039] Furthermore, if the number of status rods 140 is Q=15, the noise reduction effect can be further enhanced and the compressor performance can be improved. This is advantageous in reducing the additional air gap and improving motor performance by improving the structure of status rods 140, while meeting the needs of using a multi-slot stator core.

[0040] In one embodiment, the height of the contact projection 110 is h, and the range of h is 0.5 mm ≤ h ≤ 1 mm. This ensures a reliable holding force between the stator and the stator housing 300, thereby reducing compressor vibration. If h < 0.5 mm, the contact projection 110 cannot contact the stator housing 300, causing the stator and stator housing 300 to vibrate and generating further noise. If h > 1 mm, the contact projection 110 abuts excessively against the stator housing 300, causing the stator housing 300 to deform, and consequently making it impossible to attach the stator core to the stator housing 300.

[0041] In one embodiment, the arc length of the contact projection 110 gradually decreases in the direction away from the outer annular surface of the stator punching sheet 100, and such a setting facilitates transitions. Of course, this application is not limited thereto. In other embodiments, the arc length of the contact projection 110 does not have to change in the direction away from the outer annular surface of the stator punching sheet 100.

[0042] In one embodiment, the contact protrusions 110 are installed at equal intervals, which allows the stator core to contact the stator housing 300 in all directions. This improves the overall rigidity of the stator housing 300 and stator core after shrink-fitting, and improves the natural frequency of the stator.

[0043] In one embodiment, the contact protrusion 110 is integrally molded with the stator punching sheet 100. This integrally formed structure is easy to process and manufacture, and also has high overall structural strength and uniformity. Of course, this application is not limited to this. In other embodiments, the contact protrusion 110 can also be formed by welding to the stator punching sheet 100.

[0044] In one embodiment, the stator punching sheet 100 has a one-piece structure, which increases the structural strength of the stator punching sheet 100. In another embodiment, the stator punching sheet 100 has a block structure. A block structure involves dividing the stator punching sheet 100 into multiple substructures, processing each substructure, and then assembling them. In one embodiment, each substructure includes stator teeth 130 and some stator yokes 120, and after processing each substructure into individual stator teeth 130, they can be assembled together. These two structures each have their own advantages and can be selected according to the actual needs.

[0045] In one embodiment, the magnet slot 210 is configured as a V-shaped slot, a U-shaped slot, a W-shaped slot, a straight-line slot, or an I-shaped slot.

[0046] Furthermore, in this embodiment, the magnet slots 210 are installed as "single" shaped magnet slots 210, because the structure of the "single" shaped magnet slots 210 is simple, the process cost is low, and it is easy to reduce the manufacturing cost of the device core.

[0047] In one embodiment, the magnet slots 210 are arranged in a V-shape. By installing the V-shaped magnet slots 210 in the rotor punching sheet 200 and optimizing the angular parameters of the V-shaped magnet slots 210, the amount of permanent magnets embedded in the rotor punching sheet 200 proposed in this application is significantly increased compared to the prior art. The V-shaped magnet slots 210 can increase the amount of permanent magnets embedded, thereby increasing the torque density of the motor and effectively improving the motor's back electromotive force and motor efficiency. This V-shaped magnet slot structure allows for a significant increase in the amount of permanent magnets embedded, thereby increasing the motor's torque density and meeting the requirements for higher efficiency and miniaturization of the motor.

[0048] In other embodiments, the magnet slot 210 may be configured as a U-shaped slot, a W-shaped slot, or an I-shaped slot, which can be selected based on the actual needs when implementing the invention.

[0049] One point that needs to be explained is that different shaped magnet slots 210 can be installed to suit different needs; that is, the shapes of the magnet slots 210 on the same rotor core may be the same or different.

[0050] Furthermore, the structure of the magnet slot 210 is symmetrical along the pole centerline of the rotor core magnetic pole, which can be implemented as a preferred solution in the embodiments of this application.

[0051] In one embodiment, the mass percentage of heavy rare earth elements in the permanent magnet is 0, meaning the permanent magnet does not contain heavy rare earth elements, thereby reducing the consumption of strategic resources, being advantageous for the sustainable development of resources, and reducing the manufacturing cost of the motor, making it suitable for widespread use and application. As can be understood, the mass percentage of heavy rare earth elements in the permanent magnet may be other values, for example, 0.005%, 0.01%, 0.025%, etc. Heavy rare earth elements may also include other elements that can be components of the permanent magnet.

[0052] In one embodiment, a neodymium-iron-boron permanent magnet, which has excellent magnetic properties and meets the motor's usage needs, can be used as the material for the permanent magnet. As can be understood, the permanent magnet may be any other permanent magnet that meets the requirements.

[0053] In one embodiment, the material of the stator punching sheet 100 and / or the rotor punching sheet 200 is configured as a soft magnetic material, which can achieve a large magnetization strength with a small external magnetic field, and has low coercivity and high permeability, which is advantageous in reducing losses in the rotor core and stator core, i.e., reducing iron loss in the motor, and further advantageous in improving the performance of the motor.

[0054] In one embodiment, the stator punching sheet 100 and / or the rotor punching sheet 200 are formed from silicon steel, and the silicon content of the silicon steel is 1.0 to 4.5%. Any silicon alloy steel with a carbon content of less than 0.08% can be called silicon steel. Because silicon steel has the characteristics of high permeability, low coercivity, and high resistivity, hysteresis loss and eddy current loss are small. The low iron loss of silicon steel can save a large amount of electrical energy and extend the operating time of the motor and transformer. Furthermore, the high magnetic inductance of silicon steel can reduce the excitation current and save electrical energy. The high magnetic inductance of silicon steel can increase the maximum magnetic inductance when designing the stator core and rotor core, while simultaneously reducing the volume of the stator core and rotor core, reducing the weight of the stator core and rotor core, saving silicon steel, conductors, insulating materials, and structural materials, etc. This not only reduces motor losses and manufacturing costs but also makes assembly and transportation easier. Of course, this application is not limited thereto. In some other embodiments, the stator punching sheet 100 and / or the rotor punching sheet 200 may be made of neodymium iron boron, ferrite, or other permanent magnet material.

[0055] In one embodiment, the stator teeth 130 are made of grain-oriented electrical steel sheet material, and the stator yoke 120 is made of non-grain-oriented electrical steel sheet material. Non-grain-oriented electrical steel sheet material is less expensive, while grain-oriented electrical steel sheet material has lower iron loss and superior magnetic induction properties. This configuration avoids the need to replace the entire stator punching sheet 100 with grain-oriented electrical steel sheet material, allowing only the stator teeth 130 to be replaced with grain-oriented electrical steel sheet material. This is advantageous for cost reduction, and also allows for improved magnetic permeability of the teeth portion of the stator core by utilizing the superior magnetic orientation of grain-oriented electrical steel sheet material, thereby reducing iron loss in the teeth portion and improving motor efficiency.

[0056] In one embodiment, the rotor punching sheet 200 and the stator punching sheet 100 may be made of different materials or have different shapes, thereby meeting the needs of different processing processes for the stator and rotor. Selecting an appropriate punching sheet according to the motor's performance requirements is advantageous for forming the rotor core and stator core, further ensuring good motor performance and simultaneously expanding the motor's range of application. Of course, this application is not limited thereto. In some other embodiments, the stator punching sheet 100 laminated on the stator core and the rotor punching sheet 200 laminated on the rotor core are made of the same material, which is advantageous for mass production of punching sheets and thereby reduces manufacturing costs.

[0057] In one embodiment, the thickness of the stator punching sheet 100 and / or the rotor punching sheet 200 is d, and the range of d is 0.2 mm ≤ d ≤ 0.35 mm. This allows the rotor and stator to cooperate with each other to generate a sufficient induced current for user use, avoids the occurrence of large eddy current damage due to the stator punching sheet 100 and rotor punching sheet 200 being too thick, extends the service life of the motor, and, while satisfying functional requirements, limits the thickness of the rotor punching sheet 200 and stator punching sheet 100, thereby avoiding the use of unnecessary product materials, reducing manufacturing costs, reducing product weight, and improving the user experience.

[0058] This application further proposes a compressor equipped with a motor, the specific structure of which is described in the above embodiments, and since this compressor employs all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, but a detailed explanation is omitted here.

[0059] This application further proposes a cooling device equipped with a compressor, the specific structure of which is described in the above embodiments, and since this cooling device employs all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, but a detailed explanation is omitted here.

[0060] The above description is merely an example of an optional embodiment of this application and does not limit the scope of the patent provided herein. All equivalent structural transformations based on the inventive concept of this application, performed using the specifications and drawings of this application, or applied directly or indirectly in other related technical fields, are included within the scope of the patent protection of this application. [Explanation of symbols]

[0061] 100 Stator Punching Sheet 110 Contact protrusion 120 Stater York 130 stator teeth 140 Status Lots 200 Rotor Punching Sheets 210 magnetic slots 300 Stator Housing

Claims

1. A motor comprising a stator perforated sheet and a rotor perforated sheet, wherein the rotor perforated sheet is rotatably mounted inside the stator perforated sheet, the outer annular surface of the stator perforated sheet is provided with n outwardly projecting contact protrusions, the rotor perforated sheet is provided with 2P magnet slots for mounting permanent magnets, and the relationship between n and P is n = P ± 2.

2. The motor according to claim 1, wherein the stator punching sheet includes an annular stator yoke and a plurality of stator teeth provided on the inner annular surface of the stator yoke, the plurality of stator teeth are spaced apart along the circumferential direction of the annular stator yoke to form stator lots between any two adjacent stator teeth, the number of stator lots is Q, the width of the stator teeth is W, the arc length of the contact protrusions is L, and the range of the value of L is 2P + 4 (Q / W) ≤ L ≤ 2P + 6 (Q / W).

3. The motor according to claim 2, wherein the number of status slots is Q = 15 and the number of magnet slots is 2P = 10.

4. The motor according to any one of claims 1 to 3, wherein the height of the projection of the contact protrusion is h, and the range of h is 0.5 mm ≤ h ≤ 1 mm.

5. The motor according to any one of claims 1 to 4, wherein the arc length of the contact protrusion gradually decreases in the direction away from the outer annular surface of the stator punching sheet.

6. The motor according to any one of claims 1 to 5, wherein the contact protrusions are installed at equal intervals.

7. The motor according to any one of claims 1 to 6, wherein the contact protrusion and the stator punching sheet are integrally molded.

8. The motor according to any one of claims 1 to 7, wherein the magnet slot is configured as a V-shaped slot, a U-shaped slot, a W-shaped slot, a straight-line slot, or an I-shaped slot.

9. The motor according to any one of claims 1 to 8, wherein the material of the stator punching sheet and / or the rotor punching sheet is configured as a soft magnetic material.

10. The motor according to any one of claims 1 to 9, wherein the thickness of the stator punching sheet and / or the rotor punching sheet is d, and the range of d is 0.2 mm ≤ d ≤ 0.35 mm.

11. A compressor including the motor according to any one of claims 1 to 10.

12. A cooling device including the compressor described in claim 11.

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