WO2021203909A1 - 电动工具、电机及其转子 - Google Patents

电动工具、电机及其转子 Download PDF

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Publication number
WO2021203909A1
WO2021203909A1 PCT/CN2021/080437 CN2021080437W WO2021203909A1 WO 2021203909 A1 WO2021203909 A1 WO 2021203909A1 CN 2021080437 W CN2021080437 W CN 2021080437W WO 2021203909 A1 WO2021203909 A1 WO 2021203909A1
Authority
WO
WIPO (PCT)
Prior art keywords
rotor
housing
bottom wall
cooling fan
rotating shaft
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2021/080437
Other languages
English (en)
French (fr)
Inventor
马全同
周明伟
马德里阿伦
赵安平
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson Electric Guangdong Co Ltd
Original Assignee
Johnson Electric Guangdong Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Electric Guangdong Co Ltd filed Critical Johnson Electric Guangdong Co Ltd
Priority to EP21785560.0A priority Critical patent/EP4135162A4/en
Publication of WO2021203909A1 publication Critical patent/WO2021203909A1/zh
Priority to US17/959,270 priority patent/US12424890B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2786—Outer rotors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • 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
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/003—Couplings; Details of shafts
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
    • H02K9/04—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
    • H02K9/06—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
    • 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
    • H02K1/2786—Outer rotors
    • H02K1/2787—Outer rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/2789—Outer rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/279—Magnets embedded in the magnetic core
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • 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
    • H02K21/22—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating around the armatures, e.g. flywheel magnetos
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/08—Arrangements for cooling or ventilating by gaseous cooling medium circulating wholly within the machine casing

Definitions

  • the present invention relates to the field of electric technology, in particular to a rotor, a motor with the rotor and an electric tool with the motor.
  • the outer rotor motor includes a rotor and a stator arranged in the rotor.
  • the stator includes an iron core and windings wound on the iron core.
  • the rotor usually includes a housing, a yoke mounted on the housing, a permanent magnet mounted on the yoke, and a rotating shaft connected to the housing.
  • the stator winding will generate a lot of heat. If this heat is not discharged in time, it will affect the service life and performance of the motor.
  • cooling fans or cooling fan blades are usually installed at the axial end of the housing, and vents are opened at the same time to help dissipate heat.
  • this design inevitably increases the assembly process and materials of the motor. Cost, and the cooling effect is not good.
  • the present invention aims to provide a rotor that can solve or at least alleviate the above-mentioned problems, a motor with the rotor, and an electric tool with the motor.
  • the present invention provides a rotor including a housing, a rotating shaft fixed on the housing, a magnetic yoke accommodated in the housing, and a permanent magnet installed on the magnetic yoke.
  • the housing includes a bottom wall and a side wall extending from the outer periphery of the bottom wall in the axial direction of the rotor.
  • the rotor further includes a cooling fan located at the axial end of the side wall away from the bottom wall, The rotating shaft, the yoke, the permanent magnet, the cooling fan (13) and the housing (12) are formed into a non-detachable whole by overmolding.
  • the bottom wall of the casing is formed with an airflow inlet, and the airflow enters the casing of the rotor through the airflow inlet and is discharged from the radial outside of the cooling fan.
  • the cooling fan includes a first connecting ring and a second connecting ring that are spaced apart along the axial direction, and a plurality of fan blades connected between the first connecting ring and the second connecting ring, adjacent to each other.
  • the fan blades are spaced to form air outlets.
  • the first connecting ring is located at the axial end of the housing of the rotor, and is formed by an axial end surface of the side wall of the housing.
  • the extending direction of the fan blade is inclined with respect to the radial direction of the housing.
  • the bottom wall includes a plurality of radial connecting sections arranged in a radial direction, and the air flow inlets are formed at intervals between adjacent radial connecting sections.
  • the bottom wall further includes a spacer ring, which is coaxial with the side wall and arranged in the bottom wall, and is connected to the radial middle section of the connecting section, thereby connecting The air flow inlets are spaced in a plurality in the radial direction.
  • the rotating shaft includes a shaft portion and a connecting portion integrally extending radially outward from the shaft portion, and the connecting portion and the housing are integrally connected by overmolding.
  • the connecting portion of the rotating shaft is provided with a plurality of ribs extending in the radial direction toward the shaft portion, and the ribs are at least partially covered and fixed in the bottom wall of the housing .
  • the rotating shaft is made of carbon structural steel through a cold forging process.
  • the present invention also provides a motor including a stator and the above-mentioned rotor, the stator is arranged in the rotor, and the rotor can rotate relative to the stator.
  • the winding of the stator is located between the bottom wall of the housing and the cooling fan in the axial direction.
  • the present invention also provides an electric tool including the above-mentioned motor.
  • the rotor provided by the embodiment of the present invention has a simple structure, is easy to produce and has a good cooling effect, reduces the number of components of the rotor assembly, is convenient to assemble, and effectively reduces the manufacturing cost.
  • Fig. 1 shows a three-dimensional assembly diagram of a motor according to an embodiment of the present invention.
  • Fig. 2 shows a perspective exploded view of the motor shown in Fig. 1.
  • Fig. 3 shows a perspective view of the rotor of the motor shown in Fig. 1.
  • Fig. 4a shows a perspective view of the rotor shown in Fig. 3 from another angle.
  • Fig. 4b shows an axial sectional view of the rotor shown in Fig. 4a, in which the shaft, yoke and permanent magnets are omitted.
  • Fig. 5 shows a perspective cross-sectional view of the rotor shown in Fig. 3 when a stator is assembled.
  • Fig. 6 shows a schematic diagram of an electric tool according to an embodiment of the present invention.
  • Fig. 1 shows a three-dimensional assembly diagram of a motor 100 according to an embodiment of the present invention.
  • the motor 100 includes a rotor 1 and a stator 2 housed in the rotor 1.
  • the stator 2 is fixedly arranged, and the rotor 1 can rotate relative to the stator 2.
  • the motor 100 is a brushless DC motor.
  • the rotor 1 includes a housing 12, a rotating shaft 11 fixedly connected to the housing 12, a yoke 14 housed in the housing 12, and a permanent magnet 15 mounted on the yoke 14.
  • the stator 2 includes a bracket 25, a stator core 21 and a terminal block 23 fixed to the bracket 25, and a winding 22 wound on the stator core 21.
  • the bracket 25 is used to fix the motor 100 in a suitable part or position.
  • the stator core 21 and the terminal block 23 are relatively fixed to each other.
  • the rotating shaft 11 of the rotor 1 is rotatably supported in the bracket 25 of the stator 2 through a bearing 24 so that the rotor 1 can rotate relative to the stator 2. Referring to FIGS.
  • the rotor 1 further includes a cooling fan 13 arranged on the housing 12.
  • the rotor 1 is integrally formed by overmolding.
  • the housing 12 and the cooling fan 13 of the rotor 1 are molded by plastic injection molding.
  • the rotating shaft 11, the yoke 14, and the permanent magnet 15 are overmolded with the housing 12 and the cooling fan 13
  • One-piece molding constitutes a non-detachable whole.
  • the cooling fan 13 may be attached to the housing 12.
  • the housing 12 is substantially in the shape of a hollow column with an open end.
  • the housing 12 includes a bottom wall 121 and a side wall 120 extending from the outer periphery of the bottom wall 121 in the axial direction.
  • the yoke 14 and the permanent magnet 15 are embedded in the side wall 120 by overmolding.
  • the cooling fan 13 has a ring shape and is arranged at the axial end of the side wall 120 away from the bottom wall 121.
  • the cooling fan 13 includes a first connecting ring 133 and a second connecting ring 134 arranged at intervals along the axial direction, and a number of fan blades 130 connected between the two connecting rings 133 and 134.
  • the first connecting ring 133 is located at the axial end of the side wall 120 of the housing 12 of the rotor 1, and it may be formed by the axial end surface of the side wall 120.
  • the second connecting ring 134 and the first connecting ring 133 are parallel and spaced apart.
  • the fan blades 130 are evenly arranged between the two connecting rings 133 and 134 along the circumferential direction, and the adjacent fan blades 130 are spaced apart to form air flow channels (or air flow outlets 132).
  • the two axial ends of the fan blade 130 are connected to the two connecting rings 133 and 134 respectively.
  • Each fan blade 130 extends from the outer periphery of the first connecting ring 133 and the second connecting ring 134 toward the inner periphery, but in this embodiment, the extending direction of the fan blade 130 is inclined relative to the radial direction of the housing 12, and all the The inclination directions of the leaves 130 are approximately the same.
  • the outer diameter of the cooling fan 13 is greater than the outer diameter of the housing 12, that is, the outer diameters of the first connecting ring 133 and the second connecting ring 134 are greater than the outer diameter of the housing 12.
  • the inner diameter of the cooling fan 13 is substantially equal to the inner diameter of the casing 12.
  • the bottom wall 121 of the housing 12 includes a plurality of radial connecting sections 123 extending in the radial direction.
  • the radial connecting section 123 is connected to the side wall 120.
  • the plurality of radial connecting sections 123 are arranged at intervals in the circumferential direction, and the adjacent radial connecting sections 123 are spaced apart to form air flow inlets 131.
  • the bottom wall 121 further includes a spacer ring 191, which is arranged coaxially with the side wall 120 in the bottom wall 121, and is connected to the radial middle section of all the connecting sections 123, thereby reducing the air flow
  • the inlets 131 are spaced in plural in the radial direction.
  • the cooling fan 13 on the housing 12 at least partially exceeds the winding 22 of the stator 2 in the axial direction, so that the winding 22 is located at the bottom of the housing 12 in the axial direction.
  • the air inlet 131 of the housing 12 is arranged corresponding to the winding 22.
  • the winding 22 is arranged between the air inlet 131 and the air outlet 132 of the cooling fan 13 so that the winding 22 is completely placed in the cooling area. As shown in Fig.
  • the rotating shaft 11 is a one-piece structure and includes a shaft portion 111 and a connecting portion 112 integrally extending outward in the radial direction from one end portion of the shaft portion 111.
  • the rotating shaft 11 is integrally fixed in the housing 12 through the connecting portion 112.
  • the connecting portion 112 is at least partially covered at the center of the bottom wall 121 of the housing 12.
  • the center of the bottom wall 121 has a supporting portion 192 for supporting the connecting portion 112 of the rotating shaft 11, so that the rotating shaft 11 is overmolded at the bottom wall 121 of the housing 12.
  • the support portion 192 has a through opening 193 in the center, and the outer surface of the connecting portion 112 of the rotating shaft 11 is exposed through the through opening 193.
  • a plurality of protruding ribs 113 are provided on the inner surface of the connecting portion 112 of the rotating shaft 11 to further strengthen the connection and fixing of the rotating shaft 11 in the housing 12.
  • the rib 113 is at least partially wrapped in the bottom wall 121 to prevent the rotation shaft 11 from rotating relative to the housing 12.
  • the ribs 113 are radially arranged on the connecting portion 112 and extend radially inward to the outer circumference of the shaft portion 111.
  • between the rib 113 and the shaft portion 111 is provided with a circumferentially arranged fixing reinforcement portion 114 to strengthen the rib 113 and the shaft portion 111 and the connection therebetween.
  • the fixing reinforcement 114 is wrapped in the bottom wall 121.
  • the fixing reinforcement portion 114 may protrude from the bottom wall 121.
  • the outer diameter of the fixing reinforcement portion 114 on the connecting portion 112 is slightly larger than the outer diameter of the shaft portion 111, which enhances the bending and torsion resistance of the rotating shaft 11.
  • the bottom wall 121 is further provided with a plurality of notches 125 between the ribs 113 to reduce the quality of the housing 12 without affecting the stability of the rotating shaft 11 on the bottom wall 121.
  • the shaft portion 111 is provided with an axial groove 115 on the outer periphery of the other end portion, and an axial hole 116 is opened at the center of the other end portion.
  • the axial groove 115 and the axial hole 116 are used to meet the required Loads such as tools are connected to drive the load rotation of the required tools.
  • the rotating shaft 11 is made of 45 steel (carbon structural steel, SWRCH45K) through a cold forging process
  • the diameter of the shaft portion 111 is 25 mm
  • the connecting portion 112 is preferably circular with a diameter of 60 mm.
  • the rotating shaft 11 is formed integrally with the shaft portion 111 and the connecting portion 112 through a cold forging process, thereby saving cost and simplifying the assembly of the rotating shaft 11.
  • the yoke 14 is integrally embedded and housed in the side wall 120 of the housing 12.
  • Figure 2 shows the yoke 14 and the housing 12 in an exploded state, but in fact, since the housing 12 is overmolded outside the yoke 14, both Form an inseparable whole.
  • the yoke 14 has a hollow cylindrical shape.
  • the side wall 120 of the housing 12 is provided with an annular groove 122 surrounding the stator core 21 at a position corresponding to the stator core 21 of the stator 2.
  • the annular groove 122 is arranged below the cooling fan 13.
  • the yoke 14 is received in the annular groove 122 of the housing 12.
  • the outer side of the side wall 120 of the housing 12 is provided with a protrusion 126 extending radially outward and corresponding to the annular groove 122.
  • the design of the boss 126 is for the passage of fluid plastic during the injection molding process.
  • a positioning groove 127 is formed between two adjacent protrusions 126.
  • a through hole 128 is opened at the bottom of the positioning groove 127, and the through hole 128 is in communication with the annular groove 122.
  • the positioning groove 127 and the through hole 128 are used to position an applicable support body during the injection molding process, so as to support and position the yoke 14 during the overmolding process.
  • the yoke 14 includes a main body portion 141 and a plurality of magnetic pole portions 147 connected to the main body portion 141, and the plurality of magnetic pole portions 147 are distributed at intervals in the circumferential direction and located inside the main body portion 141.
  • the inner side of the main body portion 141 includes a plurality of V-shaped grooves, and each magnetic pole portion 147 is connected to the main body portion 141 in a corresponding V-shaped groove.
  • each magnetic pole portion 147 is substantially triangular.
  • a first mounting groove 142 and a second mounting groove 144 are formed at intervals between each magnetic pole portion 147 and its corresponding side surface of the V-shaped groove.
  • the first installation groove 142 and the second installation groove 144 are arranged in a V shape.
  • the permanent magnets 15 of the same polarity are accommodated in the first installation groove 142 and the second installation groove 144, so that after the permanent magnet 15 is embedded in the first installation groove 142 and the second installation groove 144, between the two installation grooves 142, 144
  • the magnetic pole surface 148 is magnetized into a magnetic pole.
  • the magnetic poles arranged in this way can significantly improve the magnetization effect, thereby increasing the power density of the motor 100.
  • the permanent magnet 15 is rectangular.
  • An opening 143 is formed between two adjacent magnetic pole portions 147 at intervals. As a result, a larger magnetic resistance can be generated, thereby reducing magnetic flux leakage.
  • the body portion 141 of the yoke 14 is positioned in the housing 12 through the opening 143.
  • the housing 12 and the yoke 14 form a first pillar 124 that is engaged with the opening 143 on the inner side of the annular groove 122 at a position corresponding to the opening 143, so that the body portion 141 is arranged in the circumferential and radial directions. fixed.
  • the annular groove 122 is also formed with a second pillar 129 that can be engaged in the first installation groove 142 and the second installation groove 144 to enhance the connection between the housing 12 and the yoke 14 Connection strength.
  • the second pillar 129 is integrally formed by injection molding, and fixes the permanent magnet 15 in the first installation groove 142 and the second installation groove 144 without a gap.
  • an annular connector 16 is connected to the top end of the yoke 14.
  • the annular connecting member 16 can be fixedly connected with the yoke 14 in a snap-fit manner, and then the yoke 14 is fixed in the axial direction.
  • an inner protrusion 145 may be provided at the top of each magnetic pole portion 147
  • an outer protrusion 146 may be provided at the top of the body portion 141 between adjacent magnetic pole portions 147.
  • the annular connector 16 is provided with inner and outer through holes 161, 162 for the inner and outer protrusions 145, 146 to pass through, and the yoke 14 and the magnetic yoke 14 The connection of the ring connector 16.
  • the annular connector 16 is provided with a perforation 164.
  • the first connecting ring 133 of the cooling fan 13 is formed with a boss that is inserted into the perforation 164 on the side facing the housing 12 163, so as to realize the connection between the housing 12 and the annular connecting member 16, and further realize the fixed connection between the housing 12 and the magnetic yoke 14.
  • the annular connecting member 16 is also provided with a notch 165 corresponding to the opening 143 between the adjacent magnetic pole portions 147.
  • the rotor 1 of the present invention is formed by overmolding.
  • the integral rotating shaft 11 having the shaft portion 111 and the connecting portion 112, the yoke 14 and the permanent magnet 15 are connected at the same time As a whole, the manufacture of the rotor 1 is easier and the cost is lower.
  • Fig. 6 shows a power tool 300 having a motor 100 of the present invention.
  • the power tool may be, for example, a lawn mower.
  • the motor 100 is used for mowing and driving the lawn mower of the lawn mower.
  • the motor 100 of the present invention can also be used in other electric tools.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Cooling System (AREA)

Abstract

一种电动工具、电机及其转子，该转子（1）包括壳体（12）、固定在该壳体（12）上的转轴（11）、收容于该壳体（12）内的磁轭（14）、以及装设于该磁轭（14）上的永磁体（15），该壳体（12）包括底壁（121）和自该底壁（121）的外周沿转子（1）的轴向延伸的侧壁（120），该转子（1）还包括冷却扇（13），该冷却扇（13）位于该侧壁（120）远离该底壁（121）的轴向末端，该转轴（11）、该磁轭（14）、该永磁体（15）、该冷却扇（13）与该壳体（12）通过包覆成型的方式形成为一个不可拆卸的整体。

Description

电动工具、电机及其转子 技术领域
本发明涉及电动技术领域，尤其涉及一种转子、具有该转子的电机以及具有该电机的电动工具。
 背景技术
外转子电机包括转子和布置在转子内的定子。定子包括铁芯和绕制在铁芯上的绕组。转子通常包括壳体、安装在壳体上的磁轭、装设在磁轭上的永磁体，以及连接于壳体的转轴。电机运行时，定子的绕组会产生大量的热量，如果这些热量未能及时排放出去，将影响电机的使用寿命和性能。为此，现有技术通常在壳体的轴向端部装配冷却风扇或者设置冷却扇叶，并同时开设通风口，以此帮助散热，但这种设计不可避免地增加了电机的组装工序和材料成本，而且冷却效果不佳。
 技术问题
有鉴于此，本发明旨在提供一种可以解决或至少减轻上述问题的转子、具有该转子的电机，以及具有该电机的电动工具。
 技术解决方案
为此，本发明提供了一种转子，包括壳体、固定在所述壳体上的转轴、收容于所述壳体内的磁轭，以及装设于所述磁轭上的永磁体，所述壳体包括底壁和自所述底壁的外周沿转子的轴向延伸的侧壁，所述转子还包括冷却扇，所述冷却扇位于所述侧壁远离所述底壁的轴向末端，所述转轴、所述磁轭、所述永磁体、所述冷却扇（13）与所述壳体（12）通过包覆成型的方式形成为一个不可拆卸的整体。
在一些实施例中，所述壳体的底壁形成有气流入口，气流由所述气流入口进入所述转子的所述壳体后由所述冷却扇的径向外侧排出。
在一些实施例中，所述冷却扇包括沿轴向间隔设置的第一连接环和第二连接环，以及连接在所述第一连接环和第二连接环之间的若干扇叶，相邻的扇叶之间间隔形成气流出口。
在一些实施例中，所述第一连接环位于所述转子的所述壳体的所述轴向末端，由所述壳体的所述侧壁的轴向端面形成。
在一些实施例中，所述扇叶的延伸方向相对所述壳体的径向倾斜。
在一些实施例中，所述底壁包括多个沿径向布置的径向连接段，相邻的径向连接段之间间隔形成所述气流入口。
在一些实施例中，所述底壁还包括一间隔环，所述间隔环与所述侧壁同轴并布置在所述底壁内，并与所述连接段的径向中段连接，从而将所述气流入口在径向方向上间隔成多个。
在一些实施例中，所述转轴包括轴部和自所述轴部沿径向向外一体延伸的连接部，所述连接部与所述壳体通过包覆成型连接为一体。
在一些实施例中，所述转轴的连接部上设有多个朝向所述轴部沿径向延伸的肋条，所述肋条至少被部分地包覆固定在所述壳体的所述底壁中。
在一些实施例中，所述转轴采用碳素结构钢通过冷锻工艺加工而成。
本发明还提供了一种电机，包括定子和上述转子，所述定子布置在所述转子内，所述转子能够相对所述定子转动。
在一些实施例中，所述定子的绕组在轴向上位于所述壳体的底壁和所述冷却扇之间。
本发明还提供了一种包括上述电机的电动工具。
 有益效果
本发明实施例提供的转子，结构简单、易于生产且冷却效果良好，并且减少了转子组件的元件数量、装配方便，有效地降低了制造成本。
 附图说明
图1示出了本发明一实施例的电机的立体组合图。
图2示出了图1所示的电机的立体分解图。
图3示出了图1所示的电机的转子的立体图。
图4a示出了图3所示的转子的另一角度的立体图。
图4b示出了图4a所示的转子的轴向剖面图，其中省略了转轴、磁轭和永磁体。
图5示出了图3所示转子组装有定子时的立体剖面图。
图6示出了本发明一实施例的电动工具的示意图。
附图标记：100-电机；1-转子；11-转轴；111-轴部；112-连接部；113-肋条；114-固定加强部；115-轴向槽；116-轴向孔；12-壳体；120-侧壁；121-底壁；122-环形槽；123-径向连接段；124-第一支柱；125-凹口；126-凸柱；127-定位槽；128-通孔；129-第二支柱；191-间隔环；192-支撑部；193-通口；13-冷却扇；130-扇叶；131-气流入进口；132-气流出口；133-第一连接环；134-第二连接环；14-磁轭；141-本体部；142-第一安装槽；143-开口；144-第二安装槽；145-内凸起；146-外凸起；147-磁极部；148-磁极面；15-永磁体；16-环形连接件；161-内贯穿孔；162-外贯穿孔；163-凸台；164-穿孔；165-缺口；2-定子；21-定子铁芯；22-绕组；23-接线座；24-轴承；25-支架；300-电动工具。
 本发明的实施方式
以下将结合附图以及具体实施方式对本发明进行详细说明，以使得本发明的技术方案及其有益效果更为清晰明了。可以理解，附图仅提供参考与说明用，并非用来对本发明加以限制，附图中显示的尺寸仅仅是为了便于清晰描述，而并不限定比例关系。
图1示出了本发明一实施例的电机100的立体组合图。电机100包括转子1以及收容于转子1内的定子2。定子2固定设置，转子1能够相对定子2旋转。在本实施例中，电机100为无刷直流电机。
同时参考图2，转子1包括壳体12、与壳体12固定连接的转轴11、收容于壳体12内的磁轭14，以及装设于磁轭14上的永磁体15。定子2包括支架25、固定在支架25的定子铁芯21和接线座23，以及绕制于定子铁芯21上的绕组22。支架25用于将电机100固定在适合的部件或位置。定子铁芯21与接线座23彼此相对固定。转子1的转轴11通过轴承24可旋转地支撑在定子2的支架25内，使得转子1能够相对定子2旋转。同时参考图3至图5，转子1还包括设置在壳体12上的冷却扇13。转子1通过包覆成型的方式一体形成。具体地，转子1的壳体12和冷却扇13由塑料注塑成型，同时，在注塑过程中，将转轴11、磁轭14、永磁体15通过包覆成型的方式与壳体12和冷却扇13一体成型构成不可拆卸的整体。在可选的实施例中，冷却扇13可附接到壳体12上。壳体12大致呈一端开口的中空柱状。本实施例中，壳体12包括底壁121和自底壁121的外周沿轴向延伸的侧壁120。磁轭14和永磁体15通过包覆成型的方式嵌设于侧壁120内。冷却扇13呈环形，设置在侧壁120远离底壁121的轴向末端。
冷却扇13包括沿轴向间隔设置的第一连接环133和第二连接环134，以及连接在两连接环133、134之间的若干扇叶130。其中第一连接环133位于转子1的壳体12的侧壁120的轴向末端，其可以由侧壁120的轴向端面形成。第二连接环134与第一连接环133平行且间隔设置。扇叶130沿周向均匀地布置在两连接环133、134之间，相邻的扇叶130之间间隔形成气流通道（或气流出口132）。扇叶130的轴向两端分别与两连接环133、134连接。每一扇叶130从第一连接环133和第二连接环134的外周缘朝向内周缘延伸，但在本实施例中，扇叶130的延伸方向相对壳体12的径向倾斜，且所有扇叶130的倾斜方向大致一致。
本实施例中，冷却扇13的外径大于壳体12的外径，即，第一连接环133和第二连接环134的外径大于壳体12的外径。冷却扇13的内径与壳体12的内径基本相等。
壳体12的底壁121包括多个沿径向延伸的径向连接段123。径向连接段123与侧壁120连接。所述多个径向连接段123沿周向间隔布置，相邻的径向连接段123之间间隔形成气流入口131。在本实施例中，底壁121还包括一间隔环191，所述间隔环191与侧壁120同轴地布置在底壁121内，并与所有连接段123的径向中段连接，从而将气流入口131在径向方向上间隔成多个。在定子2组装于转子1的壳体12中时，壳体12上的冷却扇13在其轴向上至少部分地超过定子2的绕组22，使得绕组22在轴向上位于壳体12的底壁121和冷却扇13之间。壳体12的气流入口131对应绕组22设置。所述绕组22被设置在气流入口131和冷却扇13的气流出口132之间，使得绕组22完全置于冷却区域内。如图5所示，转子1在运转时，气流在冷却扇13的作用下，从气流入口131流入壳体12并经过通电的绕组22，然后从气流出口132流出，从而对绕组22进行更好且全面地冷却。
转轴11为一件式构造，包括轴部111和自轴部111的一端部沿径向一体向外延伸的连接部112。转轴11通过连接部112一体地固定在壳体12中。连接部112被至少部分地包覆在壳体12的底壁121的中心处。具体地，底壁121的中心具有用于支撑转轴11的连接部112的支撑部192，从而使得转轴11包覆成型于壳体12的底壁121处。本实施例中，支撑部192的中央具有一通口193，转轴11的连接部112的外表面经由该通口193暴露。优选地，在转轴11的连接部112的内表面上设有多个凸出的肋条113，以进一步加固转轴11在壳体12中的连接与固定。肋条113被至少部分地包覆在底壁121中，以防止转轴11相对于壳体12的转动。优选地，肋条113呈放射状布置在连接部112上，并沿径向向内延伸至轴部111外周处。本实施例中，肋条113和轴部111之间设有一周向布置的固定加强部114，以加固肋条113和轴部111及其之间的连接。固定加强部114被包覆于底壁121中。可选地，固定加强部114可突出于底壁121。连接部112上的固定加强部114的外径略大于轴部111的外径，增强了转轴11的抗弯抗扭性能。在本实施例中，底壁121在肋条113之间还设有多个凹口125，以在不影响转轴11在底壁121上的稳固性的情况下减轻壳体12的质量。
轴部111在其另一端部处的外周设有一轴向槽115，并在所述另一端部的中心处开设一轴向孔116，轴向槽115和轴向孔116用于与所需的工具等负载连接以驱动所需的工具的负载旋转。优选地，转轴11采用45号钢（碳素结构钢，SWRCH45K）通过冷锻工艺加工而成，轴部111的直径为25mm，连接部112优选呈圆形，其直径为60mm。采用冷锻工艺加工转轴11避免了现有技术中所采用的粉末冶金零件加工工艺，从而节省成本和保证转轴11的强度。转轴11通过冷锻工艺将轴部111和连接部112一体成型，从而节省成本并简化了转轴11的组装。
本实施例中，磁轭14一体地嵌置收容在壳体12的侧壁120内。为了更清楚地显示磁轭14和壳体12的具体构造，图2呈现了磁轭14和壳体12的分解状态，但事实上，由于壳体12包覆成型在磁轭14外，两者形成不可分离的整体。具体地，如图中所示，磁轭14呈中空柱状。壳体12的侧壁120在对应定子2的定子铁芯21处设有环绕定子铁芯21的环形槽122。在本实施例中，环形槽122布置在冷却扇13的下方。磁轭14收容在壳体12的环形槽122中。壳体12的侧壁120的外侧设有径向向外延伸且对应该环形槽122的凸柱126。凸柱126的设计是在注塑过程中用于流体塑料的通过。相邻的两个凸柱126之间形成为定位槽127。在定位槽127的底部开设有通孔128，通孔128与环形槽122连通。定位槽127和通孔128的设置在注塑过程中用于定位可适用的支撑体，从而在包覆成型工艺中支撑并定位所述磁轭14。
磁轭14包括本体部141和若干与所述本体部141连接的磁极部147，所述若干磁极部147沿周向间隔分布并在本体部141的内侧。本体部141的内侧包括多个V形槽，每一磁极部147在一相应的V形槽中与本体部141形成连接。本实施例中，每一磁极部147大致呈三角形。每一磁极部147与其相应的V形槽相对的侧面之间间隔形成第一安装槽142和第二安装槽144。第一安装槽142和第二安装槽144呈V形排列。相同极性的永磁体15收容于第一安装槽142和第二安装槽144中，使得在第一安装槽142和第二安装槽144中嵌入永磁体15后，两安装槽142、144之间的磁极面148被磁化为一个磁极，如此设置的磁极，能显著提高聚磁效果，从而提高电机100的功率密度。在本实施例中，永磁体15呈长方形。相邻的两磁极部147之间间隔形成开口143。由此可产生较大的磁阻，进而减少漏磁。磁轭14的本体部141通过开口143定位在壳体12中。壳体12与磁轭14在包覆成型的过程中在环形槽122的内侧对应所述开口143的位置形成与该开口143接合的第一支柱124，从而将本体部141在周向与径向上固定。本实施例中，在包覆成型过程中，环形槽122中还形成有可接合在第一安装槽142和第二安装槽144中的第二支柱129，以增强壳体12与磁轭14的连接强度。第二支柱129通过注塑一体形成，将永磁体15无间隙地固定在第一安装槽142和第二安装槽144中。
优选地，磁轭14的顶端连接有一环形连接件16。环形连接件16可以采用卡接配合的方式与磁轭14固定连接，进而在轴向上固定磁轭14。例如，可在每一磁极部147的顶端设置一内凸起145，相邻的磁极部147之间的本体部141部分的顶端设置一外凸起146。在环形连接件16上设置供内、外凸起145、146穿过的内、外贯穿孔161、162，通过凸起145、146和贯穿孔161、162的卡接配合从而实现磁轭14和环形连接件16的连接。同时参考图2和图4b，环形连接件16上设置有穿孔164，在包覆成型过程中，冷却扇13的第一连接环133朝向壳体12的一侧形成有卡入穿孔164的凸台163，从而实现壳体12和环形连接件16的连接，进而实现固定连接壳体12与磁轭14。本实施例中，环形连接件16上还设有对应相邻磁极部147之间的开口143的缺口165。
本发明的转子1，通过包覆成型形成，在形成所述壳体12和冷却扇13时，同时将具有轴部111和连接部112的一体式的转轴11、磁轭14和永磁体15连接成一个整体，使得转子1的制造更简便、成本更低。
图6所示为具有本发明的电机100的电动工具300，该电动工具可以是例如割草机，该电机100用于割草机的割草设备的割草与驱动。本发明的电机100还可用于其他电动工具。
以上所述仅为本发明较佳的具体实施方式，本发明的保护范围不限于以上列举的实施例，任何熟悉本技术领域的技术人员在本发明披露的技术范围内，可显而易见地得到的技术方案的简单变化或等效替换均落入本发明的保护范围内。

Claims (13)

  1. 一种转子，包括壳体（12）、固定在所述壳体（12）上的转轴（11）、收容于所述壳体（12）内的磁轭（14），以及装设于所述磁轭（14）上的永磁体（15），所述壳体（12）包括底壁（121）和自所述底壁（121）的外周沿转子的轴向延伸的侧壁（120），其特征在于，所述转子还包括冷却扇（13），所述冷却扇（13）位于所述侧壁（120）远离所述底壁（121）的轴向末端，所述转轴（11）、所述磁轭（14）、所述永磁体（15）、所述冷却扇（13）与所述壳体（12）通过包覆成型的方式形成为一个不可拆卸的整体。
  2. 根据权利要求1所述的转子，其特征在于，所述壳体（12）的底壁（121）形成有气流入口（131），气流由所述气流入口（131）进入所述转子的所述壳体（12）后由所述冷却扇（13）的径向外侧排出。
  3. 根据权利要求2所述的转子，其特征在于，所述冷却扇（13）包括沿轴向间隔设置的第一连接环（133）和第二连接环（134），以及连接在所述第一连接环（133）和第二连接环（134）之间的若干扇叶（130），相邻的扇叶之间间隔形成气流出口（132）。
  4. 根据权利要求3所述的转子，其特征在于，所述第一连接环（133）位于所述转子的所述壳体（12）的所述轴向末端，由所述壳体（12）的所述侧壁（120）的轴向端面形成。
  5. 根据权利要求3所述的转子，其特征在于，所述扇叶（130）的延伸方向相对所述壳体（12）的径向倾斜。
  6. 根据权利要求2所述的转子，其特征在于，所述底壁（121）包括多个沿径向布置的径向连接段（123），相邻的径向连接段（123）之间间隔形成所述气流入口（131）。
  7. 根据权利要求6所述的转子，其特征在于，所述底壁（121）还包括一间隔环（191），所述间隔环（191）与所述侧壁（120）同轴并布置在所述底壁（121）内，并与所述连接段（123）的径向中段连接，从而将所述气流入口（131）在径向方向上间隔成多个。
  8. 根据权利要求1所述的转子，其特征在于，所述转轴（11）包括轴部（111）和自所述轴部（111）沿径向向外一体延伸的连接部（112），所述连接部（112）与所述壳体（12）通过包覆成型连接为一体。
  9. 根据权利要求8所述的转子，其特征在于，所述转轴（11）的连接部（112）上设有多个朝向所述轴部（111）沿径向延伸的肋条（113），所述肋条（113）至少被部分地包覆固定在所述壳体（12）的所述底壁（121）中。
  10. 根据权利要求8所述的转子，其特征在于，所述转轴（11）采用碳素结构钢通过冷锻工艺加工而成。
  11. 一种电机，其特征在于，包括定子（2）和根据权利要求1至10中任意一项所述的转子，所述定子（2）布置在所述转子内，所述转子能够相对所述定子转动。
  12. 根据权利要求11所述的电机，其特征在于，所述定子（2）的绕组（22）在轴向上位于所述壳体（12）的底壁（121）和所述冷却扇（13）之间。
  13. 一种电动工具，其特征在于，包括根据权利要求11所述的电机。
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