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WO-2026092093-A1 - ROTOR LAMINATION FOR HIGH-EFFICIENCY PERMANENT MAGNET SYNCHRONOUS ELECTRIC MOTOR

WO2026092093A1WO 2026092093 A1WO2026092093 A1WO 2026092093A1WO-2026092093-A1

Abstract

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

Inventors

  • WANG, JIANHUI
  • GAO, Jianfei
  • LI, Menghan
  • WANG, BO
  • LU, HAILING
  • Wang, Kaili
  • LIU, RUI

Assignees

  • 上海电机系统节能工程技术研究中心有限公司
  • 上海电科电机科技有限公司
  • 上海格立特电力电子有限公司

Dates

Publication Date
20260507
Application Date
20251011
Priority Date
20241031

Claims (10)

  1. A rotor lamination for a high-efficiency permanent magnet synchronous motor, characterized in that the rotor lamination is designed and manufactured through the following steps: S1: Based on symmetry, one pole of the motor rotor lamination is designed as a sector, with an unfolding angle of 180/ p degrees, where p is the number of pole pairs. The rotor structure under one pole is symmetrical about the central axis X of the sector. The straight line of the left boundary of the sector is Y. The part of the inner circle of the motor stator corresponding to this one pole is an arc L1 , with the center of the circle being the center of the motor shaft O. The radius of the arc L1 is R1 . The arc L1 is offset towards the center by the air gap length g1 to obtain the outer circle boundary arc L2 of the motor rotor . The radius of L2 is R2 , where R2 = R1 - g1 . S2: The arc L2 is offset by a distance g2 towards the center of the circle to obtain the arc L3 , whose radius is R3 , R3 = R2 - g2 ; S3: The central axis X is rotated by an angle a 1/2 in the direction of the boundary line Y with O as the center to obtain the line OA . The line OA intersects L3 at point A. S4: Draw a straight line L4 through point A , perpendicular to the central axis X. The distance from point A to the central axis is b1 . Shift L4 a distance h1 towards the center of the circle to obtain a straight line L5 . L5 intersects the central axis at point K. Switch to S5.1, S6.1, or S7.1; S5.1: The central axis X is offset by a distance g 3 / 2 in the Y direction of the boundary line to obtain line segment JH . JH intersects L4 at point H and JH intersects L5 at point J. S5.2: The straight line JH is offset by a distance b2 in the direction of the boundary straight line Y to obtain the line segment DE . DE intersects L5 at point D. The length of DJ is b2 , the length of DE is g4 , and the direction from point D to point E points towards the side of the straight line L4 . S5.3: Draw a line segment EF perpendicular to DE through point E , with a length of g 5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F , with a length of g 4. The direction from point F to point G points towards the center of the circle. S5.4: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB . The line OB intersects L3 and point B. A line BC parallel to the boundary line Y is drawn through point B. A line perpendicular to BC is drawn through point G , with the foot of the perpendicular at point C. S5.5: The polygon BCGFEDJHA forms a hole. After mirroring this hole about the central axis, two holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets inside the holes are of the same size, and the sharp corners of each hole are rounded. Proceed to step S8; S6.1: The central axis X intersects line L4 and line L5 at points M and K ; S6.2: The central axis X is offset by a distance b 3 / 2 in the direction of the boundary line Y to obtain line segment QR . QR intersects L4 at point R and QR intersects L5 at point Q. S6.3: QR is offset by a distance g3 in the Y direction of the boundary line to obtain line segment PN . PN intersects L4 at point N and L5 at point P. S6.4: PN is offset by a distance b3 in the Y direction of the boundary line to obtain line segment DE . DE intersects L5 at point D. The length of DJ is b2 , and the length of DE is g4 . The direction from point D to point E points towards one side of line L4 . S6.5: Draw a line segment EF perpendicular to DE through point E , with a length of g 5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F , with a length of g 4. The direction from point F to point G points towards the center of the circle. S6.6: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB . The line OB intersects L3 and point B. A line BC parallel to the boundary line Y is drawn through point B. A line perpendicular to BC is drawn through point G , with the foot of the perpendicular at point C. S6.7: Polygon BCGEDPNA forms one hole, and quadrilateral RQKM forms another hole. After mirroring the above two holes about the central axis, three holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets in the holes are of the same specifications, and the sharp corners of each hole are rounded. Proceed to step S8; S7.1: The central axis X intersects lines L4 and L5 at points M and K , respectively ; S7.2: The straight line KM is offset by a distance g 3 /2 in the Y direction of the boundary line to obtain the line segment JH . JH intersects L4 at point H and JH intersects L5 at point J. S7.3: The straight line JH is offset by a distance b4 in the direction of the boundary straight line Y to obtain the line segment QR . QR intersects L4 at point R and QR intersects L5 at point Q. S7.4: The straight line QR is offset by a distance g3 in the direction of the boundary straight line Y to obtain the line segment PN . PN intersects L4 at point N and L5 at point P. S7.5: PN is offset by a distance b4 in the Y direction of the boundary line to obtain line segment DE . DE intersects L5 at point D. The length of DJ is b2 , and the length of DE is g4 . The direction from point D to point E points towards one side of line L4 . S7.6: Draw a line segment EF perpendicular to DE through point E , with a length of g 5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicular to EF through point F , with a length of g 4. The direction from point F to point G points towards the center of the circle. S7.7: The boundary line Y is rotated by an angle a2 in the direction of the central axis X with O as the center to obtain the line OB . The line OB intersects L3 and B. A line BC parallel to the boundary line Y is drawn through point B. A line perpendicular to BC is drawn through point G , with the foot of the perpendicular at point C. S7.8: Polygon BCGEDPNA forms one hole, and quadrilateral RQJH forms another hole. After mirroring the above two holes about the central axis, four holes are formed for inserting permanent magnets with rectangular cross sections. The permanent magnets in the holes are of the same size, and the sharp corners of each hole are rounded. S8: The hole structure under other residual poles is replicated by a circular array.
  2. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1 is characterized in that: straight line L5 is offset by a distance h2 towards the center to obtain straight line L6 ; the inner arc line L8 of the rotor is offset by a distance h3 away from the center to obtain arc line L7 ; a straight line L9 is drawn through point K , and the angle between L9 and the central axis X is α3 , where α3 is 40 to 50 degrees; the boundary straight line Y is offset by a distance h4 towards the central axis X to obtain straight line L10 ; the aforementioned straight line L6 ... Arc L 7 Line L9 A hole is formed by straight line L10 and the central axis X. A larger hole is created by mirroring this hole about the central axis X , where L6 ... The fillet between L10 and L9 is r1 , and L10 is rounded . The fillet between L7 and L9 is rounded by r2 . The corner r3 between L10 and L10 is rounded, and the above hole structure is replicated for other residual electrodes through a circular array.
  3. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1 is characterized in that, in S1, the number of pole pairs p is one of the following: 2, 3, 4 ; and in S1, the radius R1 ranges from 25 mm to 220 mm.
  4. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1 is characterized in that, in S2, the value range of g2 is from g1 to 2× g1 ; and in S3 , the value range of a1 is from 0.64×180/ p degree to 0.8×180/ p degree.
  5. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1 is characterized in that , in S4, the value of h1 ranges from 3 × g1 to 5 × g1 ; and in S5.1, S6.3 and S7.2, the value of g3 ranges from 0 or 0.5 mm to 2 mm.
  6. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1 is characterized in that, in S5.2, the value range of b2 is 0.85 × b1 to 0.91 × b1 ; in S5.2, S6.4 and S7.5, the value range of g4 is 0.4 mm to 2 mm; and in S5.3, S6.5 and S7.6, the value range of g5 is 0.7 mm to 2 mm.
  7. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1 is characterized in that, in S5.4, S6.6 and S7.7, the value range of a2 is from 0.024×180/ p degree to 0.026×180/ p degree.
  8. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1 is characterized in that, in S6.2, the value range of b3 is 0.56 × b1 to 0.61 × b1 ; and in S7.3, the value range of b4 is 0.42 × b1 to 0.46 × b1 .
  9. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 2 is characterized in that the value range of h2 is 0.15 × R1 /p to 0.4 × R1 /p, the value range of h3 is 0.15 × R1 / p to 0.5 × R1 / p , the value range of h4 is 0.05 × R1 / p to 0.5 × R1 /p, the value range of r1 is 0.04 × R1 /p to 0.4 × R1 / p , the value range of r2 is 0.04 × R1 / p to 0.2 × R1 / p, and the value range of r3 is 0.04 × R1 /p to 0.2 × R1 / p .
  10. The rotor lamination of the high-efficiency permanent magnet synchronous motor according to claim 1 is characterized in that the cavity where the permanent magnet slot is located is filled with insulating material to reduce the maximum stress on the rotor.

Description

Rotor laminations of a high-efficiency permanent magnet synchronous motor Technical Field This invention relates to the field of permanent magnet synchronous motor technology, and more specifically to a rotor lamination for a high-efficiency permanent magnet synchronous motor. Background Technology Variable frequency speed control permanent magnet synchronous motors have the advantage of high efficiency, but if the amount of permanent magnets used is too large, it will lead to excessive excitation, resulting in excessive stator magnetic flux density and increased stator iron loss. As a result, the motor cannot achieve higher efficiency by increasing the armature diameter and length. The rotor of the variable frequency speed control permanent magnet synchronous motor adopts a permanent magnet insertion structure, which reduces the difficulty of manufacturing permanent magnet rotors and facilitates automated mass production. However, the pole area of traditional V-type, double V-type, and inverted A-type permanent magnet insertion topologies is too large, which leads to excessive centrifugal stress in the magnetic bridge part. The large amount of permanent magnets used in the rotor leads to large iron loss in the stator, thereby reducing motor efficiency. Invention patent CN112653274 B, "Rotor Laminations and Permanent Magnet Motor Rotor," employs a double-V structure. The excessively large area of the silicon steel portion outside the permanent magnet leads to excessive centrifugal stress in the magnetic bridge section. CN109742879 B, "A Permanent Magnet Motor Rotor Structure," uses multiple arc segments or multiple arc segments and multiple line segments connected symmetrically along the circumference of the rotor core, forming an uneven air gap. Although this reduces stray losses in the permanent magnet motor, it increases the air gap, thereby reducing torque. Therefore, in order to further improve the efficiency of permanent magnet motors, it is necessary to provide a rotor lamination suitable for high-efficiency permanent magnet synchronous motors. The equal air gap, straight-line rotor permanent magnet topology designed in this invention reduces pole area, rotor magnetic bridge stress, stator iron loss, no-load cogging torque, and load torque fluctuation, thus realizing the rotor lamination design for a series of high-efficiency permanent magnet motors. Summary of the Invention The purpose of this invention is to address the shortcomings of the prior art by providing a rotor lamination for a high-efficiency permanent magnet synchronous motor, thereby solving the problem of rapid and serialized design and optimization of rotor laminations for high-efficiency permanent magnet synchronous motors. To achieve the above objectives, the technical solution adopted by the present invention is as follows: This invention provides a rotor lamination for a high-efficiency permanent magnet synchronous motor, which is designed and manufactured through the following steps: S1: Based on symmetry, one pole of the motor rotor lamination is designed as a sector, with an unfolding angle of 180/ p degrees, where p is the number of pole pairs. The rotor structure under one pole is symmetrical about the central axis X of the sector. The straight line of the left boundary of the sector is Y. The part of the inner circle of the motor stator corresponding to this one pole is an arc L1 , with the center of the circle being the center of the motor shaft O. The radius of the arc L1 is R1 . The arc L1 is offset towards the center by the air gap length g1 to obtain the outer circle boundary arc L2 of the motor rotor . The radius of L2 is R2 , where R2 = R1 - g1 . S2: The arc L2 is offset by a distance g2 towards the center of the circle to obtain the arc L3 , whose radius is R3 , R3 = R2 - g2 ; S3: The central axis X is rotated by an angle a 1/2 in the direction of the boundary line Y with O as the center to obtain the line OA . The line OA intersects L3 at point A. S4: Draw a straight line L4 through point A , perpendicular to the central axis X. The distance from point A to the central axis is b1 . Shift L4 a distance h1 towards the center of the circle to obtain a straight line L5 . L5 intersects the central axis at point K. Switch to S5.1, S6.1, or S7.1; S5.1: The central axis X is offset by a distance g 3 / 2 in the direction of the boundary line Y to obtain line segment JH . JH intersects L4 at point H and JH intersects L5 at point J. S5.2: The straight line JH is offset by a distance b2 in the direction of the boundary straight line Y to obtain the line segment DE . DE intersects L5 at point D. The length of DJ is b2 , the length of DE is g4 , and the direction from point D to point E points towards the side of the straight line L4 . S5.3: Draw a line segment EF perpendicular to DE through point E , with a length of g 5. The direction from point E to point F points towards the boundary line Y. Draw a line segment FG perpendicul