Rotor assembly, permanent magnet synchronous motor, electric compressor, air conditioning system and vehicle

Abstract

The present application relates to a rotor assembly, a permanent magnet synchronous motor, an electric compressor, an air conditioning system, and a vehicle. The rotor assembly includes a rotor body and a rotor rivet, the rotor body includes a rotor core, both ends of the rotor core are provided with end plates, and at least one of the end plates is provided with a balance weight, the rotor rivet fixes the rotor body together, the rotor rivet includes a rod portion, and a head portion and a crimp portion located at both ends of the rod portion, and the at least one balance weight is a first balance weight having a rivet hole, and the rivet hole includes a first hole section for fitting into the rod portion and a second hole section for fitting into the crimp portion.

Description

[Technical Field]

[0001] This application is based on the Chinese patent application filed on May 31, 2022, with application number 202210615605.6, the Chinese patent application filed on May 31, 2022, with application number 202221359939.3, the Chinese patent application filed on May 31, 2022, with application number 202210629322.7, and the Chinese patent application filed on May 31, 2022, with application number 202221359709.7, and claims priority from the above Chinese patent applications, the entire contents of which are incorporated herein by reference.

[0002] The present application relates to the technical field of manufacturing motor devices, and more particularly to rotor assemblies, permanent magnet synchronous motors, electric compressors, air conditioning systems, and vehicles. [Background technology]

[0003] As is well known, permanent magnet synchronous motors have a simple structure, high efficiency, and high motor power density, making them widely used in the field of electric compressors. When electric compressors are installed in vehicles, especially four-wheel drive or hybrid vehicles, the compressor's vibration and shock resistance is relatively high, typically between 10g and 50g, where g is the standard gravitational acceleration. During operation, the rotor temperature varies over a wide range, causing each rotor component to expand and contract. The balance weight, end plate, crimping pin, and rotor core are made of different materials, and their thermal expansion coefficients do not match. As a result, a fastening structure formed at room temperature may develop minute gaps at critical temperatures. When gaps occur, the high-intensity vibration shock and residual stress can cause the burring portion of the crimping pin to fail and eventually break, resulting in rotor destruction and compressor failure, leaving room for improvement. Summary of the Invention [Problem to be solved by the invention]

[0004] The present disclosure aims to solve at least one of the technical problems in the related art to some extent, and therefore, a first objective of the present disclosure is to propose a rotor assembly that improves the crimping process by optimizing the fitting structure between the rotor rivet and the balance weight, thereby maximizing the structural stability of the rotor assembly and increasing the reliability of the electric compressor. [Means for solving the problem]

[0005] A rotor assembly according to an embodiment of the present application includes a rotor body and a rotor rivet, the rotor body including a rotor core, end plates, and balance weights, a permanent magnet is fitted in the rotor core, the end plates are provided at both axial ends of the rotor core, and the balance weight is provided on the side of at least one of the end plates away from the rotor core, and the rotor rivet is axially oriented to fasten the rotor body together. The rotor rivet is installed through the body, and the rotor rivet includes a rod portion, a head, and a crimped portion, the head and the crimped portion being located at both ends of the longitudinal direction of the rod portion, and at least one of the balance weights is a first balance weight having a rivet hole, the rivet hole including a first hole section for fitting onto the rod portion and a second hole section for fitting onto the crimped portion, the second hole section being enlarged relative to the first hole section, and at least a portion of the crimped portion being filled within the second hole section.

[0006] In a rotor assembly according to some embodiments of the present application, the cross-sectional area of ​​the second perforated section gradually increases in a direction away from the first perforated section.

[0007] In a rotor assembly according to some embodiments of the present application, the second hole section is filled with the crimped portion.

[0008] According to some embodiments of the rotor assembly of the present application, the crimped portion includes a sunken portion located within the second hole section and an exposed portion located outside the second hole section so as to protrude from the surface of the first balance weight.

[0009] In a rotor assembly according to some embodiments of the present application, the diameter of the rod portion is D, the maximum diameter of the crimped portion is D0, and 1.2D≦D0≦2D.

[0010] In the rotor assembly according to some embodiments of the present application, the hardness of the rotor rivet satisfies HRB50 to HRB200.

[0011] In a rotor assembly according to some embodiments of the present application, the crimped portion has a solid structure without holes, and the tensile strength τ of the rotor rivet is 0.2·τ≦M·r·π·(n / D) 2 / 225≦0.7·τ, r is the distance between the central axis of the rod portion and the central axis of the rotor core, M is the mass of the balance weight, n is the maximum rotation speed of the rotor assembly, and D is the diameter of the rod portion.

[0012] According to some embodiments of the rotor assembly of the present application, the number of magnetic poles of the rotor body is A, the number of rotor rivets is B, and B≦A−2.

[0013] According to a rotor assembly according to some embodiments of the present application, the rotor rivet is provided at a position between two adjacent magnetic poles of the rotor body.

[0014] According to some embodiments of the rotor assembly of the present application, there are multiple rotor rivets, which are spaced apart along the circumferential direction of the rotor core, and the crimped portions of each rotor rivet are all located on the same axial side of the rotor core.

[0015] According to some embodiments of the rotor assembly of the present application, the outer radius of the rotor core is R, and <r / R<0.9である。

[0016] In a rotor assembly according to some embodiments of the present application, the diameter D of the rod portion has a value ranging from 3 mm to 6 mm.

[0017] In a rotor assembly according to some embodiments of the present application, the balance weights are located on both sides of the rotor body, and if the two balance weights have different masses, the mass of the heavier of the two balance weights is M.

[0018] According to a rotor assembly according to some embodiments of the present application, at least one of the balance weights is a third balance weight, the third balance weight is provided with the crimped portion, and the radial width W of the third balance weight is greater than 2D.

[0019] In a rotor assembly according to some embodiments of the present application, the thickness of the end plate interposed between the balance weight provided with the crimped portion and the rotor core is 0.8 mm or more.

[0020] In a rotor assembly according to some embodiments of the present application, the volume of the crimped portion is equal to or larger than the volume of the head portion, and / or the diameter of the crimped portion is equal to or larger than the diameter of the head portion.

[0021] The present application also proposes a permanent magnet synchronous motor.

[0022] A permanent magnet synchronous motor according to an embodiment of the present application includes a stator assembly and a rotor assembly rotatable relative to the stator assembly, the rotor assembly being the rotor assembly described in any one of the above embodiments.

[0023] The present application also proposes an electric compressor.

[0024] An electric compressor according to an embodiment of the present application includes a compression member and a drive member that drives the compression member so that the compression member performs a compression operation, and the drive member includes the permanent magnet synchronous motor described in the above embodiment.

[0025] The present application also proposes an air conditioning system.

[0026] An air conditioning system according to an embodiment of the present application includes the electric compressor described in the above embodiment.

[0027] The present application also proposes a vehicle.

[0028] A vehicle according to an embodiment of the present application includes a vehicle body and an air conditioning system mounted on the vehicle body, and the air conditioning system is the air conditioning system described in the above embodiment. [Effects of the Invention]

[0029] The vehicle, the air conditioning system, the electric compressor, the permanent magnet synchronous motor and the rotor assembly described above have the same advantages over the prior art, and therefore will not be described here.

[0030] Additional aspects and advantages of the present disclosure will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the present disclosure. [Brief explanation of the drawings]

[0031] [Figure 1] 1 is a schematic diagram illustrating a structure of a rotor assembly according to an embodiment of the present application. [Figure 2] FIG. 2 is a plan view of a rotor assembly according to an embodiment of the present application. [Figure 3] FIG. 3 is a cross-sectional view taken along line AA in FIG. 2. [Figure 4] FIG. 4 is an enlarged view of a portion B in FIG. 3. [Figure 5] FIG. 2 is a schematic diagram showing the structure of a rotor rivet according to some embodiments of the present application before crimping. [Figure 6]FIG. 2 is a schematic diagram showing the structure of a rotor rivet according to an embodiment of the present application after crimping. [Figure 7] FIG. 2 is a schematic diagram showing the structure of a rotor rivet according to an embodiment of the present application after crimping. [Figure 8] 10 is a schematic diagram (in another state) showing the structure of the rotor rivet according to the embodiment of the present application after crimping. FIG. [Figure 9] 1 is a schematic diagram illustrating a structure of an electric compressor according to an embodiment of the present application. [Figure 10] 1 is a schematic diagram illustrating a structure of a vehicle according to some embodiments of the present application. [Figure 11] 1 is a cross-sectional view of a rotor assembly according to some embodiments of the present application. [Figure 12] 1 is a schematic diagram illustrating a structure of a rotor core according to some embodiments of the present application. [Figure 13] 1 is a cross-sectional view of a rotor assembly according to some embodiments of the present application. [Figure 14] FIG. 2 is a schematic diagram of a rotor rivet before processing according to some embodiments of the present application. [Figure 15] 1 is a schematic diagram of a rotor rivet after processing according to some embodiments of the present application. FIG. [Figure 16] FIG. 1 is a plan view of a balance weight according to some embodiments of the present application. [Figure 17] FIG. 2 is a plan view of an end plate according to some embodiments of the present application. [Figure 18] FIG. 2 is a schematic diagram showing optimal positions of crimping points of a rotor core according to some embodiments of the present application. [Figure 19] 1 is a schematic diagram showing the positions of balance weights and rotor cores according to some embodiments of the present application (when r / R is less than 0.5). FIG. [Figure 20] 1 is a schematic diagram showing the positions of balance weights and rotor cores according to some embodiments of the present application (when r / R is close to 0.7); [Figure 21] 1 is a schematic diagram showing the positions of balance weights and rotor cores according to some embodiments of the present application (when r / R is greater than 0.7); [Figure 22]FIG. 2 is a schematic diagram showing the change in height and cross-sectional area of ​​a balance weight with respect to the r / R ratio according to some examples of the present application. [Figure 23] FIG. 10 is a schematic diagram showing changes in direct-axis inductance Ld and cross-axis inductance Lq relative to the caulking pin diameter of a rotor assembly according to some embodiments of the present application. [Figure 24] 1 is a schematic diagram showing the distribution of magnetic lines of force in a rotor assembly according to some embodiments of the present application (rivet hole diameter: 4.2 mm). [Figure 25] 1 is a schematic diagram showing the distribution of magnetic lines of force in a rotor assembly according to some embodiments of the present application (rivet hole diameter: 5.2 mm). [Figure 26] FIG. 1 is a schematic diagram showing the distribution of magnetic lines of force in a rotor assembly according to some embodiments of the present application (rivet hole diameter: 6 mm). DETAILED DESCRIPTION OF THE INVENTION

[0032] Hereinafter, the embodiments of the present disclosure will be described in detail. The above-mentioned examples are shown in the accompanying drawings, and the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are examples for interpreting the present disclosure, and should not be understood as limiting the present disclosure.

[0033] Hereinafter, rotor assemblies 1 according to several embodiments of the present invention will be described with reference to the accompanying drawings.

[0034] 1 and 9, a rotor assembly 1 according to an embodiment of the present application includes a rotor body 11 and a rotor rivet 12. Here, the rotor assembly 1 is used for attachment and fitting with the stator assembly so that, when the permanent magnet synchronous motor is energized and operating, the rotor assembly 1 can rotate relative to the stator assembly, thereby outputting driving force to compress air or perform other types of driving functions.

[0035] 1 to 3, rotor body 11 includes rotor core 111, end plates 112, and balance weights 113, with permanent magnets fitted within rotor core 111. If rotor core 111 has magnet grooves, the permanent magnets can be fitted into the magnet grooves to securely attach and fix rotor core 111. Furthermore, during actual installation, rotor core 111 is mounted within the stator assembly and is fitted around drive shaft 2 of electric compressor 100. Therefore, when electric compressor 100 is in operation, the windings of the stator assembly are energized, and the generated magnetic field acts on the permanent magnets to rotate rotor core 111, which in turn moves drive shaft 2 and outputs driving force.

[0036] An end plate 112 is provided at each axial end of the rotor core 111, i.e., two end plates 112 are provided, and the two end plates 112 are respectively provided at both ends of the rotor core 111 so as to be in close contact with the end faces of the rotor core 111, and a balance weight 113 is provided on the side of at least one of the end plates 112 away from the rotor core 111. That is, as shown in Fig. 3, a balance weight 113 may be provided corresponding to one end plate 112, or balance weights 113 may be provided on both sides of both end plates 112 facing back to back, and the number of balance weights 113 can be flexibly set according to actual needs.

[0037] The rotor rivets 12 penetrate the rotor body 11 in the axial direction to secure the rotor body 11 as a whole. The rotor core 111, end plates 112, and balance weights 113 are provided with hollow hole structures that allow the rotor rivets 12 to pass through the rotor core 111, end plates 112, and balance weights 113 simultaneously, thereby connecting the various parts of the rotor body 11 into a single whole and ensuring that the rotor core 111, end plates 112, and balance weights 113 are fixed relative to each other in the axial direction of the rotor body 11. This prevents the end plates 112 and balance weights 113 from moving away from the rotor core 111 while the rotor core 111 is rotating, improving the structural stability of the rotor body 11.

[0038] 6 to 8, the rotor rivet 12 includes a rod portion 121, a head portion 122, and a crimped portion 123, and the head portion 122 and the crimped portion 123 are located at both ends of the rod portion 121 in the longitudinal direction. As shown in FIGS. 6 to 8, the head portion 122 is connected to the upper end of the rod portion 121, and the crimped portion 123 is connected to the lower end of the rod portion 121. The rotor rivet 12 includes the head portion 122 and the rod portion 121 during initial molding, and after the rotor rivet 12 is crimped to the rotor body 11, the crimped portion 123 is processed in a crimping process, so that the head portion 122 and the crimped portion 123 serve to limit the position at both ends of the rotor body 11, and ultimately realize the axial positional restriction of each component of the rotor body 11.

[0039] At least one balance weight 113 is a first balance weight having a rivet hole a, and the rivet hole a includes a first hole section 1131 for fitting into the rod portion 121 and a second hole section 1132 for fitting into the crimped portion 123, the second hole section 1132 having an expanded hole shape relative to the first hole section 1131, and at least a portion of the crimped portion 123 being filled within the second hole section 1132.

[0040] Specifically, the rotor body 11 in the present application may have one or two balance weights 113, as shown in Fig. 3. Here, when one balance weight 113 is provided, this balance weight 113 may be the first balance weight, and when two balance weights 113 are provided, one or both of the balance weights 113 may be set as the first balance weight.

[0041] For example, if two balance weights 113 are provided and positioned on both axial sides of the rotor body 11, and if the crimping direction of all rotor rivets 12 is the same, all crimped portions 123 may be positioned on the same axial side of the rotor body 11, and all heads 122 may be positioned on the other axial side of the rotor body 11.In this case, if the balance weight 113 on the shaft side where the crimped portion 123 is provided is designated as the first balance weight, and the balance weight 113 on the shaft side where the head 122 is provided is designated as the second weight, the second balance weight may also have rivet holes, but the shape of the rivet holes in the second balance weight may be different from the shape of the rivet holes in the first balance weight.

[0042] For example, the rivet holes in the second balance weight do not need to include a reamed hole section, and multiple rotor rivets 12 are inserted through the rivet holes in the second balance weight, with some of the rod portions 121 of these rotor rivets 12 positioned within the rivet holes in the second balance weight, and the heads 122 of these rotor rivets 12 engaged with the outer end surface of the second balance weight.

[0043] Of course, the present application is not limited to this, and if two balance weights 113 are provided on both axial sides of the rotor body 11, and all of the rotor rivets 12 have different directions, and the crimping portions 123 corresponding to the rotor rivets 12 are crimped to each balance weight 113, both of the two balance weights 113 may be the first balance weight.

[0044] Here, since the first balance weight has two structural hole sections, the rod portion 121 can be inserted through the first hole section 1131 and the second hole section 1132 during installation and crimping. Furthermore, during the crimping process, pressure can be applied to the end of the rod portion 121 away from the head 122 to form the crimped portion 123, and at least a portion of the crimped portion 123 can be positioned within the second hole section 1132. Here, the second hole section 1132 has an enlarged hole configuration relative to the first hole section 1131, and the inner diameter of the second hole section 1132 is made larger than the inner diameter of the first hole section 1131. Thus, when the portion of the crimping portion 123 located within the second hole section 1132 is fitted into the second hole section 1132, the diameter of the fitting surface between the crimping portion 123 and the second hole section 1132 is made larger than the fitting diameter between the first hole section 1131 and the rod portion 121, thereby increasing the fitting surface between the crimping section and the second hole section 1132 and thereby improving the connection stability between the rotor rivet 12 and the rotor body 11. Here, because the crimping portion 123 and the rod portion 121 are formed from the same material, there is no need to process and mold them from different materials, which is advantageous for reducing processing steps, reducing processing costs, and mass production.

[0045] Furthermore, by positioning at least a portion of the crimping portion 123 within the second hole section 1132, the connection portion between the crimping portion 123 and the rod portion 121 can be positioned within the second hole section 1132, so that the crimping portion does not completely protrude outside the balance weight as in a general design, improving the molding quality of the crimping portion 123, and in particular, the inner peripheral wall of the second hole section 1132 serves to support and reinforce at least a portion of the crimping portion 123, thereby preventing the crimping portion 123 from fracturing relative to the rod portion 121, improving the structural quality of the crimping portion 123, and improving the mounting stability of the rotor assembly 1. Here, during actual crimping, it is possible to position a portion of the crimping portion 123 within the second hole section 1132 or to position the crimping portion 123 completely within the second hole section 1132, allowing for flexible structural design and easy adjustment of the crimping depth.

[0046] In related technology, the crimped portion of the rotor rivet is often located on the end plate side of the rotor body, and is not provided on the balance weight. In this case, if a portion of the rivet is to fit into the crimped portion on the balance weight, the rivet must be designed to be thick, which can result in the crimped portion completely protruding from the balance weight after crimping, or the balance weight being too hard and causing structural fatigue, which can loosen the rotor body. On the other hand, in the present application, the rivet hole a in the first balance weight is arranged to include the first hole section 1131 and the second hole section 1132, and is engaged with the rod portion 121 and the crimping portion 123 of the rotor rivet 12. This not only increases the crimping depth, makes it less likely to loosen, and ensures the stability of the crimping, but also prevents the crimping portion 123 from breaking relative to the rod portion 121, improving the structural reliability of the rotor rivet 12, and prevents the crimping portion 123 from protruding excessively from the first balance weight.

[0047] The rotor assembly 1 of the embodiment of the present application has a first hole section 1131 and a second hole section 1132 with different hole diameters to achieve engagement with the rod portion 121 and the crimping portion 123 of the rotor rivet 12, respectively. This increases the crimping depth, improves the stability of the crimping, and ensures that the structure of the crimping portion 123 is effectively supported by the outer wall of the second hole section 1132, preventing the crimping portion 123 from breaking relative to the rod portion 121, increasing the structural safety of the rotor rivet 12, and improving the reliability of the rotor assembly 1.

[0048] The rotor assembly 1 according to the embodiment of the present application improves the crimping process by optimizing the fitting structure between the rotor rivet 12 and the balance weight 113, and even when the rotor rivet 12 and the balance weight 113 are fitted together at a critical temperature, there is no problem of the rotor rivet 12 structurally fracturing at the crimped portion 123, improving the structural stability of the rotor rivet 12 and improving the safety and reliability of the rotor assembly 1 and a permanent magnet synchronous motor equipped with the same.

[0049] In addition, in some related art solutions, the balance weight disposed at the rivet crimping portion is made of a material softer than the rivet to prevent fatigue depressions and a decrease in fastening strength at the contact surface between the crimping portion and the balance weight during crimping, thereby resolving the problem of crimp failure. However, using a soft material such as brass at the crimping position reduces design flexibility and increases costs. In other solutions, a material harder than the rivet material is interposed between the rivet head and the balance weight to prevent fatigue depressions in the rivet head and maintain fastening strength. However, interposing a material harder than the rivet material between the rivet head and the balance weight further complicates the crimping and manufacturing processes, leaving room for improvement. On the other hand, the rotor assembly 1 according to the embodiment of the present application effectively avoids the above series of technical problems by adopting the above technical solution without changing the material hardness.

[0050] In some embodiments, as shown in FIG. 4, the cross-sectional area of ​​the second hole section 1132 gradually increases in a direction away from the first hole section 1131. For example, the first hole section 1131 and the second hole section 1132 are both circular hole structures, but the first hole section 1131 has a constant cross-sectional area hole structure and the second hole section 1132 has a variable cross-sectional area hole structure, i.e., the inner diameter of the first hole section 1131 remains constant at each position along its length, while the inner diameter of the second hole section 1132 gradually changes at each position along its length.

[0051] As shown in Figure 4, the second hole section 1132 is connected to the right side of the first hole section 1131, the first hole section 1131 penetrates to the left end face of the first balance weight, and the second hole section 1132 penetrates to the right end face of the first balance weight, and the cross-sectional area of ​​the second hole section 1132 gradually increases from left to right, forming a flared structure on the right side of the first hole section 1131.

[0052] Furthermore, as shown in Figure 4, the cross-sectional area of ​​the second hole section 1132 increases linearly, that is, the second hole section 1132 has a horizontal funnel-shaped structure. In this way, after the rotor rivet 12 is inserted through the first hole section 1131 and the second hole section 1132, pressure is applied to the rotor rivet 12 to form a crimped portion 123 at the end of the rod portion 121. In the process of the crimped portion 123 being crimped and fitted into the second hole section 1132, the crimped portion 123 is formed into a structure that is compatible with the second hole section 1132, for example, the crimped portion 123 is also compressed into a horizontal funnel structure.

[0053] As a result, the crimping portion 123 and the second hole section 1132 have a relatively large mating surface, which is particularly larger than the cross-sectional area of ​​the mating surface between the first hole section 1131 and the rod portion 121, making the mating between the second hole section 1132 and the crimping portion 123 more compact, improving the crimping effect between the crimping portion 123 and the first balance weight, and supporting the crimping portion 123 with the inner wall of the second hole section 1132 greatly reduces the risk of the crimping portion 123 breaking relative to the rod portion 121, improving the reliability of the rotor rivet 12.

[0054] In some embodiments, the second hole section 1132 is filled with the crimped portion 123, i.e., the length of the crimped portion 123 in the axial direction of the rotor rivet 12 is greater than or equal to the depth of the second hole section 1132 in the thickness direction of the first balance weight.

[0055] If the structural dimensions of both are the same, the crimped portion 123 can be fully extended into the second hole section 1132, and the outer surface of the crimped portion 123 can be flush with the outer surface of the first balance weight, forming a structure in which the crimped portion 123 can be fitted into the second hole section 1132.In this way, when the electric compressor 100 is operating, the crimped portion 123 will not protrude outward from the first balance weight and come into contact with structures outside the first balance weight, causing impact, thereby improving the safety of the crimped portion 123, and since the outer peripheral wall of the first balance weight is relatively flat, it does not get in the way of the structure.

[0056] Alternatively, the length corresponding to the crimped portion 123 is greater than the depth of the second hole section 1132, and as shown in Figure 4, the portion where the left end of the crimped portion 123 connects to the rod portion 121 is located within the second hole section 1132, and the right end portion of the crimped portion 123 is located outside the second hole section 1132. In addition, the portion of the crimping portion 123 that protrudes from the second hole section 1132 may also be used as a spare section.In this way, during radial riveting, the radial riveting punch is prevented from coming into contact with the first balance weight, or the spare section is made to protrude outward from the second hole section 1132.If the rotor assembly 1 is used for a long period of time and a large gap occurs between the crimping portion 123 and the inner wall of the second hole section 1132, the rotor assembly 1 can be radially crimped again to further crimp and press the spare section, thereby filling the gap between the crimping portion 123 and the second hole section 1132 and improving the stability of the crimping.

[0057] In some embodiments, the crimping portion 123 includes a sunken portion 1231 located within the second hole section 1132 and an exposed portion 1232 located on the surface of the first balance weight. Here, the sunken portion 1231 and the exposed portion 1232 are processed and formed during the radial crimping process of the rotor rivet 12. For example, after the rod portion 121 is inserted through the first hole section 1131 and the second hole section 1132, one end of the rod portion 121 away from the head portion 122 is radially crimped so that the end of the rod portion 121 first forms the sunken portion 1231 within the second hole section 1132. As the radial crimping punch is further processed, the rod portion 121 forms the exposed portion 1232 on the surface of the first balance weight, and the exposed portion 1232 is suitable for pressing against the surface of the first balance weight. Here, as shown in FIGS. 6 to 8, the exposed portion 1232 can be processed into different shapes during actual processing.

[0058] As a result, by processing one end of the rod portion 121 with a radial crimping punch, the sunken portion 1231 is tightly pressed against the inner wall of the second hole section 1132 within the second hole section 1132, increasing the degree of fit between the crimped portion 123 and the second hole section 1132, and a tight press-fit structure is also formed between the exposed portion 1232 and the surface of the first balance weight, increasing the degree of fit between the crimped portion 123 and the surface of the first balance weight and improving the fit stability between the first balance weight and the crimped portion 123.

[0059] Furthermore, after the rotor rivet 12 and the rotor body 11 are fitted with position restriction, the rotor rivet 12 is not only limited in position by the sunken portion 1231 and the inner wall of the second hole section 1132 on one side of the first balance weight, but also by the exposed portion 1232 and the surface of the first balance weight, that is, a two-layer position restriction fit is formed between the crimped portion 123 and the first balance weight, which in turn improves the stability of position restriction between the crimped portion 123 and the first balance weight and improves the crimping reliability.

[0060] In some embodiments, as shown in Figures 6 to 8, the diameter of the rod portion 121 is D and the maximum diameter of the crimped portion 123 is D0, where 1.2D≦D0≦2D, i.e., the maximum diameter of the crimped portion 123 is greater than 1.2 times the diameter of the rod portion 121 and less than twice the diameter of the rod portion 121, for example, D0 is set to 1.4D, 1.6D, or 1.7D.

[0061] Here, by setting the structural dimensions of the crimping portion 123 and the structural dimensions of the rod portion 121 within the above-mentioned dimensional range, the crimping portion 123 and the second hole section 1132 can have a relatively large fitting depth and fitting area, which improves crimping stability and ensures the crimping quality of the rotor rivet 12. Furthermore, the radial dimension of the crimping portion 123 is not excessively large, and the crimping portion 123 does not extend excessively outside the second hole section 1132, which saves material and prevents other quality issues caused by the crimping portion 123 protruding from the outer radius of the rotor core 111 after crimping, thereby improving the rationality of the structural design.

[0062] This enables the installation of the caulking portion 123 to achieve both caulking quality and material-saving effect.

[0063] In some embodiments, the number of magnetic poles of the rotor body 11 is A, and the number of rotor rivets 12 is B, where B ≤ A - 2. That is, the number of installed rotor rivets 12 is no more than the number of magnetic poles of the rotor body 11 minus 2. When the number of magnetic poles is set to 8, the number of rotor rivets 12 is 6 or 4.

[0064] Thereby, after connecting and fitting the first balance weight through the caulking portion 123 of the rotor rivet 12 in the present application, on the premise of ensuring caulking quality, the number of rotor rivets 12 can be reduced to the maximum extent, and the installation cost, material cost, and processing process cost of the rotor rivets 12 can be reduced. Of course, the number of rotor rivets 12 cannot be set too few, such as 1. That is, it is necessary to ensure that the rotor rivets 12 can effectively limit and fix the position at a plurality of different positions in the circumferential direction of the rotor assembly 1.

[0065] In some embodiments, as shown in FIG. 2, the outer radius of the rotor core 111 is R, and the diameter of the cylindrical surface that is coaxial with the rotor core 111 and passes through the central axis of the rotor rivet 12 is r (or r is the distance between the central axis of the rod portion and the central axis of the rotor core), satisfying 0.4 < r / R < 0.9. For example, r / R is set to 0.6, 0.7, or 0.8. Here, by reasonably providing the hole structure of the avoidance hole for penetrating the rotor rivet 12 in the rotor core 111, the position of the rotor rivet 12 on the rotor core 111 can be kept away from the outer peripheral wall of the rotor core 111, and a sufficient safety distance can be maintained.

[0066] Furthermore, when rotor rivets 12 are attached in the prior art, the gap between the hole structure in rotor core 111 for inserting rotor rivets 12 therethrough and the outer peripheral wall of rotor core 111 is small, which results in low structural strength of the outer peripheral wall of rotor core 111 at the position corresponding to rotor rivet 12. In other words, when rotor core 111 is used for a long period of time and frequently rotates at high speeds, the hole structure of rotor core 111 is significantly worn away by rotor rivets 12, resulting in structural damage to rotor core 111. In the present application, by setting the ratio of r / R within the above range, it is possible to effectively avoid the problem of the outer peripheral wall of rotor core 111 bursting, improve the structural stability of rotor core 111, and ensure crimping quality.

[0067] In some embodiments, the value of diameter D of rod portion 121 ranges from 3 mm to 6 mm, for example, the diameter of rod portion 121 is 4 mm or 5 mm. Note that rod portion 121 is for fitting into rivet hole a, and the gap between rod portion 121 and the inner wall of rivet hole a is 0.1 mm to 0.2 mm, i.e., the diameter of rivet hole a changes according to the diameter of rod portion 121 so that the two can be attached and fitted together within a reasonable fitting gap range.

[0068] In some embodiments, multiple rotor rivets 12 are provided and installed at intervals along the circumferential direction of the rotor core 111, so that the rotor core 111 and the end plates 112 can be connected and fixed by the rotor rivets 12 at multiple positions around the circumference, thereby maximizing the structural stability and reliability of the rotor body 11.

[0069] Here, the spacing between the multiple rotor rivets 12 in the circumferential direction of the rotor core 111 can be made uniform; for example, if there are four rotor cores 111, the four rotor rivets 12 are evenly spaced and distributed in the circumferential direction of the rotor core 111, i.e., the circumferential angle between two adjacent rotor rivets 12 is 90°, thereby making it possible to uniformly apply the circumferential mounting force of the four rotor rivets 12 to each component of the rotor body 11, and avoiding the problem of the connecting force at local positions being too small or too large.

[0070] In some embodiments, the crimped portions 123 of each rotor rivet 12 are all located on the same axial side of the rotor core 111. That is, when connecting and fitting to the rotor body 11 via multiple rotor rivets 12, the multiple rotor rivets 12 can be attached from the same axial side of the rotor core 111 so that the heads 122 of the multiple rotor rivets 12 are all located on a first side of the rotor core 111 and the crimped portions 123 of the multiple rotor rivets 12 are all located on a second side of the rotor core 111. As shown in FIG. 3 , the heads 122 of the multiple rotor rivets 12 are all located on the left end face of the rotor core 111, and the crimped portions 123 are all located on the right end face of the rotor core 111.

[0071] Furthermore, after the rotor rivets 12 are driven through the rotor core 111, a radial crimping process must be performed. This allows multiple rotor rivets 12 to be assembled from the same side of the rotor core 111, and when the worker crimps the rotor rivets 12, after all of the multiple rotor rivets 12 have been driven through, the multiple rotor rivets 12 can be simultaneously crimped from the same side of the rotor core 111. In other words, there is no need to change or adjust the position of the crimping head when crimping different rotor rivets 12, which greatly improves crimping efficiency and improves the assembly efficiency of the rotor assembly 1.

[0072] In some embodiments, the radial width W of the first balance weight is greater than 2D, where D is the diameter of the rod portion 121, i.e., the radial width of the first balance weight is greater than twice the diameter of the rod portion 121. As a result, when the first balance weight and the rod portion 121 are fitted together, it is necessary to provide a dowel hole in the first balance weight and set the gap between the rod portion 121 and the inner wall of the rivet hole a to 0.1 mm to 0.2 mm. Therefore, by setting the radial width of the first balance weight within the above range, it is possible to avoid the dimensional ratio of the dowel hole in the first balance weight becoming excessively large, which would affect the structural strength of the first balance weight, and ensure the structural stability of the first balance weight.

[0073] As a result, after the rotor rivet 12 is inserted into the first balance weight, the process of forming the crimped portion 123 by radial crimping does not have a significant impact on the structural state of the rotor rivet 12 and the first balance weight, meaning that there is no problem of significant structural fracture occurring in the first balance weight.

[0074] In some embodiments, the thickness of the end plate 112 interposed between the first balance weight and the rotor core 111 is 0.8 mm or more. That is, when actually installed, the thickness of the end plate 112 located between the first balance weight and the rotor core 111 is set to at least 0.8 mm, for example, 1 mm or 1.1 mm.

[0075] Here, by setting the thickness of this end plate 112 within the above range, the structural strength of the end plate 112 itself is effectively ensured, the problem of the end plate 112 being significantly deformed during the process of crimping the rotor rivet 12 is avoided, crimping quality is ensured, and this contributes to reducing the discreteness of the natural frequency of the rotor assembly 1. Of course, the thickness of the end plate 112 should not be set too large, and the thickness of the end plate 112 needs to be set within a reasonable cost range.

[0076] In some embodiments, the thickness of the end plate 112 interposed between the first balance weight and the rotor core 111 is 0.8 mm or more. That is, when actually installed, the thickness of the end plate 112 located between the first balance weight and the rotor core 111 is set to at least 0.8 mm, for example, 1 mm or 1.1 mm.

[0077] Here, by setting the thickness of this end plate 112 within the above range, the structural strength of the end plate 112 itself is effectively ensured, the problem of the end plate 112 being significantly deformed during the process of crimping the rotor rivet 12 is avoided, crimping quality is ensured, and this contributes to reducing the discreteness of the natural frequency of the rotor assembly 1. Of course, the thickness of the end plate 112 should not be set too large, and the thickness of the end plate 112 needs to be set within a reasonable cost range.

[0078] In addition, in some embodiments, the volume of the crimping portion 123 is equal to or greater than the volume of the head portion 122, so that the structural strength and torsional resistance of the crimping portion 123 are high, making crimping easy. Furthermore, when the crimping portion 123 crimps the first balance weight, problems such as fracture or structural deformation of the crimping portion 123 are unlikely to occur, improving the structural safety of the rotor rivet 12.

[0079] In this way, when the crimped portion 123 abuts against the side surface of the first balance weight to restrict its position, the crimped portion 123 exerts an excellent position restriction function, and the crimped portion 123 does not come off the first balance weight, improving the reliability of the crimped position restriction.

[0080] And / or, in some other embodiments, the diameter of the crimped portion 123 is equal to or greater than the diameter of the head 122, i.e., the cross-sectional area of ​​the crimped portion 123 is greater than the cross-sectional area of ​​the head 122. Similarly, the torsional resistance of the crimped portion 123 can be increased, i.e., the torsional resistance can be increased, which can prevent the crimped portion 123 from shifting position relative to the rod portion 121 and breaking during rotation of the rotor assembly 1, thereby improving the safety of the structural design. By making the diameter of the crimped portion 123 greater than the diameter of the head 122, the crimped portion 123 has a larger positional limiting surface relative to the head 122, and the positional limiting effect is improved.

[0081] After the rotor rivet 12 is inserted into the rotor body 11, as the rotation speed of the electric compressor 100 increases, the force received by the crimped portion 123 reaches a maximum. In addition, by setting the volume and / or diameter of the crimped portion 123 in the present application to be larger than that of the head portion 122, the crimped portion 123 is less likely to break even when subjected to a large pressure, and when a radial crimping process is employed, the requirements for the crimping quality of the crimped portion 123 are lowered, further contributing to a reduction in the cost of radial crimping equipment and processing.

[0082] In some embodiments, the hardness of the rotor rivet 12 is between HRB 50 and HRB 200, for example, the hardness of the rotor rivet 12 is HRB 70 or HRB 150. Setting the hardness of the rotor rivet 12 within the above range not only prevents the hardness from becoming too small, but also ensures the crimping effect of the rotor rivet 12 in the rotor assembly 1, improves crimping quality, and prevents the head 122 from being significantly deformed during crimping, and also prevents the hardness from becoming too large, shortens the radial crimping time of the rotor rivet 12 during crimping, and improves crimping efficiency.

[0083] The present application also proposes a permanent magnet synchronous motor.

[0084] A permanent magnet synchronous motor according to an embodiment of the present application includes a stator assembly and a rotor assembly 1 rotatable relative to the stator assembly, the rotor assembly 1 being the rotor assembly 1 described in any of the above embodiments. Here, the stator assembly includes a stator core and a winding, the rotor assembly 1 is installed inside the stator core, and the rotor assembly 1 is rotatable within the stator core.

[0085] Here, this permanent magnet synchronous motor is provided with the rotor assembly 1 of the above embodiment, and uses the first hole section 1131 and the second hole section 1132 of different hole diameters to respectively fit the rod portion 121 and the crimping portion 123 of the rotor rivet 12, thereby contributing to increasing the crimping depth and improving the crimping stability, and ensuring that the structure of the crimping portion 123 is effectively supported by the outer peripheral wall of the second hole section 1132, preventing the crimping portion 123 from breaking against the rod portion 121, enhancing the structural stability of the rotor rivet 12, improving the reliability of the rotor assembly 1, and ensuring the operating stability of the permanent magnet synchronous motor.

[0086] The present application also proposes an electric compressor 100.

[0087] According to an electric compressor 100 according to an embodiment of the present application, as shown in FIG. 9 , the electric compressor 100 includes a compression member 3 and a drive member that drives the compression member 3 so that the compression member 3 performs a compression operation, the drive member including the permanent magnet synchronous motor according to the embodiment described above, and both the compression member 3 and the drive member are provided within a housing member of the electric compressor 100, and the housing member includes a high-pressure housing 41, a low-pressure housing 42, and a bracket 43 attached between the high-pressure housing 41 and the low-pressure housing 42.

[0088] 9 , low-pressure housing 42 is attached to the left of bracket 43 and defines, together with bracket 43, a low-pressure cavity 421 for mounting a drive member, and low-pressure housing 42 is provided with a refrigerant inlet 422, high-pressure housing 41 is attached to the right of bracket 43 and defines, together with bracket 43, a high-pressure cavity 411 for mounting a compression member, and high-pressure housing 41 is provided with a refrigerant discharge port 412. During operation of electric compressor 100, low-pressure refrigerant enters low-pressure cavity 421 from refrigerant inlet 422 of low-pressure housing 42, passes through bracket 43, enters compression member 3 and is compressed, and the compressed high-pressure refrigerant is discharged into high-pressure cavity 411 and is discharged to the outside of electric compressor 100 from refrigerant discharge port 412 of high-pressure housing 41. As shown in FIG. 9, a cover plate 44 is connected to the side of the low-voltage housing 42 away from the high-voltage housing 41, and an installation space is defined between the cover plate 44 and the low-voltage housing 42. An electric control member 5 for controlling the operating state of the permanent magnet synchronous motor is provided within the installation space.

[0089] Here, by providing the permanent magnet synchronous motor of the above-described embodiment in the electric compressor 100, the electric compressor 100 can operate in a stable state, and the driving member can ensure that the operation of the compression member 3 is accurately and reliably driven, thereby achieving a stable output of high-pressure refrigerant.

[0090] The present application also proposes an air conditioning system 200 .

[0091] According to an air conditioning system 200 according to an embodiment of the present application, as shown in FIG. 10 , the air conditioning system 200 is provided with the electric compressor 100 according to the above embodiment, and the electric compressor 100 is less likely to stall due to a failure of the rotor assembly 1 while in operation. The provision of the electric compressor 100 makes the heat exchange function of the air conditioning system 200 relatively stable, and enables the air conditioning system 200 to adjust the temperature state in the space accurately and in a timely manner.

[0092] The present application also proposes a vehicle 1000 .

[0093] As shown in FIG. 10, a vehicle 1000 according to an embodiment of the present application includes a vehicle body 300 and an air conditioning system 200 mounted on the vehicle body. Here, the vehicle's air conditioning system 200 is the air conditioning system 200 in the above embodiment. By installing the air conditioning system 200 to perform airflow heat exchange in the interior space of the vehicle body 300, the space temperature within the vehicle body 300 can accurately meet the user's thermal needs and improve the user's riding experience.

[0094] Hereinafter, rotor assemblies 1 according to several embodiments of the present invention will be described with reference to the drawings.

[0095] 1, 2, and 11 to 13, a rotor assembly 1 according to an embodiment of the present application includes a rotor body 11 and a rotor rivet 12. Here, the rotor assembly 1 is used for attachment and fitting with a stator assembly, and when the permanent magnet synchronous motor is energized and operating, the rotor assembly 1 can rotate relative to the stator assembly, thereby outputting driving force to compress air or perform other types of driving functions.

[0096] As shown in Figures 1, 2, and 11, the rotor body 11 includes a rotor core 111, end plates 112, and balance weights 113. Permanent magnets are fitted into the rotor core 111; for example, magnet grooves may be formed in the rotor core 111, and the permanent magnets may be fitted into the magnet grooves to secure the rotor core 111 to the rotor. During actual installation, the rotor core 111 is mounted within a stator assembly and placed over the drive shaft 2 of the electric compressor 100. During operation of the electric compressor 100, current is applied to the windings of the stator assembly to generate a magnetic field that acts on the permanent magnets, driving the rotor core 111 to rotate, and thereby moving the drive shaft 2 and outputting driving force. The rotor core 111 has a laminated structure of silicon steel pieces, and crimping points b must be provided in the core to form-fit the layers together. The engagement positions are uniformly distributed around the rotor core 111, and are located, for example, in an area close to the middle part in the radial direction of the rotor. As shown in FIG. 18, the area surrounded by the dotted line is the distribution area of ​​the crimping points b. However, the number of crimping points b can be four or eight. Because there are gaps between the crimping points b, the positions of the two "crimping points b" cannot be completely fixed on a plane, and a minimum of three is required, so the optimal number is four. The crimping points b are ultimately set to the positions shown in FIG. 18.

[0097] An end plate 112 is provided at each axial end of the rotor core 111, and two end plates 112 are provided, one at each end of the rotor core 111 so as to be in close contact with the end face of the rotor core 111, and a balance weight 113 is provided on the side of at least one of the end plates 112 that is away from the rotor core 111. That is, as shown in Fig. 11, a balance weight 113 may be provided corresponding to one end plate 112, or as shown in Fig. 13, a balance weight 113 may be provided on each of the opposing side surfaces of the two end plates 112, so the number of balance weights 113 can be flexibly set according to actual needs.

[0098] Rotor rivets 12 penetrate rotor body 11 along the axial direction to secure rotor body 11 as a unit. As shown in Figures 9 and 16, rotor core 111, end plates 112, and balance weights 113 are all provided with hollow rivet holes a so that rotor rivets 12 pass through rotor core 111, end plates 112, and balance weights 113 simultaneously, and thus the various parts of rotor body 11 are connected to one another as a whole. This ensures that rotor core 111, end plates 112, and balance weights 113 are fixed relative to one another in the axial direction of rotor body 11, preventing the end plates 112 and balance weights 113 from separating from rotor core 111 while rotor core 111 is rotating, improving the structural stability of rotor body 11.

[0099] 15, the rotor rivet 12 includes a rod portion 121, a head portion 122, and a crimped portion 123, and the head portion 122 and the crimped portion 123 are located at both longitudinal ends of the rod portion 121. As shown in Fig. 15, the head portion 122 is connected to the upper end of the rod portion 121, and the crimped portion 123 is connected to the lower end of the rod portion 121. The rotor rivet 12 includes the head portion 122 and the rod portion 121 during initial molding, and after the rotor rivet 12 is crimped to the rotor body 11, the crimped portion 123 is processed in a crimping process so that the head portion 122 and the crimped portion 123 exert a position limiting function at both ends of the rotor body 11, and ultimately realizes the axial position limiting function of the rotor body 11 with respect to each member. As a result, by inserting the rotor rivet 12 into the rotor body 11, each structural component of the rotor body 11 is fixedly attached between the head 122 and the crimped portion 123 of the rotor rivet 12, preventing the rotor body 11, end plate 112, and balance weight 113 from separating relative to each other along the axial direction of the rotor body 11.

[0100] Here, the crimping portion 123 has a solid structure without holes, that is, the crimping portion 123 in the present application has no hollow area, which increases the overall structural strength of the crimping portion 123, avoiding problems such as torsional deformation in the hollow area of ​​the crimping portion 123, improving the structural stability of the rotor rivet 12, and ensuring crimping quality.

[0101] The tensile strength τ of the rotor rivet 12 is 0.2·τ≦M·r·π·(n / D) 2 / 225≦0.7·τ, where r is the distance between the central axis of the rod portion 121 and the central axis of the rotor core 111, M is the mass of the balance weight 113, n is the maximum rotation speed of the rotor assembly 1, and D is the diameter of the rod portion 121. Note that M·r·π·(n / D) 2 / 225 is the shear stress that the rotor rivet 12 receives after being attached to the rotor body 11. By setting the relationship between the shear stress and the tensile strength of the rotor rivet 12, the shear stress can be controlled to 0.2 to 0.7 times the tensile strength, for example, set to 0.4 or 0.6 times. As a result, after the rotor rivet 12 has penetrated each structural member of the rotor body 11, even when the rotor assembly 1 maintains a high rotation speed during operation of the electric compressor 100, the rotor rivet 12 can maintain a good structural state, that is, the rotor rivet 12 is not easily subject to structural fracture, and usage needs are met.

[0102]

[0033] By setting the shear stress and tensile strength of the rotor rivet 12 within the above ranges, the position of the balance weight 113 is less likely to change, thereby avoiding an increase in unbalance under high-speed operating conditions and reducing vibration and noise. Furthermore, when the electric compressor 100 operates at a relatively high rotation speed for a long period of time, the tangential and axial forces of the rotor rivet 12 meet safety requirements, making the rotor rivet 12 less likely to break down. Furthermore, the rotor volume can be made as compact as possible, provided that the mass of the balance weight 113 in the rotor meets the counterweight requirements. The rotor core 111, balance weight 113, and end plate 112 are provided with rivet holes a for receiving the rotor rivets 12, allowing the components of the rotor body 11 to be assembled easily and reliably. Furthermore, the placement of the rivets minimizes the impact on the performance of the motor's magnetic circuit.

[0103] The rotor assembly 1 according to the embodiment of the present application maximizes the layout performance of the rotor assembly 1 by setting the relationship between the fitting parameters of each structural member of the rotor body 11 and the tensile strength of the rotor rivet 12, thereby ensuring the structural strength of the rotor rivet 12 during use and effectively avoiding the problem of the rotor rivet 12 easily breaking, making the structure of the rotor assembly 1 more compact and reliable and ensuring the quality of the crimping.

[0104] In this embodiment, the rotor assembly 1 optimizes the relationship between each structural member and the tensile strength of the rotor rivet 12 so that after the rotor rivet 12 is inserted into the rotor core 111, the quality of the crimping between the rotor rivet 12 and the rotor core 111 and the balance weight is guaranteed, and the various members of the rotor body 11 can be stably connected. Therefore, when the cooling output demand of the electric compressor 100 is high and the rotor core 111 rotates at high speed, the crimped portion 123 still maintains a good structural state, ensuring a stable and large cooling output of the electric compressor 100 and improving the operating stability of the electric compressor 100.

[0105] In some embodiments, when there are balance weights 113 on both sides of the rotor body 11 and the two balance weights 113 have different masses, the mass of the heavier of the two balance weights 113 is M, i.e., 0.2·τ≦M·r·π·(n / D) 2 In / 225≦0.7·τ, M is the mass of the heavier of the two balance weights 113. This can better ensure the structural strength of the rotor rivet 12 during use and better avoid the problem of the rotor rivet 12 being prone to breakage.

[0106] In some embodiments, the number of magnetic poles 114 on the rotor body 11 is A, and the number of rotor rivets 12 is B, where B≦A. That is, the number of rotor rivets 12 is less than or equal to the number of magnetic poles 114 on the rotor body 11. If the number of magnetic poles 114 is set to 8, the number of rotor rivets 12 will be 8, 6, or 4.

[0107] As a result, under the premise that the crimping quality is guaranteed after the rotor body 11 is connected and fitted via the rotor rivets 12 in this application, the number of rotor rivets 12 can be reduced to the minimum, thereby reducing the installation costs, material costs, and processing costs of the rotor rivets 12. Of course, the number of rotor rivets 12 cannot be too small, such as one; it is necessary to ensure that the rotor assembly 1 can be effectively limited and fixed by the rotor rivets 12 at multiple different positions in the circumferential direction.

[0108] In a further embodiment, B≦A−2, i.e., the number of rotor rivets 12 is equal to or less than the number of magnetic poles 114 of the rotor body 11 minus 2. If the number of magnetic poles 114 is set to 8, the number of rotor rivets 12 is 6 or 4. In this way, after the rotor rivets 12 and the rotor body 11 are fitted together, the number of rotor rivets 12 not only ensures the crimping quality, but also reduces the installation cost of the rotor rivets 12.

[0109] In some embodiments, the rotor rivet 12 is positioned between two adjacent magnetic poles 114 of the rotor body 11, so that the installation of the rotor rivet 12 does not affect the magnetic poles 114 of the rotor body 11, thereby improving the rationality of the structural installation.

[0110] In a further embodiment, there are multiple rotor rivets 12, and the multiple rotor rivets 12 are arranged at intervals along the circumferential direction of the rotor core 111. As shown in Figure 12, the rotor body 11 has eight magnetic poles 114 and four rotor rivets 12, i.e., the number of rotor rivets 12 is less than the number of magnetic poles 114 of the rotor body 11. In actual arrangement, the eight magnetic poles 114 are evenly spaced apart along the circumferential direction of the rotor body 11, and the four rotor rivets 12 are also evenly spaced apart along the circumferential direction of the rotor body 11, i.e., the circumferential angle between two adjacent rotor rivets 12 is 90°. This allows the circumferential mounting force of the four rotor rivets 12 to be uniform for each member of the rotor body 11, and avoids the problem of the connecting force being too small or too large at certain locations.

[0111] Furthermore, as shown in Figure 12, four rotor rivets 12 are evenly spaced apart and intersect among the eight magnetic poles 114, and the magnetic grooves of the rotor core 111 are distributed in an approximately "V" shape.In this way, the magnetic poles 114 of the rotor body 11 are evenly distributed in the circumferential direction, and the number of rotor rivets 12 is also set relatively even, balancing the driving force at each position in the circumferential direction of the rotor body 11 and balancing the crimping effect.

[0112] Also, the caulking portions 123 of each rotor rivet 12 are all located on the same side in the axial direction of the rotor core 111. That is, when connecting and fitting the rotor body 11 via a plurality of rotor rivets 12, the heads 122 of the plurality of rotor rivets 12 are all located on the first side of the rotor core 111, and the caulking portions 123 of the plurality of rotor rivets 12 are all located on the second side of the rotor core 111. Thus, the plurality of rotor rivets 12 can be attached from the same side in the axial direction of the rotor core 111. As shown in FIG. 11, the heads 122 of each rotor rivet 12 are all located on the left end face of the rotor core 111, and the caulking portions 123 are all located on the right end face of the rotor core 111.

[0113] Note that after the rotor rivet 12 is penetrated through the rotor core 111, it is necessary to perform a radial caulking process operation. Thereby, when incorporating the plurality of rotor rivets 12 from the same side of the rotor core 111, when the operator caulks the rotor rivets 12, after all the plurality of rotor rivets 12 are penetrated, the caulking operation can be performed on the plurality of rotor rivets 12 simultaneously from the same side of the rotor core 111. That is, when performing the caulking operation on different rotor rivets 12, there is no need to change or adjust the position of the caulking head. The caulking efficiency is greatly improved, and the assembly efficiency of the rotor assembly 1 is improved.

[0114] In some embodiments, as shown in FIGS. 18 to 21, the outer radius of the rotor core 111 is R, and 0.5 < r / R < 0.9, where r is the distance between the central axis of the rod portion 121 and the central axis of the rotor core 111. That is, the ratio of the distance between the central axis of the rod portion 121 and the central axis of the rotor core 111 to the outer radius of the rotor core 111 is greater than 0.5 and less than 0.9. For example, it is set to 0.6, 0.7, or 0.8.

[0115] As shown in FIG. 22, when the ratio r / R changes, the cross-sectional area and height of the balance weight 113 change. As the ratio r / R gradually increases, the height of the balance weight 113 gradually decreases. When the ratio r / R exceeds 0.9, the width of the balance weight 113 becomes insufficient, and after the rotor rivet 12 is radially crimped, the crimped portion 123 protrudes into the external space of the rotor body 11. Furthermore, as the ratio r / R decreases, the cross-sectional area of ​​the balance weight 113 decreases. If the weight of the balance weight 113 does not change, the height of the balance weight 113 increases. However, referring to the cross-sectional view of FIG. 9, the distance between the balance weight 113 and the compressor bearing fixing position is limited. If the height of the balance weight 113 exceeds 12 mm, the axial length of the compressor needs to be increased, resulting in a corresponding increase in volume and weight.

[0116] Therefore, in the present application, the ratio of r / R is limited to the range of 0.6 to 0.9, thereby making the height of the balance weight 113 sufficiently small and making the radial width of the balance weight 113 sufficiently large, thereby ensuring sufficient space for installing the crimped portion 123 after radial crimping.

[0117] Furthermore, when the ratio of r / R is set to 0.7, the rotor rivets 12 can be positioned between the magnetic poles 114 and can be arranged at a circumferential distance from the position of the crimping point b. In this way, the number of rotor rivets 12 meets the assembly requirements of the rotor assembly 1, and the arrangement is symmetrical, improving the symmetry of the entire rotor magnetic path.

[0118] In some embodiments, the value of diameter D of rod portion 121 ranges from 3 mm to 6 mm, for example, the diameter of rod portion 121 is 4 mm or 5 mm. Note that rod portion 121 is for fitting into rivet hole a, and the gap between rod portion 121 and the inner wall of rivet hole a is 0.1 mm to 0.2 mm, i.e., the diameter of rivet hole a changes according to the diameter of rod portion 121 so that the two can be attached and fitted together within a reasonable fitting gap range.

[0119] In addition, when the diameter of rivet hole a changes, the direction of the magnetic field lines, magnetic resistance, and inductance of the motor's magnetic path change accordingly, and the AC-DC inductance value is reflected in the motor control. Here, when the r / R ratio is close to 0.7, rivet hole a is located in the middle of the two magnetic poles 114, and the material of the crimping pin can be No. 10 cold-headed steel or a similar number, whose magnetic permeability is lower than that of silicon steel or close to that of air. At this time, the magnetic resistance in the direction of the rotor's cross-axis magnetic path increases, and the cross-axis inductance value decreases accordingly. The direct-axis inductance value does not change significantly, so the difference in cross-axis inductance becomes smaller with the change in the diameter of the crimping pin.

[0120] As shown in Figure 23, this shows the change in motor AC / DC-axis inductance when the diameter of the rod portion 121 is increased from 3.2 mm to 6 mm. As can be seen from the figure, when the diameter of the rod portion 121 is larger than 4 mm, the value of AC-axis inductance drops sharply, the AC-DC-axis inductance difference also drops accordingly, the reluctance torque supplied from the rotor also drops correspondingly, and the power density of the motor drops. Therefore, by setting the diameter of the rod portion 121 within the above range, the power density of the motor can be maintained at a constant level.

[0121] In some embodiments, at least one balance weight 113 is the third balance weight, that is, the balance weight 113 of the rotor body 11 in the present application may be one as shown in Fig. 11 or two as shown in Fig. 13. Here, when one balance weight 113 is set, this balance weight 113 can be set as the third balance weight, and when two balance weights 113 are set, one or both of the balance weights 113 can be set as the third balance weight.

[0122] Here, the third balance weight is provided with a crimped portion 123; that is, after the rotor rivet 12 is inserted into the rotor body 11, the end of the rod portion 121 away from the head 122 extends away from the end plate 112 of the third balance weight; at this time, by radially crimping the end of the rod portion 121 with a radial crimping punch, the end of the rod portion 121 is processed into the crimped portion 123, and the crimped portion 123 is pressed against the surface of the third balance weight while restricting its position, thereby realizing positional restriction and fixation of the third balance weight, the end plate 112, and the rotor core 111.

[0123] In some embodiments, the diameter of the rod portion 121 is D and the maximum diameter of the crimped portion 123 is D0, where 1.2D≦D0≦2D, i.e., the maximum diameter of the crimped portion 123 is greater than 1.2 times the diameter of the rod portion 121 and less than twice the diameter of the rod portion 121, for example, D0 is set to 1.4D, 1.6D, or 1.7D.

[0124] Here, by setting the structural dimensions of the crimping portion 123 and the structural dimensions of the rod portion 121 within the above-mentioned dimensional range, the crimping portion 123 and the second hole section can have a relatively large fitting depth and fitting area, which improves crimping stability and ensures the crimping quality of the rotor rivet 12. Furthermore, the radial dimension of the crimping portion 123 is not excessively large, and the crimping portion 123 does not excessively extend outside the second hole section, which saves material and prevents other quality issues caused by the crimping portion 123 protruding from the outer radius of the rotor core 111 after crimping, thereby improving the rationality of the structural design.

[0125] As a result, the provision of the crimped portion 123 can achieve both crimping quality and material saving effects.

[0126] In some embodiments, as shown in FIG. 2, the radial width W of the third balance weight is greater than 2D, i.e., the radial width of the third balance weight is greater than twice the diameter of the rod portion 121. As a result, when the third balance weight and the rod portion 121 are fitted together, it is necessary to provide a dowel hole in the third balance weight and set the gap between the rod portion 121 and the inner wall of the rivet hole a to 0.1 mm to 0.2 mm. Therefore, by setting the radial width of the third balance weight within the above range, it is possible to avoid the dimensional ratio of the dowel hole in the third balance weight becoming excessively large, which would affect the structural strength of the third balance weight, and ensure the structural stability of the third balance weight.

[0127] As a result, after the rotor rivet 12 is inserted into the third balance weight, the process of forming the crimped portion 123 by radial crimping does not have a significant impact on the structural state of the rotor rivet 12 and the third balance weight, meaning that there is no problem of significant structural fracture occurring in the third balance weight.

[0128] In some embodiments, the thickness of the end plate 112 interposed between the third balance weight and the rotor core 111 is 0.8 mm or more. That is, when actually installed, the thickness of the end plate 112 located between the third balance weight and the rotor core 111 is set to at least 0.8 mm, for example, 1 mm or 1.1 mm.

[0129] Here, by setting the thickness of this end plate 112 within the above range, the structural strength of the end plate 112 itself is effectively ensured, the problem of the end plate 112 being significantly deformed during the process of crimping the rotor rivet 12 is avoided, crimping quality is ensured, and this contributes to reducing the discreteness of the natural frequency of the rotor assembly 1. Of course, the thickness of the end plate 112 should not be set too large, and the thickness of the end plate 112 needs to be set within a reasonable cost range.

[0130] In addition, in some embodiments, the volume of the crimping portion 123 is equal to or greater than the volume of the head portion 122, so that the structural strength and torsional resistance of the crimping portion 123 are great, making crimping easy. Furthermore, when the crimping portion 123 crimps the third balance weight, problems such as fracture or structural deformation of the crimping portion 123 are unlikely to occur, improving the structural safety of the rotor rivet 12.

[0131] In this way, when the crimped portion 123 abuts against the side surface of the third balance weight to restrict its position, the crimped portion 123 exerts an excellent position restriction function, and the crimped portion 123 does not come off the third balance weight, improving the reliability of the crimped position restriction.

[0132] And / or, in some other embodiments, the diameter of the crimped portion 123 is equal to or greater than the diameter of the head 122, i.e., the cross-sectional area of ​​the crimped portion 123 is greater than the cross-sectional area of ​​the head 122. Similarly, the torsional resistance of the crimped portion 123 can be increased, i.e., the torsional resistance can be increased, which can prevent the crimped portion 123 from shifting position relative to the rod portion 121 and breaking during rotation of the rotor assembly 1, thereby improving the safety of the structural design. By making the diameter of the crimped portion 123 greater than the diameter of the head 122, the crimped portion 123 has a larger positional limiting surface relative to the head 122, and the positional limiting effect is improved.

[0133] After the rotor rivet 12 is inserted into the rotor body 11, as the rotation speed of the electric compressor 100 increases, the force received by the crimped portion 123 reaches a maximum. In addition, by setting the volume and / or diameter of the crimped portion 123 in the present application to be larger than that of the head portion 122, the crimped portion 123 is less likely to break even when subjected to a large pressure, and when a radial crimping process is employed, the requirements for the crimping quality of the crimped portion 123 are lowered, further contributing to a reduction in the cost of radial crimping equipment and processing.

[0134] In some embodiments, the hardness of the rotor rivet 12 is between HRB 50 and HRB 200, for example, the hardness of the rotor rivet 12 is HRB 70 or HRB 150. Setting the hardness of the rotor rivet 12 within the above range not only prevents the hardness from becoming too small, but also ensures the crimping effect of the rotor rivet 12 in the rotor assembly 1, improves crimping quality, and prevents the head 122 from being significantly deformed during crimping, and also prevents the hardness from becoming too large, shortens the radial crimping time of the rotor rivet 12 during crimping, and improves crimping efficiency.

[0135] The present application also proposes a permanent magnet synchronous motor.

[0136] A permanent magnet synchronous motor according to an embodiment of the present application includes a stator assembly and a rotor assembly 1 rotatable relative to the stator assembly, the rotor assembly 1 being the rotor assembly 1 described in any of the above embodiments. Here, the stator assembly includes a stator core and a winding, the rotor assembly 1 is installed inside the stator core, and the rotor assembly 1 is rotatable within the stator core.

[0137] Here, in this permanent magnet synchronous motor, by setting the relationship between the fitting parameters of each structural member of the rotor body 11 and the tensile strength of the rotor rivets 12, the layout performance of the rotor assembly 1 is maximized, the structural strength of the rotor rivets 12 during use is ensured, the problem of the rotor rivets 12 easily breaking is well avoided, the structure of the rotor assembly 1 is made more compact and reliable, the rivet quality is ensured, and the operating stability of the permanent magnet synchronous motor is improved.

[0138] The present application also proposes an electric compressor 100.

[0139] According to an electric compressor 100 according to an embodiment of the present application, as shown in FIG. 9 , the electric compressor 100 includes a compression member 3 and a drive member that drives the compression member 3 so that the compression member 3 performs a compression operation, the drive member including the permanent magnet synchronous motor according to the embodiment described above, and both the compression member 3 and the drive member are provided within a housing member of the electric compressor 100, and the housing member includes a high-pressure housing 41, a low-pressure housing 42, and a bracket 43 attached between the high-pressure housing 41 and the low-pressure housing 42.

[0140] 16 , low-pressure housing 42 is attached to the left side of bracket 43 and defines, together with bracket 43, a low-pressure cavity 421 for mounting a drive member, and is provided with a refrigerant inlet 422. High-pressure housing 41 is attached to the right side of bracket 43 and defines, together with bracket 43, a high-pressure cavity 411 for mounting a compression member, and is provided with a refrigerant discharge port 412. During operation of electric compressor 100, low-pressure refrigerant enters low-pressure cavity 421 from refrigerant inlet 422 of low-pressure housing 42, passes through bracket 43, enters compression member 3, and is compressed. The compressed high-pressure refrigerant is discharged into high-pressure cavity 411 and is discharged to the outside of electric compressor 100 from refrigerant discharge port 412 of high-pressure housing 41. As shown in FIG. 16, a cover plate 44 is connected to the side of the low-voltage housing 42 away from the high-voltage housing 41, and an installation space is defined between the cover plate 44 and the low-voltage housing 42. An electric control member 5 for controlling the operating state of the permanent magnet synchronous motor is provided within the installation space.

[0141] Here, by providing the permanent magnet synchronous motor of the above-described embodiment in the electric compressor 100, the electric compressor 100 can operate in a stable state, and the driving member can ensure that the operation of the compression member 3 is accurately and reliably driven, thereby achieving a stable output of high-pressure refrigerant.

[0142] The present application also proposes an air conditioning system 200 .

[0143] According to an air conditioning system 200 according to an embodiment of the present application, as shown in FIG. 10 , the air conditioning system 200 is provided with the electric compressor 100 according to the above embodiment, and the electric compressor 100 is less likely to stall due to a failure of the rotor assembly 1 while in operation. The provision of the electric compressor 100 makes the heat exchange function of the air conditioning system 200 relatively stable, and enables the air conditioning system 200 to adjust the temperature state in the space accurately and in a timely manner.

[0144] The present application also proposes a vehicle 1000 .

[0145] As shown in FIG. 10 , the vehicle 1000 according to the embodiment of the present application includes a vehicle body 300 and an air conditioning system 200 mounted on the vehicle body 300. Here, the air conditioning system 200 of the vehicle 1000 is the air conditioning system 200 in the above embodiment. By installing the air conditioning system 200 to perform airflow heat exchange in the interior space of the vehicle body 300, the space temperature inside the vehicle body 300 can accurately meet the user's thermal needs and improve the user's riding experience.

[0146] It should be noted that the vehicle 1000 described herein may be a new energy vehicle, and in some embodiments, the new energy vehicle may be a pure electric vehicle using a motor as the main driving force, or in other embodiments, a hybrid vehicle using both an internal combustion engine and a motor as the main driving force. Regarding the internal combustion engine and motor that provide driving power to the new energy vehicle mentioned in the above embodiments, the internal combustion engine may use gasoline, diesel, hydrogen, etc. as fuel, and the method for supplying electrical energy to the motor may use a power battery, a hydrogen fuel cell, etc., but this is not particularly limited here. It should be noted that the structure of a new energy vehicle and the like are described here as an example, and are not intended to limit the scope of protection of the present application.

[0147] In the description of this application, orientations or positional relationships indicated by terms such as "center," "longitudinal direction," "lateral direction," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial direction," "radial direction," and "circumferential direction" are orientations or positional relationships shown based on the accompanying drawings, and are intended merely for the convenience and simplification of the description of this application. They do not indicate or imply that the indicated devices or elements must have a specific orientation or be constructed or operated in a specific orientation, and therefore should not be understood as limitations on the application.

[0148] Additionally, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or the number of technical features shown. Therefore, a feature qualified by "first" or "second" may explicitly or implicitly include one or more of the feature. In the description of this application, "plurality" means two or more, unless otherwise specified.

[0149] In this application, unless otherwise expressly specified or limited, the terms "attached," "connected," "coupled," and "fixed" should be broadly understood, and may refer to, for example, a fixed connection, a detachable connection, or an integral connection, a mechanical connection, an electrical connection, a direct connection, or an indirect connection via an intermediate medium, an internal communication between two elements, or an interactive relationship between two elements. The specific meaning of the above terms in this application can be understood by those skilled in the art based on the specific situation.

[0150] In this application, unless otherwise expressly stated or specified, a first feature being "above" or "below" a second feature can mean that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, a first feature being "above," "above," or "on the upper surface" of a second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the horizontal height of the first feature is higher than that of the second feature. A first feature being "below," "below," or "on the lower surface" of a second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the horizontal height of the first feature is lower than that of the second feature.

[0151] In the description herein, the use of reference terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that the specific features, structures, materials, or characteristics described in connection with this embodiment or example are included in at least one embodiment or example of the present application. In this specification, general expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, if not mutually inconsistent, a person skilled in the art may combine and combine different embodiments or examples and features of different embodiments or examples described herein.

[0152] Although the embodiments of the present application have been shown and described above, the above-described embodiments are merely examples and should not be understood as limitations on the present application. Those skilled in the art may change, modify, substitute, and alter the above-described embodiments within the scope of the present application. [Explanation of symbols]

[0153] 1000 vehicle, 100 electric compressor, 1 rotor assembly, 11 rotor body, 111 rotor core, 112 end plate, 113 balance weight, 1131 first hole section, 1132 second hole section, 114 magnetic pole, a rivet hole, b crimping point, 12 rotor rivet, 121 rod portion, 122 head, 123 crimping portion, 1231 sinking portion, 1232 exposed portion, 2 drive shaft, 3 compression member, 41 high-pressure housing, 411 high-pressure cavity, 412 refrigerant discharge port, 42 low-pressure housing, 421 low-pressure cavity, 422 refrigerant intake port, 43 bracket, 44 cover plate, 5 electric control member, 200 air conditioning system, 300 vehicle body.

Claims

1. a rotor body and a rotor rivet; the rotor body includes a rotor core, end plates, and balance weights, a permanent magnet is fitted in the rotor core, the end plates are provided at both axial ends of the rotor core, and the balance weight is provided on at least one of the end plates on a side away from the rotor core, The rotor rivet penetrates the rotor body along the axial direction to fix the rotor body together, the rotor rivet includes a rod portion, a head, and a crimped portion with a solid structure without a hole, the head and the crimped portion are located at both ends of the rod portion in the longitudinal direction, at least one of the balance weights is a first balance weight having a rivet hole, the rivet hole includes a first hole section for fitting into the rod portion and a second hole section for fitting into the crimped portion, the second hole section has an enlarged shape relative to the first hole section, and at least a portion of the crimped portion is filled within the second hole section, The second hole section is filled with the crimped portion, a rotor assembly, wherein the crimped portion includes a sunken portion located within the second hole section and an exposed portion located outside the second hole section so as to protrude from the surface of the first balance weight.

2. 2. The rotor assembly of claim 1, wherein the cross-sectional area of ​​the second perforation section gradually increases in a direction away from the first perforation section.

3. 3. The rotor assembly according to claim 1, wherein the diameter of the rod portion is D, the maximum diameter of the crimped portion is D0, and 1.2D≦D0≦2D.

4. The rotor assembly of claim 1 , wherein the hardness of the rotor rivet meets HRB50 to HRB200.

5. 2. The rotor assembly of claim 1, wherein the number of rotor body poles is A, the number of rotor rivets is B, and B≦A−2.

6. 2. The rotor assembly of claim 1, wherein the rotor rivet is provided at a position between two adjacent magnetic poles on the rotor body.

7. 2. The rotor assembly according to claim 1, wherein the rotor rivets are plural and are arranged at intervals along the circumferential direction of the rotor core, and the crimped portions of each rotor rivet are all located on the same axial side of the rotor core.

8. 2. The rotor assembly of claim 1, wherein R is an outer radius of the rotor core, and 0.5<r / R<0.

9.

9. 2. The rotor assembly according to claim 1, wherein the diameter D of the rod portion ranges from 3 mm to 6 mm.

10. 2. The rotor assembly of claim 1, wherein the balance weights are located on both sides of the rotor body, and when the masses of the two balance weights are different, the mass of the heavier of the two balance weights is M.

11. 2. The rotor assembly according to claim 1, wherein at least one of the balance weights is a third balance weight, the third balance weight is provided with the crimped portion, and the radial width W of the third balance weight is greater than 2D.

12. 2. The rotor assembly according to claim 1, wherein the thickness of the end plate interposed between the balance weight having the crimped portion and the rotor core is 0.8 mm or more.

13. The rotor assembly according to claim 1 , wherein the volume of the crimped portion is equal to or greater than the volume of the head portion, and / or the diameter of the crimped portion is equal to or greater than the diameter of the head portion.

14. A permanent magnet synchronous motor comprising: a stator assembly; and a rotor assembly rotatable relative to said stator assembly, said rotor assembly being the rotor assembly of claim 1 .

15. 15. An electric compressor comprising: a compression member; and a drive member for driving the compression member so that the compression member performs a compressing action, the drive member comprising the permanent magnet synchronous motor according to claim 14.

16. An air conditioning system comprising the electric compressor of claim 15.

17. A vehicle comprising: a vehicle body; and an air conditioning system mounted on the vehicle body, the air conditioning system being the air conditioning system according to claim 16.

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