CN109962584A - Disc type electric machine and its manufacturing method - Google Patents
Disc type electric machine and its manufacturing method Download PDFInfo
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- CN109962584A CN109962584A CN201711401696.9A CN201711401696A CN109962584A CN 109962584 A CN109962584 A CN 109962584A CN 201711401696 A CN201711401696 A CN 201711401696A CN 109962584 A CN109962584 A CN 109962584A
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- permanent magnet
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 53
- 239000000696 magnetic material Substances 0.000 claims abstract description 46
- 238000004804 winding Methods 0.000 claims description 70
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 68
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 16
- 238000009413 insulation Methods 0.000 claims description 15
- 239000000853 adhesive Substances 0.000 claims description 13
- 230000001070 adhesive effect Effects 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 12
- 239000000843 powder Substances 0.000 claims description 11
- 239000003973 paint Substances 0.000 claims description 10
- 239000007921 spray Substances 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- 229910052782 aluminium Inorganic materials 0.000 claims description 8
- 239000011324 bead Substances 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 8
- 229920006351 engineering plastic Polymers 0.000 claims description 8
- 230000002093 peripheral effect Effects 0.000 claims description 8
- 238000012387 aerosolization Methods 0.000 claims description 5
- 238000004512 die casting Methods 0.000 claims description 5
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- 238000012545 processing Methods 0.000 claims description 5
- 238000000034 method Methods 0.000 claims description 4
- 238000000465 moulding Methods 0.000 claims description 4
- 238000000137 annealing Methods 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 230000005389 magnetism Effects 0.000 claims description 2
- 230000017525 heat dissipation Effects 0.000 abstract description 11
- 230000008901 benefit Effects 0.000 abstract description 10
- 230000000694 effects Effects 0.000 abstract description 7
- 238000010586 diagram Methods 0.000 description 19
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 11
- 229910052742 iron Inorganic materials 0.000 description 11
- 239000010949 copper Substances 0.000 description 10
- 229910052802 copper Inorganic materials 0.000 description 10
- 229910000976 Electrical steel Inorganic materials 0.000 description 4
- 238000000748 compression moulding Methods 0.000 description 4
- 238000013461 design Methods 0.000 description 3
- 239000004411 aluminium Substances 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 238000004513 sizing Methods 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 239000004836 Glue Stick Substances 0.000 description 1
- 241000233855 Orchidaceae Species 0.000 description 1
- QJVKUMXDEUEQLH-UHFFFAOYSA-N [B].[Fe].[Nd] Chemical compound [B].[Fe].[Nd] QJVKUMXDEUEQLH-UHFFFAOYSA-N 0.000 description 1
- PXAWCNYZAWMWIC-UHFFFAOYSA-N [Fe].[Nd] Chemical compound [Fe].[Nd] PXAWCNYZAWMWIC-UHFFFAOYSA-N 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 230000001095 motoneuron effect Effects 0.000 description 1
- 229910001172 neodymium magnet Inorganic materials 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
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- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/20—Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
- H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
- H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K16/00—Machines with more than one rotor or stator
- H02K16/02—Machines with one stator and two or more rotors
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/16—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields
- H02K5/161—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields radially supporting the rotary shaft at both ends of the rotor
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The present invention relates to a kind of disc type electric machine and its manufacturing method, the manufacturing method includes: powdered soft magnetic materials to be pressed into stator core and rotor core, then complete production stator assembly and rotor assembly；Fore bearing and rear bearing are separately positioned in the fore bearing room and rear bearing room of the stator inner ring of stator module；The middle shaft part of shaft is arranged in the inner hole of fore bearing and the inner hole of rear bearing；Two pieces rotor assembly mirror image is separately fixed in the preceding axle portion and rear axle portion of shaft, first end cover and second end cover are separately fixed to the both ends of the stator cage of stator module, makes stator assembly and rotor assembly to be enclosed in the interior intracavitary of stator cage.The disc type electric machine of manufacturing method production of the present invention not only has the advantages that axial dimension is short, but also have many advantages, such as that various losses are small, good heat dissipation effect, temperature rise is low, high-efficient, power density is big and stock utilization is high, structure is also unique and firm, is a kind of energy-efficient motor.
Description
[technical field]
The present invention relates to disc type electric machines, more particularly to the stator module and/or rotor assembly of disc type electric machine, more particularly to electricity
Pivot winding is characterized and/or stator module and/or rotor assembly characterized by magnetic material.
[background technique]
Disc type electric machine is to be invented by faraday for 1821, over more than 100 years, due to the limitation of material and technological level, always not
It can be further developed.Four the fifties of last century, disc type electric machine are taken seriously again, be used in hard disc of computer and
On the products such as tape recorders.Disc type electric machine is short with axial dimension compared with conventional radial magnetic circuit motor, movement portion
The advantages that part is few and electric efficiency is high, has the occasion strictly limited particularly suitable for motor axial direction installation dimension.
Conventional permanent magnet motor uses magnet radial poles structure, it embeds winding in core lamination stack according to certain rules, but
This motor axial dimension is long, is not suitable for installing in slim space.For this purpose, it is axial having a size of target with compression, change and passes
The disc type electric machine that motor radial magnetic circuit is axial magnetic circuit structure of uniting increasingly is paid attention to by people.
With the development step by step of disc type electric machine technology, it has been found that, it is very that the utilization rate of disc type electric machine, which is made always not,
It is ideal.Prior art disc type motor includes at least a set of rotor assembly and motor shaft;Every set rotor assembly all includes disc again
Rotor frame and even numbered blocks permanent magnet;It is evenly spaced apart to be equipped on the rotor frame being adapted to the permanent magnet, same
The through-hole of quantity, and which is provided with center through hole;By the center through hole, the rotor frame is axially fixed in the electricity
On arbor;Respectively the permanent magnet is fixed in each through-hole of the rotor frame, and the pole N, S is alternately arranged;Each of rotor frame is logical
Permanent magnet in hole is a monolith, and in the case where permanent magnet equal volume, air gap flux density is relatively low, and magnetic flux utilizes
Rate is low, and cost is also relatively high when the thicker permanent magnet of a monolith thickness produces.
As everybody knows conventional motors stator rotor packet inside, heat dissipation effect be not very well, although disc type electric machine is being tied
Make some improvement on structure, heat dissipation effect makes moderate progress, but in the number of stator teeth of same volume disc motor generally than passing
The number of teeth of system motor is more, also means that iron loss is more, low efficiency, heat dissipation effect also needs to be promoted.
In the loss of motor, iron loss occupies sizable ratio, these losses are all dissipated in the form of generating heat, can not
The renewable sources of energy, while motor temperature rise is improved, reduce electric efficiency.Reducing motor iron loss is the big project of design of electrical motor one, is used
Magnetic permeability is high, and resistance is big, stator core that the small new material of eddy-current loss and new method replace silicon steel sheet to be directly stamped to form and/
Or rotor core is a direction of motor research and development.The stator core and/or rotor core that silicon steel sheet is directly stamped to form are being led
The inherent defect of magnetic rate, resistance, eddy-current loss and high frequency characteristics etc. makes us that can not produce the disk of higher efficiency with it
Formula motor.
[summary of the invention]
The technical problem to be solved in the present invention is that provided in place of avoiding above-mentioned the deficiencies in the prior art a kind of disc type electric machine and
Its manufacturing method not only has the advantages that axial dimension is short, but also have the small, good heat dissipation effect of various losses, temperature rise it is low,
High-efficient, the advantages that power density is big and stock utilization is high, structure is also unique and firm, is a kind of energy-efficient motor.
The present invention solve the technical problem the technical solution adopted is that:
A kind of manufacturing method of disc type electric machine is provided, which includes the first end cover for being equipped with the 9th central through hole, is equipped with
Second end cover, stator module, rotor assembly, shaft, fore bearing and the rear bearing of 8th central through hole, wherein the rotor assembly
There is two pieces；The manufacturing method includes the following steps:
A, the production of stator module, the stator module include hollow stator cage, N number of stator winding part, are equipped with first
The stator first end plate of central through hole, the second end plate of stator and hollow stator inner ring equipped with the second central through hole；Each
Stator winding part all includes stator core and stator winding again;Wherein N >=3m, m are positive integer；
a1, stator core production: soft magnetic materials is made powdered, powdered soft magnetic materials is pressed into stator mould
Stator core；Then the stator core is subjected to insulation processing, i.e., will be all sprayed on whole outer surfaces of the stator core
There is anticorrosion, anti-get rusty and the insulated paint of anti-insulation；The stator core shape to complete is I-shaped structure, including both ends are fanned
The first baffle and second baffle are connected in by the first baffle and second baffle of shape, and intermediate mandrel, the mandrel
Together, the first baffle, mandrel and second baffle form the open cavity of a circle;
a2, stator winding part production, by stator winding insulation be wrapped on the mandrel of the stator core and be located at institute
It states in the cavity of stator core, has just made a stator winding part in this way；
a3, a circle N number of compatible with the first baffle of the stator core first is evenly provided in stator first end plate
Through-hole；It is logical that a circle N number of compatible with the second baffle of the stator core second is evenly provided on the second end plate of stator
Hole；The inner cavity of stator inner ring is successively arranged interconnected fore bearing room, third central through hole and rear bearing room；
a4, stator first end plate is screwed in intracavitary in the stator cage, and an end face of stator inner ring is used
Screw is fixed in the stator first end plate, so that the of the fore bearing room of the stator inner ring and the stator first end plate
One central through hole is connected；The first baffle of N number of stator winding part is respectively put into the corresponding stator first end plate
First through hole in, there is radial gap in the inner cavity of the outer end of N number of stator winding part and the stator cage, then will
The second end plate of stator is also screwed in the interior intracavitary of the stator cage, and makes the second gear of each stator winding part
Plate is stuck in the second through-hole of corresponding the second end plate of the stator, so that N number of stator winding part is uniformly lined up
One circle ground is between the second end plate of the stator first end plate and stator；Also with screw by the second end plate of stator and stator inner ring
Other end fix, and the rear bearing room of the stator inner ring and the second central through hole of second end plate of stator is made to be connected
It is logical；
a5, with adhesive whole encapsulating is carried out to said stator component, stick into each components of the stator module firmly
One waits adhesive curing molding, and this completes the production of stator module；
B, fore bearing and rear bearing are separately positioned in the fore bearing room and rear bearing room of stator inner ring of the stator module；
C, it is Step Shaft by pivot design, includes successively preceding axle portion, middle shaft part and rear axle portion, described in the outer diameter ratio of the middle shaft part
The outer diameter of preceding axle portion and rear axle portion is all big, the middle shaft part of the shaft is arranged in the inner hole and rear bearing of the fore bearing
In hole；
D, two pieces rotor assembly mirror image is separately fixed in the preceding axle portion and rear axle portion of the shaft, and turned described in two pieces
Sub-component forms respective axial direction close to first baffle and the second baffle of the stator winding part in parallel respectively therewith
Air gap；
E, first end cover and second end cover are separately fixed to the both ends of the stator cage with screw, make the stator module and
Rotor assembly is enclosed in the interior intracavitary of the stator cage, and this completes the entirety assembly of the disc type electric machine.
In step a4In, before fixation second end plate of stator, circulating cooling pipe is arranged in the radial gap
It is interior, the water inlet tube head at both ends and water outlet tube head respectively on stator cage water inlet pipe and outlet pipe be connected.
It further include step d before step d0, rotor assembly production, the rotor assembly includes with non-magnetic aluminium
Discoidal rotor flange, even numbered blocks permanent magnet and the discoidal rotor frame made of engineering plastics of material production, with
And the small iron core of rotor with permanent magnet equivalent amount;The specific production step of rotor assembly is as follows:
d01The production of the small iron core of rotor: soft magnetic materials is made it is powdered, by powdered soft magnetic materials with rotor mold suppress
At the small iron core of rotor, the small core configuration of the rotor to complete is up big and down small sector structure, the exterior arc surface including top
With the inner arc surface of lower part, and left side and right side that the exterior arc surface and inner arc surface are coupled, the external arc
The arc length in face is bigger than the arc length of inner arc surface；
d02Among rotor flange and periphery is separately designed to the intermediate convex block and a circle outer peripheral bead stretched out for the same direction,
The intermediate convex block is equipped with the 7th central through hole, and it is small that the receiving rotor is formed between the intermediate convex block and outer peripheral bead
The cavity of iron core, permanent magnet and rotor frame；
d03It will be evenly spaced apart to be designed as the through-hole and the 6th central through hole with the permanent magnet equivalent amount on rotor frame,
Respectively the permanent magnet is evenly spaced apart to be fixed in each through-hole of the rotor frame, and the pole N, S is alternately arranged；
d04The small iron core of each rotor is seamless spliced at the cavity for being tightly attached to the rotor flange after an annulus together along a circle
Bottom surface, then permanent magnet by rotor frame and thereon is screwed in together in the cavity of the rotor flange, thus
So that each small iron core of rotor is located at the bottom surface of the cavity of the rotor flange and together respectively between the permanent magnet.
In step d03In, each piece of permanent magnet all includes first piece of permanent magnet unit to K block permanent magnet unit,
Respectively first piece of permanent magnet unit is to K block permanent magnet unit together radially fixed each through-hole in the rotor frame
It is interior, wherein 2≤K≤7, K are integer, such as K=3.
In step a1In the manufacturing process of stator core, soft magnetic materials is powdered made of melting and aerosolization；
Before powdered soft magnetic materials is pressed into stator core with stator mould, surface spray also is carried out to powdered soft magnetic materials
It applies, powdered soft magnetic materials is made to spray a upper layer insulating；And powdered soft magnetic materials is pressed into stator mould and is determined
After sub- iron core and all before spray insulation paint, the stator core will be moved back on whole outer surfaces of the stator core
Fire processing.
Correspondingly, the present invention also provides a kind of disc type electric machines, including being equipped with the first end cover of the 9th central through hole, being equipped with
Second end cover, stator module, rotor assembly, shaft, fore bearing and the rear bearing of 8th central through hole;The rotor assembly has
Two pieces；The stator module includes hollow stator cage, N number of stator winding part, the stator equipped with the first central through hole
End plate, the second end plate of stator and hollow stator inner ring equipped with the second central through hole；Each stator winding part is again
Including stator core and stator winding made of the powder die-casting that is formed as soft magnetic materials, the stator core shape is I-shaped
Structure, first baffle and second baffle including both ends sector, and intermediate mandrel, the mandrel by the first baffle and
Second baffle is linked together, and the first baffle, mandrel and second baffle form the open cavity of a circle, the stator around
The insulated winding of group is on the mandrel and in the cavity；It is N number of that a circle is evenly provided in the stator first end plate
It is N number of with described second to be evenly provided with a circle on second end plate of stator for first through hole compatible with the first baffle
Compatible second through-hole of baffle；It is logical that the inner cavity of the stator inner ring is successively arranged interconnected fore bearing room, third center
Hole and rear bearing room；It is fixed on the interior intracavitary of the stator cage before and after the second end plate of the stator first end plate and stator, it is N number of
Stator winding part is with uniformly lining up a circle between the second end plate of the stator first end plate and stator, and each is fixed
The first baffle and second baffle of sub- coil assembly are stuck in the first through hole and stator of the corresponding stator first end plate
In second through-hole of the second end plate, there is radial gap in the inner cavity of the outer end of N number of stator winding part and the stator cage,
The stator inner ring is fixed between the second end plate of the stator first end plate and stator, and the fore bearing of the stator inner ring
Room is connected with the first central through hole of the stator first end plate, the rear bearing room of the stator inner ring and the stator the
Second central through hole of two end plates is connected；Wherein N >=3m, m are positive integer；The fore bearing and rear bearing are located at described
In the fore bearing room and rear bearing room of stator inner ring；The shaft is Step Shaft, successively includes preceding axle portion, middle shaft part and rear axle
The outer diameter in portion, the middle shaft part is all bigger than the outer diameter of the preceding axle portion and rear axle portion, and the middle shaft part of the shaft is arranged described
In the inner hole of fore bearing and the inner hole of rear bearing；The preceding axle portion of the shaft is separately fixed to rotor assembly mirror image described in two pieces
In rear axle portion, and rotor assembly described in two pieces is respectively in parallel close to the first baffle of the stator winding part and second
Baffle and form respective axial air-gap therewith;The first end cover and second end cover are separately fixed at the stator cage
Both ends, by it is described be stator assembly and rotor assembly enclosed in it is intracavitary in the stator cage.
Stator core whole outer surface is all coated with anticorrosion, anti-gets rusty and the insulated paint of anti-insulation.
The stator module further includes the circulating cooling pipe of annular, which is arranged in the diameter of the stator module
Into gap, the water inlet tube head at both ends and water outlet tube head respectively on the stator cage water inlet pipe and outlet pipe connect
It is logical.
After the stator module assembles, whole encapsulating is carried out to the stator module with adhesive, makes the stator pack
Each components of part firmly stick into one.
The rotor assembly include with non-magnetic aluminum material make discoidal rotor flange, even numbered blocks permanent magnet and
The discoidal rotor frame made of engineering plastics, and with permanent magnet equivalent amount, the powder that is formed by soft magnetic materials
The small iron core of rotor made of die casting, the small core configuration of rotor are up big and down small sector structure, the external arc including top
The inner arc surface in face and lower part, and left side and right side that the exterior arc surface and inner arc surface are coupled, the outer circle
The arc length of cambered surface is bigger than the arc length of inner arc surface;Among the rotor flange and periphery, which is respectively equipped with to the same direction, to be stretched out
Intermediate convex block and a circle outer peripheral bead, intermediate convex block is equipped with the 7th central through hole, the intermediate convex block and outer peripheral bead it
Between form the cavity for accommodating the small iron core of the rotor, permanent magnet and rotor frame；It is evenly spaced apart on the rotor frame
Equipped with the through-hole and the 6th central through hole with the permanent magnet equivalent amount, respectively the permanent magnet is evenly spaced apart to be fixed on described turn
In each through-hole of subframe, the pole N, S is alternately arranged, and rotor frame and permanent magnet thereon are fixed on the rotor flange together
In cavity, respectively the small iron core of the rotor is seamless spliced at the cavity that the rotor flange is arranged in after an annulus together along a circle
Bottom surface and respectively between the permanent magnet.
The each piece of permanent magnet all includes first piece of permanent magnet unit to K block permanent magnet unit, and respectively this first piece forever
Magnet unit is radially fixed in each through-hole 345 of the rotor frame together to K block permanent magnet unit, wherein 2≤
K≤7, K are integer.
Compared with the existing technology compared with the beneficial effect of disc type electric machine of the present invention and its manufacturing method is:
One, powder made of stator core soft magnetic materials of the present invention is by stator mould compression moulding, so that magnetic field energy is each
A dimension direction movement, while the iron loss of part is significantly reduced, improve electric efficiency；
Two, the present invention uses N number of independent stator winding part, is not only convenient for the manufacture of stator core, and coiling also facilitates,
Iron loss and copper loss are reduced simultaneously, and heat dissipation performance improves the whole efficiency of motor, and assembly also facilitates and also saves
Working hour；
Three, stator winding of the present invention is directly wound on stator core, is considerably reduced the dosage of the invalid copper in end, is reduced
Copper loss improves the copper factor of coiling, while perfect heat-dissipating, also improves the whole efficiency of motor；
Four, the present invention uses stator cage, N number of stator winding part, stator first end plate, the second end plate of stator and stator inner ring
It is assembled together to form stator module, unique structure and firm；
Five, the fore bearing of fixed rotating shaft and rear bearing are all mounted in stator inner ring, take full advantage of the thickness of stator cage,
Keep the axial dimension of the disc type electric machine shorter；
Six, by pivot design at Step Shaft, directly two pieces rotor assembly is fixed in the both ends of the surface of Step Shaft, keeps the disc type electric
The used unit of machine is less, and axial dimension is shorter；
Seven, the present invention is using single stator and birotor, and wherein stator module is located at centre, and birotor component is located at stator pack
The two sides of part form a kind of sandwich structure；This structure compared to single stator and single rotor form so that stator and
It offsets each other between rotor in axial magnetic pull, has reached more firm structure；And this structure is compared to bimorph transducer and list
Rotor type, due to having there are two the component rotated, so that the output torque of motor increases, the torque for effectively increasing motor is close
Degree and power density；
Eight, the small iron core of rotor of the present invention also uses powder made of soft magnetic materials by the compression moulding of rotor mold, so that magnetic field energy
It is moved in each dimension direction, while significantly reducing the iron loss of part, improve electric efficiency；
Nine, the present invention is not only convenient for the system of the small iron core of rotor using each independent small iron core of rotor with permanent magnet equivalent amount
It makes, while can also reduce iron loss, heat dissipation performance can also increase, and correspondingly also improve the whole efficiency of motor；
Ten, using even numbered blocks permanent magnet, each permanent magnet is all separated by a distance and the certain angle that has been staggered, it is possible to reduce motor is solid
Some cogging torques；
11, each piece of permanent magnet is divided into the small permanent magnet unit of muti-piece, it is possible to reduce the vortex of permanent magnet itself is damaged
Consumption, and when the single permanent magnet unit of production, the temperature in sintering furnace can be correspondingly lower, the material neodymium iron of permanent magnet unit
Boron is also easy to control in sintering furnace, and the production cost of every piece of permanent magnet unit of the invention in this way can also accordingly decrease, whole
The cost of a disc type electric machine can also accordingly decrease;
12, the present invention uses rotor flange, even numbered blocks permanent magnet, rotor frame and the small iron of rotor with permanent magnet equivalent amount
Core is assembled together to form rotor assembly, unique structure and firm.
In conclusion disc type electric machine of the present invention and its manufacturing method not only have the advantages that axial dimension is short, but also have
Have the advantages that various losses are small, good heat dissipation effect, temperature rise is low, high-efficient, power density is big and stock utilization is high, structure
It is unique and firm, it is a kind of energy-efficient motor.
[Detailed description of the invention]
Fig. 1 is the overall structure orthographic projection vertical section schematic diagram of disc type electric machine preferred embodiment of the present invention;
Fig. 2 is the axonometric projection schematic diagram after the disc type electric machine decomposed, in order to save space, fixed first end cover and
The screw 97 of second end cover is still placed in the threaded hole of stator cage；
Fig. 3 is the axonometric projection schematic diagram of the stator module of the disc type electric machine;
Fig. 4 is the orthographic projection vertical section schematic diagram of the stator module;
Fig. 5 is the axonometric projection schematic diagram that the stator module is cut out a part;
Fig. 6 is the axonometric projection schematic diagram after the stator module decomposed, in order to save space, fixed stator first end
The screw 99 of the second end plate of plate and stator is still placed in the threaded hole of stator cage, and the screw 99 of fixed stator inner ring is then put
In the threaded hole of stator inner ring;
Fig. 7 is the axonometric projection schematic diagram of the stator first end plate 23 of the stator module;
Fig. 8 is the axonometric projection schematic diagram of the second end plate of stator 24 of the stator module；
Fig. 9 is the axonometric projection schematic diagram of the stator winding part 22 of the stator module；
Figure 10 is the axonometric projection schematic diagram of the stator core 221 of the stator winding part 22；
The two pieces rotor assembly 30 and the positional relationship axonometric projection schematic diagram after the decomposition of shaft 50 that Figure 11 is shown disc type electric machine；
Figure 12 is the axonometric projection schematic diagram of shown rotor assembly 30；
Figure 13 is the axonometric projection schematic diagram after shown rotor assembly 30 decomposes, and the spiral shell of fixed rotor frame 34 is not drawn in figure
Silk；
Figure 14 is the axonometric projection schematic diagram of the rotor flange 31 of the rotor assembly 30;
Figure 15 is the axonometric projection schematic diagram of the rotor frame 34 of the rotor assembly 30；
Figure 16 is that the small iron core 32 of multiple rotors of the rotor assembly 30 surveys throwing along the seamless spliced axis at an annulus of a circle
Shadow schematic diagram；
Figure 17 is the amplified axonometric projection schematic diagram of the small iron core 32 of single rotor；
Figure 18 is the axonometric projection schematic diagram of the single permanent magnet 33 of the rotor assembly 30, which is divided into again
K block permanent magnet unit, K=3 in figure；
Figure 19 is that single permanent magnet 33 is divided into the axonometric projection schematic diagram after K block permanent magnet unit decomposes, K=3 in figure.
[specific embodiment]
Below with reference to each attached drawing, invention is further described in detail.
Referring to Fig. 1 to Figure 12, a kind of manufacturing method of disc type electric machine is provided, which includes that the 9th center that is equipped with is logical
The first end cover 10 in hole 11, the second end cover 40 equipped with the 8th central through hole 41, stator module 20, rotor assembly 30, shaft 50,
Fore bearing 68 and rear bearing 69, wherein the rotor assembly 30 has two pieces；The manufacturing method includes the following steps:
A, the production of stator module 20, the stator module 20 include hollow stator cage 21, N number of stator winding part 22,
Stator first end plate 23 equipped with the first central through hole 231, the second end plate of stator 24 equipped with the second central through hole 241 and hollow
Stator inner ring 25；Each stator winding part 22 includes stator core 221 and stator winding 222 again;Wherein N >=3m, m
For positive integer；
a1, stator core 221 production: soft magnetic materials is made it is powdered, by powdered soft magnetic materials stator mould pressure
Stator core 221 is made；Then the stator core 221 is subjected to insulation processing, i.e., by all outer of the stator core 221
It is all coated with anticorrosion on surface, anti-gets rusty and the insulated paint of anti-insulation；221 shape of stator core to complete is I-shaped
Structure, first baffle 2211 and second baffle 2212 including both ends sector, and intermediate mandrel 2213, the mandrel 2213
The first baffle 2211 and second baffle 2212 are linked together, the first baffle 2211, mandrel 2213 and second gear
Plate 2212 forms the open cavity 2214 of a circle;Since the stator core of prior art silicon steel sheet punching press limits Three-Dimensional Magnetic
The performance of performance advantage, and present invention powder soft magnetic materials made of, then with stator mould compression moulding, be fabricated to calmly
Sub- iron core so that magnetic field energy moves in each dimension direction, while significantly reducing the iron loss of part, improves motor effect
Rate；
a2, stator winding part 22 production, by the insulated mandrel for being wrapped in the stator core 221 of stator winding 222
On 2213 and it is located in the cavity 2214 of the stator core 221, has just made a stator winding part 22 in this way；Existing skill
Art stator winding mostly uses greatly span winding, causes winding end portion too long, and the dosage of invalid copper increases, and is lost bigger；And this hair
Stator winding 222 is formed on the bright mandrel 2213 for being directly wound in the stator core 221 using flat type copper wire or enameled wire, greatly
Ground reduces the dosage of the invalid copper in end, reduces copper loss, improves the copper factor of coiling, while heat dissipation performance is very good,
Also the whole efficiency of motor is improved；
a3, to be evenly provided in stator first end plate 23 circle N number of suitable with 2211 phase of first baffle of the stator core 221
The first through hole 232 matched；The N number of second gear with the stator core 221 of a circle is evenly provided on the second end plate of stator 24
Compatible second through-hole 242 of plate 2212；The inner cavity of stator inner ring 25 is successively arranged interconnected fore bearing room 251,
Three central through holes 252 and rear bearing room 253；
a4, the screw 99 of stator first end plate 23 is fixed on it is intracavitary in the stator cage 21, and by stator inner ring 25
One end face screw 99 is fixed in the stator first end plate 23, so that the fore bearing room 251 of the stator inner ring 25 and institute
The first central through hole 231 for stating stator first end plate 23 is connected；The first baffle 2211 of N number of stator winding part 22 is distinguished
It is put into the first through hole 232 of the corresponding stator first end plate 23, the outer end of N number of stator winding part 22 and institute
There is radial gap 29 in the inner cavity for stating stator cage 21, and it is described fixed to be then also fixed on the second end plate of stator 24 with screw 99
Handset shell 21 it is interior intracavitary, and the second baffle 2212 of each stator winding part 22 is made to be stuck in the corresponding stator
In second through-hole 242 of the second end plate 24, so that N number of stator winding part 22 is uniformly located at the stator with lining up a circle
Between first end plate 23 and the second end plate of stator 24；Also use screw 99 by the other end of the second end plate of stator 24 and stator inner ring 25
Face is fixed, and makes 241 phase of the second central through hole of the rear bearing room 253 of the stator inner ring 25 with second end plate of stator 24
Connection；
Stator first end plate 23 and the second end plate of stator 24 are made of engineering plastics, and the outer ring of stator first end plate 23 is equipped with one
Ring through hole 239, the inner ring of stator first end plate 23 are equipped with a ring through hole 238, and it is logical that the outer ring of the second end plate of stator 24 is equipped with a circle
The inner ring in hole 249, the second end plate of stator 24 is equipped with a ring through hole 248；Stator cage 21 is made of casting aluminium material, inner cavity
A circle protrusion 215 is equipped in the middle part of inner wall, which is equipped with threaded hole, and screw 99 passes through the through-hole 239 of stator first end plate 23
Stator first end plate 23 is fixed on afterwards in the threaded hole of the protrusion 215 of the inner cavity of the stator cage 21, similarly screw 99 is worn
It crosses after the through-hole 249 of the second end plate of stator 24 and the second end plate of stator 24 is fixed on to the protrusion of the inner cavity of the stator cage 21
In 215 threaded hole；Stator inner ring 25 is made of stainless steel, and the outer ring of stator inner ring 25 is equipped with a circle threaded hole, spiral shell
Silk 99 will be screwed into the threaded hole of stator inner ring 25 after the through-hole 238 of stator first end plate 23, and similarly screw 99 is worn
It is screwed into the threaded hole of stator inner ring 25 after crossing the through-hole 248 of the second end plate of stator 24, to keep stator inner ring 25 fixed
Between stator first end plate 23 and the second end plate of stator 24；
a5, with adhesive whole encapsulating is carried out to said stator component 20, make each components of the stator module 20 firmly
One is sticked into, waits adhesive curing molding, this completes the production of stator module 20；
Adhesive can be any adhesive for being not less than the motor class of insulation heatproof level using heatproof, such as glue
Stick can use epoxy resin；Adhesive curing molding can solidify a period of time at normal temperature, can also toast sizing, such as
It is 60 ± 2 degrees Celsius in temperature, the time is that sizing is toasted under conditions of 2.5~4.0 hours；
The present invention uses N number of independent stator winding part 22, is not only convenient for the manufacture of stator core 221, and coiling is also square
Just, while iron loss and copper loss are reduced, heat dissipation performance improves the whole efficiency of motor；
B, fore bearing 68 and rear bearing 69 are separately positioned on to 251 and of fore bearing room of the stator inner ring 25 of the stator module 20
In rear bearing room 253；
C, shaft 50 is designed as Step Shaft, successively include preceding axle portion 51, middle shaft part 52 and rear axle portion 53, the middle shaft part 52
Outer diameter is all bigger than the outer diameter of the preceding axle portion 51 and rear axle portion 53, and the middle shaft part 52 of the shaft 50 is arranged in the fore bearing
In 68 inner hole and the inner hole of rear bearing 69；The front and rear end of middle shaft part 52 is designed with a circle threaded hole；
D, 30 mirror image of two pieces rotor assembly is separately fixed in the preceding axle portion 51 and rear axle portion 53 of the shaft 50, actually
Two pieces rotor assembly 30 can be separately fixed at screw in the threaded hole of the front/rear end of the middle shaft part 52 of shaft 50, and two
Rotor assembly 30 described in part is respectively in parallel close to the first baffle 2211 and second baffle 2212 of the stator winding part 22
And respective axial air-gap 98 is formed therewith；
The present invention is using single stator and birotor, and wherein stator module is located at centre, and birotor component is located at stator module
Two sides, form a kind of sandwich structure；This structure is compared to single stator and single rotor form, so that stator and turning
It offsets each other between son in axial magnetic pull, has reached more firm structure；And this structure is compared to bimorph transducer and single-turn
Subtype formula, due to having, there are two the components rotated to effectively increase the torque density of motor so that the output torque of motor increases
And power density；
E, first end cover 10 and second end cover 40 are separately fixed to the both ends of the stator cage 21 with screw 97, it is described fixed to make
Sub-component 20 and rotor assembly 30 are enclosed in the interior intracavitary of the stator cage 21, and this completes the whole of the disc type electric machine
Body assembly.
Referring to Fig. 3 to Fig. 6, in step a4In, before fixation second end plate of stator 24, by circulating cooling pipe 26
Be arranged in the radial gap 29, the water inlet tube head 261 and water outlet tube head 262 at both ends respectively on stator cage 21 into
Water pipe 219 and outlet pipe 218 are connected.Circulating cooling pipe 26 is made into using copper pipe.Circulating cooling pipe 26 plays heat spreading function.
It further include step d before step d referring to Figure 12 to Figure 190, rotor assembly 30 production, the rotor assembly
30 include making of the discoidal rotor flange 31 of non-magnetic aluminum material production, even numbered blocks permanent magnet 33 and of engineering plastics
Discoidal rotor frame 34, and the small iron core 32 of rotor with 33 equivalent amount of permanent magnet;The material of permanent magnet 33 is neodymium
Iron boron high magnetic energy alloy；Magnetic circuit leakage field in order to prevent, improves and stores magnetic energy power, and rotor flange 31 uses non-magnetic aluminum material system
Make, rotor frame 34 is made of engineering plastics；The specific production step of rotor assembly 30 is as follows:
d01The production of the small iron core 32 of rotor: soft magnetic materials is made it is powdered, by powdered soft magnetic materials rotor mold pressure
The small iron core 32 of rotor is made, small 32 shape of iron core of the rotor to complete is up big and down small sector structure, outer including top
Arc surface 321 and the inner arc surface of lower part 322, and the left side that the exterior arc surface 321 and inner arc surface 322 are coupled
323 and right side 324, the arc length of the exterior arc surface 321 it is bigger than the arc length of inner arc surface 322；The small iron core 32 of rotor it
Positioning protrusion 3211 is additionally provided on exterior arc surface 321；
Since the rotor core of prior art silicon steel sheet punching press limits the performance of three-dimensional magnetic field performance advantage, and the present invention passes through
Powder made of soft magnetic materials, then with rotor mold compression moulding, it is fabricated to the small iron core 32 of rotor, so that magnetic field energy is in each dimension
Direction movement is spent, while significantly reducing the iron loss of part, improves electric efficiency；
d02Among rotor flange 31 and periphery is separately designed into the intermediate convex block 311 stretched out for the same direction and a circle periphery
Flange collar 312, which is equipped with the 7th central through hole 3111, between the intermediate convex block 311 and outer peripheral bead 312
Form the cavity 313 for accommodating the small iron core 32 of the rotor, permanent magnet 33 and rotor frame 34；The cavity of rotor flange 31
313 outer edge is equipped with a circle the first recess 319 compatible with the positioning protrusion 3211 of the small iron core 32 of rotor；
d03To be evenly spaced apart to be designed as on rotor frame 34 in the through-hole 342 and the 6th of 33 equivalent amount of permanent magnet
Heart through-hole 341, respectively the permanent magnet 33 is evenly spaced apart in each through-hole 345 for being fixed on the rotor frame 34, and the pole N, S is alternately arranged
Column；A circle the second recess 349 compatible with the positioning protrusion 3211 of the small iron core 32 of rotor also is provided on rotor frame 34；
d04By the small iron core 32 of each rotor along one circle it is seamless spliced at be tightly attached to together after an annulus rotor flange 31 it
The bottom surface of cavity 313, the positioning protrusion 3211 of each small iron core 32 of rotor are located at the cavity 313 of corresponding rotor flange 31
Permanent magnet 33 in first recess 319, then by rotor frame 34 and thereon reinstates screw 96 and is fixed on the rotor flange 31
Cavity 313 in, the positioning protrusion 3211 of each small iron core 32 of rotor is also located at the second of corresponding rotor frame 34 simultaneously
In recess 349, the small iron core 32 of each rotor is allowed in this way and is somebody's turn to do together positioned at the bottom surface of the cavity 313 of the rotor flange 31 and respectively
Between permanent magnet 33, positioning protrusion 3211 and the first recess 319 and the second recess 349 with the effect for closing positioning and fixation.
In order to fixed, can also be fixed using adhesive between the small iron core 32 of each rotor and permanent magnet 33.Each permanent magnet 33 is all
The separated by a distance and certain angle that has been staggered, it is possible to reduce the intrinsic cogging torque of motor.After rotor assembly 30 assembles,
Rotor frame 34 will not be higher by rotor flange 31, make axial dimension shorter in this way.
Referring to Figure 13, Figure 18 and Figure 19, in step d03In, each piece of permanent magnet 33 all includes first piece of permanent magnet
Unit 33-1 to K block permanent magnet unit 33-K, respectively first piece of permanent magnet unit 33-1 to K block permanent magnet unit 33-K mono-
Rise it is radially fixed in each through-hole 345 of the rotor frame 34, wherein 2≤K≤7, K are integer, such as K=3.It is each
It is the eddy-current loss in order to reduce permanent magnet itself that permanent magnet 33 described in block, which is divided into the small permanent magnet unit of muti-piece, and processing side
Just.
In step a1In the manufacturing process of stator core 221, soft magnetic materials is the powder made of melting and aerosolization
Shape；Before powdered soft magnetic materials is pressed into stator core 221 with stator mould, also to powdered soft magnetic materials into
The spraying of row surface, makes powdered soft magnetic materials spray a upper layer insulating；And by powdered soft magnetic materials stator mould
Tool is pressed into after stator core 221 and by whole outer surface of the stator core 221 all before spray insulation paint, by institute
Stator core 221 is stated to be made annealing treatment.That is, the manufacturing process of stator core 221 includes: to pass through soft magnetic materials
It is powdered made of melting and aerosolization；Surface spraying is carried out to powdered soft magnetic materials, sprays powdered soft magnetic materials
Coat a layer insulating；Powdered soft magnetic materials is pressed into stator core 221 with stator mould；By the stator core
221 are made annealing treatment；By all spray insulation paint on whole outer surfaces of the stator core 221.
In the manufacturing process of the small iron core 32 of step d01 rotor, soft magnetic materials is also made of melting and aerosolization
It is powdered.
Soft magnetic materials of the present invention includes the soft magnetic materials for including ferro-silicium.
Referring to Fig. 1 to Figure 19, the stator core 221 of stator module 20 has 12, and stator winding part 22 is 12, and 12
The stator winding of a centralization forms three-phase windings after the connection type by setting, and draws three the end of a thread, as motor
UVW three-phase output end；The permanent magnet 33 of each rotor assembly 30 is 10 pieces, and the small iron core 32 of rotor is 10 pieces.It is N number of fixed referring to Fig. 5
It is cold that circulation not only can be set in the radial gap 29 that the outer end of sub- coil assembly 22 and the inner cavity of the stator cage 21 are formed
But pipe 26, and the end of a thread of each stator winding is also to draw from this, but also can play the role of ventilation and heat dissipation.
Referring to Fig. 1 and Figure 11,50 both ends of shaft of the invention are not from the 9th central through hole 11 of first end cover 10 and
8th central through hole 41 of two end caps 40 stretches out so that and disc type electric machine axial dimension of the present invention is smaller, but in shaft 50
Center axially engages through-hole 54 equipped with what is be connected with exterior part.
Referring to Fig. 1 to Figure 12, correspondingly, the present invention also provides a kind of disc type electric machines, including are equipped with the 9th central through hole 11
First end cover 10, the second end cover 40 equipped with the 8th central through hole 41, stator module 20, rotor assembly 30, shaft 50, front axle
Hold 68 and rear bearing 69;The rotor assembly 30 has two pieces；The stator module 20 includes hollow stator cage 21, N number of fixed
Sub- coil assembly 22, the stator first end plate 23 equipped with the first central through hole 231, the stator equipped with the second central through hole 241
Two end plates 24 and hollow stator inner ring 25；Each stator winding part 22 includes again the powder pressure formed by soft magnetic materials
Stator core 221 and stator winding 222 made of casting, 221 shape of stator core are I-shaped structure, including both ends sector
First baffle 2211 and second baffle 2212, and intermediate mandrel 2213, the mandrel 2213 is by the first baffle
2211 and second baffle 2212 be linked together, the first baffle 2211, mandrel 2213 and second baffle 2212 form a circle
Open cavity 2214, the stator winding 222 is insulated to be wrapped on the mandrel 2213 and is located at the cavity 2214
It is interior；The N number of first through hole compatible with the first baffle 2211 of a circle is evenly provided in the stator first end plate 23
232, N number of second through-hole compatible with the second baffle 2212 of a circle is evenly provided on second end plate of stator 24
242；The inner cavity of the stator inner ring 25 is successively arranged interconnected fore bearing room 251, third central through hole 252 and rear bearing
Room 253；The interior intracavitary of the stator cage 21 is fixed on before and after the stator first end plate 23 and the second end plate of stator 24, it is N number of
Stator winding part 22 is uniformly with lining up a circle positioned at the stator first end plate 23 and the second end plate of stator 24 between, and often
The first baffle 2211 and second baffle 2212 of one stator winding part 22 are stuck in the corresponding stator first end plate
In 23 first through hole 232 and the second through-hole 242 of the second end plate of stator 24, the outer end of N number of stator winding part 22 and institute
There is radial gap 29 in the inner cavity for stating stator cage 21, and the stator inner ring 25 is fixed on the stator first end plate 23 and stator
Between second end plate 24, and the first center of the fore bearing room 251 of the stator inner ring 25 and the stator first end plate 23
Through-hole 231 is connected, the second central through hole of the rear bearing room 253 of the stator inner ring 25 and second end plate of stator 24
241 are connected；Wherein N >=3m, m are positive integer；The fore bearing 68 and rear bearing 69 are located at the stator inner ring 25
In fore bearing room 251 and rear bearing room 253；The shaft 50 is Step Shaft, successively includes preceding axle portion 51, middle shaft part 52 and rear axle
The outer diameter in portion 53, the middle shaft part 52 is all bigger than the outer diameter of the preceding axle portion 51 and rear axle portion 53, the middle shaft part of the shaft 50
52 are arranged in the inner hole of the fore bearing 68 and the inner hole of rear bearing 69；It is fixed respectively to 30 mirror image of rotor assembly described in two pieces
In the preceding axle portion 51 and rear axle portion 53 of the shaft 50, and rotor assembly 30 described in two pieces is respectively in parallel close to described fixed
The first baffle 2211 and second baffle 2212 of sub- coil assembly 22 and form respective axial air-gap 98 therewith;Described first
End cap 10 and second end cover 40 are separately fixed at the both ends of the stator cage 21, by the stator module 20 and rotor assembly 30
It is enclosed in the interior intracavitary of the stator cage 21.
The whole outer surfaces of the stator core 221 are all coated with anticorrosion, anti-get rusty and the insulated paint of anti-insulation.
Referring to Fig. 3 to Fig. 6, the stator module 20 further includes the circulating cooling pipe 26 of annular, which sets
Set in the radial gap 29 of the stator module 20, the water inlet tube head 261 at both ends and water outlet tube head 262 respectively with it is described fixed
Water inlet pipe 219 and outlet pipe 218 on handset shell 21 are connected.
After the stator module 20 assembles, whole encapsulating is carried out to the stator module 20 with adhesive, it is described fixed to make
Each components of sub-component 20 firmly stick into one.
Referring to Figure 12 to Figure 19, the rotor assembly 30 includes the discoidal rotor method made of non-magnetic aluminum material
Orchid 31, even numbered blocks permanent magnet 33 and the discoidal rotor frame 34 made of engineering plastics, and counted on an equal basis with permanent magnet 33
The small iron core 32 of rotor made of amount, the powder die-casting that is formed as soft magnetic materials, small 32 shape of iron core of rotor be it is upper greatly under
Small sector structure, the inner arc surface 322 of exterior arc surface 321 and lower part including top, and by 321 He of exterior arc surface
The left side 323 and right side 324 that inner arc surface 322 couples, the arc of the arc length of the exterior arc surface 321 than inner arc surface 322
It is long big;Among the rotor flange 31 and periphery is respectively equipped with outside the intermediate convex block 311 that the same direction is stretched out and a circle
Flange collar 312 is enclosed, intermediate convex block 311 is equipped with the 7th central through hole 3111, between the intermediate convex block 311 and outer peripheral bead 312
Form the cavity 313 for accommodating the small iron core 32 of the rotor, permanent magnet 33 and rotor frame 34；On the rotor frame 34
Even compartment of terrain is equipped with through-hole 342 and the 6th central through hole 341 with 33 equivalent amount of permanent magnet, and respectively the permanent magnet 33 is uniform
Compartment of terrain is fixed in each through-hole 345 of the rotor frame 34, and the pole N, S is alternately arranged, rotor frame 34 and permanent magnetism thereon
Body 33 is fixed on together in the cavity 313 of the rotor flange 31, and respectively the small iron core 32 of the rotor is seamless spliced at one along a circle
The bottom surface of the cavity 313 of the rotor flange 31 is set together after a annulus and respectively between the permanent magnet 33.
Referring to Figure 13, Figure 18 and Figure 19, each piece of permanent magnet 33 all includes first piece of permanent magnet unit 33-1 to K
Block permanent magnet unit 33-K, respectively first piece of permanent magnet unit 33-1 to K block permanent magnet unit 33-K together it is radially fixed
In each through-hole 345 of the rotor frame 34, wherein 2≤K≤7, K are integer.
The preferred embodiment of the present invention above described embodiment only expresses, the description thereof is more specific and detailed, but simultaneously
Limitations on the scope of the patent of the present invention therefore cannot be interpreted as;It should be appreciated that for those of ordinary skill in the art
For, without departing from the inventive concept of the premise, various modifications and improvements can be made, these belong to guarantor of the invention
Protect range;Therefore, all equivalents and modification done with scope of the invention as claimed, should belong to the claims in the present invention
Covering scope.
Claims (10)
1. a kind of manufacturing method of disc type electric machine, which includes the first end cover equipped with the 9th central through hole (11)
(10), equipped with the second end cover (40) of the 8th central through hole (41), stator module (20), rotor assembly (30), shaft (50), preceding
Bearing (68) and rear bearing (69), wherein the rotor assembly (30) has two pieces；The manufacturing method includes the following steps:
A, the production of stator module (20), the stator module (20) include hollow stator cage (21), N number of stator winding portion
Part (22), the stator first end plate (23) for being equipped with the first central through hole (231), the stator for being equipped with the second central through hole (241)
Two end plates (24) and hollow stator inner ring (25)；Each stator winding part (22) again include stator core (221) and
Stator winding (222);Wherein N >=3m, m are positive integer；
a1, stator core (221) production: soft magnetic materials is made it is powdered, by powdered soft magnetic materials stator mould pressure
Stator core (221) are made；Then the stator core (221) are subjected to insulation processing, i.e., by the stator core (221)
It is all coated with anticorrosion on whole outer surfaces, anti-gets rusty and the insulated paint of anti-insulation；Stator core (221) shape to complete
For I-shaped structure, first baffle (2211) and second baffle (2212) including both ends sector, and intermediate mandrel
(2213), the first baffle (2211) and second baffle (2212) are linked together by the mandrel (2213), and described first
Baffle (2211), mandrel (2213) and second baffle (2212) form the open cavity (2214) of a circle;
a2, stator winding part (22) production, by the insulated stator core (221) of being wrapped in of stator winding (222)
On mandrel (2213) and it is located in the cavity (2214) of the stator core (221), has just made a stator winding portion in this way
Part (22)；
a3, be evenly provided on stator first end plate (23) the N number of first baffle with the stator core (221) of a circle
(2211) compatible first through hole (232)；It is N number of with the stator that a circle is evenly provided on the second end plate of stator (24)
Compatible second through-hole (242) of the second baffle (2212) of iron core (221)；The inner cavity of stator inner ring (25) is successively arranged phase
Intercommunicated fore bearing room (251), third central through hole (252) and rear bearing room (253)；
a4, stator first end plate (23) is fixed on the interior intracavitary of the stator cage (21) with screw (99), and by stator inner ring
(25) a end face is fixed on the stator first end plate (23) with screw (99), so that the front axle of the stator inner ring (25)
Room (251) is held to be connected with the first central through hole (231) of the stator first end plate (23)；By N number of stator winding part
(22) first baffle (2211) is respectively put into the first through hole (232) of the corresponding stator first end plate (23), the N
The outer end of a stator winding part (22) and the inner cavity of the stator cage (21) have radial gap (29), then by stator
Second end plate (24) is also fixed on the interior intracavitary of the stator cage (21) with screw (99), and makes each stator winding portion
The second baffle (2212) of part (22) is stuck in the second through-hole (242) of corresponding the second end plate of the stator (24), this
Sample makes N number of stator winding part (22) uniformly be located at the stator first end plate (23) and the second end plate of stator with lining up a circle
(24) between；Also the second end plate of stator (24) and the other end of stator inner ring (25) are fixed with screw (99), and made described
The rear bearing room (253) of stator inner ring (25) is connected with the second central through hole (241) of second end plate of stator (24)；
a5, with adhesive whole encapsulating is carried out to said stator component (20), make each components of the stator module (20) firmly
Ground sticks into one, waits adhesive curing molding, this completes the production of stator module (20)；
B, fore bearing (68) and rear bearing (69) are separately positioned on to the front axle of the stator inner ring (25) of the stator module (20)
It holds in room (251) and rear bearing room (253)；
C, shaft (50) is designed as Step Shaft, successively includes preceding axle portion (51), middle shaft part (52) and rear axle portion (53), it is described in
The outer diameter of axle portion (52) is all bigger than the outer diameter of the preceding axle portion (51) and rear axle portion (53), by the middle shaft part of the shaft (50)
(52) it is arranged in the inner hole of the fore bearing (68) and the inner hole of rear bearing (69)；
D, two pieces rotor assembly (30) mirror image is separately fixed to the preceding axle portion (51) and rear axle portion (53) of the shaft (50)
On, and rotor assembly described in two pieces (30) is respectively in parallel close to the first baffle (2211) of the stator winding part (22)
Respective axial air-gap (98) are formed therewith with second baffle (2212)；
E, first end cover (10) and second end cover (40) are separately fixed to the both ends of the stator cage (21) with screw (97),
The stator module (20) and rotor assembly (30) is set to be enclosed in the interior intracavitary of the stator cage (21), this completes institutes
State the whole assembly of disc type electric machine.
2. the manufacturing method of disc type electric machine according to claim 1, it is characterised in that:
In step a4In, before fixation second end plate of stator (24), circulating cooling pipe (26) are arranged in the radial direction
In gap (29), the water inlet tube head (261) at both ends and be discharged tube head (262) respectively with the water inlet pipe on stator cage (21)
(219) it is connected with outlet pipe (218).
3. the manufacturing method of disc type electric machine according to claim 1, it is characterised in that:
It further include step d before step d0, rotor assembly (30) production, the rotor assembly (30) includes with non-magnetic
Aluminum material production discoidal rotor flange (31), even numbered blocks permanent magnet (33) and with engineering plastics make discoidal turn
Subframe (34), and the small iron core of rotor (32) with permanent magnet (33) equivalent amount;The specific production of rotor assembly (30) walks
It is rapid as follows:
d01The production of the small iron core of rotor (32): soft magnetic materials is made it is powdered, by powdered soft magnetic materials rotor mold
It is pressed into the small iron core of rotor (32), the rotor to complete small iron core (32) shape is up big and down small sector structure, including upper
The exterior arc surface (321) in portion and the inner arc surface (322) of lower part, and by the exterior arc surface (321) and inner arc surface (322)
The left side (323) and right side (324) of connection, the arc length of the exterior arc surface (321) is than the arc length of inner arc surface (322)
Greatly；
d02Among rotor flange (31) and periphery is separately designed outside the intermediate convex block (311) and a circle stretched out for the same direction
Flange collar (312) are enclosed, which is equipped with the 7th central through hole (3111), and the intermediate convex block (311) and periphery are convex
It encloses between (312) and forms the cavity for accommodating the small iron core of rotor (32), permanent magnet (33) and rotor frame (34)
(313)；
d03It will be evenly spaced apart to be designed as and the through-hole (342) of the permanent magnet (33) equivalent amount and on rotor frame (34)
Six central through holes (341), respectively the permanent magnet (33) is evenly spaced apart to be fixed on each through-hole (345) of the rotor frame (34)
Interior, the pole N, S is alternately arranged；
d04The small iron core of each rotor (32) is seamless spliced at being tightly attached to the rotor flange together after an annulus along a circle
(31) bottom surface of cavity (313), then permanent magnet (33) one by rotor frame (34) and thereon are reinstated screw (96) and are fixed on
In the cavity (313) of the rotor flange (31), the small iron core of each rotor (32) is allowed in this way and is located at the rotor flange together
(31) between the bottom surface of cavity (313) and the respectively permanent magnet (33).
4. the manufacturing method of disc type electric machine according to claim 3, it is characterised in that:
In step d03In, each piece of permanent magnet (33) is all including first piece of permanent magnet unit (33-1) to K block permanent magnet
Unit (33-K), respectively first piece of permanent magnet unit (33-1) is radially fixed in institute together to K block permanent magnet unit (33-K)
In each through-hole (345) for stating rotor frame (34), wherein 2≤K≤7, K are integer.
5. the manufacturing method of disc type electric machine according to claim 1, it is characterised in that:
In step a1In the manufacturing process of stator core (221), soft magnetic materials is powdered made of melting and aerosolization；
Before powdered soft magnetic materials is pressed into stator core (221) with stator mould, also to powdered soft magnetic materials into
The spraying of row surface, makes powdered soft magnetic materials spray a upper layer insulating；And by powdered soft magnetic materials stator mould
Tool is pressed into after stator core (221) and by whole outer surface of the stator core (221) all before spray insulation paint,
The stator core (221) is made annealing treatment.
6. a kind of disc type electric machine, including being equipped with the first end cover (10) of the 9th central through hole (11), being equipped with the 8th central through hole
(41) second end cover (40), stator module (20), rotor assembly (30), shaft (50), fore bearing (68) and rear bearing (69);
It is characterized by:
The rotor assembly (30) has two pieces；
The stator module (20) includes hollow stator cage (21), N number of stator winding part (22), to be equipped with the first center logical
The stator first end plate (23) in hole (231), the second end plate of stator (24) and hollow stator for being equipped with the second central through hole (241)
Inner ring (25)；Each stator winding part (22) includes stator core made of the powder die-casting formed as soft magnetic materials again
(221) and stator winding (222), stator core (221) shape are I-shaped structure, the first baffle including both ends sector
(2211) and second baffle (2212), and intermediate mandrel (2213), the mandrel (2213) is by the first baffle
(2211) it is linked together with second baffle (2212), the first baffle (2211), mandrel (2213) and second baffle
(2212) the open cavity (2214) of a circle is formed, the stator winding (222) is insulated to be wrapped in the mandrel (2213)
It goes up and is located in the cavity (2214)；It is N number of with the first gear that a circle is evenly provided on the stator first end plate (23)
The compatible first through hole (232) of plate (2211), be evenly provided on second end plate of stator (24) circle it is N number of with it is described
Compatible second through-hole (242) of second baffle (2212)；The inner cavity of the stator inner ring (25) is successively arranged interconnected
Fore bearing room (251), third central through hole (252) and rear bearing room (253)；The stator first end plate (23) and stator second
The interior intracavitary of the stator cage (21) is fixed on before and after end plate (24), N number of stator winding part (22) is uniform with lining up a circle
Between the stator first end plate (23) and the second end plate of stator (24), and the of each stator winding part (22)
One baffle (2211) and second baffle (2212) are stuck in the first through hole (232) of the corresponding stator first end plate (23)
In the second through-hole (242) of the second end plate of stator (24), the outer end of N number of stator winding part (22) and the stator cage
(21) inner cavity has radial gap (29), and the stator inner ring (25) is fixed on the stator first end plate (23) and stator
Between two end plates (24), and the of the fore bearing room (251) of the stator inner ring (25) and the stator first end plate (23)
One central through hole (231) is connected, the rear bearing room (253) of the stator inner ring (25) and second end plate of stator (24)
The second central through hole (241) be connected；Wherein N >=3m, m are positive integer；
The fore bearing (68) and rear bearing (69) are located at fore bearing room (251) and the rear bearing of the stator inner ring (25)
In room (253)；The shaft (50) is Step Shaft, described successively including preceding axle portion (51), middle shaft part (52) and rear axle portion (53)
The outer diameter of middle shaft part (52) is all bigger than the outer diameter of the preceding axle portion (51) and rear axle portion (53), the middle shaft part of the shaft (50)
(52) it is arranged in the inner hole of the fore bearing (68) and the inner hole of rear bearing (69)；Rotor assembly described in two pieces (30) mirror image
It is separately fixed in the preceding axle portion (51) and rear axle portion (53) of the shaft (50), and rotor assembly described in two pieces (30) is respectively
In parallel close to the stator winding part (22) first baffle (2211) and second baffle (2212) and formed therewith respectively
Axial air-gap (98);
The first end cover (10) and second end cover (40) are separately fixed at the both ends of the stator cage (21), by the stator
Component (20) and rotor assembly (30) are enclosed in the interior intracavitary of the stator cage (21).
7. disc type electric machine according to claim 6, it is characterised in that:
The whole outer surfaces of the stator core (221) are all coated with anticorrosion, anti-get rusty and the insulated paint of anti-insulation.
8. disc type electric machine according to claim 1, it is characterised in that:
The stator module (20) further includes the circulating cooling pipe (26) of annular, which is arranged in the stator
In the radial gap (29) of component (20), the water inlet tube head (261) at both ends and be discharged tube head (262) respectively with the stator
Water inlet pipe (219) and outlet pipe (218) on shell (21) are connected.
9. according to described in any item disc type electric machines of claim 6 to 8, it is characterised in that:
After the stator module (20) assembles, whole encapsulating is carried out to the stator module (20) with adhesive, it is described fixed to make
Each components of sub-component (20) firmly stick into one.
10. disc type electric machine according to claim 6, it is characterised in that:
The rotor assembly (30) includes discoidal rotor flange (31), the even numbered blocks permanent magnetism made of non-magnetic aluminum material
Body (33) and with engineering plastics make discoidal rotor frame (34), and with permanent magnet (33) equivalent amount, by soft
The small iron core of rotor (32) made of the powder die-casting that magnetic material is formed, the small iron core of rotor (32) shape are up big and down small fan
Shape structure, the inner arc surface (322) of exterior arc surface (321) and lower part including top, and by the exterior arc surface (321) and
The left side (323) and right side (324) of inner arc surface (322) connection, the arc length of the exterior arc surface (321) compare inner arc surface
(322) arc length is big;The rotor flange (31) is intermediate and periphery is respectively equipped with the intermediate convex block stretched out to the same direction
(311) and circle outer peripheral bead (312), intermediate convex block (311) are equipped with the 7th central through hole (3111), the intermediate convex block
(311) one is formed between outer peripheral bead (312) accommodate the small iron core of rotor (32), permanent magnet (33) and rotor frame
(34) cavity (313)；It is evenly spaced apart to be equipped on the rotor frame (34) logical with the permanent magnet (33) equivalent amount
Hole (342) and the 6th central through hole (341), respectively the permanent magnet (33) is evenly spaced apart to be fixed on each of the rotor frame (34)
In through-hole (345), the pole N, S is alternately arranged, and rotor frame (34) and permanent magnet (33) thereon are fixed on the rotor method together
In the cavity (313) of blue (31), respectively the small iron core of the rotor (32) is seamless spliced at being arranged in together after an annulus along a circle
Between the bottom surface of the cavity (313) of the rotor flange (31) and the respectively permanent magnet (33)；
The each piece of permanent magnet (33) all includes first piece of permanent magnet unit (33-1) to K block permanent magnet unit (33-K),
Respectively first piece of permanent magnet unit (33-1) is radially fixed in the rotor frame together to K block permanent magnet unit (33-K)
(34) in each through-hole (345), wherein 2≤K≤7, K are integer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201711401696.9A CN109962584A (en) | 2017-12-22 | 2017-12-22 | Disc type electric machine and its manufacturing method |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201711401696.9A CN109962584A (en) | 2017-12-22 | 2017-12-22 | Disc type electric machine and its manufacturing method |
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| CN109962584A true CN109962584A (en) | 2019-07-02 |
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| CN201711401696.9A Pending CN109962584A (en) | 2017-12-22 | 2017-12-22 | Disc type electric machine and its manufacturing method |
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Cited By (5)
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| CN111682679A (en) * | 2020-06-08 | 2020-09-18 | 齐鲁工业大学 | Double-rotor single-stator disc type motor |
| CN111682678A (en) * | 2020-06-08 | 2020-09-18 | 齐鲁工业大学 | Novel double-rotor single-stator amorphous alloy disc type motor |
| CN112688520A (en) * | 2020-12-31 | 2021-04-20 | 南通理工学院 | Novel generator and assembling method thereof |
| CN115395739A (en) * | 2022-10-28 | 2022-11-25 | 深圳大学 | Machining method of coreless flat wire disc type vertical axis wind driven generator |
| CN115566818A (en) * | 2022-10-18 | 2023-01-03 | 无锡星驱动力科技有限公司 | Stator core assembly, stator assembly and driving motor |
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| CN115566818A (en) * | 2022-10-18 | 2023-01-03 | 无锡星驱动力科技有限公司 | Stator core assembly, stator assembly and driving motor |
| CN115395739A (en) * | 2022-10-28 | 2022-11-25 | 深圳大学 | Machining method of coreless flat wire disc type vertical axis wind driven generator |
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