TW202139568A - Improved rotor assemblies for axial flux machines - Google Patents

Improved rotor assemblies for axial flux machines Download PDF

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TW202139568A
TW202139568A TW109139278A TW109139278A TW202139568A TW 202139568 A TW202139568 A TW 202139568A TW 109139278 A TW109139278 A TW 109139278A TW 109139278 A TW109139278 A TW 109139278A TW 202139568 A TW202139568 A TW 202139568A
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support structure
magnet
point
rotor
rotor assembly
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TW109139278A
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Chinese (zh)
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喬治 哈迪 米爾漢姆
史蒂芬 羅伯特 蕭
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美商E電路馬達股份有限公司
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Priority claimed from US17/086,549 external-priority patent/US11005322B2/en
Application filed by 美商E電路馬達股份有限公司 filed Critical 美商E電路馬達股份有限公司
Publication of TW202139568A publication Critical patent/TW202139568A/en

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    • 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
    • H02K1/2793—Rotors axially facing stators
    • 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
    • H02K1/2793—Rotors axially facing stators
    • H02K1/2795—Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2798—Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets where both axial sides of the stator face a rotor
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
    • 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
    • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
    • 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
    • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
    • H02K1/30—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures using intermediate parts, e.g. spiders
    • 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
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/26—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2201/00—Specific aspects not provided for in the other groups of this subclass relating to the magnetic circuits
    • H02K2201/03—Machines characterised by aspects of the air-gap between rotor and stator
    • 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

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

A rotor assembly for an axial flux machine may include at least one magnet and first and second support structures. The first support structure may be configured to have the at least one magnet attached thereto and to provide a flux return path for the at least one magnet. The second support structure may be configured to be attached to the first support structure so as to allow torque to be transferred between the at least one magnet and the second support structure via the first support structure, and may be further configured (A) to be attached to a rotatable shaft of the axial flux machine, or (B) to function as an output or input flange of the axial flux machine.

Description

用於軸向磁通機器之改良轉子組合件Improved rotor assembly for axial flux machines

本發明係關於用於軸向磁通馬達或產生器之轉子組合件。The present invention relates to a rotor assembly used in an axial flux motor or generator.

永磁軸向磁通馬達及產生器係已知的。此等馬達或產生器(本文中統稱為「機器」)之實例闡述於以下各項中：美國專利第7,109,625號、第9,673,688號、第9,800,109號、第9,673,684號及第10,170,953號；以及美國專利申請公開案第2018-0351441 A1 (「’441公開案」)號，其中之每一者之全部內容以引用方式併入本文中。Permanent magnet axial flux motors and generators are known. Examples of these motors or generators (collectively referred to herein as "machines") are described in the following: U.S. Patent Nos. 7,109,625, 9,673,688, 9,800,109, 9,673,684, and 10,170,953; and U.S. Patent Applications Public Case No. 2018-0351441 A1 ("'441 Public Case"), the entire content of each of which is incorporated herein by reference.

在所揭示實施例中之某些實施例中，一種用於一軸向磁通機器之轉子組合件包括至少一個磁鐵以及第一及第二支撐結構。該第一支撐結構經構形以使該至少一個磁鐵附接至其且提供該至少一個磁鐵之一磁通返迴路徑。該第二支撐結構經構形以附接至該第一支撐結構以便允許經由該第一支撐結構在該至少一個磁鐵與該第二支撐結構之間轉移扭矩，其中該第二支撐結構進一步經構形以：(A) 附接至該軸向磁通機器之一可旋轉軸，或(B) 充當該軸向磁通機器之一輸出或輸入凸緣。In some of the disclosed embodiments, a rotor assembly for an axial flux machine includes at least one magnet and first and second support structures. The first support structure is configured to attach the at least one magnet to it and provide a magnetic flux return path for the at least one magnet. The second support structure is configured to be attached to the first support structure so as to allow torque to be transferred between the at least one magnet and the second support structure via the first support structure, wherein the second support structure is further configured The shape is: (A) attached to a rotatable shaft of the axial flux machine, or (B) acting as an output or input flange of the axial flux machine.

在某些實施例中，一種方法包括：將至少一個磁鐵附接至用於一軸向磁通機器之一轉子組合件之一第一支撐結構，使得該第一支撐結構提供該至少一個磁鐵之一磁通返迴路徑；及將一第二支撐結構附接至具有附接至其之該至少一個磁鐵之該第一支撐結構以便允許經由該第一支撐結構在該至少一個磁鐵與該第二支撐結構之間轉移扭矩，其中該第二支撐結構進一步經構形以：(A) 附接至該軸向磁通機器之一可旋轉軸，或(B) 充當該軸向磁通機器之一輸出或輸入凸緣。In some embodiments, a method includes attaching at least one magnet to a first support structure for a rotor assembly of an axial flux machine, such that the first support structure provides the at least one magnet A magnetic flux return path; and attaching a second support structure to the first support structure having the at least one magnet attached to it so as to allow the at least one magnet and the second support structure to pass through the first support structure Torque is transferred between support structures, wherein the second support structure is further configured to: (A) be attached to a rotatable shaft of the axial flux machine, or (B) act as one of the axial flux machine Export or import flange.

在某些實施例中，一種用於一軸向磁通機器之轉子組合件包括：至少一個磁鐵；第一構件，其用於提供該至少一個磁鐵之一磁通返迴路徑；及第二構件，其經構形以附接至該第一構件，用於經由該第一構件將扭矩轉移至該至少一個磁鐵或自該至少一個磁鐵轉移扭矩，其中該第二構件進一步構形以：(A) 附接至該軸向磁通機器之一可旋轉軸，或(B) 充當該軸向磁通機器之一輸出或輸入凸緣。In some embodiments, a rotor assembly for an axial flux machine includes: at least one magnet; a first member for providing a magnetic flux return path of the at least one magnet; and a second member , Which is configured to be attached to the first member for transferring torque to or from the at least one magnet via the first member, wherein the second member is further configured to: (A ) Attach to a rotatable shaft of the axial flux machine, or (B) act as an output or input flange of the axial flux machine.

相關申請案之交叉參考Cross reference of related applications

本申請案主張於2019年11月12日提出申請之標題為「IMPROVED ROTOR ASSEMBLIES FOR AXIAL FLUX MACHINES」之美國臨時申請案第62/934,059號之35 U.S. C. § 119(e)下之權益。本申請案亦係一部分接續案且主張於2018年5月18日提出申請之標題為「PRE-WARPED ROTORS FOR CONTROL OF MANGET-STATOR GAP IN AXIAL FLUX MACHINES」之美國專利申請案序號15/983,985且公開為美國專利申請公開案第2018/0351441號之35 U.S.C. § 120下之權益，美國專利申請公開案第2018/0351441號主張以下各項中之一者之35 U.S.C. § 119(e)下之權益：(1) 2017年6月5日提出申請之標題為「PRE-WARPED ROTORS FOR CONTROL OF MAGNET-STATOR GAP IN AXIAL FLUX MACHINES」之美國臨時專利申請案序號62/515,251，及 (2) 2017年6月5日提出申請之標題為「AIR CIRCULATION IN AXIAL FLUX MACHINES」之美國臨時專利申請案序號62/515,256。前述申請案中之每一者之內容出於所有目的以全文引用之方式併入本文中。This application claims the rights under 35 U.S. C. § 119(e) of the U.S. Provisional Application No. 62/934,059 filed on November 12, 2019, entitled "IMPROVED ROTOR ASSEMBLIES FOR AXIAL FLUX MACHINES". This application is also part of the continuation and claims that the U.S. Patent Application No. 15/983,985 filed on May 18, 2018, titled ``PRE-WARPED ROTORS FOR CONTROL OF MANGET-STATOR GAP IN AXIAL FLUX MACHINES'' and published U.S. Patent Application Publication No. 2018/0351441 for the rights under 35 USC § 120, U.S. Patent Application Publication No. 2018/0351441 claims one of the following rights and interests under 35 USC § 119(e): (1) The U.S. Provisional Patent Application No. 62/515,251, filed on June 5, 2017, entitled "PRE-WARPED ROTORS FOR CONTROL OF MAGNET-STATOR GAP IN AXIAL FLUX MACHINES", and (2) June 2017 The US provisional patent application serial number 62/515,256, titled "AIR CIRCULATION IN AXIAL FLUX MACHINES", filed on the 5th. The content of each of the aforementioned applications is incorporated herein by reference in its entirety for all purposes.

永磁軸向磁通馬達及產生器，諸如上文所說明之專利文件中所闡述之永磁軸向磁通馬達及產生器，可以一平坦印刷電路板(PCB)定子組合件為特徵，該平坦印刷電路板(PCB)定子組合件定位於具有永久磁鐵之兩個轉子部分之間，或定位於具有一或多個永久磁鐵之一個轉子部分與有效地呈現至PCB定子之交替南北磁極之一移動或靜止磁通返回磁軛之間。由定子支持之電流與由轉子建立之磁通密度之交互作用在馬達操作中產生扭矩，或在產生器操作中將扭矩應用於轉子可在定子中感應電流。Permanent magnet axial flux motors and generators, such as the permanent magnet axial flux motors and generators described in the patent documents described above, may feature a flat printed circuit board (PCB) stator assembly. The flat printed circuit board (PCB) stator assembly is positioned between two rotor sections with permanent magnets, or one rotor section with one or more permanent magnets and one of the alternating north and south magnetic poles effectively present to the PCB stator Moving or stationary magnetic flux returns between the yokes. The interaction between the current supported by the stator and the magnetic flux density established by the rotor generates torque during motor operation, or applying torque to the rotor during generator operation can induce current in the stator.

在闡述一軸向磁通機器之幾何結構中，術語「軸向地」、「徑向地」及「成角度地」通常用於闡述各種組件及/或磁通線之定向。如本文中所使用，術語「軸向」及「軸向地」係指平行於機器之轉子之旋轉軸線之一方向，術語「徑向」及「徑向地」係指交切機器之轉子之旋轉軸線且正交於機器之轉子之旋轉軸線之一方向，且術語「成角度」及「成角度地」係指沿著正交於機器之旋轉軸線之一平面內之一圓之曲線之一方向，其中該圓之中心被旋轉軸線交切。In describing the geometry of an axial flux machine, the terms "axially", "radially" and "angularly" are usually used to describe the orientation of various components and/or flux lines. As used herein, the terms "axial" and "axially" refer to a direction parallel to the axis of rotation of the rotor of the machine, and the terms "radial" and "radially" refer to the direction of the rotor of the intersecting machine The axis of rotation and a direction orthogonal to the axis of rotation of the rotor of the machine, and the terms "angled" and "angled" refer to a direction along a curve of a circle in a plane orthogonal to the axis of rotation of the machine , Where the center of the circle is intersected by the axis of rotation.

對於低於一特定大小之轉子，使用一單件磁性材料(有時稱為一「環形磁鐵」)係實務的，該磁性材料已使用交替磁極磁化。此一環形磁鐵可附接至一轉子支撐件(有時稱為一「背鐵」)，該轉子支撐件向磁鐵提供機械支撐並提供至機器之軸之一連接。For rotors below a certain size, it is practical to use a single piece of magnetic material (sometimes called a "ring magnet") that has been magnetized with alternating magnetic poles. This ring magnet can be attached to a rotor support (sometimes called a "back iron") that provides mechanical support to the magnet and provides a connection to one of the shafts of the machine.

在’441公開案中，闡述一種「預翹曲」轉子組件之方法，其中轉子支撐件可經機加工使得，當轉子半體隔離時一轉子之兩個各別半體之永久磁鐵之面向定子之表面經「翹曲」，但當兩個轉子半體併入至一機器中時經「扁平化」，使得磁力將轉子半體彼此吸引且導致結構偏轉，且因此在永久磁鐵之對置表面之間建立一均勻間隙。在彼文件中所揭示之所有實例中，單件式支撐結構亦用於提供一磁通返迴路徑。In the '441 publication, a method of "pre-warping" a rotor assembly is described, in which the rotor support can be machined so that when the rotor halves are separated, the permanent magnets of two separate halves of a rotor face the stator The surface is "warped", but when the two rotor halves are incorporated into a machine, they are "flattened", so that the magnetic force attracts the rotor halves to each other and causes the structure to deflect, and therefore on the opposite surface of the permanent magnet Establish a uniform gap between. In all the examples disclosed in that document, the one-piece support structure is also used to provide a magnetic flux return path.

對於較大機器，特定而言，具有半徑超出八釐米之機器，將一環形磁鐵用於磁鐵結構可係不切實務的。較之一單件式磁鐵，可更容易且經濟地產生及磁化每一磁極之個別或經分段磁鐵。經分段磁鐵之轉子支撐件亦可包含將個別磁鐵定位成一交替磁極圖案之凹入特徵，或「承窩」。此等承窩可徑向地且軸向地約束磁鐵。與用於具有多個磁極之一單件式磁鐵之一轉子支撐件相比，製作承窩可涉及額外機加工工作。另外，由於轉子支撐件通常經由例如鋼鐵之軟磁性材料提供一磁通返迴路徑，因此較大轉子之重量及慣性可係顯著的。可難以將磁鐵精確地放置於承窩中，且一旦***，可難以移除該等磁鐵。此可使得在一經破壞或經損壞磁鐵的情況下重新裝配一轉子困難，且當一機器自服務移除時亦可潛在地限制磁性材料之恢復及重新使用。For larger machines, particularly machines with a radius exceeding eight centimeters, it may be impractical to use a ring magnet for the magnet structure. Compared with a single-piece magnet, it is easier and more economical to generate and magnetize individual or segmented magnets for each pole. The rotor support of segmented magnets may also include recessed features, or "sockets," that position individual magnets in an alternating magnetic pole pattern. These sockets can constrain the magnet radially and axially. Compared to a rotor support used for a single-piece magnet with multiple magnetic poles, making the socket may involve additional machining work. In addition, since the rotor support usually provides a magnetic flux return path through a soft magnetic material such as steel, the weight and inertia of a larger rotor can be significant. It can be difficult to accurately place the magnets in the socket, and once inserted, it can be difficult to remove the magnets. This can make it difficult to reassemble a rotor in the event of a damaged or damaged magnet, and can potentially limit the recovery and reuse of magnetic materials when a machine is removed from service.

提供一轉子設計，其中用於一轉子之一部分(例如，一轉子半體)之一轉子支撐件可由包含至少一第一支撐結構及一第二支撐結構之多個組件製成。在某些實施方案中，經分段磁鐵可定位於第一支撐結構上。第一支撐結構可舉例而言由例如鋼鐵之一第一材料製成，為轉子部分提供一磁通返迴路徑。此第一支撐結構可經由第二支撐結構支撐且連接至一軸向磁通機器之一軸。在某些實施方案中，第二支撐結構由一第二材料製成，該第二材料不同於第一材料。可針對其磁性質選擇第一材料。另一方面，可針對其勁度、拉伸強度、低重量及/或可製造性選擇第二材料。A rotor design is provided in which a rotor support for a part of a rotor (for example, a rotor half) can be made of multiple components including at least a first support structure and a second support structure. In certain embodiments, the segmented magnet can be positioned on the first support structure. The first support structure may be made of a first material such as steel, for example, to provide a magnetic flux return path for the rotor part. The first supporting structure can be supported by the second supporting structure and connected to a shaft of an axial magnetic flux machine. In some embodiments, the second support structure is made of a second material that is different from the first material. The first material can be selected for its magnetic properties. On the other hand, the second material can be selected for its stiffness, tensile strength, low weight, and/or manufacturability.

在某些實施方案中，第一支撐結構可成角度地且軸向地定位磁鐵，而第二支撐結構可徑向地定位磁鐵。此外，在某些實施方案中，第一支撐結構可以第一支撐結構可與第二支撐結構分離之此一方式由第二支撐結構支撐。在某些此等實施方案中，當第一支撐結構與第二支撐結構分離時，可在徑向方向上移除及替換個別磁鐵分段。In certain embodiments, the first support structure may position the magnet angularly and axially, and the second support structure may position the magnet radially. In addition, in some embodiments, the first support structure may be supported by the second support structure in such a way that the first support structure can be separated from the second support structure. In some of these embodiments, when the first support structure is separated from the second support structure, individual magnet segments can be removed and replaced in the radial direction.

對於使用經分段磁鐵之較大機器(例如，具有超出八釐米之一半徑)，本文中所闡述之設計可係尤為有利的。然而，本文中所闡述之原理亦可適用於使用經分段磁鐵或環形磁鐵之較小機器。該設計可應用於任何類型之軸向磁通機器，包含採用例如具有形成磁極之銅線繞組之習用定子結構以及基於PCB之定子結構(諸如上文所說明之專利文件中所闡述之基於PCB之定子結構)之軸向磁通機器。For larger machines that use segmented magnets (for example, having a radius exceeding one eight centimeters), the design described herein can be particularly advantageous. However, the principles described in this article can also be applied to smaller machines that use segmented magnets or ring magnets. The design can be applied to any type of axial flux machine, including conventional stator structures with copper wire windings forming magnetic poles and PCB-based stator structures (such as the PCB-based ones described in the patent documents described above). Stator structure) axial flux machine.

一軸向磁通機器中之轉子之功能通常包含：定位磁鐵，提供一磁通返迴路徑，且將間隙維持至一規定設計幾何結構。The function of the rotor in an axial flux machine usually includes positioning magnets, providing a magnetic flux return path, and maintaining the gap to a specified design geometry.

磁鐵位置可涉及成角度地約束磁鐵，使得該等磁鐵形成與定子電流密度交互之一交替系列磁極，從而導致淨扭矩產出。此外，磁鐵通常機械地連接至軸使得其可將扭矩傳輸至軸，用於有用機械輸出。磁鐵亦可被徑向地約束以維持磁極之幾何結構。當採用一單件式環形磁鐵時，徑向及成角度約束條件可憑藉環之完整性達成。然而，若轉子包括經分段磁鐵，則需要明確地考量此等約束。Magnet position can involve constraining the magnets at an angle so that the magnets form an alternating series of poles that interact with the stator current density, resulting in a net torque output. In addition, the magnet is usually mechanically connected to the shaft so that it can transmit torque to the shaft for useful mechanical output. Magnets can also be constrained radially to maintain the geometry of the magnetic poles. When a single-piece ring magnet is used, the radial and angular constraints can be achieved by virtue of the integrity of the ring. However, if the rotor includes segmented magnets, these constraints need to be explicitly considered.

轉子之磁通返回功能較佳地完成磁極之間的磁路，而不允許一顯著磁通量「洩露」於既定間隙外部。既定間隙外部之轉子磁通並不貢獻於產生扭矩/電流，且可感應導電材料中之電流並與之交互作用，此增加阻力。磁通返回功能通常使用諸如鋼鐵之一軟磁性材料達成。The magnetic flux return function of the rotor better completes the magnetic circuit between the magnetic poles, and does not allow a significant magnetic flux to "leak" outside the predetermined gap. The rotor flux outside the predetermined gap does not contribute to the torque/current generation, and can induce and interact with the current in the conductive material, which increases the resistance. The magnetic flux return function is usually achieved using a soft magnetic material such as steel.

磁鐵之軸向位置或維持磁鐵面之間的一間隙在諸多應用中可係至關重要的。當組裝於一軸上時，轉子部分(例如，轉子半體)之間的吸引力傾向於使其中放置定子之轉子部分之間的間隙塌縮。將此間隙維持在設計值處對於馬達/產生器效能可係重要的，且過度減小間隙大小可導致轉子部分與定子之間的機械干涉。The axial position of the magnet or maintaining a gap between the magnet faces can be critical in many applications. When assembled on a shaft, the attractive force between the rotor parts (e.g., rotor halves) tends to collapse the gap between the rotor parts in which the stator is placed. Maintaining this gap at the design value can be important for motor/generator performance, and excessive reduction in the gap size can cause mechanical interference between the rotor part and the stator.

一有吸引力解決方案係將一轉子部分構造為組件之一組合件，其中材料被最佳化至所需功能性。在某些實施方案中，一或多個磁鐵分段可成角度地定向在由例如鋼鐵之一軟磁性材料製成之一第一支撐結構上。第一支撐結構可舉例而言具有一圓盤形狀。在某些實施方案中，第一支撐結構可自一單件坯料機加工。在其他實施方案中，第一支撐結構可自多個個別地形成之組件組裝。第一支撐結構或「背鐵」可用作磁鐵分段之一磁通返迴路徑或磁軛。在某些實施方案中，此件可例如藉由水刀(water-jet)、雷射或衝壓程序由扁平片坯料極快速且準確地製成。部分地，此係可能的，此乃因需要相對少特徵且需要移除少許材料。最小化軟磁性材料之量可避免時間及能源密集型機加工程序。最小化軟磁性材料在某些情形中可係重要的，此乃因其可減少機器之慣性矩，減小機器之總體質量，及/或減小機器之時間常數。An attractive solution is to construct a rotor part as an assembly of components in which the materials are optimized to the required functionality. In certain embodiments, one or more magnet segments may be oriented at an angle on a first support structure made of a soft magnetic material, such as steel. The first supporting structure may have a disc shape, for example. In certain embodiments, the first support structure can be machined from a single piece of blank. In other embodiments, the first support structure may be assembled from a plurality of individually formed components. The first support structure or "back iron" can be used as one of the magnetic flux return paths or yokes of the magnet segments. In certain embodiments, this piece can be made extremely quickly and accurately from a flat sheet blank, such as by a water-jet, laser, or stamping process. In part, this is possible because relatively few features are required and a little material needs to be removed. Minimizing the amount of soft magnetic material can avoid time and energy-intensive machining procedures. Minimizing soft magnetic materials can be important in certain situations because it can reduce the moment of inertia of the machine, reduce the overall mass of the machine, and/or reduce the time constant of the machine.

在某些實施方案中，可使用一第二支撐結構達成以下功能：徑向地定位磁性分段，將磁性組件機械地耦合至軸及維持間隙。在某些實施方案中，此一第二支撐結構可由具有良好強度/勁度與重量比率之一種材料(若干種材料)製作。由於不存在磁性效能要求，因此諸如鎂合金、碳纖維複合物及鋁之若干種相對堅硬/剛硬材料係此第二組件之候選。與鋼鐵之習用機加工相比，在諸多情形中，此等材料傾向於更容易形成且機加工。此外，在某些實施方案中，此等第二支撐結構可經構形以執行額外功能，諸如直接整合將原本安裝至外部軸之組件。如下文結合圖12A、圖12B、圖13及圖14更詳細解釋，此一構形可促進可與各種負載或扭矩源更緊密地整合之「無軸」機器之設計。In some embodiments, a second support structure can be used to achieve the following functions: radially position the magnetic segment, mechanically couple the magnetic component to the shaft, and maintain the gap. In some embodiments, this second support structure can be made of one material (several materials) with a good strength/stiffness to weight ratio. Since there is no requirement for magnetic performance, several relatively hard/rigid materials such as magnesium alloy, carbon fiber composite and aluminum are candidates for this second component. Compared with the conventional machining of steel, these materials tend to be easier to form and machine in many cases. In addition, in certain embodiments, these second support structures can be configured to perform additional functions, such as directly integrating components that would otherwise be mounted to the external shaft. As explained in more detail below in conjunction with FIGS. 12A, 12B, 13 and 14, this configuration can facilitate the design of "shaftless" machines that can be more closely integrated with various loads or torque sources.

第一與第二支撐結構可以若干種方式中之任一方式緊固在一起以形成一經整合組合件。在某些實施方案中，舉例而言，第一與第二支撐結構可使用定位銷、黏合劑及/或緊固件彼此緊固。在某些實施方案中，此一兩件式組合件可允許在不具有一冶具或其他機構來對準並將磁鐵分段下放至其各別承窩中之情形下容易地操縱磁鐵分段且適當地配置用於一轉子部分(例如，一轉子半體)。由於在將第一支撐結構組裝至第二支撐結構之前，第一支撐結構不需要徑向地約束磁鐵分段，因此與將磁鐵分段軸向地***一承窩中相比，以低力自徑向方向***磁鐵分段可係可能的。因此，在某些實施方案中，第一支撐結構可在對準及維持與毗鄰磁鐵分段之餘隙，以及使磁極至軸之序列轉位中用作其自身之冶具，使得轉子半體在最終組合件上對準。一旦磁鐵分段被組裝至第一支撐結構，包含第一支撐結構及磁鐵分段之組合件便可組裝至可徑向地存留磁鐵分段之第二支撐結構。The first and second support structures can be fastened together in any of several ways to form an integrated assembly. In certain embodiments, for example, the first and second support structures may be fastened to each other using positioning pins, adhesives, and/or fasteners. In some embodiments, this one-two-piece assembly may allow easy manipulation of the magnet segments without having a jig or other mechanism to align and lower the magnet segments into their individual sockets. Appropriately configured for a rotor part (e.g., a rotor half). Since the first support structure does not need to radially constrain the magnet segments before assembling the first support structure to the second support structure, compared to inserting the magnet segments axially into a socket, the first support structure is self-contained with low force. It is possible to insert the magnet segments in the radial direction. Therefore, in some embodiments, the first support structure can be used as its own fixture in aligning and maintaining the clearance with the adjacent magnet segment, and in indexing the sequence of the magnetic pole to the axis, so that the rotor half is in Align on the final assembly. Once the magnet segments are assembled to the first support structure, the assembly including the first support structure and the magnet segments can be assembled to the second support structure that can radially retain the magnet segments.

在某些實施方案中，作為如本文中所闡述之一多件式轉子組合件之一額外特徵，「預翹曲」可建構至可更容易地機加工之第二支撐結構中。因此，在某些此等實施方案中，第一支撐結構可機加工為扁平的。當第一支撐結構被組裝至第二支撐結構時，兩個件可經歪曲。總體上，第一與第二支撐結構之組合件可近似一截頭錐體，其隨著半徑之增加而成角度地遠離間隙。當兩個此等轉子部分經組裝以在一轉子中形成間隙時，磁性吸引力可進一步使組合件歪曲使得間隙係實質上均勻的。In certain embodiments, as an additional feature of a multi-piece rotor assembly as described herein, "pre-warping" can be built into a second support structure that can be machined more easily. Therefore, in some of these embodiments, the first support structure may be machined to be flat. When the first support structure is assembled to the second support structure, the two pieces may be distorted. In general, the assembly of the first and second support structures can approximate a truncated cone, which is angled away from the gap as the radius increases. When two such rotor parts are assembled to form a gap in a rotor, the magnetic attraction can further distort the assembly so that the gap is substantially uniform.

可使用以上方法及技術之某些實施方案達成優點之實例包含以下： 1. 基於產生正確幾何結構所需之操作種類、材料及餘隙，在多件式設計之機加工操作中之顯著成本節省。 2. 磁鐵至轉子背鐵之極大簡化之無冶具組合件。 3. 最小化軟磁性材料質量。 4. 適用於磁鐵分段及環形磁鐵轉子類型。 5. 更容易恢復磁性材料；徑向方向上之提取。Examples of the advantages that can be achieved using certain implementations of the above methods and techniques include the following: 1. Based on the types of operations, materials and clearances required to produce the correct geometric structure, significant cost savings in the machining operations of multi-piece designs. 2. A greatly simplified non-smelting tool assembly from magnet to rotor back iron. 3. Minimize the quality of soft magnetic materials. 4. Suitable for magnet segment and ring magnet rotor type. 5. It is easier to recover magnetic materials; extraction in the radial direction.

圖1展示一實例軸向磁通氣隙機器100之一總平面之一剖視圖。如所展示，機器100可包含一印刷電路板(PCB)定子102及一轉子，該轉子包含機械地耦合至一軸108之一對轉子部分104a、104b。如所展示，轉子部分104a、104b可各自包含具有附接至其之一各別環形磁鐵110a、110b之一轉子支撐件112a、112b。在此情形中，轉子部分104a至104b中之每一者(除了環形磁鐵110a至110b之外)係為一單件式習用構造，此需要選擇用於轉子支撐件112之材料提供良好勁度、強度及磁性質。FIG. 1 shows a cross-sectional view of a general plane of an example axial flux air gap machine 100. As shown, the machine 100 may include a printed circuit board (PCB) stator 102 and a rotor that includes a pair of rotor portions 104a, 104b mechanically coupled to a shaft 108. As shown, the rotor portions 104a, 104b may each include a rotor support 112a, 112b having a respective ring magnet 110a, 110b attached to it. In this case, each of the rotor parts 104a to 104b (except the ring magnets 110a to 110b) is a one-piece conventional structure, which requires the selection of the material for the rotor support 112 to provide good stiffness, Strength and magnetic properties.

圖2展示與圖1中所展示之軸向磁通機器100類似之一軸向磁通機器200中之一氣隙106歸因於轉子支撐件112a至112b之變形而塌縮從而潛在地導致環形磁鐵110a、110b與定子102之間的干涉之趨勢。雖然放大了圖解說明，但機加工至既定平衡幾何結構之任何轉子支撐件112將經歷某些偏轉。FIG. 2 shows an air gap 106 in an axial flux machine 200 similar to the axial flux machine 100 shown in FIG. The tendency of interference between 110a, 110b and stator 102. Although the illustration is exaggerated, any rotor support 112 machined to a predetermined balance geometry will experience some deflection.

圖3A展示具有一坡口錐形表面304之一實例轉子支撐件302之一剖視圖。圖3B展示包含轉子支撐件302及附接至錐形表面304之一環形磁鐵110之一轉子部分300 (例如，一轉子半體)。在某些實施方案中，轉子支撐件302可經構形使得當如圖4中所展示地組裝時其外邊緣306相對於間隙中心線變形至既定平衡轉子位置。FIG. 3A shows a cross-sectional view of an example rotor support 302 having a grooved tapered surface 304. Figure 3B shows a rotor portion 300 (eg, a rotor half) that includes a rotor support 302 and an annular magnet 110 attached to a tapered surface 304. In certain embodiments, the rotor support 302 may be configured such that when assembled as shown in FIG. 4, its outer edge 306 deforms to a predetermined balanced rotor position relative to the gap centerline.

圖4展示諸如圖3B中所展示之轉子部分300之兩個轉子部分(例如，轉子半體)可如何安裝於一軸向磁通機器400中，使得轉子之一平衡位置與轉子部分之間的一間隙106之一中心線402等距。如所圖解說明，與圖3B相比，轉子支撐件302a、302b之背部404a、404b歸因於環形磁鐵110a、110b之間的吸引力而歪曲。此外，亦如所圖解說明，當轉子部分被安裝於機器400中時，環形磁鐵110a、110b之外邊緣306a、306b相對於間隙106之中心線402變形至既定平衡轉子位置。FIG. 4 shows how two rotor parts (eg, rotor halves) such as the rotor part 300 shown in FIG. 3B can be installed in an axial flux machine 400 such that a balance position between the rotor and the rotor part A centerline 402 of a gap 106 is equidistant. As illustrated, compared to FIG. 3B, the backs 404a, 404b of the rotor supports 302a, 302b are distorted due to the attractive force between the ring magnets 110a, 110b. In addition, as also illustrated, when the rotor part is installed in the machine 400, the outer edges 306a, 306b of the ring magnets 110a, 110b deform relative to the centerline 402 of the gap 106 to a predetermined balanced rotor position.

圖5展示可用於舉例而言具有超出大約四釐米之一半徑之轉子組合件之一典型磁鐵分段502。磁鐵分段502可具有數個半徑及尺寸公差參數，此可使得機加工將分段502約束在一平面內之一承窩具有挑戰性。如所展示，磁鐵502可具有一內邊緣504及一外邊緣506，其中內邊緣504具有一寬度W1 ，該寬度較外邊緣506之一寬度W2 短。Figure 5 shows a typical magnet segment 502 that can be used for a rotor assembly having a radius in excess of about four centimeters, for example. The magnet segment 502 can have several radii and dimensional tolerance parameters, which can make it challenging for machining to constrain the segment 502 to a socket in a plane. As shown, the magnet 502 may have an inner edge 504 and an outer edge 506, wherein the inner edge 504 having a width W 1, the width of one 506 shorter than the width W 2 of the outer edge.

圖6A展示根據本發明之某些實施例構形之一轉子部分(例如，一轉子半體)之一第一支撐結構602或「轉子背鐵」之一實例。如所圖解說明，在某些實施方案中，第一支撐結構602可具有一環形形狀，該環形形狀具有一中心開口608，且可包含接納諸如圖5中所展示之磁鐵分段502之磁鐵分段之定位肋狀物604。此外，在某些實施方案中，第一支撐結構602可包含可用於將第一支撐結構602固定至諸如圖7中所展示之一第二支撐結構702之一或多個銷及/或螺桿緊固件孔606。在某些實施方案中，第一支撐結構602可由鋼鐵製成。FIG. 6A shows an example of a first support structure 602 or a "rotor back iron" of a rotor part (eg, a rotor half) configured according to some embodiments of the present invention. As illustrated, in some embodiments, the first support structure 602 may have a ring shape with a central opening 608, and may include a magnet portion that receives a magnet segment 502 such as that shown in FIG. 5 Section of positioning ribs 604. In addition, in certain embodiments, the first support structure 602 may include one or more pins and/or screw fasteners that can be used to fix the first support structure 602 to a second support structure 702 such as the one shown in FIG. 7. Firmware hole 606. In some embodiments, the first support structure 602 may be made of steel.

圖6B展示當例如已藉由在定位肋狀物604之間滑動磁鐵分段502來將一組磁鐵分段502附接至第一支撐結構602時，但在如下文所闡述地將第一支撐結構602附接至第二支撐結構702之前，第一支撐結構602可如何出現。如所展示，磁鐵分段502之內邊緣504可定位於距第一支撐結構602之開口608之一中心點610之一第一徑向距離R1 處，且磁鐵分段502之外邊緣506可定位於距第一支撐結構602之開口608之中心點610之一第二徑向距離R2 。6B shows when a set of magnet segments 502 have been attached to the first support structure 602, for example by sliding the magnet segments 502 between the positioning ribs 604, but the first support is set as explained below. Before the structure 602 is attached to the second support structure 702, how the first support structure 602 may appear. As shown, the inner edge 504 of the magnet segment 502 can be positioned at a first radial distance R 1 from a center point 610 of the opening 608 of the first support structure 602, and the outer edge 506 of the magnet segment 502 can be It is located at a second radial distance R 2 from the center point 610 of the opening 608 of the first support structure 602.

圖7展示根據本發明之某些實施例構形之一第二支撐結構702或「轉子支撐板」之一實例。如所展示，在某些實施方案中，第二支撐結構702可經構形以將第一支撐結構602定位至一軸108 (例如，如圖11A及圖11B中所展示)，從而將磁鐵分段502徑向地約束在第二徑向距離R2 處(例如，經由一圓形唇部704)及/或以錐形表面區域706為特徵，該錐形表面區域判定轉子部分(例如，轉子半體)在組合件上如何變形。在某些實施方案中，第二支撐結構702可使用車床及/或銑床型操作製成。在某些實施方案中，第二支撐結構702可由一鎂合金、一碳纖維複合物或鋁製成。FIG. 7 shows an example of a second support structure 702 or "rotor support plate" configured according to some embodiments of the present invention. As shown, in certain embodiments, the second support structure 702 can be configured to position the first support structure 602 to a shaft 108 (eg, as shown in FIGS. 11A and 11B), thereby segmenting the magnet 502 is constrained radially at a second radial distance R 2 (e.g., via a circular lip 704) and/or is characterized by a tapered surface area 706 that determines the rotor portion (e.g., rotor half Body) how to deform on the assembly. In certain embodiments, the second support structure 702 may be made using a lathe and/or milling machine type operation. In some embodiments, the second support structure 702 may be made of a magnesium alloy, a carbon fiber composite, or aluminum.

圖8A展示在將最終扭矩施加至組合件螺桿802之前的一實例轉子組合件800，其包含諸如圖6B中所展示之一第一支撐結構602，其中磁鐵分段安裝於該第一支撐結構上；及諸如圖7中所展示之一第二支撐結構702。在某些實施方案中，可舉例而言藉由首先將磁鐵分段502定位於第一支撐結構602之定位肋狀物604之間，且隨後將第一支撐件602定位於第二支撐結構702之圓形唇部704內來達成圖8A中所展示之構形。如圖8A所圖解說明，在擰緊螺桿802之前，在第一支撐結構602與第二支撐結構702之間存在一間隙804。FIG. 8A shows an example rotor assembly 800 before the final torque is applied to the assembly screw 802, which includes a first support structure 602 such as that shown in FIG. 6B, where magnets are mounted on the first support structure in sections ; And a second support structure 702 such as shown in FIG. 7. In some implementations, for example, by first positioning the magnet segment 502 between the positioning ribs 604 of the first support structure 602, and then positioning the first support 602 on the second support structure 702 The rounded lip 704 can achieve the configuration shown in FIG. 8A. As illustrated in FIG. 8A, before the screw 802 is tightened, there is a gap 804 between the first support structure 602 and the second support structure 702.

圖8B展示當螺桿802已被擰緊至設計扭矩時的圖8A之轉子組合件800。如所展示，擰緊螺桿802可導致第一支撐結構602貼合第二支撐結構702，使得對應於錐形表面706 (圖7中所展示)之一錐體808可被轉移至第一支撐結構602且因此轉移至磁鐵分段502之面810。Figure 8B shows the rotor assembly 800 of Figure 8A when the screw 802 has been tightened to the design torque. As shown, tightening the screw 802 can cause the first support structure 602 to fit the second support structure 702 so that a cone 808 corresponding to the tapered surface 706 (shown in FIG. 7) can be transferred to the first support structure 602 And therefore it is transferred to the surface 810 of the magnet segment 502.

圖9展示圖8B中所展示之同一轉子組合件800，但其中出於說明性目的而放大了錐體808之度數。如圖9中所圖解說明，磁鐵分段502 (或另一選擇係一環形磁鐵110)可附接至第一支撐結構602之背對第二支撐結構702之一表面，使得磁鐵分段502之面810 (或一環形磁鐵110之一環形面)採取錐體808之形狀。Figure 9 shows the same rotor assembly 800 shown in Figure 8B, but with the cone 808 exaggerated for illustrative purposes. As illustrated in Figure 9, the magnet segment 502 (or another option is a ring magnet 110) can be attached to a surface of the first support structure 602 facing away from the second support structure 702, such that the magnet segment 502 The surface 810 (or an annular surface of a ring magnet 110) takes the shape of a cone 808.

如圖9中所圖解說明，第二支撐結構702之錐形表面706之錐體808之一度數可藉由以下操作來量測：識別在第二支撐結構702之表面上接觸第一支撐結構602之兩個點902、904，及判定轉子組合件800之一旋轉軸線930法向於的且分別交切第一點902及第二點904之兩個平面906、908之間的一距離D1 。在某些實施方案中，可找到距離D1 實質上大於零之兩個接觸點902、904 (與一磁鐵分段502之內半徑R1 及外半徑R2 或其他對準)。在此內容脈絡中，術語「實質上」意欲排除歸因於處理及/或允許公差內之材料瑕疵之略微變化。在某些實施方案中，距離D1 可舉例而言大於「0.003」英吋，或大於「0.01」英吋，或甚至大於「0.02」英吋。另外或另一選擇係，在某些實施例中，可找到兩個接觸點902、904使得距離D1 與兩個點之間的距離及/或一對應磁鐵分段502之內半徑R1 與外半徑R2 之間的差之一比率實質上大於零。在某些實施方案中，此比率可舉例而言大於「0.002」，或大於「0.005」，或甚至大於「0.01」。As illustrated in FIG. 9, one degree of the cone 808 of the tapered surface 706 of the second support structure 702 can be measured by the following operation: Identify the first support structure 602 on the surface of the second support structure 702 The two points 902, 904, and a distance D 1 between two planes 906, 908 that are normal to a rotation axis 930 of the rotor assembly 800 and intersect the first point 902 and the second point 904, respectively . In some implementations, two contact points 902, 904 (aligned with the inner radius R 1 and outer radius R 2 of a magnet segment 502 or other alignments) with a distance D 1 substantially greater than zero can be found. In this context, the term "substantially" is intended to exclude slight variations due to material defects within processing and/or allowable tolerances. In some implementations, the distance D 1 can be, for example, greater than "0.003" inches, or greater than "0.01" inches, or even greater than "0.02" inches. Additionally or alternatively, in some embodiments, two contact points 902, 904 can be found such that the distance D 1 and the distance between the two points and/or the inner radius R 1 of a corresponding magnet segment 502 and A ratio of the difference between the outer radii R 2 is substantially greater than zero. In certain embodiments, this ratio can be, for example, greater than "0.002", or greater than "0.005", or even greater than "0.01".

亦如圖9中所圖解說明，在某些實施方案中，可在第二支撐結構702之一表面上找到接觸第一支撐結構602之至少一個點910，對於該點，延伸遠離該表面且法向於該表面(使得射線912與磁鐵之一磁化方向對準)之一射線912與旋轉軸線930法向於的一平面形成實質上小於「90」度之一角α1 。在某些實施方案中，角α1 可舉例而言小於「89.9」度，小於「89.7」度或甚至小於「89.5」度。點910可舉例而言與一磁鐵分段502之內半徑R1 、一磁鐵分段502之外半徑R2 或此兩個半徑之間的某一點對準。As also illustrated in FIG. 9, in some embodiments, at least one point 910 that contacts the first support structure 602 can be found on a surface of the second support structure 702, for which point, extends away from the surface and the method A ray 912 toward the surface (such that the ray 912 is aligned with a magnetization direction of the magnet) and a plane normal to the axis of rotation 930 form an angle α 1 that is substantially smaller than "90" degrees. In certain embodiments, the angle α 1 can be, for example, less than "89.9" degrees, less than "89.7" degrees, or even less than "89.5" degrees. The point 910 can be aligned with the inner radius R 1 of a magnet segment 502, the outer radius R 2 of a magnet segment 502, or a point between the two radii, for example.

另外或另一選擇係，且亦如圖9中所展示，當第一支撐結構602附接至第二支撐結構702時被轉移至磁鐵分段502之面810 (或一環形磁鐵110之一面)之錐體808之一度數可藉由以下操作來量測：識別一磁鐵分段502 (或環形磁鐵110)之一表面上正交於磁鐵分段502 (或環形磁鐵110)之一磁化方向，例如，圖9中所展示之磁鐵分段502之面810之兩個點914、916，及判定旋轉軸線930法向於的且分別交切第一點914及第二點916之兩個平面926、928之間的一距離D2 。在所展示實例中，磁鐵分段502之接觸第一支撐結構602之相對表面亦正交於磁鐵分段502之磁化方向。在某些實施例中，可找到距離D2 實質上大於零之兩個磁鐵表面點914、916 (在磁鐵分段502之內半徑R1 及外半徑R2 處或別處)。在某些實施方案中，距離D2 可舉例而言大於「0.002」英吋，或大於「0.005」英吋，或甚至大於「0.01」英吋。另外或另一選擇係，在某些實施例中，可找到兩個磁鐵表面點914、916使得距離D2 與兩個點之間的距離及/或磁鐵分段502之內半徑R1 與外半徑R2 之間的差之一比率實質上大於零。在某些實施方案中，此比率可舉例而言大於「0.002」，或大於「0.005」，或甚至大於「0.01」。Additionally or alternatively, and also as shown in FIG. 9, when the first support structure 602 is attached to the second support structure 702, it is transferred to the face 810 of the magnet segment 502 (or one face of a ring magnet 110) The degree of the cone 808 can be measured by the following operations: identifying a magnetization direction on a surface of a magnet segment 502 (or ring magnet 110) orthogonal to the magnet segment 502 (or ring magnet 110), For example, the two points 914 and 916 of the surface 810 of the magnet segment 502 shown in FIG. 9 and the two planes 926 that are normal to the rotation axis 930 and intersect the first point 914 and the second point 916 respectively , A distance D 2 between 928. In the example shown, the opposite surface of the magnet segment 502 that contacts the first support structure 602 is also orthogonal to the magnetization direction of the magnet segment 502. In some embodiments, two magnet surface points 914, 916 (at the inner radius R 1 and outer radius R 2 of the magnet segment 502 or elsewhere) whose distance D 2 is substantially greater than zero can be found. In some implementations, the distance D 2 can be, for example, greater than "0.002" inches, or greater than "0.005" inches, or even greater than "0.01" inches. In addition or alternatively, in some embodiments, two magnet surface points 914, 916 can be found such that the distance D 2 and the distance between the two points and/or the inner radius R 1 of the magnet segment 502 and the outer A ratio of the difference between the radii R 2 is substantially greater than zero. In certain embodiments, this ratio can be, for example, greater than "0.002", or greater than "0.005", or even greater than "0.01".

亦如圖9中所圖解說明，在某些實施方案中，可在正交於磁鐵分段502 (或環形磁鐵11)之一磁化方向且背對第一支撐結構602之一磁鐵分段502之一表面上，例如圖9中所展示之磁鐵分段502之面810上找到至少一個點922，對於該點，延伸遠離磁鐵之表面且法向於磁鐵之表面之一射線924 (使得射線924與磁鐵分段502之一磁化方向對準)與旋轉軸線930法向於的一平面形成實質上小於「90」度之一角α2 。在某些實施方案中，角α2 可舉例而言小於「89.9」度，小於「89.7」度，或甚至小於「89.5」度。點922可舉例而言定位於一磁鐵分段502之內半徑R1 處，一磁鐵分段502之外半徑R2 處，或此兩個半徑之間的某一點處。此外，如圖9中所展示，第一支撐結構602、第二支撐結構702及磁鐵分段502可經構形且配置使得射線924 (其法向於磁鐵分段502之表面810且延伸遠離磁鐵分段502之表面810，該磁鐵分段之該表面背對第一支撐結構602)交切平面926。As also illustrated in FIG. 9, in some embodiments, the magnetization direction of one of the magnet segments 502 (or ring magnet 11) orthogonal to the magnet segment 502 (or ring magnet 11) and opposite to the first support structure 602 can be On a surface, for example, at least one point 922 is found on the surface 810 of the magnet segment 502 shown in FIG. The magnetization direction of the magnet segment 502 is aligned with a plane normal to the rotation axis 930 to form an angle α 2 that is substantially smaller than "90" degrees. In certain embodiments, the angle α 2 can be, for example, less than "89.9" degrees, less than "89.7" degrees, or even less than "89.5" degrees. The point 922 can be located, for example, at an inner radius R 1 of a magnet segment 502, an outer radius R 2 of a magnet segment 502, or at a point between these two radii. In addition, as shown in FIG. 9, the first support structure 602, the second support structure 702, and the magnet segment 502 can be configured and arranged such that the ray 924 (which is normal to the surface 810 of the magnet segment 502 and extends away from the magnet The surface 810 of the segment 502, the surface of the magnet segment faces away from the first support structure 602) the intersection plane 926.

如圖10中所展示，當兩個轉子組合件800a、800b (包含各自的第一支撐結構602a、602b、第二支撐結構702a、702b及磁鐵分段502a、502b) 附接至一軸108 (圖10中未展示)或以其他方式安裝於一軸向磁通機器中時，磁鐵分段502a、502b之磁通可在磁鐵分段502a、502b之間的一間隙1002中產生一吸引力，其導致轉子組合件800a、800b翹曲使得轉子組合件800a、800b之端朝向彼此移動。圖10中之虛線圖解說明在轉子組合件800a、800b組裝至一馬達或產生器，諸如，下文結合圖11A至圖11B、圖12A至圖12B、圖13及圖14所闡述之馬達或產生器中之後，轉子組合件800a、800b可如何定形狀。在某些實施方案中，可在組裝之前翹曲轉子組合件800a、800b，使得兩個磁鐵分段502a、502b之面向彼此的表面在經組裝馬達或產生器中係實質上平行的，因此使得間隙1002之寬度在各處皆係實質上均勻的。在其他實施方案中，可略微「過翹曲」轉子組合件800a、800b，使得一旦經組裝，便獲得依據半徑增加之一錐體。雖然此可具有減少較大半徑處之間隙之不期望效應，但其可允許使用一較小平均間隙寬度G，因此增加平均磁場強度並存留磁鐵分段502a、502b之外半徑R2 處之餘隙。As shown in Figure 10, when two rotor assemblies 800a, 800b (including respective first support structures 602a, 602b, second support structures 702a, 702b and magnet segments 502a, 502b) are attached to a shaft 108 (Figure 10) or when installed in an axial flux machine in other ways, the magnetic flux of the magnet segments 502a and 502b can generate an attractive force in a gap 1002 between the magnet segments 502a and 502b. The rotor assembly 800a, 800b is caused to warp so that the ends of the rotor assembly 800a, 800b move toward each other. The dotted line in FIG. 10 illustrates that the rotor assembly 800a, 800b is assembled to a motor or generator, such as the motor or generator described below in conjunction with FIGS. 11A to 11B, 12A to 12B, 13 and 14 After centering, how to shape the rotor assembly 800a, 800b. In certain embodiments, the rotor assembly 800a, 800b can be warped before assembly so that the surfaces of the two magnet segments 502a, 502b facing each other are substantially parallel in the assembled motor or generator, thus making The width of the gap 1002 is substantially uniform everywhere. In other embodiments, the rotor assembly 800a, 800b may be slightly "over-warped" so that once assembled, a cone with an increase in radius is obtained. Although this may have the undesirable effect of reducing the gap at a larger radius, it may allow the use of a smaller average gap width G, thus increasing the average magnetic field strength and leaving the magnet segments 502a, 502b outside the radius R 2 Gap.

如圖10中所展示，可舉例而言藉由以下操作來量測使轉子組合件800b翹曲的量(在組裝之後旋即經歷的)：識別位於磁鐵分段502b之外半徑R2 處之一點1004，及判定組裝之後點在與旋轉軸線930重合之一方向上移動之一距離D3 。距離D3 可舉例而言藉由以下操作來量測：識別交切點1004且旋轉軸線930法向於的一平面，及判定此一平面相對於在轉子元件組合件800b之中心處或附近交切一點1006且旋轉軸線930亦法向於的另一平面移動之一距離。在某些實施方案中，距離D3 可大於「0.001」英吋，或大於「0.005」英吋，或甚至大於「0.01」英吋。另外或另一選擇係，在某些實施方案中，距離D3 與間隙1002之平均寬度G之比率可大於「0.01」，或大於「0.05」，或甚至大於「0.1」。另外或另一選擇係，距離D3 與磁鐵分段502b與定子102之一表面(圖10中未展示)之間的一平均餘隙距離之比率可大於「0.25」，大於「0.5」，或甚至大於「1」。因此，在某些實施方案中，轉子組合件800b可偏轉得與平均磁鐵/定子餘隙距離一樣多或較平均磁鐵/定子餘隙距離多。As shown in FIG. 10, the amount of warping of the rotor assembly 800b (which is experienced immediately after assembly) can be measured by, for example, the following operation: Identify a point located at the radius R 2 outside the magnet segment 502b 1004, and it is determined that after assembly, the point moves a distance D 3 in a direction coincident with the rotation axis 930. The distance D 3 can be measured by, for example, the following operations: identifying a plane to which the intersection point 1004 and the axis of rotation 930 are normal, and determining that this plane intersects at or near the center of the rotor element assembly 800b One point 1006 and the axis of rotation 930 also move a distance in another plane normal to. In some embodiments, the distance D 3 may be greater than "0.001" inches, or greater than "0.005" inches, or even greater than "0.01" inches. Additionally or alternatively, in certain embodiments, the ratio of the distance D 3 to the average width G of the gap 1002 may be greater than "0.01", or greater than "0.05", or even greater than "0.1". Alternatively or alternatively, the ratio of the distance D 3 to an average clearance distance between the magnet segment 502b and a surface of the stator 102 (not shown in FIG. 10) can be greater than "0.25", greater than "0.5", or Even greater than "1". Therefore, in certain embodiments, the rotor assembly 800b can be deflected as much as or more than the average magnet/stator clearance distance.

結合圖10參考圖9，應瞭解，在某些實施例中，轉子組合件800a、800b可經構形且配置使得，對於每一轉子組合件，當轉子組合件800a、800b被安裝於一馬達或產生器中且導致如圖10中所展示地偏轉時，以下值中之一或多者可減小百分之五十或更多：(1) 平面906與908之間的距離D1 ，(2) 距離D1 與點902與點904之間的距離及/或一磁鐵分段502之內半徑R1 與外半徑R2 之間的差之比率，(3) 平面926與平面928之間的距離D2 ，及(4) 距離D2 與點914與點916之間的距離及/或一磁鐵分段502之內半徑R1 與外半徑R2 之間的差之比率。9 in conjunction with FIG. 10, it should be understood that, in some embodiments, the rotor assembly 800a, 800b may be configured and configured such that, for each rotor assembly, when the rotor assembly 800a, 800b is installed in a motor Or in the generator and cause deflection as shown in Figure 10, one or more of the following values can be reduced by fifty percent or more: (1) the distance D 1 between the planes 906 and 908, (2) The ratio of the distance D 1 to the distance between the point 902 and the point 904 and/or the difference between the inner radius R 1 and the outer radius R 2 of a magnet segment 502, (3) the difference between the plane 926 and the plane 928 the distance D between the two, and (4) the distance D 2 and the distance between the point 914 and the point 916 and / or a ratio of a difference between the magnet between the radius R 1 and outer radius R of the segment 502.

圖11A展示諸如圖8B中所展示之轉子組合件800之兩個轉子組合件可如何安裝於一軸向磁通機器1100中，其中一定子102 (例如，一基於PCB之定子)定位於磁鐵分段502之面之間的一實質上均勻間隙內。圖11B展示圖11A中所展示之軸向磁通機器1100之一剖視圖。圖11A及圖11B中所展示之「均勻間隙」構形可產生，此乃因在安裝之後，兩個轉子組合件800之對置磁鐵分段502之間的吸引力可旋即導致轉子組合件800偏轉，使得第一支撐結構602採取其原始、標稱扁平之形狀(例如，如圖6A中所展示)。磁鐵分段502之面之間的所得間隙可因此依據半徑而係實質上均勻的。Figure 11A shows how two rotor assemblies, such as the rotor assembly 800 shown in Figure 8B, can be installed in an axial flux machine 1100, where stator 102 (for example, a PCB-based stator) is positioned on the magnet Within a substantially uniform gap between the faces of the segments 502. Figure 11B shows a cross-sectional view of the axial flux machine 1100 shown in Figure 11A. The "uniform gap" configuration shown in FIGS. 11A and 11B can be produced because after installation, the attractive force between the opposing magnet segments 502 of the two rotor assemblies 800 can immediately cause the rotor assembly 800 The deflection causes the first support structure 602 to take its original, nominally flat shape (for example, as shown in FIG. 6A). The resulting gap between the faces of the magnet segment 502 can therefore be substantially uniform in terms of radius.

圖12A展示諸如圖8B中所展示之轉子組合件800之兩個轉子組合件可如何安裝於具有一無軸構形之一軸向磁通機器1200中。圖12B展示圖12A中所展示之軸向磁通機器1200之一剖視圖。如所圖解說明，在某些實施方案中，軸向磁通機器1200可包含至少部分地暴露一殼體1206外部之環境，因此使得第二支撐結構1202亦能夠用作機器1200之一機械連接之一第二支撐結構1202。外部組件可舉例而言直接安裝至第二支撐結構1202之一經暴露部分1204，或以其他方式與第二支撐結構1202之一經暴露部分1204機械地嚙合。在某些實施方案中，軸向磁通機器1200中之第一支撐結構602之構形可與上文結合圖11A及圖11B所闡述之軸向磁通機器1100中之第一支撐結構602相同或類似。Figure 12A shows how two rotor assemblies, such as the rotor assembly 800 shown in Figure 8B, can be installed in an axial flux machine 1200 having a shaftless configuration. Figure 12B shows a cross-sectional view of the axial flux machine 1200 shown in Figure 12A. As illustrated, in some embodiments, the axial flux machine 1200 may include an environment that at least partially exposes the exterior of a housing 1206, so that the second support structure 1202 can also be used as a mechanical connection of the machine 1200 A second support structure 1202. The external component may be directly mounted to one of the exposed portions 1204 of the second support structure 1202, or mechanically engaged with one of the exposed portions 1204 of the second support structure 1202, for example. In some embodiments, the configuration of the first support structure 602 in the axial flux machine 1200 can be the same as the first support structure 602 in the axial flux machine 1100 described above in conjunction with FIGS. 11A and 11B Or similar.

圖13展示在一「先行者」構形中之一「無軸」軸向磁通機器1300之一實例。如所展示，在此一構形中，一定子102可在一內直徑處固定地連接至一殼體1306，且兩個第二支撐結構1302a、1302b可在定子102之外部處固定地連接至彼此(例如，經由一或多個連接器1304)，且可各自相對於殼體1306旋轉。在某些實施方案中，軸向磁通機器1300中之第一支撐結構602之構形可與上文結合圖11A及圖11B所闡述之軸向磁通機器1100中之第一支撐結構602相同或類似。Figure 13 shows an example of a "shaftless" axial flux machine 1300 in a "first mover" configuration. As shown, in this configuration, the stator 102 can be fixedly connected to a housing 1306 at an inner diameter, and the two second support structures 1302a, 1302b can be fixedly connected to the outside of the stator 102 Each other (e.g., via one or more connectors 1304), and each can rotate relative to the housing 1306. In some embodiments, the configuration of the first support structure 602 in the axial flux machine 1300 can be the same as the first support structure 602 in the axial flux machine 1100 described above in conjunction with FIGS. 11A and 11B Or similar.

圖14展示具有一單側轉子之一「無軸」軸向磁通機器1400之一實例。在此一構形中，兩個轉子半體中的一者可被替換為一磁性材料1402，該磁性材料提供一磁通返迴路徑且固定至一殼體1404。如所圖解說明，一定子102可放置於固定磁性材料1402與一單個轉子組合件之磁鐵分段502之間，該轉子組合件包含一第一支撐結構602 (磁鐵分段502可安裝至該第一支撐結構)及一第二支撐結構1406 (其可在磁性元件與機器1400外部之一或多個組件之間提供一機械連接)。在某些實施方案中，軸向磁通機器1400中之第一支撐結構602之構形可與上文結合圖11A及圖11B所闡述之軸向磁通機器1100中之第一支撐結構602相同或類似。發明性概念 / 特徵 / 技術之實例 Figure 14 shows an example of a "shaftless" axial flux machine 1400 with a single-sided rotor. In this configuration, one of the two rotor halves can be replaced with a magnetic material 1402, which provides a magnetic flux return path and is fixed to a housing 1404. As illustrated, the stator 102 can be placed between the fixed magnetic material 1402 and the magnet segment 502 of a single rotor assembly that includes a first support structure 602 (the magnet segment 502 can be mounted to the second A support structure) and a second support structure 1406 (which can provide a mechanical connection between the magnetic element and one or more components outside the machine 1400). In some embodiments, the configuration of the first support structure 602 in the axial flux machine 1400 can be the same as the first support structure 602 in the axial flux machine 1100 described above in conjunction with FIGS. 11A and 11B Or similar. Examples of inventive concepts / features /technologies

以下段落闡述本文中所揭示之新穎概念、特徵及/或技術之實例。The following paragraphs describe examples of the novel concepts, features, and/or technologies disclosed in this article.

(A1) 一種用於一軸向磁通馬達或產生器之轉子，該轉子包括安置在由至少一種第一材料製成之一第一支撐結構上之至少一個磁鐵，其中該第一支撐結構提供該至少一個磁鐵之一磁通返迴路徑且經由由至少一種第二材料製成之一第二支撐結構連接至一軸。(A1) A rotor for an axial flux motor or generator, the rotor comprising at least one magnet arranged on a first support structure made of at least a first material, wherein the first support structure provides The at least one magnet has a magnetic flux return path and is connected to a shaft via a second support structure made of at least a second material.

(A2) 如段落(A1)之轉子，其中該至少一個磁鐵包含磁鐵分段且該第一支撐結構提供該等磁鐵分段之徑向對準。(A2) The rotor of paragraph (A1), wherein the at least one magnet includes magnet segments and the first support structure provides radial alignment of the magnet segments.

(A3) 如段落(A1)或段落(A2)之轉子，其中該至少一個磁鐵包含磁鐵分段且該第一支撐結構被構形為可自該第二支撐結構拆離以允許藉由在一徑向方向上滑動而移除該等磁鐵分段。(A3) The rotor of paragraph (A1) or paragraph (A2), wherein the at least one magnet includes magnet segments and the first support structure is configured to be detachable from the second support structure to allow Slide in the radial direction to remove the magnet segments.

(A4) 如段落(A1)至(A3)中任一段落之轉子，該至少一個磁鐵包含磁鐵分段且其中該第一支撐結構包含提供該等磁鐵分段之成角度對準之肋狀物。(A4) As in the rotor of any of paragraphs (A1) to (A3), the at least one magnet includes magnet segments and wherein the first support structure includes ribs that provide angular alignment of the magnet segments.

(A5) 如段落(A1)至(A4)中任一段落之轉子，其中該第二支撐結構經構形以當該組合件附接至該第二支撐結構時致使包含該第一支撐結構及該至少一個磁鐵之一組合件變得預翹曲。(A5) The rotor of any of paragraphs (A1) to (A4), wherein the second support structure is configured to include the first support structure and the second support structure when the assembly is attached to the second support structure At least one magnet assembly becomes pre-warped.

(A6) 如段落(A1)至(A5)中任一段落之轉子，其中一預翹曲特徵併入至該第一支撐結構中。(A6) For the rotor of any of paragraphs (A1) to (A5), one of the pre-warping features is incorporated into the first support structure.

(A7) 如段落(A1)至(A6)中任一段落之轉子，其中該第一支撐結構呈一圓盤之形狀。(A7) The rotor of any one of paragraphs (A1) to (A6), wherein the first support structure is in the shape of a disc.

(A8) 如段落(A1)至(A7)中任一段落之轉子，其中該第一支撐結構包含經組裝以形成一圓盤形狀之多個部件。(A8) The rotor of any one of paragraphs (A1) to (A7), wherein the first support structure includes a plurality of parts assembled to form a disc shape.

(A9) 如段落(A1)至(A8)中任一段落之轉子，其中該第二支撐結構經構形以充當該馬達或產生器之一輸出或輸入凸緣。(A9) The rotor of any of paragraphs (A1) to (A8), wherein the second support structure is configured to serve as an output or input flange of the motor or generator.

(B1) 一種用於一軸向磁通馬達或產生器之轉子，該轉子包括安置在由至少一種第一材料製成之一第一支撐結構上之一環形磁鐵，其中該第一支撐結構提供該環形磁鐵之一磁通返迴路徑且經由由至少一種第二材料製成之一第二支撐結構連接至一軸。(B1) A rotor for an axial flux motor or generator, the rotor comprising a ring magnet arranged on a first support structure made of at least a first material, wherein the first support structure provides A magnetic flux return path of the ring magnet is connected to a shaft via a second support structure made of at least a second material.

(B2) 如段落(B1)之轉子，其中該第二支撐結構經構形以當該組合件附接至該第二支撐結構時致使包含該第一支撐結構及該環形磁鐵之一組合件變得預翹曲。(B2) The rotor of paragraph (B1), wherein the second support structure is configured to cause an assembly including the first support structure and the ring magnet to change when the assembly is attached to the second support structure Get pre-warped.

(B3) 如段落(B1)或段落(B2)之轉子，其中一預翹曲特徵併入至該第一支撐結構中。(B3) For the rotor of paragraph (B1) or paragraph (B2), one of the pre-warping features is incorporated into the first support structure.

(B4) 如段落(B1)至(B3)中任一段落之轉子，其中該第一支撐結構呈一圓盤之形狀。(B4) The rotor of any one of paragraphs (B1) to (B3), wherein the first support structure is in the shape of a disc.

(B5) 如段落(B1)至(B4)中任一段落之轉子，其中該第一支撐結構包含經組裝以形成一圓盤形狀之多個部件。(B5) The rotor of any one of paragraphs (B1) to (B4), wherein the first support structure includes a plurality of parts assembled to form a disc shape.

(B6) 如段落(B1)至(B5)中任一段落之轉子，其中該第二支撐結構經構形以充當該馬達或產生器之一輸出或輸入凸緣。(B6) The rotor of any of paragraphs (B1) to (B5), wherein the second support structure is configured to serve as an output or input flange of the motor or generator.

(C1) 一種用於一軸向磁通馬達或產生器之轉子，該轉子包括安置在由至少一種第一材料製成之一第一支撐結構上之至少一個磁鐵，其中該第一支撐結構提供該至少一個磁鐵之一磁通返迴路徑且附接至由至少一種第二材料製成之一第二支撐結構，該第二支撐結構經構形以將扭矩提供至一機械負載或自一機械驅動器接收扭矩。(C1) A rotor for an axial flux motor or generator, the rotor comprising at least one magnet arranged on a first support structure made of at least a first material, wherein the first support structure provides The at least one magnet has a magnetic flux return path and is attached to a second support structure made of at least one second material, the second support structure being configured to provide torque to a mechanical load or from a mechanical The drive receives torque.

(C2) 如段落(C1)之轉子，其中該至少一個磁鐵包含磁鐵分段且該第一支撐結構提供該等磁鐵分段之徑向對準。(C2) The rotor of paragraph (C1), wherein the at least one magnet includes magnet segments and the first support structure provides radial alignment of the magnet segments.

(C3) 如段落(C1)或段落(C2)之轉子，其中該至少一個磁鐵包含磁鐵分段且該第一支撐結構被構形為可自該第二支撐結構拆離以允許藉由在一徑向方向上滑動而移除該等磁鐵分段。(C3) The rotor of paragraph (C1) or paragraph (C2), wherein the at least one magnet includes magnet segments and the first support structure is configured to be detachable from the second support structure to allow Slide in the radial direction to remove the magnet segments.

(C4) 如段落(C1)至(C3)中任一段落之轉子，該至少一個磁鐵包含磁鐵分段且其中該第一支撐結構包含提供該等磁鐵分段之成角度對準之肋狀物。(C4) As in the rotor of any of paragraphs (C1) to (C3), the at least one magnet includes magnet segments and wherein the first support structure includes ribs that provide angular alignment of the magnet segments.

(C5) 如段落(C1)至(C4)中任一段落之轉子，其中該第二支撐結構經構形以當該組合件附接至該第二支撐結構時致使包含該第一支撐結構及該至少一個磁鐵之一組合件變得預翹曲。(C5) The rotor of any of paragraphs (C1) to (C4), wherein the second support structure is configured to include the first support structure and the second support structure when the assembly is attached to the second support structure At least one magnet assembly becomes pre-warped.

(C6) 如段落(C1)至(C5)中任一段落之轉子，其中一預翹曲特徵併入至該第一支撐結構中。(C6) For the rotor of any of paragraphs (C1) to (C5), one of the pre-warping features is incorporated into the first support structure.

(C7) 如段落(C1)至(C6)中任一段落之轉子，其中該第一支撐結構呈一圓盤之形狀。(C7) The rotor of any one of paragraphs (C1) to (C6), wherein the first support structure is in the shape of a disc.

(C8) 如段落(C1)至(C7)中任一段落之轉子，其中該第一支撐結構包含經組裝以形成一圓盤形狀之多個部件。(C8) The rotor of any one of paragraphs (C1) to (C7), wherein the first support structure includes a plurality of parts assembled to form a disc shape.

(C9) 如段落(C1)至(C8)中任一段落之轉子，其中該第二支撐結構經構形以充當該馬達或產生器之一輸出或輸入凸緣。(C9) The rotor of any of paragraphs (C1) to (C8), wherein the second support structure is configured to serve as an output or input flange of the motor or generator.

(D1) 一種用於一軸向磁通馬達或產生器之轉子，該轉子包括安置在由至少一種第一材料製成之一第一支撐結構上之一環形磁鐵，其中該第一支撐結構提供該環形磁鐵之一磁通返迴路徑且附接至由至少一種第二材料製成之一第二支撐結構，該第二支撐結構經構形以將扭矩提供至一機械負載或自一機械驅動器接收扭矩。(D1) A rotor for an axial flux motor or generator, the rotor comprising a ring magnet arranged on a first support structure made of at least a first material, wherein the first support structure provides The ring magnet has a magnetic flux return path and is attached to a second support structure made of at least one second material, the second support structure being configured to provide torque to a mechanical load or from a mechanical drive Receive torque.

(D2) 如段落(D1)之轉子，其中該第二支撐結構經構形以當該組合件附接至該第二支撐結構時致使包含該第一支撐結構及該環形磁鐵之一組合件變得預翹曲。(D2) The rotor of paragraph (D1), wherein the second support structure is configured to cause an assembly including the first support structure and the ring magnet to change when the assembly is attached to the second support structure Get pre-warped.

(D3) 如段落(D1)或段落(D2)之轉子，其中一預翹曲特徵併入至該第一支撐結構中。(D3) For the rotor of paragraph (D1) or paragraph (D2), one of the pre-warping features is incorporated into the first support structure.

(D4) 如段落(D1)至(D3)中任一段落之轉子，其中該第一支撐結構呈一圓盤之形狀。(D4) The rotor of any one of paragraphs (D1) to (D3), wherein the first support structure is in the shape of a disc.

(D5) 如段落(D1)至(D4)中任一段落之轉子，其中該第一支撐結構包含經組裝以形成一圓盤形狀之多個部件。(D5) The rotor of any one of paragraphs (D1) to (D4), wherein the first support structure includes a plurality of parts assembled to form a disc shape.

(D6) 如段落(D1)至(D5)中任一段落之轉子，其中該第二支撐結構經構形以充當該馬達或產生器之一輸出或輸入凸緣。(D6) The rotor of any of paragraphs (D1) to (D5), wherein the second support structure is configured to serve as an output or input flange of the motor or generator.

(E1) 一種用於一軸向磁通機器之轉子組合件，其包括：至少一個磁鐵；一第一支撐結構，其經構形以使該至少一個磁鐵附接至其且提供該至少一個磁鐵之一磁通返迴路徑；及一第二支撐結構，其經構形以附接至該第一支撐結構，以便允許經由該第一支撐結構在該至少一個磁鐵與該第二支撐結構之間轉移扭矩，其中該第二支撐結構進一步經構形以：(A) 附接至該軸向磁通機器之一可旋轉軸，或(B) 充當該軸向磁通機器之一輸出或輸入凸緣。(E1) A rotor assembly for an axial flux machine, comprising: at least one magnet; a first support structure configured to attach the at least one magnet to it and provide the at least one magnet A magnetic flux return path; and a second support structure configured to be attached to the first support structure so as to allow between the at least one magnet and the second support structure via the first support structure Transfer torque, wherein the second support structure is further configured to: (A) be attached to a rotatable shaft of the axial flux machine, or (B) act as an output or input convex of the axial flux machine edge.

(E2)  如段落(E1)之轉子組合件，其中該第二支撐結構經構形以附接至該軸向磁通機器之一可旋轉軸。(E2) The rotor assembly of paragraph (E1), wherein the second support structure is configured to be attached to a rotatable shaft of the axial flux machine.

(E3)  如段落(E1)之轉子組合件，其中該第二支撐結構經構形以充當該軸向磁通機器之一輸出或輸入凸緣。(E3) The rotor assembly of paragraph (E1), wherein the second support structure is configured to serve as an output or input flange of the axial flux machine.

(E4)  如段落(E1)至(E3)之轉子組合件，其中該第一支撐結構由至少一種第一材料製成；且該第二支撐結構由至少一種第二材料製成，該至少一種第二材料不同於該至少一種第二材料。(E4) The rotor assembly of paragraphs (E1) to (E3), wherein the first support structure is made of at least one first material; and the second support structure is made of at least one second material, and the at least one The second material is different from the at least one second material.

(E5)  如段落(E1)至(E4)中任一段落之轉子組合件，其中該至少一個磁鐵包括磁鐵分段；且該第二支撐結構進一步經構形以當該等磁鐵分段附接至該第一支撐結構且該第二支撐結構附接至該第一支撐結構時限制該等磁鐵分段之徑向移動。(E5) The rotor assembly of any one of paragraphs (E1) to (E4), wherein the at least one magnet includes magnet segments; and the second support structure is further configured to be attached to the magnet segments When the first support structure and the second support structure are attached to the first support structure, the radial movement of the magnet segments is restricted.

(E6)  如段落(E5)之轉子組合件，其中該第二支撐結構進一步包括經構形以嚙合該等磁鐵分段之最外邊緣以限制該等磁鐵分段之該徑向移動之一圓形唇部。(E6) The rotor assembly of paragraph (E5), wherein the second support structure further includes a circle configured to engage the outermost edges of the magnet segments to limit the radial movement of the magnet segments Shaped lips.

(E7)  如段落(E5)或段落(E6)之轉子組合件，其中該第一支撐結構進一步經構形以當該第二支撐結構自該第一支撐結構拆離時允許該等磁鐵分段徑向地滑動。(E7) The rotor assembly of paragraph (E5) or paragraph (E6), wherein the first support structure is further configured to allow the magnets to be segmented when the second support structure is detached from the first support structure Sliding radially.

(E8)  如段落(E5)至(E7)中任一段落之轉子組合件，其中該第二支撐結構被進一步構形為可自該第一支撐結構拆離以允許藉由在一徑向方向上滑動而自該第一支撐結構移除該等磁鐵分段。(E8) The rotor assembly of any one of paragraphs (E5) to (E7), wherein the second support structure is further configured to be detachable from the first support structure to allow Sliding to remove the magnet segments from the first support structure.

(E9)  如段落(E1)至(E8)之轉子組合件，其中該至少一個磁鐵包括磁鐵分段；且該第一支撐結構進一步包括經構形以當該等磁鐵分段附接至該第一支撐結構時限制該等磁鐵分段之成角度移動之肋狀物。(E9) The rotor assembly of paragraphs (E1) to (E8), wherein the at least one magnet includes magnet segments; and the first support structure further includes a structure configured to attach the magnet segments to the first A supporting structure restricts the angular movement of the magnet segments.

(E10)  如段落(E1)至(E9)之轉子組合件，其中該第二支撐結構進一步包括在一徑向方向上漸縮之至少一個表面，以便當該第二支撐結構附接至該第一支撐結構時致使該第一支撐結構翹曲以貼合該至少一個表面之一形狀。(E10) The rotor assembly of paragraphs (E1) to (E9), wherein the second support structure further includes at least one surface tapered in a radial direction, so that when the second support structure is attached to the first A supporting structure causes the first supporting structure to warp to fit a shape of the at least one surface.

(E11)  如段落(E1)至(E4)、(E9)或(E10)中任一段落之轉子組合件，其中該至少一個磁鐵包括經構形以附接至該第一支撐結構之一環形磁鐵。 (E12)  如段落(E1)至(E11)中任一段落之轉子組合件，其中該第二支撐結構被調適為圍繞該軸向磁通機器之一旋轉軸線旋轉；該至少一個磁鐵具有正交於該至少一個磁鐵之一磁化方向且背對該第一支撐結構之一第一表面；該第一支撐結構、該第二支撐結構及該至少一個磁鐵經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則交切該第一表面上之一第一點且該旋轉軸線法向於的一第一平面與交切該第一表面上之一第二點且該旋轉軸線法向於的一第二平面之間的一距離實質上大於零；該第二點係在距該旋轉軸線較該第一點大之一徑向距離處；且該第一支撐結構、該第二支撐結構及該至少一個磁鐵進一步經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則在該第二點處延伸遠離該第一表面且法向於該第一表面之一射線交切該第一平面。(E11) The rotor assembly of any of paragraphs (E1) to (E4), (E9) or (E10), wherein the at least one magnet includes a ring magnet that is configured to be attached to the first support structure . (E12) The rotor assembly of any one of paragraphs (E1) to (E11), wherein the second support structure is adapted to rotate around a rotation axis of the axial flux machine; the at least one magnet has a perpendicular to The at least one magnet has a magnetization direction and faces away from a first surface of the first support structure; the first support structure, the second support structure, and the at least one magnet are configured and arranged such that if the first support The structure, the second support structure, and the at least one magnet are stationary with respect to the rotation axis and are not affected by any other magnetic components, then intersect a first point on the first surface and a first point normal to the rotation axis A distance between a plane and a second plane that intersects a second point on the first surface and the axis of rotation is normal to is substantially greater than zero; A point greater than a radial distance; and the first support structure, the second support structure and the at least one magnet are further configured and arranged such that if the first support structure, the second support structure and the at least one magnet A magnet is stationary with respect to the rotation axis and is not affected by any other magnetic components, and extends away from the first surface at the second point and a ray normal to the first surface intersects the first plane.

(E13)  如段落(E12)之轉子組合件，其中該至少一個磁鐵具有安置於該第一點處之一內邊緣；該至少一個磁鐵具有與該內邊緣相對且安置於該第二點處之一外邊緣；且該第一支撐結構、該第二支撐結構及該至少一個磁鐵進一步經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則該第一平面與該第二平面之間的該距離與該第一點與該第二點之間的一距離之一比率大於0.002。(E13) The rotor assembly of paragraph (E12), wherein the at least one magnet has an inner edge arranged at the first point; the at least one magnet has an inner edge opposite to the inner edge and arranged at the second point An outer edge; and the first support structure, the second support structure and the at least one magnet are further configured and arranged such that if the first support structure, the second support structure and the at least one magnet rotate relative to the If the axis is stationary and not affected by any other magnetic components, the ratio of the distance between the first plane and the second plane to the distance between the first point and the second point is greater than 0.002.

(E14)  如段落(E1)至(E13)之轉子組合件，其中該轉子組合件安裝於該軸向磁通機器中且該第一平面與該第二平面之間的該距離實質上等於零。(E14) The rotor assembly of paragraphs (E1) to (E13), wherein the rotor assembly is installed in the axial flux machine and the distance between the first plane and the second plane is substantially equal to zero.

(F1) 一種方法，其包括：將至少一個磁鐵附接至用於一軸向磁通機器之一轉子組合件之一第一支撐結構，使得該第一支撐結構提供該至少一個磁鐵之一磁通返迴路徑；及將一第二支撐結構附接至具有附接至其之該至少一個磁鐵之該第一支撐結構以便允許經由該第一支撐結構在該至少一個磁鐵與該第二支撐結構之間轉移扭矩，其中該第二支撐結構進一步經構形以：(A) 附接至該軸向磁通機器之一可旋轉軸，或(B) 充當該軸向磁通機器之一輸出或輸入凸緣。(F1) A method comprising: attaching at least one magnet to a first support structure of a rotor assembly for an axial flux machine such that the first support structure provides a magnetic field of the at least one magnet Through the return path; and attaching a second support structure to the first support structure having the at least one magnet attached to it so as to allow the at least one magnet and the second support structure to pass through the first support structure The second support structure is further configured to: (A) be attached to a rotatable shaft of the axial flux machine, or (B) act as an output of the axial flux machine or Enter the flange.

(F2) 如段落(F1)中之方法，其中該第二支撐結構經構形以附接至該軸向磁通機器之一可旋轉軸。(F2) The method in paragraph (F1), wherein the second support structure is configured to be attached to a rotatable shaft of the axial flux machine.

(F3) 如段落(F1)中之方法，其中該第二支撐結構經構形以充當該軸向磁通機器之一輸出或輸入凸緣。(F3) The method in paragraph (F1), wherein the second support structure is configured to serve as an output or input flange of the axial flux machine.

(F4) 如段落(F1)至(F3)中任一段落之方法，其中該第一支撐結構由至少一種第一材料製成；且該第二支撐結構由至少一種第二材料製成，該至少一種第二材料不同於該至少一種第二材料。(F4) The method of any one of paragraphs (F1) to (F3), wherein the first support structure is made of at least one first material; and the second support structure is made of at least one second material, and the at least A second material is different from the at least one second material.

(F5) 如段落(F1)至(F4)中任一段落之方法，其中該至少一個磁鐵包括磁鐵分段，且將該第二支撐結構附接至該第一支撐結構進一步包括將該第二支撐結構附接至該第一支撐結構使得該第二支撐結構限制該等磁鐵分段之徑向移動。(F5) The method of any one of paragraphs (F1) to (F4), wherein the at least one magnet includes magnet segments, and attaching the second support structure to the first support structure further includes the second support The structure is attached to the first support structure so that the second support structure restricts the radial movement of the magnet segments.

(F6) 如段落(F5)中之方法，其進一步包括自該第一支撐結構拆離該第二支撐結構以允許藉由在一徑向方向上滑動而自該第一支撐結構移除該等磁鐵分段。(F6) The method in paragraph (F5), which further comprises detaching the second support structure from the first support structure to allow the removal of the first support structure by sliding in a radial direction Magnet segments.

(F7) 如段落(F1)至(F6)中任一段落之方法，其中該第二支撐結構進一步包括在一徑向方向上漸縮之至少一個表面；且將該第二支撐結構附接至該第一支撐結構進一步包括將該第二支撐結構附接至該第一支撐結構以便致使該第一支撐結構翹曲以貼合該至少一個表面之一形狀。(F7) The method of any one of paragraphs (F1) to (F6), wherein the second support structure further includes at least one surface tapered in a radial direction; and the second support structure is attached to the The first support structure further includes attaching the second support structure to the first support structure to cause the first support structure to warp to conform to a shape of the at least one surface.

(F8)  如段落(F1)至(F7)中任一段落之方法，其中該第二支撐結構被調適為圍繞該軸向磁通機器之一旋轉軸線旋轉；該至少一個磁鐵具有正交於該至少一個磁鐵之一磁化方向且背對該第一支撐結構之一第一表面；該第一支撐結構、該第二支撐結構及該至少一個磁鐵經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則交切該第一表面上之一第一點且該旋轉軸線法向於的一第一平面與交切該第一表面上之一第二點且該旋轉軸線法向於的一第二平面之間的一距離實質上大於零；該第二點係在距該旋轉軸線較該第一點大之一徑向距離處；且該第一支撐結構、該第二支撐結構及該至少一個磁鐵進一步經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則在該第二點處延伸遠離該第一表面且法向於該第一表面之一射線交切該第一平面。(F8) The method of any one of paragraphs (F1) to (F7), wherein the second support structure is adapted to rotate around a rotation axis of the axial flux machine; the at least one magnet has a perpendicular to the at least A magnet has a magnetization direction and faces away from a first surface of the first support structure; the first support structure, the second support structure, and the at least one magnet are configured and arranged such that, if the first support structure, The second support structure and the at least one magnet are stationary with respect to the rotation axis and are not affected by any other magnetic components, then intersect a first point on the first surface and a first plane normal to the rotation axis A distance from a second plane that intersects a second point on the first surface and that is normal to the axis of rotation is substantially greater than zero; A larger radial distance; and the first support structure, the second support structure, and the at least one magnet are further configured and arranged such that if the first support structure, the second support structure, and the at least one magnet It is stationary with respect to the rotation axis and is not affected by any other magnetic components, and a ray that extends away from the first surface at the second point and is normal to the first surface intersects the first plane.

(F9)  如段落(F8)中之方法，其中該至少一個磁鐵具有安置於該第一點處之一內邊緣；該至少一個磁鐵具有與該內邊緣相對且安置於該第二點處之一外邊緣；且該第一支撐結構、該第二支撐結構及該至少一個磁鐵進一步經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，該第一平面與該第二平面之間的該距離與該第一點與該第二點之間的一距離之一比率大於0.002。(F9) The method in paragraph (F8), wherein the at least one magnet has an inner edge disposed at the first point; the at least one magnet has an inner edge opposite to the inner edge and disposed at the second point Outer edge; and the first support structure, the second support structure and the at least one magnet are further configured and configured such that if the first support structure, the second support structure and the at least one magnet are relative to the rotation axis Static and unaffected by any other magnetic components, a ratio of the distance between the first plane and the second plane to the distance between the first point and the second point is greater than 0.002.

(F10)  如段落(F1)至(F9)中任一段落之方法，其進一步包括將該轉子組合件安裝在該軸向磁通機器中使得該第一平面與該第二平面之間的該距離變得實質上等於零。(F10) The method of any one of paragraphs (F1) to (F9), which further includes installing the rotor assembly in the axial flux machine such that the distance between the first plane and the second plane Becomes substantially equal to zero.

因此已闡述至少一項實施例之數個態樣，應瞭解，熟習此項技術者將易於做出各種更改、修改及改良。此等更改、修改及改良意欲作為本發明之部分且意欲在本發明之精神及範疇內。因此，前述說明及圖式係僅藉由實例之方式。Therefore, several aspects of at least one embodiment have been described. It should be understood that those who are familiar with the technology can easily make various changes, modifications and improvements. These changes, modifications, and improvements are intended to be part of the present invention and are intended to be within the spirit and scope of the present invention. Therefore, the foregoing description and drawings are by way of example only.

可單獨地、以組合方式或以前文中所闡述之實施例中未加以具體論述之各種配置來使用本發明之各項態樣，且因此在本申請案中不限於前述說明中所陳述或圖式中所圖解說明之細節及組件之配置。舉例而言，一項實施例中所闡述之態樣可以任何方式與其他實施例中所闡述之態樣組合。The various aspects of the present invention can be used individually, in combination or in various configurations that are not specifically discussed in the embodiments described in the foregoing, and therefore, the present application is not limited to the statements or drawings in the foregoing description The details and the configuration of the components illustrated in the diagram. For example, the aspect explained in one embodiment can be combined with the aspect explained in other embodiments in any way.

此外，所揭示態樣可體現為一實例已提供之一方法。作為方法之一部分實施之行動可以任一適宜方式排序。因此，實施例可經構造，其中以不同於所圖解說明之一次序執行行動，其可包含同時執行某些行動，即使在說明性實施例中展示為依序行動。In addition, the disclosed aspect can be embodied as a method provided by an example. The actions implemented as part of the method can be sequenced in any suitable way. Thus, embodiments may be constructed in which actions are performed in a different order than that illustrated, which may include performing certain actions at the same time, even if shown as sequential actions in the illustrative embodiment.

在申請專利範圍中，使用諸如「第一」、「第二」、「第三」等序數術語來修飾一申請專利範圍要素本身並不暗示一個申請專利範圍要素具有優於另一申請專利範圍要素之任何優先性、在先性或次序，或執行一方法之動作之時間次序，而是僅用作區分具有一特定名稱之一個所主張要素與具有一相同名稱(序數術語之使用除外)之另一要素以區分申請專利範圍要素之標注。In the scope of patent application, the use of ordinal terms such as "first", "second", "third" to modify an element of the patent application does not imply that one element of the patent application is superior to another element of the patent application Any priority, precedence or order, or the chronological order of the actions of a method, is only used to distinguish a claimed element with a specific name from another with the same name (except for the use of ordinal terms) One element is the label to distinguish the elements of the scope of patent application.

此外，本文中所使用之措辭及術語係出於說明目的且不應視為具限制性。本文中使用「包含(including)」、「包括(comprising)」、「具有(having)」、「含有(containing)」、「涉及(involving)」及其變化形式意指囊括其後所列之項目及其等效物以及額外項目。In addition, the wording and terminology used herein are for illustrative purposes and should not be considered restrictive. The use of "including", "comprising", "having", "containing", "involving" and their variations in this article means to include the items listed thereafter And its equivalents and additional items.

100:實例軸向磁通氣隙機器/機器/軸向磁通機器 102:印刷電路板(PCB)定子/定子 104a:轉子部分 104b:轉子部分 106:氣隙 108:軸 110:環形磁鐵 110a:各別環形磁鐵/環形磁鐵 110b:各別環形磁鐵/環形磁鐵 112a:轉子支撐件 112b:轉子支撐件 200:軸向磁通機器 300:轉子部分 302:實例轉子支撐件/轉子支撐件 302a:轉子支撐件 302b:轉子支撐件 304:坡口錐形表面/錐形表面 306:外邊緣 306a:外邊緣 306b:外邊緣 400:軸向磁通機器/機器 402:中心線 404a:背部 404b:背部 502:磁鐵分段/典型磁鐵分段/分段/磁鐵 502a:磁鐵分段 502b:磁鐵分段 504:內邊緣 506:外邊緣 602:第一支撐結構 602a:第一支撐結構 602b:第一支撐結構 604:定位肋狀物 606:銷及/或螺桿緊固件孔 608:中心開口/開口 610:中心點 702:第二支撐結構 702a:第二支撐結構 702b:第二支撐結構 704:圓形唇部 706:錐形表面區域/錐形表面 800:實例轉子組合件/轉子組合件 800a:轉子組合件 800b:轉子組合件/轉子元件組合件 802:組合件螺桿/螺桿 804:間隙 808:錐體 810:面/表面 902:點/第一點/接觸點 904:點/第二點/接觸點 906:平面 908:平面 910:點 912:射線 914:點/第一點/磁鐵表面點 916:點/第二點/磁鐵表面點 922:點 924:射線 926:平面 928:平面 930:旋轉軸線 1002:間隙 1004:點 1006:點 1200:軸向磁通機器/機器 1202:第二支撐結構 1204:經暴露部分 1206:殼體 1300:「無軸」軸向磁通機器/軸向磁通機器 1302a:第二支撐結構 1302b:第二支撐結構 1304:連接器 1306:殼體 1400:「無軸」軸向磁通機器/機器/軸向磁通機器 1402:磁性材料/固定磁性材料 1404:殼體 1406:第二支撐結構 D1 :距離 D2 :距離 D3 :距離 G:較小平均間隙寬度/平均寬度 R1 :第一徑向距離/內半徑 R2 :第二徑向距離/外半徑 W1 :寬度 W2 :寬度 α1 :角 α2 :角100: Example Axial Flux Air Gap Machine/Machine/Axial Flux Machine 102: Printed Circuit Board (PCB) Stator/Stator 104a: Rotor Part 104b: Rotor Part 106: Air Gap 108: Shaft 110: Ring Magnet 110a: Each Individual ring magnet/ring magnet 110b: Individual ring magnet/ring magnet 112a: Rotor support 112b: Rotor support 200: Axial flux machine 300: Rotor section 302: Example rotor support/Rotor support 302a: Rotor support Piece 302b: Rotor support 304: Bevel tapered surface / tapered surface 306: Outer edge 306a: Outer edge 306b: Outer edge 400: Axial flux machine/machine 402: Centerline 404a: Back 404b: Back 502: Magnet segment/typical magnet segment/segment/magnet 502a: magnet segment 502b: magnet segment 504: inner edge 506: outer edge 602: first support structure 602a: first support structure 602b: first support structure 604 : Positioning rib 606: pin and/or screw fastener hole 608: center opening/opening 610: center point 702: second support structure 702a: second support structure 702b: second support structure 704: circular lip 706 : Conical surface area/cone surface 800: example rotor assembly/rotor assembly 800a: rotor assembly 800b: rotor assembly/rotor element assembly 802: assembly screw/screw 804: gap 808: cone 810: Surface/Surface 902: Point/First Point/Contact Point 904: Point/Second Point/Contact Point 906: Plane 908: Plane 910: Point 912: Ray 914: Point/First Point/Magnet Surface Point 916: Point/ The second point/magnet surface point 922: point 924: ray 926: plane 928: plane 930: axis of rotation 1002: gap 1004: point 1006: point 1200: axial flux machine/machine 1202: second support structure 1204: warp Exposed part 1206: housing 1300: ``shaftless'' axial flux machine / axial flux machine 1302a: second support structure 1302b: second support structure 1304: connector 1306: housing 1400: ``shaftless'' shaft Toward Flux Machine/Machine/Axial Flux Machine 1402: Magnetic Material/Fixed Magnetic Material 1404: Housing 1406: Second Support Structure D 1 : Distance D 2 : Distance D 3 : Distance G: Smaller Average Gap Width/ Average width R 1 : first radial distance / inner radius R 2 : second radial distance / outer radius W 1 : width W 2 : width α 1 : angle α 2 : angle

圖1展示具有一印刷電路板定子之一實例軸向磁通氣隙機器之一總平面之一剖視圖；Figure 1 shows a cross-sectional view of a general plane of an axial flux air gap machine with an example of a printed circuit board stator;

圖2展示一軸向磁通馬達中之氣隙歸因於轉子支撐件之變形而塌縮從而潛在地導致與定子之干涉之趨勢；Figure 2 shows the tendency of the air gap in an axial flux motor to collapse due to the deformation of the rotor support, potentially causing interference with the stator;

圖3A展示具有一坡口錐體之一實例轉子支撐件之一剖視圖；Figure 3A shows a cross-sectional view of an example rotor support having a grooved cone;

圖3B展示具有附接至其之一環形磁鐵之圖3A中所展示之實例轉子支撐件之一剖視圖；Figure 3B shows a cross-sectional view of the example rotor support shown in Figure 3A with one of the ring magnets attached to it;

圖4展示如圖3B中所展示之轉子組合件之兩個轉子組合件可如何安裝在一軸向磁通機器中使得轉子之一平衡位置與間隙中心線等距；Figure 4 shows how the two rotor assemblies of the rotor assembly shown in Figure 3B can be installed in an axial flux machine such that the balance position of one of the rotors is equidistant from the gap centerline;

圖5展示可用於舉例而言具有超出大約四釐米之一半徑之轉子組合件之一實例磁鐵分段；Figure 5 shows an example magnet segment that can be used for, for example, a rotor assembly having a radius exceeding about four centimeters;

圖6A展示根據本發明之某些實施例構形之一轉子部分(例如，一轉子半體)之一第一支撐結構或「轉子背鐵」之一實例；6A shows an example of a first support structure or "rotor back iron" of a rotor part (eg, a rotor half) configured according to some embodiments of the present invention;

圖6B展示具有安裝於其上之一組磁鐵分段502之圖6A中所展示之第一支撐結構；Figure 6B shows the first support structure shown in Figure 6A with a set of magnet segments 502 mounted thereon;

圖7展示根據本發明之某些實施例構形之一第二支撐結構或「轉子背鐵」之一實例；FIG. 7 shows an example of a second support structure or "rotor back iron" configured according to some embodiments of the present invention;

圖8A展示在將最終扭矩施加至組合件螺桿之前的一實例轉子組合件，其包含：諸如圖6B中所展示之一第一支撐結構，其中磁鐵分段安裝於該第一支撐結構上，及諸如圖7中所展示之一第二支撐結構；Figure 8A shows an example rotor assembly before the final torque is applied to the assembly screw, which includes: a first support structure such as that shown in Figure 6B, where magnets are mounted on the first support structure in sections, and A second supporting structure such as the one shown in FIG. 7;

圖8B展示當螺桿已被擰緊至設計扭矩時之圖8A之轉子組合件；Figure 8B shows the rotor assembly of Figure 8A when the screw has been tightened to the design torque;

圖9展示圖8B中所展示之同一轉子組合件，但出於說明性目的放大了錐體之度數；Figure 9 shows the same rotor assembly shown in Figure 8B, but with the cone degrees enlarged for illustrative purposes;

圖10展示諸如圖9中所展示之一對預翹曲轉子組合件之一側視圖，其圖解說明當轉子組合件併入至一軸向磁通機器中時，該等轉子組合件可如何彎曲為一所期望構形；Figure 10 shows a side view of a pair of pre-warped rotor assemblies such as that shown in Figure 9, which illustrates how the rotor assemblies can be bent when the rotor assemblies are incorporated into an axial flux machine In a desired configuration;

圖11A展示如圖8B中所展示之兩個轉子組合件可如何安裝於具有定位於磁鐵分段之面之間的一實質上均勻間隙內之一印刷電路板定子之一軸向磁通機器中；Figure 11A shows how the two rotor assemblies as shown in Figure 8B can be installed in an axial flux machine with a printed circuit board located in a substantially uniform gap between the faces of the magnet segments. ；

圖11B展示圖11A中所展示之組合件一剖視圖；Figure 11B shows a cross-sectional view of the assembly shown in Figure 11A;

圖12A展示如圖8B中所展示之兩個轉子組合件可如何安裝於具有一無軸構形之一軸向磁通機器中；Figure 12A shows how the two rotor assemblies shown in Figure 8B can be installed in an axial flux machine with a shaftless configuration;

圖12B展示圖12A中所展示之組合件之一剖視圖；Figure 12B shows a cross-sectional view of the assembly shown in Figure 12A;

圖13展示在一先行者(out-runner)構形中之一實例軸向磁通機器之一剖視圖，其中第二支撐結構在經構造以在其內直徑處安裝至一殼體之一定子之外部處相交；及Figure 13 shows a cross-sectional view of an example axial flux machine in an out-runner configuration, in which the second support structure is configured to be mounted at its inner diameter to the outside of a stator of a housing Intersect at; and

圖14展示具有一單側轉子之一實例軸向磁通機器之一剖視圖。Figure 14 shows a cross-sectional view of an example axial flux machine with a single-sided rotor.

502:磁鐵分段/典型磁鐵分段/分段/磁鐵 502: Magnet Segment/Typical Magnet Segment/Segment/Magnet

602:第一支撐結構 602: The first support structure

702:第二支撐結構 702: second support structure

704:圓形唇部 704: round lips

800:實例轉子組合件/轉子組合件 800: Example rotor assembly/rotor assembly

802:組合件螺桿/螺桿 802: Assembly screw/screw

808:錐體 808: Cone

810:面/表面 810: surface/surface

Claims (20)

一種用於一軸向磁通機器之轉子組合件，其包括： 至少一個磁鐵； 一第一支撐結構，其經構形以使該至少一個磁鐵附接至其且提供該至少一個磁鐵之一磁通返迴路徑；及 一第二支撐結構，其經構形以附接至該第一支撐結構，以便允許經由該第一支撐結構在該至少一個磁鐵與該第二支撐結構之間轉移扭矩，其中該第二支撐結構進一步經構形以： (A) 附接至該軸向磁通機器之一可旋轉軸，或 (B) 充當該軸向磁通機器之一輸出或輸入凸緣。A rotor assembly for an axial flux machine, which includes: At least one magnet; A first support structure configured to attach the at least one magnet to it and provide a magnetic flux return path for the at least one magnet; and A second support structure configured to be attached to the first support structure so as to allow torque to be transferred between the at least one magnet and the second support structure via the first support structure, wherein the second support structure It is further configured to: (A) be attached to a rotatable shaft of the axial flux machine, or (B) act as an output or input flange of the axial flux machine. 如請求項1之轉子組合件，其中： 該第二支撐結構被調適為圍繞該軸向磁通機器之一旋轉軸線旋轉； 該至少一個磁鐵具有正交於該至少一個磁鐵之一磁化方向且背對該第一支撐結構之一第一表面； 該第一支撐結構、該第二支撐結構及該至少一個磁鐵經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則交切該第一表面上之一第一點且該旋轉軸線法向於的一第一平面與交切該第一表面上之一第二點且該旋轉軸線法向於的一第二平面之間的一距離實質上大於零； 該第二點係在距該旋轉軸線較該第一點大之一徑向距離處；且 該第一支撐結構、該第二支撐結構及該至少一個磁鐵進一步經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則在該第二點處延伸遠離該第一表面且法向於該第一表面之一射線交切該第一平面。Such as the rotor assembly of claim 1, where: The second support structure is adapted to rotate around a rotation axis of the axial flux machine; The at least one magnet has a first surface orthogonal to a magnetization direction of the at least one magnet and facing away from the first support structure; The first support structure, the second support structure and the at least one magnet are configured and arranged such that if the first support structure, the second support structure and the at least one magnet are stationary relative to the rotation axis and are not affected by any If other magnetic components are affected, a first plane that intersects a first point on the first surface and the rotation axis is normal to intersects a second point on the first surface and the rotation axis is normal to A distance between a second plane of is substantially greater than zero; The second point is at a radial distance greater than the first point from the axis of rotation; and The first support structure, the second support structure, and the at least one magnet are further configured and arranged so that if the first support structure, the second support structure, and the at least one magnet are stationary relative to the rotation axis and not affected Any other magnetic component influences, a ray that extends away from the first surface at the second point and is normal to the first surface intersects the first plane. 如請求項2之轉子組合件，其中： 該至少一個磁鐵具有安置於該第一點處之一內邊緣； 該至少一個磁鐵具有與該內邊緣相對且安置於該第二點處之一外邊緣；且 該第一支撐結構、該第二支撐結構及該至少一個磁鐵進一步經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則該第一平面與該第二平面之間的該距離與該第一點與該第二點之間的一距離之一比率大於0.002。Such as the rotor assembly of claim 2, where: The at least one magnet has an inner edge disposed at the first point; The at least one magnet has an outer edge opposite to the inner edge and disposed at the second point; and The first support structure, the second support structure, and the at least one magnet are further configured and arranged so that if the first support structure, the second support structure, and the at least one magnet are stationary relative to the rotation axis and not affected If any other magnetic components are affected, the ratio of the distance between the first plane and the second plane to the distance between the first point and the second point is greater than 0.002. 如請求項2或請求項3之轉子組合件，其中該轉子組合件安裝於該軸向磁通機器中，且該第一平面與該第二平面之間的該距離實質上等於零。Such as the rotor assembly of claim 2 or claim 3, wherein the rotor assembly is installed in the axial flux machine, and the distance between the first plane and the second plane is substantially equal to zero. 如請求項1至4中任一項之轉子組合件，其中： 該第二支撐結構進一步包括在一徑向方向上漸縮之至少一個表面，以便當該第二支撐結構附接至該第一支撐結構時致使該第一支撐結構翹曲以貼合該至少一個表面之一形狀。Such as the rotor assembly of any one of claims 1 to 4, wherein: The second support structure further includes at least one surface that is tapered in a radial direction so as to cause the first support structure to warp to fit the at least one surface when the second support structure is attached to the first support structure One of the surface shapes. 如請求項1至5中任一項之轉子組合件，其中該第二支撐結構經構形以附接至該軸向磁通機器之一可旋轉軸。The rotor assembly of any one of claims 1 to 5, wherein the second support structure is configured to be attached to a rotatable shaft of the axial flux machine. 如請求項1至5中任一項之轉子組合件，其中該第二支撐結構經構形以充當該軸向磁通機器之一輸出或輸入凸緣。The rotor assembly of any one of claims 1 to 5, wherein the second support structure is configured to serve as an output or input flange of the axial flux machine. 如請求項1至7中任一項之轉子組合件，其中： 該第一支撐結構由至少一種第一材料製成；及 該第二支撐結構由至少一種第二材料製成，該至少一種第二材料不同於該至少一種第一材料。Such as the rotor assembly of any one of claims 1 to 7, in which: The first support structure is made of at least one first material; and The second support structure is made of at least one second material, which is different from the at least one first material. 如請求項1至8中任一項之轉子組合件，其中： 該至少一個磁鐵包括磁鐵分段；且 該第二支撐結構進一步經構形以當該等磁鐵分段附接至該第一支撐結構且該第二支撐結構附接至該第一支撐結構時限制該等磁鐵分段之徑向移動。Such as the rotor assembly of any one of claims 1 to 8, in which: The at least one magnet includes magnet segments; and The second support structure is further configured to limit the radial movement of the magnet segments when the magnet segments are attached to the first support structure and the second support structure is attached to the first support structure. 如請求項9之轉子組合件，其中： 該第二支撐結構進一步包括經構形以嚙合該等磁鐵分段之最外邊緣以限制該等磁鐵分段之該徑向移動之一圓形唇部。Such as the rotor assembly of claim 9, where: The second support structure further includes a circular lip that is configured to engage the outermost edges of the magnet segments to limit the radial movement of the magnet segments. 如請求項9或請求項10之轉子組合件，其中： 該第一支撐結構進一步經構形以當該第二支撐結構自該第一支撐結構拆離時允許該等磁鐵分段徑向地滑動。Such as the rotor assembly of claim 9 or claim 10, where: The first support structure is further configured to allow the magnet segments to slide radially when the second support structure is detached from the first support structure. 如請求項9至11中任一項之轉子組合件，其中： 該第二支撐結構被進一步構形為可自該第一支撐結構拆離以允許藉由在一徑向方向上滑動而自該第一支撐結構移除該等磁鐵分段。Such as the rotor assembly of any one of claims 9 to 11, wherein: The second support structure is further configured to be detachable from the first support structure to allow the magnet segments to be removed from the first support structure by sliding in a radial direction. 如請求項1至12中任一項之轉子組合件，其中： 該至少一個磁鐵包括磁鐵分段；且 該第一支撐結構進一步包括經構形以當該等磁鐵分段附接至該第一支撐結構時限制該等磁鐵分段之成角度移動之肋狀物。Such as the rotor assembly of any one of claims 1 to 12, wherein: The at least one magnet includes magnet segments; and The first support structure further includes ribs configured to restrict angular movement of the magnet segments when the magnet segments are attached to the first support structure. 如請求項1至8中任一項之轉子組合件，其中： 該至少一個磁鐵包括經構形以附接至該第一支撐結構之一環形磁鐵。Such as the rotor assembly of any one of claims 1 to 8, in which: The at least one magnet includes an annular magnet that is configured to be attached to the first support structure. 一種方法，其包括： 將至少一個磁鐵附接至用於一軸向磁通機器之一轉子組合件之一第一支撐結構，使得該第一支撐結構提供該至少一個磁鐵之一磁通返迴路徑；及 將一第二支撐結構附接至具有附接至其之該至少一個磁鐵之該第一支撐結構，以便允許經由該第一支撐結構在該至少一個磁鐵與該第二支撐結構之間轉移扭矩，其中該第二支撐結構進一步經構形以： (A) 附接至該軸向磁通機器之一可旋轉軸，或 (B) 充當該軸向磁通機器之一輸出或輸入凸緣。A method including: Attaching at least one magnet to a first support structure of a rotor assembly for an axial flux machine such that the first support structure provides a magnetic flux return path for the at least one magnet; and Attaching a second support structure to the first support structure having the at least one magnet attached thereto so as to allow torque transfer between the at least one magnet and the second support structure via the first support structure, The second support structure is further configured to: (A) be attached to a rotatable shaft of the axial flux machine, or (B) act as an output or input flange of the axial flux machine. 如請求項15之方法，其中： 該第二支撐結構被調適為圍繞該軸向磁通機器之一旋轉軸線旋轉； 該至少一個磁鐵具有正交於該至少一個磁鐵之一磁化方向且背對該第一支撐結構之一第一表面； 該第一支撐結構、該第二支撐結構及該至少一個磁鐵經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則交切該第一表面上之一第一點且該旋轉軸線法向於的一第一平面與交切該第一表面上之一第二點且該旋轉軸線法向於的一第二平面之間的一距離實質上大於零； 該第二點係在距該旋轉軸線較該第一點大之一徑向距離處；且 該第一支撐結構、該第二支撐結構及該至少一個磁鐵進一步經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則在該第二點處延伸遠離該第一表面且法向於該第一表面之一射線交切該第一平面。Such as the method of claim 15, where: The second support structure is adapted to rotate around a rotation axis of the axial flux machine; The at least one magnet has a first surface orthogonal to a magnetization direction of the at least one magnet and facing away from the first support structure; The first support structure, the second support structure and the at least one magnet are configured and arranged such that if the first support structure, the second support structure and the at least one magnet are stationary relative to the rotation axis and are not affected by any If other magnetic components are affected, a first plane that intersects a first point on the first surface and the rotation axis is normal to intersects a second point on the first surface and the rotation axis is normal to A distance between a second plane of is substantially greater than zero; The second point is at a radial distance greater than the first point from the axis of rotation; and The first support structure, the second support structure, and the at least one magnet are further configured and arranged so that if the first support structure, the second support structure, and the at least one magnet are stationary relative to the rotation axis and not affected Any other magnetic component influences, a ray that extends away from the first surface at the second point and is normal to the first surface intersects the first plane. 如請求項16之方法，其中： 該至少一個磁鐵具有安置於該第一點處之一內邊緣； 該至少一個磁鐵具有與該內邊緣相對且安置於該第二點處之一外邊緣；且 該第一支撐結構、該第二支撐結構及該至少一個磁鐵進一步經構形且配置使得，若該第一支撐結構、該第二支撐結構及該至少一個磁鐵相對於該旋轉軸線靜止且不受任何其他磁性組件影響，則該第一平面與該第二平面之間的該距離與該第一點與該第二點之間的一距離之一比率大於0.002。Such as the method of claim 16, where: The at least one magnet has an inner edge disposed at the first point; The at least one magnet has an outer edge opposite to the inner edge and disposed at the second point; and The first support structure, the second support structure, and the at least one magnet are further configured and arranged so that if the first support structure, the second support structure, and the at least one magnet are stationary relative to the rotation axis and not affected If any other magnetic components are affected, the ratio of the distance between the first plane and the second plane to the distance between the first point and the second point is greater than 0.002. 如請求項15至17中任一項之方法，其中： 該第一支撐結構由至少一種第一材料製成；且 該第二支撐結構由至少一種第二材料製成，該至少一種第二材料不同於該至少一種第一材料。Such as the method of any one of claims 15 to 17, wherein: The first support structure is made of at least one first material; and The second support structure is made of at least one second material, which is different from the at least one first material. 如請求項15至18中任一項之方法，其中： 該至少一個磁鐵包括磁鐵分段，且 將該第二支撐結構附接至該第一支撐結構進一步包括：將該第二支撐結構附接至該第一支撐結構使得該第二支撐結構限制該等磁鐵分段之徑向移動。Such as the method of any one of claims 15 to 18, wherein: The at least one magnet includes magnet segments, and Attaching the second support structure to the first support structure further includes: attaching the second support structure to the first support structure such that the second support structure restricts radial movement of the magnet segments. 如請求項19之方法，其進一步包括： 自該第一支撐結構拆離該第二支撐結構以允許藉由在一徑向方向上滑動而自該第一支撐結構移除該等磁鐵分段。Such as the method of claim 19, which further includes: The second support structure is detached from the first support structure to allow the magnet segments to be removed from the first support structure by sliding in a radial direction.
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