Rotor lamination for high-efficiency permanent magnet synchronous electric motor

Abstract

The present invention relates to the technical field of permanent magnet synchronous electric motors. Provided is a rotor lamination for a high-efficiency permanent magnet synchronous electric motor. The rotor lamination provided in the present invention is designed on the basis of the following steps: on the basis of symmetry, designing a pole of a rotor lamination of an electric motor as a sector, wherein the central angle of the sector is 180 / p degrees, and p is the number of pole pairs; and with the central axis , of the sector, a boundary straight line of the sector and an inner circular arc line of a stator of the electric motor as references, using a geometric construction method to draw boundary positions of holes, wherein the formed holes are configured to insert permanent magnets having rectangular cross sections, and the permanent magnets in the holes have the same specification. The present invention enables the rapid design of serialized high-efficiency permanent magnet rotor laminations, thereby reducing the cost of an electric motor. As the outer side area of a pole portion is relatively small, the stress of a rotor reinforcing rib is relatively small. The width of a linear permanent magnet is relatively small, thereby reducing the magnetic flux density of a stator and further reducing the iron loss of the stator. A rotor core formed by laminating laminations designed in the present invention can allow for the insertion of permanent magnets having rectangular cross sections, thereby reducing the manufacturing and mounting costs of the permanent magnets.

Description

Rotor laminations of a high-efficiency permanent magnet synchronous motor Technical Field

[0001] This invention relates to the field of permanent magnet synchronous motor technology, and specifically to a rotor lamination for a high-efficiency permanent magnet synchronous motor. Background Technology

[0002] Variable frequency speed control permanent magnet synchronous motors have the advantage of high efficiency, but if the amount of permanent magnets used is too large, it will lead to excessive excitation, resulting in excessive stator magnetic flux density and increased stator iron loss. As a result, the motor cannot achieve higher efficiency by increasing the armature diameter and length.

[0003] The rotor of the variable frequency speed control permanent magnet synchronous motor adopts a permanent magnet insertion structure, which reduces the difficulty of manufacturing permanent magnet rotors and facilitates automated mass production. However, the pole area of ​​traditional V-type, double V-type, and inverted A-type permanent magnet insertion topologies is too large, which leads to excessive centrifugal stress in the magnetic bridge part. The large amount of permanent magnets used in the rotor leads to large iron loss in the stator, thereby reducing motor efficiency.

[0004] Invention patent CN112653274 B, "Rotor Laminations and Permanent Magnet Motor Rotor," employs a double-V structure. The excessively large area of ​​the silicon steel portion outside the permanent magnet leads to excessive centrifugal stress in the magnetic bridge section. CN109742879 B, "A Permanent Magnet Motor Rotor Structure," uses multiple arc segments or multiple arc segments and multiple line segments connected symmetrically along the circumference of the rotor core, creating an uneven air gap. While this reduces stray losses in the permanent magnet motor, it increases the air gap, thereby reducing torque.

[0005] Therefore, in order to further improve the efficiency of permanent magnet motors, it is necessary to provide a rotor lamination suitable for high-efficiency permanent magnet synchronous motors. The equal air gap, straight-line rotor permanent magnet topology designed in this invention reduces pole area, rotor magnetic bridge stress, stator iron loss, no-load cogging torque, and load torque fluctuation, thus realizing the rotor lamination design for a series of high-efficiency permanent magnet motors. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of the prior art by providing a rotor lamination for a high-efficiency permanent magnet synchronous motor, thereby solving the problem of rapid and serialized design and optimization of rotor laminations for high-efficiency permanent magnet synchronous motors.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] This invention provides a rotor lamination for a high-efficiency permanent magnet synchronous motor, which is designed and manufactured through the following steps:

[0009] S1: Based on symmetry, one pole of the motor rotor lamination is designed as a sector with an unfolding angle of 180 / p degrees, where p is the number of pole pairs. The rotor structure under one pole is symmetrical about the central axis X of the sector. The straight line of the left boundary of the sector is Y. The part of the inner circle of the motor stator corresponding to this one pole is arc L1, with the center of the circle being the center of the motor shaft O. The radius of arc L1 is R1. Arc L1 is offset towards the center of the circle by the air gap length g1 to obtain the outer circle boundary arc L2 of the motor rotor. The radius of L2 is R2, and R2 = R1 - g1.

[0010] S2: The arc L2 is offset by a distance g2 towards the center to obtain the arc L3, whose radius is R3, and R3 = R 2 -g2;

[0011] S3: The central axis X is rotated by an angle a1 / 2 around O towards the boundary line Y to obtain the line OA, which intersects L3 at point A;

[0012] S4: Draw a straight line L4 through point A, perpendicular to the central axis X. The distance from point A to the central axis is b1. Offset L4 by a distance h1 towards the center of the circle to obtain a straight line L5. L5 intersects the central axis at point K.

[0013] Switch to S5.1, S6.1, or S7.1;

[0014] S5.1: The central axis X is offset by a distance g3 / 2 in the Y direction of the boundary line to obtain line segment JH. JH intersects L4 at point H and JH intersects L5 at point J.

[0015] S5.2: The straight line JH is offset by a distance b2 in the direction of the boundary straight line Y to obtain the line segment DE. DE intersects L5 at point D. The length of DJ is b2, the length of DE is g4, and the direction from point D to point E points towards one side of the straight line L4.

[0016] S5.3: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle.

[0017] S5.4: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 at point B. A line BC parallel to the boundary line Y is drawn through point B. A line perpendicular to BC is drawn through point G, with the foot of the perpendicular at point C.

[0018] S5.5: The polygon BCGFEDJHA forms a hole. After mirroring this hole about the central axis, two holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets inside the holes are of the same size, and the sharp corners of each hole are rounded.

[0019] Proceed to step S8;

[0020] S6.1: The central axis X intersects line L4 and line L5 at points M and K;

[0021] S6.2: The central axis X is offset by a distance b3 / 2 in the direction of the boundary line Y to obtain line segment QR. QR intersects L4 at point R and QR intersects L5 at point Q.

[0022] S6.3: QR is offset by a distance g3 in the Y direction of the boundary line to obtain line segment PN. PN intersects L4 at point N and L5 at point P.

[0023] S6.4: PN is offset by a distance b3 in the Y direction of the boundary line to obtain line segment DE. DE intersects L5 at point D. The length of DJ is b2, and the length of DE is g4. The direction from point D to point E points towards one side of line L4.

[0024] S6.5: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle.

[0025] S6.6: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 and B. A line BC parallel to the boundary line Y is drawn through B. A line perpendicular to BC is drawn through G, with the foot of the perpendicular at C.

[0026] S6.7: Polygon BCGEDPNA forms one hole, and quadrilateral RQKM forms another hole. After mirroring the above two holes about the central axis, three holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets in the holes are of the same specifications, and the sharp corners of each hole are rounded.

[0027] Proceed to step S8;

[0028] S7.1: The central axis X intersects lines L4 and L5 at points M and K, respectively;

[0029] S7.2: The straight line KM is offset by a distance g3 / 2 in the Y direction of the boundary line to obtain the line segment JH. JH intersects L4 at point H and JH intersects L5 at point J.

[0030] S7.3: The straight line JH is offset by a distance b4 in the direction of the boundary straight line Y to obtain the line segment QR. QR intersects L4 at point R and QR intersects L5 at point Q.

[0031] S7.4: The line QR is offset by a distance g3 in the direction of the boundary line Y to obtain the line segment PN. PN intersects L4 at point N and L5 at point P.

[0032] S7.5: PN is offset by a distance b4 in the Y direction of the boundary line to obtain line segment DE. DE intersects L5 at point D. The length of DJ is b2, the length of DE is g4, and the direction from point D to point E points towards one side of line L4.

[0033] S7.6: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle.

[0034] S7.7: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 and B. A line BC parallel to the boundary line Y is drawn through B. A line perpendicular to BC is drawn through G, with the foot of the perpendicular at C.

[0035] S7.8: Polygon BCGEDPNA forms one hole, and quadrilateral RQJH forms another hole. After mirroring the above two holes about the central axis, four holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets in the holes are of the same size, and the sharp corners of each hole are rounded.

[0036] S8: The hole structure under other residual poles is replicated by a circular array.

[0037] Optionally, straight line L5 is offset by a distance h2 towards the center to obtain straight line L6; the inner circular arc L8 of the rotor is offset by a distance h3 away from the center to obtain arc L7; a straight line L9 is drawn through point K, with an angle a3 between L9 and the central axis X, where a3 is between 40 and 50 degrees; the boundary straight line Y is offset by a distance h4 towards the central axis X to obtain straight line L. 10 The aforementioned straight line L6, arc L7, straight line L9, and straight line L 10 A hole is formed by L6 and L9, and this hole is mirrored about the central axis X to form a larger hole. The corner between L6 and L9 is rounded with r1. 10 The fillet between L7 and L9 is rounded with r2, and L7 and L9 are rounded with r2. 10 The corners are rounded (r3) and the above hole structures under other residual electrodes are replicated through a circular array; the value range of h2 is 0.15×R1 / p to 0.4×R1 / p, the value range of h3 is 0.15×R1 / p to 0.5×R1 / p, the value range of h4 is 0.05×R1 / p to 0.5×R1 / p, the value range of r1 is 0.04×R1 / p to 0.4×R1 / p, the value range of r2 is 0.04×R1 / p to 0.2×R1 / p, and the value range of r3 is 0.04×R1 / p to 0.2×R1 / p.

[0038] Optionally, in S1, the pole pair number p is one of the following: 2, 3, 4; and in S1, the radius R1 ranges from 25 mm to 220 mm.

[0039] Optionally, in S2, the value range of g2 is from g1 to 2×g1; in S3, the value range of a1 is from 0.64×180 / p degrees to 0.8×180 / p degrees.

[0040] Optionally, in S4, the value of h1 ranges from 3 × g1 to 5 × g1; in S5.1, S6.3 and S7.2, the value of g3 ranges from 0 or 0.5 mm to 2 mm.

[0041] Optionally, in S5.2, the value of b2 ranges from 0.85×b1 to 0.91×b1; in S5.2, S6.4 and S7.5, the value of g4 ranges from 0.4 mm to 2 mm; in S5.3, S6.5 and S7.6, the value of g5 ranges from 0.7 mm to 2 mm.

[0042] Optionally, in S5.4, S6.6 and S7.7, the value range of a2 is from 0.024×180 / p degree to 0.026×180 / p degree.

[0043] Optionally, in S6.2, the value range of b3 is 0.56×b1 to 0.61×b1; in S7.3, the value range of b4 is 0.42×b1 to 0.46×b1.

[0044] Optionally, the cavity containing the permanent magnet slot is filled with insulating material to reduce the maximum stress on the rotor.

[0045] The beneficial effects of this invention include:

[0046] The rotor laminations provided by this invention are designed according to the following steps: Based on symmetry, one pole of the motor rotor lamination is designed as a sector, with an expansion angle of 180 / p degrees, where p is the number of pole pairs; using the central axis of the sector, the boundary line, and the inner arc of the motor stator as references, the boundary position of the hole is drawn using a geometric drawing method. The formed hole is used to insert a permanent magnet with a rectangular cross-section, and the permanent magnets inside the hole have the same specifications. This invention enables the rapid design of a series of high-efficiency permanent magnet rotor laminations, improving standardization and serialization levels, thereby reducing motor costs; because the outer area of ​​the pole is small, the stress on the rotor reinforcing ribs is small; the rotor can have larger weight-reducing holes, reducing rotor weight; the narrow width of the straight permanent magnet reduces the stator magnetic flux density, thereby reducing stator iron loss; the optimization of the magnetic bridge position can reduce the rotor's no-load cogging torque and torque fluctuation under load; the rotor core with laminated laminations designed by this invention can insert a rectangular cross-section permanent magnet, reducing the manufacturing and installation costs of the permanent magnet. Attached Figure Description

[0047] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0048] Figure 1A shows a schematic diagram of the structure of one pole of an 8-pole permanent magnet synchronous motor rotor lamination provided in an embodiment of the present invention;

[0049] Figures 1B and 1C show enlarged views of parts of Figure 1A;

[0050] Figure 2A shows a schematic diagram of the structure of one pole of an 8-pole permanent magnet synchronous motor rotor lamination provided in an embodiment of the present invention;

[0051] Figure 2B shows a partial enlarged view of Figure 2A;

[0052] Figure 3 shows a schematic diagram of the structure of one pole of an 8-pole permanent magnet synchronous motor rotor lamination provided in an embodiment of the present invention;

[0053] Figure 4A shows a schematic diagram of the structure of one pole of an 8-pole permanent magnet synchronous motor rotor lamination provided in an embodiment of the present invention.

[0054] Figure 4B shows a partial enlarged view of Figure 4A;

[0055] Figure 5 shows a schematic diagram of an 8-pole complete rotor lamination with a permanent magnet inserted, provided in an embodiment of the present invention.

[0056] Figure 6 shows a schematic diagram of a complete 6-pole rotor lamination with a permanent magnet inserted, provided in an embodiment of the present invention.

[0057] Figure 7 shows a schematic diagram of a complete 4-pole rotor lamination with a permanent magnet inserted according to an embodiment of the present invention. Detailed Implementation

[0058] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0059] The rotor of a variable frequency speed-regulating permanent magnet synchronous motor adopts a permanent magnet insertion structure, which reduces the difficulty of manufacturing permanent magnet rotors and facilitates automated mass production. However, traditional V-type, double V-type, and inverted A-type permanent magnet insertion topologies suffer from excessively large pole areas, leading to excessive centrifugal stress in the magnetic bridge section. The large amount of permanent magnets used in the rotor also results in significant iron losses in the stator, thus reducing motor efficiency. Therefore, to further improve the efficiency of permanent magnet motors, it is necessary to provide a rotor lamination suitable for high-efficiency permanent magnet synchronous motors. This involves designing an equal air gap, straight-line rotor permanent magnet topology to reduce pole area, rotor magnetic bridge stress, stator iron losses, no-load cogging torque, and load torque fluctuations, thereby achieving a series of high-efficiency permanent magnet motor rotor lamination designs.

[0060] Figures 1A and 2A show a schematic diagram of the structure of one pole of a permanent magnet synchronous motor rotor lamination provided in an embodiment of the present invention; Figures 1B to 1C are enlarged views of parts I and II in Figure 1A, respectively, and Figure 2B is an enlarged view of part I in Figure 2A, with an enlargement ratio of 4:1.

[0061] Figure 3 shows a schematic diagram of the structure of one pole of a rotor lamination of another permanent magnet synchronous motor provided in an embodiment of the present invention.

[0062] Figure 4A shows a schematic diagram of the structure of one pole of a permanent magnet synchronous motor rotor lamination provided in another embodiment of the present invention; Figure 4B is an enlarged view of part I in Figure 4A, and the magnification ratio is 4:1.

[0063] Figure 5 shows a schematic diagram of a complete rotor lamination with a permanent magnet inserted according to an embodiment of the present invention; Figure 6 shows a schematic diagram of a complete 6-pole rotor lamination with a permanent magnet inserted according to an embodiment of the present invention; Figure 7 shows a schematic diagram of a complete 4-pole rotor lamination with a permanent magnet inserted according to an embodiment of the present invention.

[0064] In Figures 1A and 2A, each pole has two permanent magnet slots, holding two rectangular cross-section permanent magnets; in Figure 3, each pole has three permanent magnet slots, holding three rectangular cross-section permanent magnets; and in Figure 4A, each pole has four permanent magnet slots, holding four rectangular cross-section permanent magnets. As shown in Figures 1A to 4A, increasing the number of permanent magnet slots can reduce the centrifugal stress of the magnetic bridge and decrease the width dimension of the permanent magnet without increasing the magnetic bridge width, thus preventing the permanent magnet from becoming too flat. When the magnetic bridge width g3 is zero in Figures 1A, 3, and 4A, the permanent magnet slot is reduced to one, holding one rectangular cross-section permanent magnet. Figure 5 shows permanent magnet 52 and silicon steel sheet 51; Figure 6 shows permanent magnet 62 and silicon steel sheet 61; and Figure 7 shows permanent magnet 72 and silicon steel sheet 71.

[0065] The technical solution of the present invention will now be described in detail with reference to Figures 1A to 7.

[0066] This invention provides a rotor lamination for a high-efficiency permanent magnet synchronous motor, which is designed and manufactured through the following steps:

[0067] S1: Based on symmetry, one pole of the motor rotor lamination is designed as a sector with an unfolding angle of 180 / p degrees, where p is the number of pole pairs. The rotor structure under one pole is symmetrical about the central axis X of the sector. The straight line of the left boundary of the sector is Y. The part of the inner circle of the motor stator corresponding to this one pole is arc L1, with the center of the circle being the center of the motor shaft O. The radius of arc L1 is R1. Arc L1 is offset towards the center of the circle by the air gap length g1 to obtain the outer circle boundary arc L2 of the motor rotor. The radius of L2 is R2, and R2 = R1 - g1.

[0068] S2: The arc L2 is offset by a distance g2 towards the center to obtain the arc L3, whose radius is R3, and R3 = R 2 -g2;

[0069] S3: The central axis X is rotated by an angle a1 / 2 around O towards the boundary line Y to obtain the line OA, which intersects L3 at point A;

[0070] S4: Draw a straight line L4 through point A, perpendicular to the central axis X. The distance from point A to the central axis is b1. Offset L4 by a distance h1 towards the center of the circle to obtain a straight line L5. L5 intersects the central axis at point K.

[0071] Switch to S5.1, S6.1, or S7.1;

[0072] S5.1: The central axis X is offset by a distance g3 / 2 in the Y direction of the boundary line to obtain line segment JH. JH intersects L4 at point H and JH intersects L5 at point J.

[0073] S5.2: The straight line JH is offset by a distance b2 in the direction of the boundary straight line Y to obtain the line segment DE. DE intersects L5 at point D. The length of DJ is b2, the length of DE is g4, and the direction from point D to point E points towards one side of the straight line L4.

[0074] S5.3: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle.

[0075] S5.4: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 at point B. A line BC parallel to the boundary line Y is drawn through point B. A line perpendicular to BC is drawn through point G, with the foot of the perpendicular at point C.

[0076] S5.5: The polygon BCGFEDJHA forms a hole. After mirroring this hole about the central axis, two holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets inside the holes are of the same size, and the sharp corners of each hole are rounded.

[0077] Proceed to step S8;

[0078] S6.1: The central axis X intersects line L4 and line L5 at points M and K;

[0079] S6.2: The central axis X is offset by a distance b3 / 2 in the direction of the boundary line Y to obtain line segment QR. QR intersects L4 at point R and QR intersects L5 at point Q.

[0080] S6.3: QR is offset by a distance g3 in the Y direction of the boundary line to obtain line segment PN. PN intersects L4 at point N and L5 at point P.

[0081] S6.4: PN is offset by a distance b3 in the Y direction of the boundary line to obtain line segment DE. DE intersects L5 at point D. The length of DJ is b2, and the length of DE is g4. The direction from point D to point E points towards one side of line L4.

[0082] S6.5: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle.

[0083] S6.6: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 and B. A line BC parallel to the boundary line Y is drawn through B. A line perpendicular to BC is drawn through G, with the foot of the perpendicular at C.

[0084] S6.7: Polygon BCGEDPNA forms one hole, and quadrilateral RQKM forms another hole. After mirroring the above two holes about the central axis, three holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets in the holes are of the same specifications, and the sharp corners of each hole are rounded.

[0085] Proceed to step S8;

[0086] S7.1: The central axis X intersects lines L4 and L5 at points M and K, respectively;

[0087] S7.2: The straight line KM is offset by a distance g3 / 2 in the Y direction of the boundary line to obtain the line segment JH. JH intersects L4 at point H and JH intersects L5 at point J.

[0088] S7.3: The straight line JH is offset by a distance b4 in the direction of the boundary straight line Y to obtain the line segment QR. QR intersects L4 at point R and QR intersects L5 at point Q.

[0089] S7.4: The line QR is offset by a distance g3 in the direction of the boundary line Y to obtain the line segment PN. PN intersects L4 at point N and L5 at point P.

[0090] S7.5: PN is offset by a distance b4 in the Y direction of the boundary line to obtain line segment DE. DE intersects L5 at point D. The length of DJ is b2, the length of DE is g4, and the direction from point D to point E points towards one side of line L4.

[0091] S7.6: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle.

[0092] S7.7: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 and B. A line BC parallel to the boundary line Y is drawn through B. A line perpendicular to BC is drawn through G, with the foot of the perpendicular at C.

[0093] S7.8: Polygon BCGEDPNA forms one hole, and quadrilateral RQJH forms another hole. After mirroring the above two holes about the central axis, four holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets in the holes are of the same size, and the sharp corners of each hole are rounded.

[0094] S8: The hole structure under other residual poles is replicated by a circular array.

[0095] The rotor laminations provided by this invention are designed according to the following steps: Based on symmetry, one pole of the motor rotor lamination is designed as a sector, with an expansion angle of 180 / p degrees, where p is the number of pole pairs; using the central axis of the sector, the boundary line, and the inner arc of the motor stator as references, the boundary position of the hole is drawn using a geometric drawing method. The formed hole is used to insert a permanent magnet with a rectangular cross-section, and the permanent magnets inside the hole have the same specifications. This invention enables the rapid design of a series of high-efficiency permanent magnet rotor laminations, improving standardization and serialization levels, thereby reducing motor costs; because the outer area of ​​the pole is small, the stress on the rotor reinforcing ribs is small; the rotor can have larger weight-reducing holes, reducing rotor weight; the narrow width of the straight permanent magnet reduces the stator magnetic flux density, thereby reducing stator iron loss; the optimization of the magnetic bridge position can reduce the rotor's no-load cogging torque and torque fluctuation under load; the rotor core with laminated laminations designed by this invention can insert a rectangular cross-section permanent magnet, reducing the manufacturing and installation costs of the permanent magnet.

[0096] Optionally, straight line L5 is offset by a distance h2 towards the center to obtain straight line L6; the inner circular arc L8 of the rotor is offset by a distance h3 away from the center to obtain arc L7; a straight line L9 is drawn through point K, with an angle a3 between L9 and the central axis X, where a3 is between 40 and 50 degrees; the boundary straight line Y is offset by a distance h4 towards the central axis X to obtain straight line L. 10 The aforementioned straight line L6, arc L7, straight line L9, and straight line L 10 A hole is formed by L6 and L9, and this hole is mirrored about the central axis X to form a larger hole. The corner between L6 and L9 is rounded with r1. 10 The fillet between L7 and L9 is rounded with r2, and L7 and L9 are rounded with r2. 10 The corners are rounded (r3) and the above hole structures under other residual electrodes are replicated through a circular array; the value range of h2 is 0.15×R1 / p to 0.4×R1 / p, the value range of h3 is 0.15×R1 / p to 0.5×R1 / p, the value range of h4 is 0.05×R1 / p to 0.5×R1 / p, the value range of r1 is 0.04×R1 / p to 0.4×R1 / p, the value range of r2 is 0.04×R1 / p to 0.2×R1 / p, and the value range of r3 is 0.04×R1 / p to 0.2×R1 / p.

[0097] Optionally, in S1, the pole pair number p is one of the following: 2, 3, 4; and in S1, the radius R1 ranges from 25 mm to 220 mm.

[0098] Optionally, in S2, the value range of g2 is from g1 to 2×g1; in S3, the value range of a1 is from 0.64×180 / p degrees to 0.8×180 / p degrees.

[0099] Optionally, in S4, the value of h1 ranges from 3 × g1 to 5 × g1; in S5.1, S6.3 and S7.2, the value of g3 ranges from 0 or 0.5 mm to 2 mm.

[0100] Optionally, in S5.2, the value of b2 ranges from 0.85×b1 to 0.91×b1; in S5.2, S6.4 and S7.5, the value of g4 ranges from 0.4 mm to 2 mm; in S5.3, S6.5 and S7.6, the value of g5 ranges from 0.7 mm to 2 mm.

[0101] Optionally, in S5.4, S6.6 and S7.7, the value range of a2 is from 0.024×180 / p degree to 0.026×180 / p degree.

[0102] Optionally, in S6.2, the value range of b3 is 0.56×b1 to 0.61×b1; in S7.3, the value range of b4 is 0.42×b1 to 0.46×b1.

[0103] Optionally, the cavity containing the permanent magnet slot is filled with insulating material to reduce the maximum stress on the rotor.

[0104] In summary, the permanent magnet synchronous motor manufactured using the laminations of this invention has a smaller width of the linear permanent magnet and a lower air gap magnetic flux density, thereby reducing core losses in the stator teeth and yoke and improving motor efficiency. The permanent magnet synchronous motor manufactured using the laminations of this invention has only one rectangular cross-section permanent magnet specification, reducing the number of permanent magnet specifications and lowering manufacturing costs. The permanent magnet synchronous motor manufactured using the laminations of this invention has smaller unloaded cogging torque and smaller torque fluctuations under load, with the peak-to-peak torque under load not exceeding 5% of the rated torque. Because the permanent magnet slots of the laminations of this invention are close to the outer circumference of the rotor, and the rotor core area outside the permanent magnet slots is very small, the stress on the rotor reinforcing ribs is smaller, facilitating an increase in the maximum motor speed or an increase in the motor's outer diameter to increase motor capacity. The number of permanent magnet holes per pole of the rotor manufactured using the laminations of this invention can be 1, 2, 3, or 4, allowing for 1, 2, 3, or 4 rows of axially arranged permanent magnets. The arrangement of permanent magnets in the laminations results in smaller magnetic bridge widths and lower aspect ratios for motors of different sizes. The rotors manufactured using these laminations have larger light-reducing holes, facilitating weight reduction and bearing load reduction, which is beneficial for increasing the maximum motor speed or capacity. Furthermore, the laminations allow for segmented, staggered rotor design, achieving the same effect as stator skew slots, further reducing no-load cogging torque and torque fluctuation under load, enabling higher precision speed and position control. The design steps for these laminations can be programmed into computer software, using optional parameters as optimization variables, and an optimization algorithm to obtain the optimal optional parameters for efficiency, torque fluctuation, and other performance characteristics.

[0105] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it. They should not be used to limit the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A rotor lamination for a high-efficiency permanent magnet synchronous motor, characterized in that, The rotor laminations are designed through the following steps: S1: Based on symmetry, one pole of the motor rotor lamination is designed as a sector with an unfolding angle of 180 / p degrees, where p is the number of pole pairs. The rotor structure under one pole is symmetrical about the central axis X of the sector. The straight line of the left boundary of the sector is Y. The part of the inner circle of the motor stator corresponding to this one pole is arc L1, with the center of the circle being the center of the motor shaft O. The radius of arc L1 is R1. Arc L1 is offset towards the center of the circle by the air gap length g1 to obtain the outer circle boundary arc L2 of the motor rotor. The radius of L2 is R2, and R2 = R1 - g1. S2: The arc L2 is offset by a distance g2 towards the center to obtain the arc L3, whose radius is R3, and R3 = R 2 -g2; S3: The central axis X is rotated by an angle a1 / 2 around O towards the boundary line Y to obtain the line OA, which intersects L3 at point A; S4: Draw a straight line L4 through point A, perpendicular to the central axis X. The distance from point A to the central axis is b1. Offset L4 by a distance h1 towards the center of the circle to obtain a straight line L5. L5 intersects the central axis at point K. Switch to S5.1, S6.1, or S7.1; S5.1: The central axis X is offset by a distance g3 / 2 in the Y direction of the boundary line to obtain line segment JH. JH intersects L4 at point H and JH intersects L5 at point J. S5.2: The straight line JH is offset by a distance b2 in the direction of the boundary straight line Y to obtain the line segment DE. DE intersects L5 at point D. The length of DJ is b2, the length of DE is g4, and the direction from point D to point E points towards one side of the straight line L4. S5.3: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle. S5.4: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 at point B. A line BC parallel to the boundary line Y is drawn through point B. A line perpendicular to BC is drawn through point G, with the foot of the perpendicular at point C. S5.5: The polygon BCGFEDJHA forms a hole. After mirroring this hole about the central axis, two holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets inside the holes are of the same size, and the sharp corners of each hole are rounded. Proceed to step S8; S6.1: The central axis X intersects line L4 and line L5 at points M and K; S6.2: The central axis X is offset by a distance b3 / 2 in the direction of the boundary line Y to obtain line segment QR. QR intersects L4 at point R and QR intersects L5 at point Q. S6.3: QR is offset by a distance g3 in the Y direction of the boundary line to obtain line segment PN. PN intersects L4 at point N and L5 at point P. S6.4: PN is offset by a distance b3 in the Y direction of the boundary line to obtain line segment DE. DE intersects L5 at point D. The length of DJ is b2, and the length of DE is g4. The direction from point D to point E points towards one side of line L4. S6.5: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle. S6.6: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 and B. A line BC parallel to the boundary line Y is drawn through B. A line perpendicular to BC is drawn through G, with the foot of the perpendicular at C. S6.7: Polygon BCGEDPNA forms one hole, and quadrilateral RQKM forms another hole. After mirroring the above two holes about the central axis, three holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets in the holes are of the same specifications, and the sharp corners of each hole are rounded. Proceed to step S8; S7.1: The central axis X intersects lines L4 and L5 at points M and K, respectively; S7.2: The straight line KM is offset by a distance g3 / 2 in the Y direction of the boundary line to obtain the line segment JH. JH intersects L4 at point H and JH intersects L5 at point J. S7.3: The straight line JH is offset by a distance b4 in the direction of the boundary straight line Y to obtain the line segment QR. QR intersects L4 at point R and QR intersects L5 at point Q. S7.4: The line QR is offset by a distance g3 in the direction of the boundary line Y to obtain the line segment PN. PN intersects L4 at point N and L5 at point P. S7.5: PN is offset by a distance b4 in the Y direction of the boundary line to obtain line segment DE. DE intersects L5 at point D. The length of DJ is b2, the length of DE is g4, and the direction from point D to point E points towards one side of line L4. S7.6: Draw a line segment EF perpendicular to DE through point E, with a length of g5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F, with a length of g4. The direction from point F to point G points towards the center of the circle. S7.7: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB. The line OB intersects L3 and B. A line BC parallel to the boundary line Y is drawn through B. A line perpendicular to BC is drawn through G, with the foot of the perpendicular at C. S7.8: Polygon BCGEDPNA forms one hole, and quadrilateral RQJH forms another hole. After mirroring the above two holes about the central axis, four holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets in the holes are of the same size, and the sharp corners of each hole are rounded. S8: The hole structure under other residual poles is replicated by a circular array.

2. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1, characterized in that, Line L5 is offset by a distance h2 towards the center to obtain line L6; the inner arc L8 of the rotor is offset by a distance h3 away from the center to obtain arc L7; a line L9 is drawn through point K, with an angle a3 between L9 and the central axis X, where a3 is between 40 and 50 degrees; the boundary line Y is offset by a distance h4 towards the central axis X to obtain line L. 10 The aforementioned straight line L6, arc L7, straight line L9, and straight line L 10 A hole is formed by L6 and L9, and this hole is mirrored about the central axis X to form a larger hole. The corner between L6 and L9 is rounded with r1. 10 The fillet between L7 and L9 is rounded with r2, and L7 and L9 are rounded with r2. 10 The corners are rounded (r3) and the above hole structure is replicated in other residual poles using a circular array.

3. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1, characterized in that, In S1, the pole pair number p is one of the following: 2, 3, 4; in S1, the radius R1 ranges from 25 mm to 220 mm.

4. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1, characterized in that, In S2, the value of g2 ranges from g1 to 2×g1; in S3, the value of a1 ranges from 0.64×180 / p degrees to 0.8×180 / p degrees.

5. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1, characterized in that, In S4, the value of h1 ranges from 3 × g1 to 5 × g1; in S5.1, S6.3 and S7.2, the value of g3 ranges from 0 or 0.5 mm to 2 mm.

6. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1, characterized in that, In S5.2, the value of b2 ranges from 0.85×b1 to 0.91×b1; in S5.2, S6.4 and S7.5, the value of g4 ranges from 0.4 mm to 2 mm; in S5.3, S6.5 and S7.6, the value of g5 ranges from 0.7 mm to 2 mm.

7. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1, characterized in that, In S5.4, S6.6 and S7.7, the value range of a2 is from 0.024×180 / p degree to 0.026×180 / p degree.

8. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1, characterized in that, In S6.2, the value range of b3 is 0.56×b1 to 0.61×b1; in S7.3, the value range of b4 is 0.42×b1 to 0.46×b1.

9. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 2, characterized in that, The values ​​of h2 range from 0.15×R1 / p to 0.4×R1 / p, h3 range from 0.15×R1 / p to 0.5×R1 / p, h4 range from 0.05×R1 / p to 0.5×R1 / p, r1 range from 0.04×R1 / p to 0.4×R1 / p, r2 range from 0.04×R1 / p to 0.2×R1 / p, and r3 range from 0.04×R1 / p to 0.2×R1 / p.

10. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1, characterized in that, The cavity containing the permanent magnet slot is filled with insulating material to reduce the maximum stress on the rotor.

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