This application claims the benefit of priority to Taiwan Patent Application No. 109103474, filed on Feb. 5, 2020. The entire content of the above identified application is incorporated herein by reference.
Some references, which may include patents, patent applications and various publications, may be cited and discussed in the description of this disclosure. The citation and/or discussion of such references is provided merely to clarify the description of the present disclosure and is not an admission that any such reference is “prior art” to the disclosure described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference.
The present disclosure relates to a motor, and more particularly to a motor assembly and a motor rotor that are capable of increasing magnetic flux.
Permanent-magnet synchronous motors can be classified into two types: surface mounted permanent magnet motor (i.e., SPM) and interior permanent magnet motor (i.e., IPM), with the surface mounted permanent magnet motor being the most widely used. The surface mounted permanent magnet motor includes a plurality of magnets, a plurality of rotor cores, and a stator. The magnets are respectively attached on the outer surface of the rotor cores, and the other part of the outer surface of the rotor cores without the magnets and the outer surface of the stator have a fairly wide air gap there-between. Compared with the interior permanent magnet motor, the surface mounted permanent magnet motor has the advantages of a wider air gap, smaller armature reaction, smaller total distortion ratio of magnetic field waveform, current waveform, and voltage waveform, and lower vibration noise. Therefore, high-performance speed-regulated permanent magnet motors on the market mainly use the surface mounted permanent magnet motors.
However, the performance of the permanent magnet motor depends on the total magnetic flux, and the conventional surface mounted permanent magnet motors have a plurality of magnets attached to the outer surface of the rotor cores. In other words, the total magnetic flux of the conventional surface mounted permanent magnet motor is limited by the outer surface area of the rotor thereof. Therefore, the size of the rotor of the conventional surface mounted permanent magnet motor will need to be increased so as to increase the total magnetic flux thereof, so as to improve the motor performance. However, increasing the size of the rotor causes the volume of the conventional surface mounted permanent magnet motor to also increase. In other words, under the same volume, the conventional surface mounted permanent magnet motor is limited by the outer surface of the rotor and cannot be improved.
In response to the above-referenced technical inadequacies, the present disclosure provides a motor assembly and a motor rotor to effectively improve the issues associated with conventional permanent magnet motors.
In one aspect, the present disclosure provides a motor assembly, which includes a motor rotor and a motor stator. The motor rotor includes a mandrel, a carrier, a plurality of iron cores, and a plurality of magnets. The carrier is disposed on the mandrel. The carrier is made of non-magnetic material. An outer edge of the carrier has a plurality of protrusions that are spaced apart from each other, and a setting groove is formed between any two of the protrusions adjacent to each other. Each of the setting grooves is in a shape of a dovetail. The iron cores are respectively fixed on the setting grooves. The iron cores do not contact each other, so that an accommodating space is formed between any two of the iron cores adjacent to each other. Each of the iron cores has two opposite ends, and one of two ends of each of the iron cores has a first convex portion that is in a shape of a dovetail, so that each of the iron cores is connected to the corresponding setting groove through the first convex portion thereof. Two opposite sides of another one of the two ends of each the iron cores have a baffle portion, respectively. The magnets are respectively disposed in the accommodating spaces. In each of the accommodating spaces, the baffle portions of two corresponding ones of the iron cores adjacent to each other limit the movement of the magnet. The motor stator is assembled on a peripheral portion of the motor rotor. The motor stator includes a plurality of winding frames and a plurality of wires. The winding frames each have an installed end and an arranged end that is opposite to the installed end. Each of the installed ends has two opposite sides, one side of each of the installed ends has a second convex portion, and the other one side of each of the installed ends has a concave portion that is configured to connect to the second convex portion. In any two of the winding frames adjacent to each other, the second convex portion of one of the two winding frames and the concave portion of another one of the two winding frames are engaged with each other. Any two of the arranged ends of the winding frames adjacent to each other are provided with a gap there-between, and the arranged end of each of the winding frames has an end surface facing the motor rotor. The end surface of each of the arranged ends has two semicircular grooves that are spaced apart from each other, and a diameter of each of the two semicircular grooves is equal to a distance of the gap. The two semicircular grooves of each of the end surfaces are provided with a predetermined arc length there-between. Each of the predetermined arc lengths is ⅓ of an arc length of each of the end surfaces, so that the arc length of each of the end surfaces is divided into three equal portions. The wires are wound on the winding frames.
In certain embodiments, the present disclosure provides a motor rotor, which includes a mandrel, a carrier, a plurality of iron cores, and a plurality of magnets. The carrier is disposed on the mandrel. The carrier is disposed on the mandrel. The carrier is made of non-magnetic material. An outer edge of the carrier has a plurality of protrusions that are spaced apart from each other, and a setting groove is formed between any two of the protrusions adjacent to each other. Each of the setting grooves is in a shape of a dovetail. The iron cores are respectively fixed on the setting grooves. The iron cores do not contact each other, so that an accommodating space is formed between any two of the iron cores adjacent to each other. Each of the iron cores has two opposite ends, and one of two ends of each of the iron cores has a first convex portion that is in a shape of a dovetail, so that each of the iron cores is connected to the corresponding setting groove through the first convex portion thereof. Two opposite sides of another one of the two ends of each the iron cores have a baffle portion, respectively. The magnets are respectively disposed in the accommodating spaces. In each of the accommodating spaces, the baffle portions of two corresponding ones of the iron cores adjacent to each other limit the movement of the magnet.
Therefore, the motor assembly and the motor rotor of the present disclosure are designed to provide the accommodating spaces by spacing apart the iron cores from each other on the carrier, so that the magnets can respectively arrange in the accommodation spaces along a corresponding axial direction of the mandrel. Accordingly, the magnets arranged in the motor rotor are configured to provide a more effective area to increase the total magnetic flux of the motor assembly.
These and other aspects of the present disclosure will become apparent from the following description of the embodiment taken in conjunction with the following drawings and their captions, although variations and modifications therein may be affected without departing from the spirit and scope of the novel concepts of the disclosure.
The present disclosure will become more fully understood from the following detailed description and accompanying drawings.
The present disclosure is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Like numbers in the drawings indicate like components throughout the views. As used in the description herein and throughout the claims that follow, unless the context clearly dictates otherwise, the meaning of “a”, “an”, and “the” includes plural reference, and the meaning of “in” includes “in” and “on”. Titles or subtitles can be used herein for the convenience of a reader, which shall have no influence on the scope of the present disclosure.
The terms used herein generally have their ordinary meanings in the art. In the case of conflict, the present document, including any definitions given herein, will prevail. The same thing can be expressed in more than one way. Alternative language and synonyms can be used for any term(s) discussed herein, and no special significance is to be placed upon whether a term is elaborated or discussed herein. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms is illustrative only, and in no way limits the scope and meaning of the present disclosure or of any exemplified term. Likewise, the present disclosure is not limited to various embodiments given herein. Numbering terms such as “first”, “second” or “third” can be used to describe various components, signals or the like, which are for distinguishing one component/signal from another one only, and are not intended to, nor should be construed to impose any substantive limitations on the components, signals or the like.
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The mandrel 110 is made of medium carbon steel with magnetic properties. Specifically, the mandrel 110 has a shaft 111, a limiting groove 112 disposed on the shaft 111, and a limiting block 113 that is disposed in the limiting groove 112. The part of the limiting block 113 protrudes from the limiting groove 112 (as shown in
The carrier 120 is made of a non-magnetic material. The non-magnetic material of the carrier 120 in the present embodiment is aluminum or aluminum alloy, but the present disclosure is not limited thereto. For example, in other embodiments of the present disclosure, the non-magnetic material of the carrier 120 may be copper, non-magnetic stainless steel, copper alloy, or reinforced plastic.
The carrier 120 is fixed on the mandrel 110. Specifically, the carrier 120 is a ring frame structure, so as to have a through hole 121. A snap groove 122 is formed in the inner edge of the through hole 121 of the carrier 120. The carrier 120 is sleeved around the mandrel 110 by the through hole 121, and the snap groove 122 and the limiting block 113 of the mandrel 110 are engaged with each other, so that the carrier 120 and the mandrel 110 can be synchronously rotating. The carrier 120 has a plurality of protrusions 123 that are arranged on an outer side thereof and that are spaced apart from each other, so that a setting groove 124 is formed between any two of the protrusions 123 adjacent to each other. In detail, a cross section of each of the setting grooves 124 perpendicular to a radial direction of the mandrel 110 is tapered along a direction that extends away from the mandrel 110, and a cross section of each of the protrusions 123 perpendicular to the radial direction of the mandrel 110 is broadened along the direction that extends away from the mandrel 110. In other words, each of the setting grooves 124 is in a shape of a dovetail.
The iron cores 130 are respectively fixed in the setting grooves 124. The iron cores 130 do not contact each other, so that an accommodating space SP is formed between any two of the iron cores 130 adjacent to each other. In detail, each of the iron cores 130 in the present embodiment is composed of a plurality of silicon steel sheets, but the present disclosure is not limited thereto.
Each of the iron cores 130 has two opposite ends, and one of the two ends of each of the iron cores 130 has a first convex portion 131. A cross section of each of the first convex portions 131 protruding in the radial direction of the mandrel 110 broadens along a direction that extends toward the mandrel 110, so that each of the iron cores 130 is connected to the corresponding setting groove 124 through the first convex portion 131 thereof. In other words, each of the first convex portions 131 is in a shape of a dovetail, and is configured to be fixed in the setting groove 124 that is in the shape of a dovetail. Two opposite sides of the other one of the two ends of each of the iron cores 130 have a baffle portion 132, respectively.
Specifically, the two opposite sides of the other end of any one of the iron cores 130 respectively have the baffle portions 132 that protrude outward. In two of the iron cores 130 adjacent to each other, two of the baffle portions 132 facing each other have a predetermined distance G there-between, so that two of the baffle portions 132 do not contact each other. The predetermined distance G is within a range of 1 to 3 mm. The predetermined distance G in the present embodiment is 2.5 mm, but the present disclosure is not limited thereto.
The magnets 140 are respectively disposed in the accommodating spaces SP. In each of the accommodating spaces SP, the baffle portions 132 of two of the iron cores 130 are configured to limit the movement of the magnet 140. Further, each of the magnets 140 in the present embodiment is a rectangular sheet structure, and the total quantity of the magnets 140 is ten. Each of the magnets 140 has a width WD relative to a radial cross-section of the mandrel 110 within a range of 2 to 8 mm (as shown in
Specifically, each of the magnets 140 is disposed between two of the iron cores 130 adjacent to each other in the radial direction of the core shaft 110. In other words, the magnets 140 are arranged on the carrier 120 in a radiation configuration, so as to have more effective area that can increase the magnetic flux. In other words, any motor rotor that is not disposed on the carrier in the radiation configuration is not the motor rotor 100 of the present embodiment.
The two baffle sheets 150 are respectively disposed on two rim sides of the carrier 120, and the two baffle sheets 150 are configured to limit the movement of the iron cores 130 and the magnets 140. Specifically, each of the two baffle sheets 150 in the present embodiment is a disc-like structure. The two baffle sheets 150 are made of non-magnetic material (e.g., aluminum, aluminum alloy, copper, copper alloy, or non-magnetic stainless steel). The two baffle sheets 150 are respectively disposed on the mandrel 110 and located on both sides of the carrier 120. A radius of each of the two baffle sheets 150 is equal to or less a radius of the carrier 120. The two baffle sheets 150 can limit the movement of each of the iron cores 130 and each of the magnets 140, so as to prevent each of the iron cores 130 and each of the magnets 140 from separating along the axial direction of the mandrel 110.
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In detail, the end surfaces 2113 of each of the winding frames 210 is a curved surface. The total quantity of the winding frames 210 in the present embodiment is twelve, so that both sides of the end surfaces 2113 of each of the winding frames 210 and a center point of the mandrel 110 jointly define an angle of 30 degrees. The two semicircular grooves 2114 of each of the end surfaces 2113 and the center point of the mandrel 110 jointly define an angle of 10 degrees. In each of the end surfaces 2113, any one of the two semicircular grooves 2114, one of the two sides that is adjacent to the any one of the two semicircular grooves 2114, and the center point of the mandrel 110 jointly define an angle of 10 degrees, but the present disclosure is not limited thereto.
In the two semicircular grooves 2114 of each of the end surfaces 2113, a cogging torque of one of the two semicircular grooves 2114 is capable of offsetting a cogging torque of another one of the two semicircular grooves 2114. Any one of the semicircular grooves 2114 of each of the end surfaces 2113 is capable of offsetting a cogging torque of the gap AG adjacent thereto. In other words, the two semicircular grooves 2114 of any one of the end surfaces 2113 can offset the cogging torque of two of the gaps AG that are adjacent thereto. Further, the number of the semicircular grooves 2114 of each of the end surfaces 2113 is determined by the highest common factor of the number of poles and slots of the motor assembly 1000. The motor assembly 1000 has ten poles and twelve slots, so that the highest common factor of the number of poles and slots of the motor assembly 1000 is two. The quantity of the semicircular grooves 2114 of each of the end surfaces 2113 is two, but the present disclosure is not limited thereto. For example, in other embodiments of the present disclosure, when the motor assembly 1000 has eight poles and twelve slots, the highest common factor is four. That is to say, the number of the semicircular grooves 2114 of each of the end surfaces 2113 is four.
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In conclusion, the motor assembly 1000 and the motor rotor 100 of the present disclosure are designed to provide the accommodating spaces SP by spacing apart the iron cores 130 from each other on the carrier 120, so that the magnets 140 can respectively arrange in the accommodation spaces SP along an axial direction of the mandrel 110. Accordingly, the magnets 140 arranged in the motor rotor 100 are configured to provide a more effective area to increase the total magnetic flux of the motor assembly 1000.
The foregoing description of the exemplary embodiments of the disclosure has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching.
The embodiments were chosen and described in order to explain the principles of the disclosure and their practical application so as to enable others skilled in the art to utilize the disclosure and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present disclosure pertains without departing from its spirit and scope.
Number | Date | Country | Kind |
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109103474 | Feb 2020 | TW | national |