Retainer fabricating method, rotor structure fabricating method, rotor structure, and axial motor

Abstract

The present invention relates to the technical field of axial motors. Disclosed are a retainer fabricating method, a rotor structure fabricating method, a rotor structure, and an axial motor. The retainer fabricating method comprises the steps: fabricating a reinforcing plate, wherein gaps for reducing eddy current loss are formed in at least one reinforcing plate tooth on the reinforcing plate, and a connecting section is arranged between the end parts of the gaps close to a tooth top side and the tooth top side of the reinforcing plate tooth; fabricating an initial retainer, wherein a fiber layer and the reinforcing plate are placed in a mold, fiber layer teeth of the fiber layer are arranged corresponding to the reinforcing plate teeth of the reinforcing plate, the initial retainer is formed by means of heating and curing, and supporting parts of the initial retainer are formed at the positions of the fiber layer teeth and the reinforcing plate teeth; and fabricating a finished retainer, wherein the connecting sections of the reinforcing plate teeth of the reinforcing plate in the initial retainer are removed, so that the gaps are communicated with the tooth top sides of the reinforcing plate teeth, and the finished retainer is formed. The retainer fabricating method provided in the present invention ensures the effectiveness of slotting of the reinforcing plate in the retainer.

Description

A method for preparing a retainer and a rotor structure, a rotor structure, and an axial motor

[0001] This application claims priority to the Chinese patent application filed with the Patent Office of China on March 4, 2024, with application number 202410246505.X and invention name “A method for preparing a retaining frame and rotor structure, rotor structure and axial motor”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present invention relates to the technical field of axial motors, and more specifically, to a method for preparing a retaining frame and a rotor structure, a rotor structure, and an axial motor. Background Art

[0003] For axial motors with a single stator, single rotor, or single stator, dual rotor structures, the rotor has a back iron, and the magnets are secured to the back iron using a pressure plate or other means. However, for motors with a dual stator, single rotor structure, the rotor typically lacks a back iron, though some dual stator, single rotor motors do have a back iron. The presence of a back iron generates eddy current losses, reducing motor efficiency. For rotors without a back iron, the magnets are typically inserted into a retaining frame, and a carbon fiber ring is used to constrain the rotor's outer diameter, as shown in Figure 1. Insulating adhesive is applied between the magnets, retaining frame, and carbon fiber ring.

[0004] In the prior art, in order to reduce eddy current losses, for rotor structures without back iron, the cage is usually made of non-metal. When the outer diameter of the motor is too large or the magnetic pull on the entire rotor is too large, the non-metallic material is prone to deformation. Therefore, a reinforcing plate is added to the cage to improve the strength of the cage, and the reinforcing plate is usually made of steel plate. Due to the arrangement of the steel plate in the cage, a large amount of eddy current loss will be generated, affecting the working efficiency of the motor. In order to minimize the eddy current loss generated by the reinforcing plate, each tooth of the reinforcing plate is usually slotted, as shown in Figure 2, to reduce the path of the eddy current circuit, shorten the eddy current circuit, thereby reducing eddy current loss and improving motor efficiency. After the reinforcing plate is added during the cage manufacturing process, the cage and the reinforcing plate are molded together to form the final cage, as shown in Figure 3. However, in order to ensure the strength of the reinforcing plate teeth, the gap on each reinforcing plate tooth is made smaller. In the actual process of manufacturing the retaining frame, it is very easy for the reinforcing plate teeth after the slits to be overlapped, resulting in failure of the slits, which leads to large eddy current losses, and then the temperature of the entire rotor structure is too high, and there is a risk of demagnetization of the magnetic steel.

[0005] Therefore, how to ensure the effectiveness of the slits in the reinforcement plates of the cage has become a technical problem that needs to be urgently solved by those skilled in the art.

[0006] Summary of the Invention

[0007] In view of this, an object of the present invention is to provide a method for preparing a retaining frame to ensure the effectiveness of the slits in the reinforcing plates of the retaining frame.

[0008] Another object of the present invention is to provide a method for preparing a rotor structure using the above-mentioned retaining frame.

[0009] Another object of the present invention is to provide a rotor structure prepared using the above-mentioned method for preparing the rotor structure.

[0010] Another object of the present invention is to provide an axial motor having the above rotor structure.

[0011] To achieve the above object, the present invention provides the following technical solutions:

[0012] A method for preparing a retainer, comprising the steps of:

[0013] Prepare a reinforcement plate, the reinforcement plate comprising a plate body and reinforcement plate teeth spaced circumferentially along the plate body, a gap for reducing eddy current loss being defined in at least one of the reinforcement plate teeth on the reinforcement plate, the gap extending at least from a tooth root side of the reinforcement plate tooth to a tooth tip side of the reinforcement plate tooth, and the gap having a connecting section between an end portion of the gap near the tooth tip side and the tooth tip side of the reinforcement plate tooth;

[0014] Preparing an initial retainer, placing the fiber layer and the reinforcing plate in a mold, with the fiber layer teeth of the fiber layer corresponding to the reinforcing plate teeth of the reinforcing plate, and forming the initial retainer by heating and curing, and forming a support portion of the initial retainer at the position of the fiber layer teeth and the reinforcing plate teeth;

[0015] A finished retainer is prepared by removing the connecting section of the reinforcing plate teeth of the reinforcing plate in the initial retainer so that the gap is connected to the tooth top side of the reinforcing plate teeth to form a finished retainer.

[0016] Optionally, in the above-mentioned method for preparing the retainer, in the step of preparing the initial retainer, the fiber layers and the reinforcing plates are placed alternately in sequence, and the outermost side of the initial retainer in the axial direction is the fiber layer.

[0017] Optionally, in the above-mentioned method for preparing the retaining frame, in the step of preparing the finished retaining frame, the reinforcing plate teeth of the reinforcing plate are removed from the tooth top side to the tooth root side, so that the radial distance between the tooth top side of the reinforcing plate teeth and the center of the initial retaining frame is smaller than the radial distance between the tooth top side of the fiber layer teeth and the center of the initial retaining frame.

[0018] A method for preparing a rotor structure, the rotor structure including a retainer prepared by the retainer preparation method as described in any one of the above items, comprising the steps of:

[0019] A rotor structure is prepared, magnetic steel is installed between adjacent support portions of the finished retainer, and a carbon fiber ring is sleeved on the circumferential surface of the outer diameter side of the finished retainer to form the rotor structure.

[0020] Optionally, in the above-mentioned method for preparing the rotor structure, an insulating material is filled between the circumferential surface on the outer diameter side of the finished retainer and the inner ring wall of the carbon fiber ring.

[0021] Optionally, in the above-mentioned method for preparing the rotor structure, in the step of preparing the rotor structure, the outer circumferential surface of the magnetic steel, the circumferential surface of the outer diameter side of the finished retaining frame and the inner ring wall of the carbon fiber ring are all coated with insulating glue.

[0022] A rotor structure, wherein the rotor structure is prepared using the method for preparing a rotor structure as described in any one of the above items, comprising:

[0023] a retainer, the retainer comprising a reinforcing plate and a fiber layer arranged along the axial direction of the reinforcing plate;

[0024] The reinforcing plate includes the plate body and reinforcing plate teeth spaced apart along the circumference of the plate body, and a gap is formed on at least one of the reinforcing plate teeth of the reinforcing plate, and the gap passes through at least from the root side of the reinforcing plate tooth to the tooth top side of the reinforcing plate tooth;

[0025] The fiber layer includes a disc body and the fiber layer teeth spaced apart along the circumference of the disc body, the fiber layer teeth and the reinforcing plate teeth being arranged correspondingly to form the support portion at the positions of the fiber layer teeth and the reinforcing plate teeth of the retainer;

[0026] A magnetic steel is disposed between adjacent support portions;

[0027] The carbon fiber ring is sleeved on the circumferential surface of the outer diameter side of the retainer, and the circumferential surface of the outer diameter side of the retainer and the inner ring wall of the carbon fiber ring are filled with insulating material.

[0028] Optionally, in the above rotor structure, the gaps include at least two parallel gaps, and the gaps extend from the tooth root side of the reinforcing plate teeth toward the plate body by a preset distance.

[0029] Optionally, in the above-mentioned rotor structure, the radial distance between the tooth top side of the reinforcing plate teeth and the center of the retaining frame is smaller than the radial distance between the tooth top side of the fiber layer teeth and the center of the retaining frame, so as to form a filling gap for filling insulating material between the support portion of the retaining frame and the inner ring wall of the carbon fiber ring.

[0030] Optionally, in the above rotor structure, the magnetic steel is embedded between adjacent support parts, and the magnetic steel and the support parts are matched in a concave-convex manner in the circumferential direction.

[0031] Optionally, in the above rotor structure, the retaining frame comprises at least a reinforcing plate and fiber layers provided on both sides of the reinforcing plate;

[0032] The support portion is provided with a first groove on both sides of the circumferential direction, and the first groove extends from the top side of the support portion to the bottom side of the support portion;

[0033] The magnetic steel is provided with first protrusions matched with the first grooves on both sides of the circumferential direction, and the first protrusions extend from the outer diameter end of the magnetic steel to the inner diameter end of the magnetic steel.

[0034] Optionally, in the above rotor structure, the retainer includes at least a fiber layer and reinforcement plates provided on both sides of the fiber layer, and the outermost side of the retainer in the axial direction is the fiber layer;

[0035] The support portion is provided with a second protrusion on both sides of the circumferential direction, and the second protrusion extends from the top side of the support portion to the bottom side of the support portion;

[0036] The magnetic steel is provided with second grooves matched with the second protrusions on both sides in the circumferential direction, respectively. The second grooves extend from the outer diameter end of the magnetic steel to the inner diameter end of the magnetic steel.

[0037] An axial motor comprises a rotor structure as described in any one of the above items.

[0038] The method for preparing a retaining frame provided by the present invention comprises the steps of preparing a reinforcing plate, preparing an initial retaining frame, and preparing a finished retaining frame. Among them, in the step of preparing the reinforcing plate, a connecting section is provided between the end of the gap on the reinforcing plate teeth close to the tooth top side and the tooth top side of the reinforcing plate teeth, thereby ensuring that the reinforcing plate teeth of the reinforcing plate have strong rigidity, and preventing the reinforcing plate teeth of the reinforcing plate after the slit from being superimposed together during the preparation of the retaining frame, resulting in failure of the slit; in the step of preparing the initial retaining frame, the fiber layer and the reinforcing plate are placed in a mold, and the fiber layer teeth of the fiber layer are arranged corresponding to the reinforcing plate teeth of the reinforcing plate, and the initial retaining frame is formed by heating and curing, thereby improving the rigidity of the retaining frame; in the step of preparing the finished retaining frame, the connecting section of the reinforcing plate teeth of the reinforcing plate in the initial retaining frame is removed so that the gap is connected with the tooth top side of the reinforcing plate teeth to form a finished retaining frame, thereby ensuring the effectiveness of the reinforcing plate slit in the retaining frame, and thereby reducing the path of the eddy current circuit by dividing the reinforcing plate teeth of the reinforcing plate into multiple small teeth, so as to shorten the eddy current circuit, thereby reducing eddy current loss and improving motor efficiency.

[0039] Compared with the prior art, the preparation method of the retainer provided by the present invention ensures that the reinforcing plate teeth of the reinforcing plate have strong rigidity by providing a connecting section between the end of the slit on the reinforcing plate teeth near the tooth top side and the tooth top side of the reinforcing plate teeth during the step of preparing the reinforcing plate, thereby preventing the reinforcing plate teeth of the reinforcing plate from being overlapped together after the slit is opened during the preparation of the retainer, resulting in failure of the slit. Moreover, in the step of preparing the finished retainer, the connecting section of the reinforcing plate teeth of the reinforcing plate in the initial retainer is removed so that the slit is connected with the tooth top side of the reinforcing plate teeth to form the finished retainer, thereby ensuring the effectiveness of the slit of the reinforcing plate in the retainer, thereby solving the problem that in the traditional preparation process of the retainer, after the slit on the reinforcing plate teeth is opened from the tooth root side of the reinforcing plate teeth to the tooth top side of the reinforcing plate teeth, the small teeth of the reinforcing plate after the slit is easily overlapped together during the manufacturing process of the retainer, resulting in failure of the slit. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without any creative work.

[0041] FIG1 is a schematic structural diagram of a conventional rotor structure provided by an embodiment of the present invention;

[0042] FIG2 is a schematic structural diagram of a conventional reinforcement plate provided by an embodiment of the present invention;

[0043] FIG3 is a cross-sectional view of a conventional rotor structure provided by an embodiment of the present invention;

[0044] FIG4 is a flow chart of a method for preparing a retainer provided in an embodiment of the present invention;

[0045] FIG5 is a schematic structural diagram of a reinforcement plate slit according to an embodiment of the present invention;

[0046] FIG6 is a partial enlarged view of the slit of the reinforcing plate provided in an embodiment of the present invention;

[0047] FIG7 is a schematic structural diagram of a retainer provided in Example 1 of the present invention;

[0048] FIG8 is a schematic structural diagram of a magnetic steel provided in Example 1 of the present invention;

[0049] FIG9 is a cross-sectional view of a rotor structure provided in Embodiment 1 of the present invention;

[0050] FIG10 is a schematic structural diagram of a retainer provided in Example 2 of the present invention;

[0051] FIG11 is a schematic diagram of the structure of a magnetic steel provided in Example 2 of the present invention;

[0052] FIG12 is a cross-sectional view of the rotor structure provided in the second embodiment of the present invention.

[0053] Among them, 100 is the rotor structure;

[0054] 200 is a retainer, 201 is a reinforcing plate, 2011 is a reinforcing plate tooth, 2012 is a gap, 2013 is a plate body, 2014 is a connecting section, 202 is a fiber layer, 2021 is a fiber layer tooth, 2022 is a disc body, 203 is a supporting portion, 2031 is a first groove, 2032 is a second protrusion, and 2033 is a filling gap;

[0055] 300 is a magnetic steel, 301 is a first protrusion, and 302 is a second groove;

[0056] 400 is a carbon fiber ring. DETAILED DESCRIPTION

[0057] The core of the present invention is to provide a method for preparing a retaining frame to ensure the effectiveness of the slits in the reinforcing plates of the retaining frame.

[0058] Another core of the present invention is to provide a method for preparing a rotor structure using the above-mentioned retaining frame.

[0059] Another core of the present invention is to provide a rotor structure prepared by the above-mentioned method for preparing the rotor structure.

[0060] Another core of the present invention is to provide an axial motor having the above rotor structure.

[0061] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0062] As shown in FIG4 , an embodiment of the present invention discloses a method for preparing a retaining frame 200 , including step S100 of preparing a reinforcing plate, step S101 of preparing an initial retaining frame, and step S102 of preparing a finished retaining frame.

[0063] It should be noted that, in order to reduce eddy current losses, as shown in FIG1 , for a rotor structure 100 without a back iron, the retaining frame 200 is typically made of non-metal. When the motor's outer diameter is too large or the magnetic pull on the entire rotor is too great, non-metallic materials are susceptible to deformation. Therefore, a reinforcing plate 201 is typically added to the retaining frame 200 to increase its strength and reduce the risk of deformation. However, the reinforcing plate 201 is typically made of steel. The presence of the steel plate in the retaining frame 200 generates a significant amount of eddy current losses, impacting the motor's operating efficiency. As shown in Figure 2, in order to minimize the eddy current loss generated by the reinforcing plate 201, each reinforcing plate tooth 2011 of the reinforcing plate 201 is usually slit, and the gap 2012 is passed from the root side of the reinforcing plate tooth 2011 to the top side of the tooth, so that each reinforcing plate tooth 2011 of the reinforcing plate 201 is divided into multiple small teeth, thereby reducing the path of the eddy current circuit, shortening the eddy current circuit, and further reducing the eddy current loss and improving the motor efficiency.

[0064] However, as shown in FIG3 , after the reinforcing plate 201 is added during the process of manufacturing the retaining frame 200, when the fiber layer 202 and the reinforcing plate 201 are molded together to form the final retaining frame 200, in order to ensure the strength of the reinforcing plate teeth 2011, the gap 2012 on each reinforcing plate tooth 2011 is small. In the actual process of manufacturing the retaining frame 200, it is very easy for the reinforcing plate teeth 2011 after the slits to be overlapped, resulting in failure of the slits, thereby causing the eddy current loss to still be large, thereby causing the temperature of the entire rotor structure 100 to be too high, and there is a risk of demagnetization of the magnetic steel, which reduces the working efficiency of the motor.

[0065] The preparation method of the retaining frame 200 disclosed in the embodiment of the present invention is such that in the step of preparing the reinforcing plate S100, a connecting section 2014 is provided between the end of the gap 2012 on the reinforcing plate tooth 2011 close to the tooth top side and the tooth top side of the reinforcing plate tooth 2011, thereby ensuring that the reinforcing plate teeth 2011 of the reinforcing plate 201 have strong rigidity, and preventing the reinforcing plate teeth 2011 of the reinforcing plate 201 from being stacked together after the slits are opened during the preparation of the retaining frame 200, resulting in slit failure. Moreover, in the step of preparing the finished retaining frame S102, the connecting section 2014 of the reinforcing plate teeth 2011 of the reinforcing plate 201 in the initial retaining frame is removed so that the gap 2012 is connected with the tooth top side of the reinforcing plate teeth 2011 to form a finished retaining frame, thereby ensuring the effectiveness of the slit of the reinforcing plate 201 in the retaining frame 200, thereby solving the problem that in the traditional process of preparing the retaining frame 200, after the gap 2012 on the reinforcing plate teeth 2011 is opened from the tooth root side of the reinforcing plate teeth 2011 to the tooth top side of the reinforcing plate teeth, during the manufacturing process of the retaining frame 200, the small teeth of the reinforcing plate 201 after the slit are easily overlapped, resulting in failure of the slit.

[0066] It should be noted that, in this embodiment, the reinforcing plate 201 is made of steel plate. Of course, other materials such as silicon steel plate that can improve the strength and rigidity of the retaining frame 200 can also be used.

[0067] The following will explain and illustrate the method for preparing the retaining frame 200 disclosed in the embodiment of the present invention in detail.

[0068] Step S100, preparing a reinforcing plate 201;

[0069] As shown in FIG5 , the reinforcing plate 201 includes a plate body 2013 and reinforcing plate teeth 2011 spaced circumferentially along the plate body. A slit 2012 is machined into at least one of the reinforcing plate teeth 2011 on the reinforcing plate 201 to shorten the path of the eddy current circuit and reduce eddy current losses. The slit 2012 extends axially through the reinforcing plate 201, dividing the reinforcing plate teeth 2011 into a plurality of smaller teeth. This shifts the eddy current circuit generated by the reinforcing plate 201 from a path around the reinforcing plate teeth 2011 to a path around the teeth formed by the reinforcing plate teeth 2011, thereby shortening the path of the eddy current circuit and reducing eddy current losses. Those skilled in the art will appreciate that the greater the number of slits 2012, the greater the effect of reducing eddy current losses. Specifically, a slit 2012 can be provided on one reinforcing plate tooth 2011, or on multiple reinforcing plate teeth 2011, to further reduce eddy current losses. Of course, the more gaps 2012 there are on each reinforcing plate tooth 2011, the more small teeth are separated by the reinforcing plate teeth 2011 of the reinforcing plate 201, and the shorter the path of the eddy current circuit around the small teeth separated by the reinforcing plate teeth 2011, and the lower the eddy current loss. However, as the number of gaps 2012 increases, the strength and stiffness of the reinforcing plate teeth 2011 of the reinforcing plate 201 will be affected, resulting in a decrease in the strength and stiffness of the retaining frame 200, and the difficulty of slitting the reinforcing plate teeth 2011 of the reinforcing plate 201 will increase, thereby increasing the production cost of the retaining frame 200. In this embodiment, a gap 2012 is provided on each reinforcing plate tooth 2011 of the reinforcing plate 201, and the gaps 2012 on each reinforcing plate tooth 2011 are preferably two parallel gaps, which not only reduces the difficulty of opening the reinforcing plate teeth 2011 of the reinforcing plate 201, but also makes the path of the eddy current circuit around the small teeth separated by the reinforcing plate teeth 2011 shorter, thereby ensuring the effect of reducing eddy current loss.

[0070] For ease of understanding, the end of the reinforcing plate tooth 2011 closest to the center of the plate body 2013 of the reinforcing plate 201 is defined as the tooth root side, and the end of the reinforcing plate tooth 2011 further away from the center of the plate body 2013 of the reinforcing plate 201 is defined as the tooth tip side. The gap 2012 extends at least from the tooth root side to the tooth tip side of the reinforcing plate tooth 2011 of the reinforcing plate 201, and the gap 2012 has a connecting section 2014 between the end closest to the tooth tip side of the reinforcing plate tooth 2011 and the tooth tip side of the reinforcing plate tooth 2011, as shown in FIG6 . This ensures that the tooth tip side of the reinforcing plate tooth 2011 has a certain strength and rigidity. Compared to the conventional slitting process of the reinforcing plate 201, the slits 2012 of the reinforcing plate teeth 2011 are formed from the root side of the reinforcing plate teeth 2011 to the tooth tips of the reinforcing plate teeth 2011 of the reinforcing plate 201. This prevents the multiple small teeth on the reinforcing plate teeth 2011 of the reinforcing plate 201 from being overlapped along the circumference of the reinforcing plate 201 during the subsequent heating and curing of the fiber layer 202 and the reinforcing plate 201 during the manufacture of the retainer 200, thereby preventing the slitting from failing. As shown in FIG5 , in this embodiment, the slits 2012 extend from the root side of the reinforcing plate teeth 2011 to the plate body 2013 by a predetermined distance, thereby further reducing eddy current losses.

[0071] Step S101, preparing an initial cage;

[0072] The fiber layer 202 includes a disk body 2022 and fiber layer teeth 2021 distributed at intervals along the circumference of the disk body 2022. The fiber layer 202 and the reinforcing plate 201 are placed in a mold, and it is ensured that the fiber layer teeth 2021 of the fiber layer 202 are arranged corresponding to the reinforcing plate teeth 2011 of the reinforcing plate 201, and an initial retaining frame is formed by heating and curing, and a support portion 203 for mounting the magnetic steel 300 is formed at the position of the fiber layer teeth 2021 and the reinforcing plate teeth 2011 of the initial retaining frame. Specifically, when the fiber layer 202 and the reinforcing plate 201 are placed in the mold, when there are two or more reinforcing plates 201, it is necessary to ensure that two adjacent reinforcing plates 201 are separated by the fiber layer 202, thereby reducing the eddy current loss generated by the arrangement of the reinforcing plates 201. When placing the fiber layer 202 and the reinforcing plate 201, the fiber layer 202 and the reinforcing plate 201 can be placed alternately in sequence, or multiple fiber layers 202 can be placed overlappingly. At the same time, the outermost surface of the initial retainer in the axial direction must be the fiber layer 202. This reduces turbine losses between the retainer 200's reinforcement plate 201 and the stator in the rotor structure 100 while also increasing the strength of the retainer 200. After the fiber layer 202 and reinforcement plate 201 are placed in the mold, they are heated and cured to form the initial retainer. The thickness of the fiber layer 202 determines the thickness of the retainer 200 and also affects its strength. The thickness of the fiber layer 202 is determined by the thickness of the magnetic steel 300.

[0073] Specifically, the thickness of the fiber layer 202 can be controlled by the number of layers of the fiber layer 202 laid. When the initial retaining frame adopts one reinforcing plate 201 and the reinforcing plate 201 is located between two fiber layers 202, as shown in Figures 7 and 9, the thickness of each fiber layer 202 can be n layers, 2n layers or 3n layers, etc., and the specific thickness of the fiber layer 202 needs to be determined according to the thickness of the magnetic steel 300; when the initial retaining frame adopts two reinforcing plates 201 and a fiber layer 202 is arranged between the two reinforcing plates 201, as shown in Figures 10 and 12, the thickness of the outermost fiber layer 202 can be n layers, and the thickness of the middle fiber layer 202 can be 2n layers, 4n layers or 6n layers, etc., and the specific thickness of the fiber layer 202 needs to be determined according to the thickness of the magnetic steel 300.

[0074] Step S102, preparing a finished retainer;

[0075] The connecting segments 2014 of the reinforcing plate teeth 2011 of the reinforcing plate 201 in the initial retainer are removed so that the gaps 2012 are connected to the tooth tips of the reinforcing plate teeth 2011, forming the finished retainer. Specifically, in this embodiment, the reinforcing plate teeth 2011 of the reinforcing plate 201 are removed from the tooth tips toward the tooth roots, so that the radial distance between the tooth tips of the reinforcing plate teeth 2011 and the center of the initial retainer is less than the radial distance between the tooth tips of the fiber layer teeth 2021 and the center of the initial retainer, as shown in Figures 7 and 10. Of course, the connecting segments 2014 can also be removed from the side surfaces of the reinforcing plate teeth 2011 along the circumferential direction of the reinforcing plate 201. After the fiber layer 202 and the reinforcing plate 201 are heated and cured to form an initial retaining frame, the connecting section 2014 of the reinforcing plate teeth 2011 of the reinforcing plate 201 in the initial retaining frame is removed by milling, grinding or planing, until the gap 2012 is connected with the tooth top side of the reinforcing plate teeth 2011, so that the reinforcing plate teeth 2011 of the reinforcing plate 201 are separated into multiple small teeth. By adjusting the path of the eddy current circuit around the reinforcing plate teeth 2011 to the path around the small teeth separated by the reinforcing plate teeth 2011, the eddy current circuit is shortened, thereby reducing eddy current losses and improving motor efficiency.

[0076] Furthermore, by making the gap 2012 on the reinforcing plate teeth 2011 of the reinforcing plate 201 penetrate the tooth top side of the reinforcing plate teeth 2011 after the initial retaining frame is formed, it is avoided that in the step of preparing the initial retaining frame S101, when the fiber layer 202 and the reinforcing plate 201 are heated and cured, the multiple small teeth on the reinforcing plate teeth 2011 of the reinforcing plate 201 after the slitting are stacked together, thereby ensuring the effectiveness of the slitting of the reinforcing plate 201 in the retaining frame 200.

[0077] The present invention also discloses a method for preparing a rotor structure 100, wherein the rotor structure 100 includes a retainer. The retainer 200 is prepared by the method for preparing the retainer 200 disclosed in the above embodiment. Therefore, the retainer 200 has all the technical effects of the above method for preparing the retainer 200, and will not be described in detail herein. The method for preparing the rotor structure 100 includes the steps of preparing the rotor structure.

[0078] During the steps of preparing the rotor structure, as shown in Figures 7 and 10 , the fiber layer 202 includes a disk body 2022 and fiber layer teeth 2021 spaced circumferentially along the disk body 2022. Furthermore, the fiber layer teeth 2021 of the fiber layer 202 correspond to the reinforcing plate teeth 2011 of the reinforcing plate 201, forming support portions 203 for mounting the magnetic steel 300 at the locations of the fiber layer teeth 2021 and the reinforcing plate teeth 2011 of the finished retainer. The magnetic steel 300 is mounted between adjacent support portions 203 of the finished retainer, and the carbon fiber ring 400 is sleeved onto the outer diameter circumferential surface of the finished retainer to form the rotor structure 100. Insulating material is filled between the outer diameter circumferential surface of the finished retainer and the inner annular wall of the carbon fiber ring 400. The radial distance between the tooth tips of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the center of the finished retainer is smaller than the radial distance between the tooth tips of the fiber layer teeth 2021 and the center of the finished retainer.

[0079] Because the carbon fiber ring 400 is conductive, eddy current circuits will form between the teeth of the reinforcing plate 201, increasing eddy current losses. By ensuring that the radial distance between the tooth tops of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the center of the finished retainer is smaller than the radial distance between the tooth tops of the fiber layer teeth 2021 and the center of the finished retainer, contact between the reinforcing plate teeth 2011 of the reinforcing plate 201 and the carbon fiber ring 400 can be avoided, thereby reducing eddy current losses. Furthermore, in this embodiment, when the carbon fiber ring 400 is installed, insulating adhesive is applied to the outer diameter surface of the magnetic steel 300, the outer diameter circumferential surface of the finished retainer, and the inner ring wall of the carbon fiber ring 400. Furthermore, the recessed areas of the reinforcing plate teeth 2011 of the reinforcing plate 201 are fully coated with insulating adhesive, thereby ensuring insulation between the reinforcing plate 201, the magnetic steel 300, and the carbon fiber ring 400. Alternatively, insulating varnish, insulating resin, or oxide filler may be used as the insulating material.

[0080] The present invention also discloses a rotor structure 100, which is manufactured using the method for manufacturing the rotor structure 100 disclosed in the above embodiment. Therefore, it combines all the technical benefits of the aforementioned method for manufacturing the rotor structure 100, which will not be further described herein. As shown in Figures 7 to 12 , the rotor structure 100 includes a retaining frame 200, a magnetic steel 300, and a carbon fiber ring 400.

[0081] As shown in Figures 7 and 10, the retainer 200 includes a reinforcing plate 201 and a fiber layer 202 arranged along the axial direction of the reinforcing plate 201. The reinforcing plate 201 includes a plate body 2013 and reinforcing plate teeth 2011 spaced circumferentially along the plate body 2013. A slit 2012 is formed on at least one of the reinforcing plate teeth 2011 of the reinforcing plate 201, and the slit 2012 extends from at least the root side to the top side of the reinforcing plate tooth 2011, thereby dividing the reinforcing plate teeth 2011 of the reinforcing plate 201 into a plurality of small teeth. By adjusting the path of the eddy current circuit around the reinforcing plate teeth 2011 to the path around the small teeth separated by the reinforcing plate teeth 2011, the eddy current circuit is shortened, thereby reducing eddy current losses and improving motor efficiency. It should be noted that those skilled in the art will understand that the greater the number of slits 2012, the greater the effect of reducing eddy current losses. Therefore, slits 2012 can be provided on one reinforcing plate tooth 2011, or slits 2012 can be provided on multiple reinforcing plate teeth 2011 to further reduce eddy current losses. Of course, the greater the number of slits 2012 on each reinforcing plate tooth 2011, the shorter the path of the eddy current circuit around the small teeth separated by the reinforcing plate teeth 2011, and the lower the eddy current losses. Correspondingly, this will affect the strength and rigidity of the reinforcing plate teeth 2011 of the reinforcing plate 201, resulting in a reduction in the strength and rigidity of the retaining frame 200. It will also increase the difficulty of slits in the reinforcing plate teeth 2011 of the reinforcing plate 201, increasing the manufacturing cost of the retaining frame 200. In this embodiment, as shown in FIG5 , each reinforcing plate tooth 2011 of the reinforcing plate 201 is provided with a slit 2012 . Preferably, each slit 2012 on each reinforcing plate tooth 2011 is provided with two parallel slits. This not only reduces the difficulty of slit-forming the reinforcing plate teeth 2011 of the reinforcing plate 201 , but also shortens the path of the eddy current circuit around the separated small teeth of the reinforcing plate teeth 2011, thereby ensuring the effect of reducing eddy current losses. Furthermore, the slit 2012 extends a predetermined distance from the root side of the reinforcing plate tooth 2011 toward the plate body 2013 , further reducing eddy current losses.

[0082] Furthermore, the fiber layer 202 includes a disc body 2022 and fiber layer teeth 2021 spaced circumferentially along the disc body 2022. The fiber layer teeth 2021 are arranged corresponding to the reinforcement plate teeth 2011 to form support portions 203 at the locations of the fiber layer teeth 2021 and the reinforcement plate teeth 2011 of the retainer 200, as shown in Figures 7 and 10. Furthermore, as shown in Figures 7 to 12, the magnets 300 are positioned between adjacent support portions 203 to generate a stable magnetic field. Simultaneously, a carbon fiber ring 400 is sleeved onto the outer diameter circumferential surface of the retainer 200 to protect the magnets 300 from damage by centrifugal forces. Insulating material is filled between the outer diameter circumferential surface of the retainer 200 and the inner annular wall of the carbon fiber ring 400 to prevent current leakage, which could cause electrochemical corrosion and affect the performance and lifespan of the magnets 300. This also prevents the formation of additional current paths that could lead to magnetic flux loss and affect the efficiency and output performance of the motor. In this embodiment, the filling insulating material may be, but is not limited to, insulating glue, and may also be other insulating materials, such as insulating varnish, insulating resin, or oxide filler.

[0083] Furthermore, as shown in Figures 7 and 10, the radial distance between the tooth tops of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the center of the finished retainer is smaller than the radial distance between the tooth tops of the fiber layer teeth 2021 and the center of the finished retainer, thereby forming a filling gap 2033 for filling with insulating material between the support portion 203 of the retainer 200 and the inner ring wall of the carbon fiber ring 400. Because the carbon fiber ring 400 is conductive, eddy current circuits will form between the teeth of the reinforcing plate 201, increasing eddy current losses. By making the radial distance between the tooth tops of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the center of the finished retainer smaller than the radial distance between the tooth tops of the fiber layer teeth 2021 and the center of the finished retainer, contact between the reinforcing plate teeth 2011 of the reinforcing plate 201 and the carbon fiber ring 400 can be avoided, thereby reducing eddy current losses.

[0084] Furthermore, as shown in Figures 7 to 12 , the magnet 300 is embedded between adjacent support portions 203, and the magnet 300 and the support portions 203 are circumferentially engaged with each other through a concave-convex fit, thereby securing the magnet 300 to the holder 200. Furthermore, the axial thickness of the support portions 203 of the holder 200 is equal to the thickness of the magnet 300.

[0085] Specifically, as shown in Figures 7 to 9, in one embodiment, the retainer 200 includes at least a reinforcement plate 201 and fiber layers 202 disposed on either side of the reinforcement plate 201. When only one reinforcement plate 201 is provided in the retainer 200, that is, the retainer 200 includes the reinforcement plate 201 and the fiber layers 202 disposed on either side of the reinforcement plate 201, the support portion 203 of the retainer 200 is provided with first grooves 2031 on either side of the circumferential direction. For ease of understanding, the side of the support portion 203 of the retainer 200 closer to the center of the retainer 200 is defined as the bottom side, and the side of the support portion 203 of the retainer 200 farther from the center of the retainer 200 is defined as the top side. The first grooves 2031 extend from the top side of the support portion 203 along the radial direction of the retainer 200 to the bottom side of the support portion 203. Furthermore, the sidewalls on both sides of the first groove 2031 are formed by the fiber layers 202 on both sides of the reinforcing plate 201 extending along the circumferential direction of the retainer 200, as shown in Figure 7. Furthermore, as shown in Figures 7 and 9, the end faces of the tooth tips of the reinforcing plate teeth 2011 of the reinforcing plate 201 are lower than the end faces of the tooth tips of the fiber layer teeth 2021 of the fiber layers 202 on both sides of the reinforcing plate 201. That is, the radial distance between the tooth tips of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the center of the finished retainer is smaller than the radial distance between the tooth tips of the fiber layer teeth 2021 and the center of the finished retainer. This creates a recess between the end faces of the tooth tips of the fiber layer teeth 2021 of the fiber layers 202 on both sides of the reinforcing plate 201, ensuring that a filling gap 2033 filled with insulating material is formed between the tooth tips of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the inner ring wall of the carbon fiber ring 400, thereby preventing contact between the reinforcing plate teeth 2011 of the reinforcing plate 201 and the carbon fiber ring 400. As shown in FIG8 , the magnet 300 is provided with first protrusions 301 on both sides of the circumferential direction, which cooperate with the first grooves 2031. The first protrusions 301 extend from the outer diameter end of the magnet 300 along the radial direction of the magnet 300 to the inner diameter end of the magnet 300. During assembly, the inner diameter end of the magnet 300 only needs to be inserted between adjacent support portions 203 of the retainer 200. At this time, the first protrusions 301 provided on both sides of the circumferential direction of the magnet 300 are embedded in the corresponding first grooves 2031 on the adjacent support portions 203. The outer diameter end surface of the magnet 300 and the end surface of the fiber layer teeth 2021 of the fiber layer 202 on the tooth top side are on the same circumferential surface. This allows the preload force applied to the retainer 200 by the carbon fiber ring 400 to better protect the magnet 300 and prevent the magnet 300 from being damaged by centrifugal force, as shown in FIG9 . It should be noted that the reinforcing plates 201 may also be two or more pieces, and the fiber layer 202 may also be multiple layers. It is only necessary to ensure that adjacent reinforcing plates 201 are separated by the fiber layer 202 and the outermost side of the retaining frame 200 is the fiber layer 202.

[0086] As shown in Figures 10 to 12, in another specific embodiment, the retainer 200 includes at least a fiber layer 202 and reinforcement plates 201 disposed on both sides of the fiber layer 202, and the outermost side of the retainer 200 in the axial direction is the fiber layer 202. When two reinforcement plates 201 are provided in the retainer 200, that is, the retainer 200 includes the fiber layer 202 and the reinforcement plates 201 disposed on both sides of the fiber layer 202, and to reduce eddy current losses generated between the reinforcement plates 201 in the retainer 200 and the stator, the fiber layer 202 is disposed on the outermost side of the retainer 200. For ease of understanding, the fiber layer 202 between the two reinforcement plates 201 is defined as the first fiber layer, and the fiber layer 202 on the outermost side of the retainer 200 is defined as the second fiber layer. The support portion 203 is provided with second protrusions 2032 on both sides in the circumferential direction, and the second protrusions 2032 extend from the top side of the support portion 203 along the radial direction of the retaining frame 200 to the bottom side of the support portion 203. The second protrusions 2032 are provided on both sides of the first fiber layer along the circumferential direction of the retaining frame 200, as shown in FIG10. At the same time, as shown in FIG10 and FIG12, the end face of the tooth top side of the reinforcing plate teeth 2011 of the reinforcing plate 201 is lower than the end face of the tooth top side of the fiber layer teeth 2021 of the first fiber layer, and the end face of the tooth top side of the fiber layer teeth 2021 of the second fiber layer is flush with the end face of the tooth top side of the reinforcing plate teeth 2011 of the reinforcing plate 201, that is, the radial distance between the tooth top side of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the center of the finished retaining frame is smaller than the radial distance between the tooth top side of the fiber layer teeth 2021 of the first fiber layer and the center of the finished retaining frame, and the reinforcing plate The radial distance between the tooth tops of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the center of the finished retainer is equal to the radial distance between the tooth tops of the fiber layer teeth 2021 of the second fiber layer and the center of the finished retainer. This forms recesses on the tooth tops of the reinforcing plate teeth 2011 of the reinforcing plate 201 on both sides of the first fiber layer, ensuring that gaps 2033 filled with insulating material are formed between the tooth tops of the reinforcing plate teeth 2011 of the reinforcing plate 201 and the inner ring wall of the carbon fiber ring 400, thereby preventing contact between the reinforcing plate teeth 2011 of the reinforcing plate 201 and the carbon fiber ring 400. As shown in FIG11 , second grooves 302 that mate with the second protrusions 2032 are provided on both sides of the magnetic steel 300 in the circumferential direction. The second grooves 302 extend from the outer diameter end of the magnetic steel 300 along the radial direction of the magnetic steel 300 to the inner diameter end of the magnetic steel 300.During assembly, it is only necessary to insert the inner diameter end of the magnet 300 between the adjacent support parts 203 of the retaining frame 200. At this time, the second grooves 302 provided on both sides of the circumferential direction of the magnet 300 are embedded in the corresponding second protrusions 2032 on the adjacent support parts 203, and the end face of the outer diameter end of the magnet 300 and the end face of the tooth top side of the fiber layer teeth 2021 of the first fiber layer of the retaining frame 200 are on the same circumferential surface, so that a pre-tightening force is applied to the retaining frame 200 through the carbon fiber ring 400, thereby better protecting the magnet 300 and preventing the magnet 300 from being damaged by centrifugal force, as shown in Figure 12.

[0087] The embodiment of the present invention further discloses an axial motor, which includes the rotor structure 100 disclosed in the above embodiment, and thus has all the technical effects of the above rotor structure 100, which will not be described in detail herein.

[0088] The terms "first," "second," and the like in the specification, claims, and accompanying drawings of the present invention are used to distinguish between different items, not to describe a specific order. Furthermore, the terms "including," "having," and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or apparatus comprising a series of steps or elements is not limited to the listed steps or elements and may include steps or elements that are not listed.

[0089] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for preparing a retainer, characterized in that: Including steps: A reinforcing plate (201) is prepared, wherein the reinforcing plate (201) comprises a plate body (2013) and reinforcing plate teeth (2011) spaced apart along the circumference of the plate body (2013); a gap (2012) for reducing eddy current loss is provided on at least one of the reinforcing plate teeth (2011) on the reinforcing plate (201), and the gap (2012) extends at least from the tooth root side of the reinforcing plate tooth (2011) to the tooth top side of the reinforcing plate tooth (2011); and the gap (2012) has a connecting section (2014) between an end portion close to the tooth top side and the tooth top side of the reinforcing plate tooth (2011); An initial retainer is prepared, the fiber layer (202) and the reinforcing plate (201) are placed in a mold, the fiber layer teeth (2021) of the fiber layer (202) and the reinforcing plate teeth (2011) of the reinforcing plate (201) are arranged correspondingly, and the initial retainer is formed by heating and curing, and the support portion (203) of the initial retainer is formed at the position of the fiber layer teeth (2021) and the reinforcing plate teeth (2011); A finished retainer is prepared by removing the connecting section (2014) of the reinforcing plate teeth (2011) of the reinforcing plate (201) in the initial retainer so that the gap (2012) is connected to the tooth top side of the reinforcing plate teeth (2011) to form a finished retainer.

2. The method for preparing a retainer according to claim 1, wherein: In the step of preparing the initial retainer, the fiber layer (202) and the reinforcing plate (201) are placed alternately in sequence, and the outermost side of the initial retainer in the axial direction is the fiber layer (202).

3. The method for preparing a retainer according to claim 1, wherein: In the step of preparing the finished retainer, the reinforcing plate teeth (2011) of the reinforcing plate (201) are removed from the tooth top side to the tooth root side, so that the radial distance between the tooth top side of the reinforcing plate teeth (2011) and the center of the initial retainer is smaller than the radial distance between the tooth top side of the fiber layer teeth (2021) and the center of the initial retainer.

4. A method for preparing a rotor structure, the rotor structure comprising a retainer prepared by the method for preparing a retainer according to any one of claims 1 to 3, characterized in that: Including steps: A rotor structure is prepared, magnetic steel (300) is installed between adjacent support portions (203) of the finished retainer, and a carbon fiber ring (400) is sleeved on the circumferential surface of the outer diameter side of the finished retainer to form a rotor structure (100).

5. The method for preparing a rotor structure according to claim 4, characterized in that: Insulating material is filled between the circumferential surface on the outer diameter side of the finished retainer and the inner ring wall of the carbon fiber ring (400).

6. The method for preparing a rotor structure according to claim 4, characterized in that: In the step of preparing the rotor structure, the outer circumferential surface of the magnetic steel (300), the circumferential surface on the outer diameter side of the finished retainer, and the inner ring wall of the carbon fiber ring (400) are all coated with insulating glue.

7. A rotor structure, wherein the rotor structure is prepared by the method for preparing a rotor structure according to any one of claims 4 to 6, wherein: include: A retainer (200), the retainer (200) comprising a reinforcing plate (201) and a fiber layer (202) arranged along the axial direction of the reinforcing plate (201); The reinforcing plate (201) comprises the plate body (2013) and reinforcing plate teeth (2011) distributed at intervals along the circumference of the plate body (2013), and a gap (2012) is provided on at least one of the reinforcing plate teeth (2011) of the reinforcing plate (201), wherein the gap (2012) passes through at least from the tooth root side of the reinforcing plate tooth (2011) to the tooth top side of the reinforcing plate tooth (2011); The fiber layer (202) comprises a disc body (2022) and the fiber layer teeth (2021) distributed at intervals along the circumference of the disc body (2022), the fiber layer teeth (2021) being arranged corresponding to the reinforcing plate teeth (2011) to form the support portion (203) at the positions of the fiber layer teeth (2021) and the reinforcing plate teeth (2011) of the retaining frame (200); A magnetic steel (300) is disposed between adjacent support portions (203); The carbon fiber ring (400) is sleeved on the circumferential surface on the outer diameter side of the retaining frame (200), and an insulating material is filled between the circumferential surface on the outer diameter side of the retaining frame (200) and the inner ring wall of the carbon fiber ring (400).

8. The rotor structure according to claim 7, characterized in that: The slits (2012) include at least two parallel slits, and the slits (2012) extend from the tooth root side of the reinforcing plate teeth (2011) toward the plate body (2013) by a preset distance.

9. The rotor structure according to claim 7, characterized in that: The radial distance between the tooth top side of the reinforcing plate teeth (2011) and the center of the retaining frame is smaller than the radial distance between the tooth top side of the fiber layer teeth (2021) and the center of the retaining frame, so as to form a filling gap (2033) for filling with insulating material between the support portion (203) of the retaining frame (200) and the inner ring wall of the carbon fiber ring (400).

10. The rotor structure according to claim 7, characterized in that: The magnetic steel (300) is embedded between adjacent support portions (203), and the magnetic steel (300) and the support portions (203) are matched in a concave-convex manner in the circumferential direction.

11. The rotor structure according to claim 10, characterized in that: The retaining frame (200) comprises at least a reinforcing plate (201) and fiber layers (202) arranged on both sides of the reinforcing plate (201); The support portion (203) is provided with first grooves (2031) on both sides in the circumferential direction, respectively, and the first grooves (2031) extend from the top side of the support portion (203) to the bottom side of the support portion (203); The magnetic steel (300) is provided with first protrusions (301) respectively on both sides in the circumferential direction, which cooperate with the first groove (2031); the first protrusions (301) extend from the outer diameter end of the magnetic steel (300) to the inner diameter end of the magnetic steel (300).

12. The rotor structure according to claim 10, characterized in that: The retaining frame (200) comprises at least a fiber layer (202) and reinforcing plates (201) arranged on both sides of the fiber layer (202), and the outermost side surface of the retaining frame (200) in the axial direction is the fiber layer (202); The support portion (203) is provided with second protrusions (2032) on both sides in the circumferential direction, respectively, and the second protrusions (2032) extend from the top side of the support portion (203) to the bottom side of the support portion (203); The magnetic steel (300) is provided with second grooves (302) respectively on both sides in the circumferential direction, which cooperate with the second protrusion (2032). The second grooves (302) extend from the outer diameter end of the magnetic steel (300) to the inner diameter end of the magnetic steel (300).

13. An axial motor, characterized in that: The axial motor comprises the rotor structure according to any one of claims 7 to 12.

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