• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Disclosed is a disc rotor (10 ') for an axial flow electric machine comprising a plurality of magnet poles (12') disposed on the peripheral portion of said rotor around a shaft member (14 ') for to drive a shaft in rotation, the magnet poles being integrated in a composite material support (16 '), the rotor further comprising a cylindrical hoop (18') disposed in the peripheral portion of said rotor to surround the magnet poles (12 '), characterized in that the cylindrical collar (18') is arranged to exert a prestressing force on the underlying magnet poles (12 '), able to compress the magnet poles (12'). ') underlying the shaft element (14') via inserts (19 ') arranged radially between the magnet poles (12') and the shaft element (14 '). ').
    公开号:FR3027468A1
    申请号:FR1460123
    申请日:2014-10-21
    公开日:2016-04-22
    发明作者:Stephane Decaux；Emmanuel Motte
    申请人:Renault SAS；
    IPC主号:
    专利说明:

    [0001] The invention relates to a disc rotor with a reinforced composite structure for an axial flow rotating electrical machine, in particular for an axial flow motor. The invention may especially find an application in the automobile, particularly in the traction of an electric or hybrid vehicle, or other. An axial flow electric machine comprises a rotor and one or two stators fed with current. The rotor and the stators are mounted around a rotating shaft, which is secured to the rotor.
    [0002] It is known to use, especially for applications in the field of building, a metal rotor which can be relatively easy to manufacture. Nevertheless, when looking to design a compact electric machine, there is a risk of overheating of the permanent magnet rotor due to eddy currents, and in case of temperature rise, the magnetic flux can be disturbed so that performance may be reduced. To overcome this undesirable thermal effect, rotors made of composite material have been developed. For example, US 6,674,214 discloses an axial flow electric machine with a rotor comprising magnet poles embedded in a composite material support so that the mass of the rotor can be relatively small. The overmolded poles participate in the rigidity of the rotor, the composite material of which comprises a fiber reinforcement, without preferential orientation of the fibers. However, this technology of rotors composite material causes a number of mechanical problems, particularly related to the inertial force and centrifugal force. Also, still according to the aforementioned document, so as to subtract the magnets to the action of the centrifugal force, a hoop is disposed at the periphery of the rotor, which contains a continuous fiber-based material. However, this structure is insufficient to provide optimum mechanical strength of the magnets and, in particular, does not exclude any risk of radial displacement of magnets in rotation under the action of centrifugal forces, especially at very high speeds. There is therefore a need for a rotor of composite material capable of minimizing the movement of the magnets and which can, in addition, be achieved by a simple and economical manufacturing process.
    [0003] For this purpose, the subject of the invention relates to a disc rotor for an axial flow electrical machine comprising a plurality of magnet poles disposed on the peripheral portion of said rotor around a shaft element intended to drive a shaft. in rotation, the magnet poles being integrated in a support of composite material, the rotor further comprising a cylindrical hoop arranged in peripheral portion of said rotor for surrounding the magnet poles, characterized in that the cylindrical hoop is arranged so that exerting a prestressing force on the underlying magnet poles, able to compress the underlying magnet poles towards the shaft element via inserts arranged between the magnet poles and the tree element. Thanks to this arrangement using the prestressed cylindrical hoop, the magnet poles are held under stress, by an assembly in static equilibrium, which makes it possible to maintain the cohesion of the rotor dynamically and thus to limit the displacements of the poles. magnets, even at high speed. Advantageously, the prestressed cylindrical ring consists of a winding of unidirectional continuous fibers aligned in the circumferential direction, the winding being carried out under conditions suitable for causing the desired prestressing force large enough to prevent, during the maximum speed of the rotor, the geometrical possibility of a displacement of the magnet poles relative to the support of composite material. Advantageously and in a nonlimiting manner, the fibers of the prestressed cylindrical ring are chosen from glass fibers or carbon fibers. Preferably, the inserts arranged radially between the magnet poles and the shaft element may be made of a composite material and comprise a plurality of unidirectional continuous fibers oriented in the direction of the prestressing force exerted on the poles of the magnet. magnets.
    [0004] Alternatively, the inserts arranged radially between the magnet poles and the shaft member may be made of steel or ceramic. Advantageously, the support of composite material may comprise a mat pre-impregnated with thermosetting resin based on radially oriented unidirectional fibers. Alternatively, the support of composite material may comprise a mat pre-impregnated with thermosetting resin based bidirectional fibers oriented radially and transversely.
    [0005] Advantageously, the prestressing cylindrical hoop may have a so-called cylindrical cylindrical prismatic shape. Such a shape, with respect to a circular cylindrical shape, makes it possible to control voltage losses during the assembly of the prestressed hoop around the magnet poles.
    [0006] The invention also relates to an axial flow rotating electrical machine comprising at least one stator and a disc rotor as described above. The invention furthermore relates to a method of manufacturing a discoid rotor for an axial flux electrical machine, in particular a disc rotor according to the invention, the method comprising: (i) disposing a plurality of magnet poles in a mold and a shaft member for driving a rotating shaft, so that the plurality of magnet poles are arranged in a star-shaped configuration at the periphery of the shaft element, (ii) disposing a plurality of magnets in the mold of inserts, so that the plurality of inserts extends radially respectively between the shaft member and each magnet pole of the plurality of magnet poles, (iii) install in the mold a cylindrical hoop around of the plurality of magnet poles adapted to exert a prestressing force on the plurality of underlying magnet poles so as to compress the plurality of underlying magnet poles towards the shaft element by the intermediary the plurality of inserts arranged radially between the plurality of magnet poles and the shaft element; (iv) depositing in the mold, in the spaces separating two adjacent magnet poles, a composite material, the composite material being assembled and shaped by compression molding so as to form a composite material carrier between the plurality of magnet poles. Advantageously, the pre-stressed cylindrical hoop is made with fibers wound under tension on a mandrel between a removable fixed flange and a movable flange mounted on the mandrel, so that during the installation of the hoop, the mandrel being brought opposite the mold on the side of the removable fixed flange, it is removed from the latter and the introduction of the hoop by pushing it around the plurality of magnet poles by means of the movable flange.
    [0007] The invention will now be described with reference to the accompanying non-limiting drawings, in which: FIG. 1 is a partial schematic representation of a composite rotor illustrating the displacement of the magnet poles with respect to the composite material support; FIG. 2 is a schematic exploded perspective view of a composite material rotor for an axial flow electric machine according to an embodiment of the invention; FIG. 3 is a partial schematic representation of a face of a rotor according to FIG. an embodiment of the invention, - Figures 4 to 6 are perspective views illustrating an exemplary implementation of the method of manufacturing a rotor according to the invention; FIG. 7 is a schematic front view illustrating a detail of embodiment of the prestressed hoop according to an alternative embodiment. In this application, the term "axial" direction, the direction assumed to be that of the axis of the shaft, that is to say the normal direction to the plane of the rotor disk. The radial direction is defined with respect to this axial direction.
    [0008] Figure 1 illustrates a disc rotor of the type described in the preamble of the present application with reference to the presentation of the state of the art. Thus, the disc rotor 10 known in the state of the art comprises a plurality of magnet poles 12 disposed on the peripheral portion of the rotor 10 around a shaft element 14 or hub. These magnet poles are integrated in a support 16 of insulating and rigid material to ensure the mechanical strength of the assembly. The material used for this purpose is conventionally a composite material comprising a polymer matrix and fibers arranged randomly or without preferred direction. As explained above, such a support 16 makes it possible to reduce the losses in the rotor due to the eddy currents. To do this, the plurality of magnet poles and the shaft element are just installed in a mold, and then the composite material comprising the polymer matrix and the fibers arranged randomly or without preferred direction is overmolded so that the shaft element and the plurality of magnet poles are at least partially embedded in the composite material. In this embodiment, the magnet poles 12 have a substantially trapezoidal shape and the composite support 16 defines branches or pins 17 between each magnet pole 12, these branches 17 having a maximum radius equal to the maximum radius of each pole As shown in Figure 1, the support 16 thus has a star shape. The disc rotor 10 further comprises a cylindrical ring or collar 18. The cylindrical ring 18 is for example made of a material with continuous fibers. These juxtaposed continuous fibers are for example of total length greater than 50 mm. It may for example be glass fibers, carbon, polymer or mineral fibers. The magnet poles 12 are then held radially by the ferrule 18 against which they are directly in contact. This ferrule 18 is thus arranged at the periphery of the rotor to make it possible to strengthen the entire rotor and, in particular to absorb the centrifugal forces acting on the magnet poles, as modeled by the arrows F in FIG. However, at high rotational speeds, for example at rotational speeds of the order of 10,000 rpm, under the effect of centrifugal forces F, the magnet poles 12 push the band 18 in a radial direction. , to generate a decohesion of the magnet poles 12 with the support 16 of composite material. The security of the attachment of the magnet poles is no longer ensured, so that such speeds can not be achieved in practice.
    [0009] FIGS. 2 and 3 illustrate a discoid rotor 10 'according to one embodiment of the invention, which differs from the composite rotor of the state of the art by the implementation of a cylindrical hoop 18' prestressed radially, intended at the time of assembly in the peripheral portion of the rotor around the magnet poles 12 ', exerting a prestressing force in the radial direction, referenced F' in FIG. 3, on the magnet poles 12 'under underlying. These, under the effect of this prestressing force F 'exerted by the pre-stressed cylindrical ring 18', are compressed towards the hub 14 'by means of inserts 19' arranged between the magnet poles 12 'and the hub 14 'and which advantageously constitute an elastic reserve for managing the possible variations as a function of the temperature of the shrinking prestress which is exerted on the magnet poles 12'. The inserts 19 'disposed between the magnet poles 12' and the hub 14 'may be made of steel or ceramic. According to an advantageous embodiment, the inserts 19 'are made of a composite material and comprise a plurality of unidirectional continuous fibers oriented radially or substantially radially, that is to say preferably oriented in the direction of the prestressing force. Thus, in contrast with the state-of-the-art composite rotor illustrated in FIG. 1, where the magnet poles are embedded in the composite material of the support with an outer hoop simply acting as a frame to maintain radially the magnet poles, the magnet poles 12 'are here not embedded in the composite material and are furthermore placed under stress by being compressed by the prestressed cylindrical ring 18' towards the hub 14 'via inserts 19 'disposed between the magnet poles 12' and the hub 14 '. This pre-stressed assembly of the magnet poles 12 'makes it possible to ensure the non-radial displacement under the effect of the centrifugal forces of the rotating magnet poles, so that the force of the centrifugal forces on the magnet poles is not taken up by the support in composite material, for the benefit of the cohesion of the whole.
    [0010] The assembly consisting of the prestressed cylindrical hoop 18 ', the magnet poles 12', the inserts 19 'and the hub 14', is assembled before the composite material support 16 'is made, preferably an SMC type material ( acronym for the English expression "Sheet Molding Compound"). The latter is realized only when said assembly is assembled and balanced according to the principles explained above. Thus, during the production of the composite material support 16 ', the magnet poles 12' are held by an assembly in static equilibrium by means of the prestressed cylindrical hoop 18 'and this prestressing force exerted on the magnet poles 12 'by the preloaded ring 18' is transmitted to the hub 14 'via the inserts 19'. Thanks to this arrangement, during the production of the composite material support 16 'of the SMC type, it is possible to deposit, in particular at the branches 17', unidirectional or bidirectional fibers oriented as required, and no longer disposed of. randomly, so as to be able to work the composite material used to achieve the support 16 'optimally in traction / compression (in the direction of the fibers) and thus to be able to shrink with a certain tightening magnet poles without putting into causes the characteristics of the composite material constituting the support 16 '. In addition, the removal of the composite material support 16 'with oriented fibers makes it possible to reinforce the stiffness of the rotor, in particular its axial stiffness. The prestressed cylindrical ring 18 'is preferably constituted by a winding of unidirectional continuous fibers, for example glass or carbon fibers, aligned in the circumferential direction, the winding being carried out under conditions suitable for causing the prestressing force sought, large enough to prevent, at the maximum speed of the rotor, the geometric possibility of a displacement of the magnet poles relative to the support 16 'of composite material. To do this, it is planned to make the prestressing band with fibers wound on a mandrel (having a radius equal to the maximum radius Rmax of the magnet poles) with a certain tension in the circumferential direction, corresponding to the voltage required to be able to compress the magnet poles of the composite rotor when the pre-stressed hoop is assembled with the magnet pole, hub and insert assembly. Depending on the mass of the magnets and the desired speed of rotation of the rotor (for example 8500 rpm), the prestressing force in the hoop must be able to contain the centrifugal force experienced by the magnet poles. Each magnet pole applies a force that can vary for example from 850 daN to 1700 daN.
    [0011] This assembly can advantageously be made in the mold for pressurized hot molding of the SMC composite material for producing the support 16 '. Thus, with reference to FIG. 4, the magnet poles 12 'and the hub 14' are installed in a mold 20 so that the magnet poles 12 'are arranged in a star configuration at the periphery of the hub 14' at a certain distance from it, and the inserts 19 'are also installed in the mold 20, so that these inserts 19' extend radially between the hub 14 'and each magnet pole 12', respectively . As explained previously, preference is given to inserts of composite material comprising fibers oriented in the direction of the compressive force to be applied to the magnet poles 12 '. In a next step, with reference to FIG. 5, the pre-stressed cylindrical hoop 18 ', circular in shape according to the embodiment example, is placed around the magnet poles 12', the lateral surface of which is to come in contact with the pre-stressed hoop then defines a rounded peripheral contour. To do this, using appropriate means arranged on the mandrel on which the fibers constituting the hoop are wound under tension, it comes to arrange the preloaded ring 18 'directly against the rounded peripheral contour of the magnet poles 12'. For example, the fibers constituting the prestressed hoop can be wound under tension on the mandrel between a removable fixed flange and a movable flange mounted on the mandrel, so that during the establishment of the preloaded ring 18 ', the mandrel being brought next to the mold on the side of the removable fixed flange, it is proceeded to the disassembly of the latter and the establishment of the pre-stressed hoop by pushing it around the magnet poles by means of the movable flange. The arrow F 'represents the prestressing force exerted by the hoop 18' uniformly on each magnet pole 12 ', which preload force is uniformly transmitted by each magnet pole 12' to the insert 19 inserted between the magnet pole 12 'and the hub 14', and is finally transmitted uniformly by each insert 19 'to the hub 14'. The balance of forces involved is such that the static balance of the whole is ensured. Then, as illustrated in FIG. 6, for the manufacture of the composite material support, a composite material of the SMC type, for example a pre-impregnated mat, is deposited in the mold, in the spaces separating two adjacent magnet poles. thermosetting resin resin based on fibers whose orientation is preferred, preferably based radially oriented unidirectional fibers. It may for example be glass fibers or carbon. This composite is then assembled and shaped by compression molding, consisting of closing the hot mold (for example 140 ° C.) and then applying pressure to the previously deposited composite. Such a technique can be implemented easily and quickly. Alternatively, it is possible to use a prepreg based on bi-directional fibers oriented radially and transversely (relative to the radial orientation). It is thus possible to orient the fibers as required at each branch of the composite material support produced.
    [0012] As a variant, the prestressed cylindrical ring 18 'may have a polygonal cylindrical shape instead of a circular cylindrical shape. Such a polygonal cylindrical shape makes it possible to avoid a loss of tension when assembling the prestressed hoop around the magnet poles. The lateral surface of the magnet poles 12 'intended to come into contact with the pre-stressed hoop then has a rectilinear contour, as shown in FIG. 7, against which a face of the polygonal cylindrical hoop, which also has faces intended to come opposite branches 17 'of the composite material support 16' separating two adjacent magnet poles 12 '.
    [0013] Thus, for a rotor with N magnets, the polygonal cylindrical ring comprises 2N faces. Such a polygonal cylindrical shape of the prestressed hoop 18 'advantageously makes it possible to create tension nodes T on each edge of the magnet poles 12', so that the tension in the wound fibers constituting the prestressed hoop 18 'can be retained in look at each branch of the composite material support before it is placed in the mold.
    权利要求:
    Claims (11)
    [0001]
    REVENDICATIONS1. Discoid rotor (10 ') for an axial flow electric machine comprising a plurality of magnet poles (12') disposed on the peripheral portion of said rotor around a shaft element (14 ') for driving a shaft rotation, the magnet poles being integrated in a support of composite material (16 '), the rotor further comprising a cylindrical hoop (18') arranged in peripheral portion of said rotor to surround the magnet poles (12 '), characterized in that the cylindrical collar (18 ') is arranged to exert a prestressing force on the underlying magnet poles (12'), able to compress the underlying magnet poles (12 ') in the direction of the shaft element (14 ') via inserts (19') arranged radially between the magnet poles (12 ') and the shaft element (14').
    [0002]
    2. Discoid rotor according to claim 1, characterized in that the prestressed cylindrical hoop (18 ') consists of a winding of unidirectional continuous fibers aligned in the circumferential direction, the winding being carried out under conditions suitable for causing the prestressing stress sought sufficiently large to prevent, during the maximum speed of the rotor, the geometrical possibility of a displacement of the magnet poles relative to the support of composite material (16 ').
    [0003]
    3. Discoid rotor according to claim 2, characterized in that the fibers of the cylindrical ring (18 ') prestressed are selected from glass fibers or carbon fibers.
    [0004]
    Discoid rotor according to one of the preceding claims, characterized in that the inserts arranged radially between the magnet poles (12 ') and the shaft element (14') are made of a composite material and comprise a plurality of unidirectional continuous fibers oriented in the direction of the prestressing force exerted on the magnet poles (12 ').
    [0005]
    5. Discoid rotor according to any one of claims 1 to 3, characterized in that the inserts arranged radially between the magnet poles (12 ') and the shaft element (14') are made of steel or aluminum. ceramic.
    [0006]
    6. Discoid rotor according to any one of the preceding claims, characterized in that the support of composite material (16 ') comprises a mat pre-impregnated with thermosetting resin based radially oriented unidirectional fibers.
    [0007]
    7. Discoid rotor according to any one of claims 1 to 5, characterized in that the support of composite material (16 ') comprises a mat pre-impregnated thermosetting resin based bidirectional fibers oriented radially and transversely.
    [0008]
    8. Discoid rotor (10 ') according to any one of the preceding claims, characterized in that the cylindrical ring preload (18') has a so-called cylindrical cylindrical prismatic shape.
    [0009]
    9. An axial flow rotating electrical machine comprising at least one stator and a disc rotor (10 ') according to any one of claims 1 to 8.
    [0010]
    A method of manufacturing a disc rotor (10 ') for an axial flow electric machine, comprising: (i) disposing in a mold (20) a plurality of magnet poles (12') and a shaft element (14 ') for driving a rotating shaft so that the plurality of magnet poles (12') are arranged in a star-shaped configuration at the periphery of the shaft element (14 '), (ii) disposing in the mold (20) a plurality of inserts (19 '), so that the plurality of inserts (19') extend radially between the shaft member (14 ') and each pole respectively magnets (12 ') of the plurality of magnet poles, (iii) installing in the mold a cylindrical hoop (18') around the plurality of magnet poles adapted to exert a prestressing force on the plurality of poles of magnets. underlying magnet (12 ') so as to compress the plurality of underlying magnet poles (12') in the direction of the shaft element (14 ') via the lurality of inserts arranged radially between the plurality of magnet poles (12 ') and the shaft element (14'), (iv) depositing in the mold, in the spaces separating two adjacent magnet poles, a composite material, the composite material being assembled and shaped by compression molding so as to form a composite material support (16 ') between the plurality of magnet poles.
    [0011]
    11. The method of claim 10, characterized in that the prestressing cylindrical hoop (18 ') is made with fibers wound under tension on a mandrel between a removable fixed flange and a movable flange mounted on the mandrel, so that when of the installation of the hoop (18 '), the mandrel being brought opposite the mold on the side of the removable fixed flange, it is proceeded to the disassembly of the latter and the establishment of the hoop by pushing it around the plurality of magnet poles by means of the mobile flange.
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    同族专利:
    公开号 | 公开日
    FR3027468B1|2019-05-24|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    WO1997000549A1|1995-06-17|1997-01-03|Urenco Limited|A rotor|
    US6534894B1|1996-01-22|2003-03-18|Illinois Tool Works Inc.|Axial pole motor with specific relative rotor and stator structure|
    US20060138890A1|2004-12-14|2006-06-29|Nissan Motor Co., Ltd.|Rotor structure of an axial gap rotating electrical device|
    GB2511574A|2013-03-08|2014-09-10|Magnomatics Ltd|Apparatus and methods for magnet retention|CN106817002A|2015-11-30|2017-06-09|张黎强|A kind of switched reluctance machines|
    FR3059169A1|2016-11-18|2018-05-25|Renault S.A.S|ROTOR WITH FLOW CONCENTRATION.|
    EP3376640A1|2017-03-17|2018-09-19|General Electric Company|Electric machine with separable magnet carrier|
    FR3072222A1|2017-10-09|2019-04-12|Whylot Sas|ROTOR FOR ENGINE OR ELECTROMAGNETIC GENERATOR WITH REDUCED RIGIDITY|
    EP3480930B1|2017-11-03|2021-03-31|Miba Sinter Austria GmbH|Axial flow machine|
    WO2021176058A1|2020-03-06|2021-09-10|Renault S.A.S.|Rotor for an axial flux electromagnetic machine|
    FR3112907A1|2020-07-27|2022-01-28|Conseil Et Technique|Composite Structure Rotor for Axial Flux Electric Machine|
    法律状态:
    2015-10-23| PLFP| Fee payment|Year of fee payment: 2 |
    2016-04-22| PLSC| Publication of the preliminary search report|Effective date: 20160422 |
    2016-10-20| PLFP| Fee payment|Year of fee payment: 3 |
    2017-10-24| PLFP| Fee payment|Year of fee payment: 4 |
    2018-10-22| PLFP| Fee payment|Year of fee payment: 5 |
    2019-10-28| PLFP| Fee payment|Year of fee payment: 6 |
    2020-10-21| PLFP| Fee payment|Year of fee payment: 7 |
    2021-10-21| PLFP| Fee payment|Year of fee payment: 8 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1460123A|FR3027468B1|2014-10-21|2014-10-21|DISCOID ROTOR WITH COMPOSITE STRUCTURE|
    FR1460123|2014-10-21|FR1460123A| FR3027468B1|2014-10-21|2014-10-21|DISCOID ROTOR WITH COMPOSITE STRUCTURE|
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