Inferior permanent magnet rotor for a refrigerant compressor

Abstract

An interior permanent magnet rotor, for a drive unit disposed in the interior of a hermetically sealed housing of a refrigerant compressor, whereas the rotor includes a first axial section with permanent magnets, followed by a second axial section without permanent magnets. In order to reduce the risk of a magnetic short-circuit it is provided that the second axial section, adjacent to the first axial section, includes a first axial subsection with a reduced radial dimension not going beyond the permanent magnets in the first axial section, whereas the axial length of the first axial subsection is smaller than the axial length of the first axial section, and the second axial section, adjacent to its first axial subsection, includes a second axial subsection with a radial dimension larger than the reduced radial dimension of the first axial subsection.

Claims

1. An interior permanent magnet rotor for a drive unit disposed in an interior of a hermetically sealed housing of a refrigerant compressor, the interior permanent magnet rotor comprising: a first axial section with permanent magnets, followed by a second axial section without permanent magnets; the second axial section comprising, adjacent to the first axial section, a first axial subsection with a reduced radial dimension not going beyond the permanent magnets in the first axial section, whereas an axial length of the first axial subsection is smaller than an axial length of the first axial section; the second axial section comprises, adjacent to its first axial subsection, a second axial subsection with a radial dimension larger than the reduced radial dimension of the first axial subsection.

2. The interior permanent magnet rotor according to claim 1, wherein: the radial dimension of the second axial subsection is equal to a radial dimension of the first axial section.

3. The interior permanent magnet rotor according to claim 1, wherein: a contour of the first axial subsection, as seen in a direction of an axis of the rotor, is a regular polygon.

4. The interior permanent magnet rotor according to claim 3, wherein: corners of the regular polygon are at or near fixation elements for fixing different parts of the rotor to one another.

5. The interior permanent magnet rotor according to claim 3, wherein: at least at or near one corner of the regular polygon the contour of the first axial subsection has an enlarged portion going beyond the regular polygon so that the enlarged portion encloses fixation elements for fixing different parts of the rotor to one another.

6. The interior permanent magnet rotor according to claim 1, wherein: a contour of the second axial subsection, as seen in a direction of an axis of the rotor, is a circle.

7. The interior permanent magnet rotor according to claim 1, wherein: a diameter of a shaft insertion hole in the first axial section is larger than a diameter of the shaft insertion hole in the second axial subsection.

8. The interior permanent magnet rotor according to claim 1, wherein: a diameter of a shaft insertion hole in a first axial sub-subsection of the first axial subsection, the first axial sub-subsection being adjacent to the first axial section, is the same as in the first axial section.

9. The interior permanent magnet rotor according claim 1, wherein: a diameter of a shaft insertion hole in a second axial sub-subsection of the first axial subsection, the second axial sub-subsection being adjacent to the second axial subsection, is the same as in the second axial subsection.

10. The interior permanent magnet rotor according to claim 1, wherein: an oil pump is mounted on a free face side of the second subsection.

11. A refrigerant compressor comprising: a hermetically sealed housing and a drive unit disposed in an interior of the housing, the drive unit comprising an electric motor with an interior permanent magnet rotor according to claim 1.

12. A method of manufacturing different types of metal sheets for an interior permanent magnet rotor according to claim 1, in a form of a laminated rotor, the method comprising: producing the different types with a progressive stamping die; producing metal sheets for the second axial subsection; producing metal sheets for the first axial section from the metal sheets for the second axial subsection; producing metal sheets for the first axial subsection from the metal sheets for the first axial section.

13. The method according to claim 12, wherein: after the metal sheets for the second axial subsection are produced, the method further comprising producing a metal sheet as a holder plate for the permanent magnets.

14. A method of manufacturing different types of metal sheets for an interior permanent magnet rotor according to claim 1, in a form of a laminated rotor, the method comprising: producing the different types with a progressive stamping die; producing metal sheets for the second axial subsection; producing metal sheets for a second axial sub-subsection from the metal sheets for the second axial subsection; wherein a diameter of a shaft insertion hole in the second axial sub-subsection of the first axial subsection, the second axial sub-subsection being adjacent to the second axial subsection, is the same as in the second axial subsection.

15. The method according to claim 14, further comprising: producing metal sheets for a first axial sub-subsection from the metal sheets for the second axial sub-subsection; wherein a diameter of a shaft insertion hole in the first axial sub-subsection of the first axial subsection, the first axial sub-subsection being adjacent to the first axial section, is the same as in the first axial section.

16. The method according to claim 12, further comprising: producing metal sheets for a first axial sub-subsection from the metal sheets for the first axial section; wherein a diameter of a shaft insertion hole in the first axial sub-subsection of the first axial subsection, the first axial sub-subsection being adjacent to the first axial section, is the same as in the first axial section.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The invention will now be explained in greater detail using exemplary embodiments. The drawings are meant as examples and are supposed to present the idea of the invention, but by no means to restrict it or to reproduce it in final manner.

(2) In this regard, the figures show:

(3) FIG. 1 a longitudinal section of an IPM rotor according to the invention, according to lines A-A in FIG. 2,

(4) FIG. 2 a cross section of the IPM rotor of FIG. 1 through the first axial section,

(5) FIG. 3 a cross section of the IPM rotor of FIG. 1 at the border between first axial section and second axial section,

(6) FIG. 4 another cross section of the IPM rotor of FIG. 1 through the first axial sub-subsection of the first axial subsection of the second axial section,

(7) FIG. 5 a cross section of the IPM rotor of FIG. 1 through the second axial sub-subsection of the first axial subsection of the second axial section,

(8) FIG. 6 a cross section of the IPM rotor of FIG. 1 through the second axial subsection of the second axial section,

(9) FIG. 7 a longitudinal section of the IPM rotor of FIG. 1 according to lines A-A in FIG. 2, with an oil pump,

(10) FIG. 8 a perspective view of the IPM rotor of FIG. 7,

(11) FIG. 9 a side view of the IPM rotor of FIG. 7,

(12) FIG. 10 a top view of the IPM rotor of FIG. 7,

(13) FIG. 11 a section through a refrigerant compressor with a rotor according to the invention.

WAYS FOR IMPLEMENTATION OF THE INVENTION

(14) FIG. 1 shows a longitudinal section of an IPM rotor according to the invention, according to lines A-A in FIG. 2. In FIG. 1 the IPM rotor is shown without fixation means 16 and without permanent magnets 20.

(15) The rotor comprises a first axial section 1 with recesses 3 for permanent magnets. The recesses 3 are oriented parallel to the axis 4 of the rotor. The diameter 6 of the shaft insertion hole 5 in first axial section 1 is larger than the diameter 7 of the shaft insertion hole 5 in the lower part of second axial section 2, i.e. larger than the diameter 7 in the second axial subsection 22.

(16) The second axial section 2 of the IPM rotor is situated adjacent to the first axial section 1. The second axial section 2 is divided in a first axial subsection 21 with a reduced radial dimension 8 as compared to first axial section 1. The reduced radial dimension 8 ends before the axial projection of the recess 3 in first axial section 1. The axial length of the first axial subsection 21 is smaller than the axial length of the first axial section 1. The axial length of the first axial subsection 21 is also smaller than the axial length of the second axial subsection 22. The axial length of the second axial subsection 22 here is smaller than the axial length of the first axial section 1. Normally, as here, the axial length of the first axial section 1 is larger than the axial length of the second axial section 2. The air gap provided by the first axial subsection 21 can be dimensioned such that the permeability of the air gap between rotor and stator is bigger compared to the permeability of the air gap in the first axial subsection 21.

(17) The second axial subsection 22 has a radial dimension larger than the reduced radial dimension 8 of the first axial subsection 21. Here the radial dimension of the second axial subsection 22 is equal to the radial dimension of the first axial section 1.

(18) The diameter 6 of the shaft insertion hole 5 in the first axial sub-subsection 211 of the first axial subsection 21, which axial sub-subsection 211 is adjacent to the first axial section 1, is the same as in the first axial section 1. The diameter of the shaft insertion hole 5 in the second axial sub-subsection 212 of the first axial subsection 21, which second axial sub-subsection 212 is adjacent to the second axial subsection 22, is the same as in the second axial subsection 22.

(19) Several bores 9 for fixation means are running in axial direction through first and second axial sections 1,2.

(20) FIG. 2 shows a cross section of the IPM rotor of FIG. 1 through the first axial section 1. Since the IPM rotor in this example is a laminated rotor, i.e. is made of single metal sheets oriented normal to the axis 4 of the rotor, this cross section in fact shows a view of one such metal sheet. One can see the six recesses 3 for the permanent magnets, the six bores 9 for the fixation means and the shaft insertion hole 5. Each recess 3 resembles a rectangle with the longer sides normal to the radius.

(21) FIG. 3 shows a cross section of the IPM rotor of FIG. 1 at the border between first axial section 1 and second axial section 2. Again, this is in fact a view of one metal sheet. The contour of this metal sheet, which acts as a holder plate 23 for the permanent magnets 20 (see FIG. 7), is basically a regular hexagon. Each bore 9 is situated close to a corner 10 of the hexagon. The bore 9 is situated in the last quarter of the radial dimension of the hexagon. At the corner 10 the metal sheet has an enlarged portion 11 going beyond the hexagon. The radial dimension until the end of this enlarged portion 11 here is equal to the radius of the circular metal sheet of FIG. 2, i.e. the radius of first axial section 1. The holder plate 23 acts as a support for the permanent magnets 20 in recesses 3. The radial dimension 12 of the hexagon thus has to be still larger than that of the metal sheets of the first axial subsection 21 of FIG. 4.

(22) FIG. 4 shows another cross section of the IPM rotor of FIG. 1 through the first axial sub-subsection 211 of the first axial subsection 21 of the second axial section 2. Again, this is a view of one metal sheet of the several metal sheets that constitute the first axial sub-subsection 211. The contour of this metal sheet is basically a regular hexagon. Each bore 9 is situated close to a corner 10 of the hexagon. The bore 9 is situated in the last quarter of the radial dimension of the hexagon. At the corner 10 the metal sheet has an enlarged portion 11 going beyond the hexagon. The radial dimension until the end of this enlarged portion 11 here is equal to the radius of the circular metal sheet of FIG. 2, i.e. the radius of first axial section 1. The reduced radial dimension 8 of the hexagon is still smaller than the radial dimension 12 of the hexagon of the metal sheet of FIG. 3. The radial dimension 8 is such that the sides of the hexagon do not radially overlap with the permanent magnets 20 or the recesses 3. In other words, the straight sides of the hexagon are further inside when compared to those of FIG. 3.

(23) The radial dimension at this enlarged portion 11 here is equal to the radius of the circular metal sheet of FIG. 2, i.e. the radius of first axial section 1.

(24) In other words, in areas of the metal sheet of FIG. 4 which do not overlap with permanent magnets the radial dimension can be larger than in areas where there is an overlap with permanent magnets. The form of the enlarged portion 11 here is equal to the respective part of the metal sheet of FIG. 2 due to the production of the metal sheets with a progressive stamping die.

(25) The metal sheets of FIG. 2-4 have the same diameter 7 of the shaft insertion hole 5. The metal sheets of FIG. 5-6 have a smaller diameter 6 of the shaft insertion hole 5.

(26) FIG. 5 shows a cross section of the IPM rotor of FIG. 1 through the second axial sub-subsection 212 of the first axial subsection 21 of the second axial section 2. Again, this is a view of one of several metal sheets of this second axial sub-subsection 212. The metal sheet of FIG. 5 differs from that of FIG. 4 only in its diameter 7 of the shaft insertion hole 5. The diameter 7 is dimensioned such that the shaft of the drive unit can be press-fitted into the part of the shaft insertion hole 5 with the smaller diameter 7.

(27) FIG. 6 shows a cross section of the IPM rotor of FIG. 1 through the second axial subsection 22 of the second axial section 2. Again, this is a view of one of several metal sheets of this second axial subsection 22. The contour of the metal sheet is a circle, its radius can be larger than that of the metal sheet in FIGS. 4 and 5 since the second axial subsection 2 is away far enough from the first axial section 1 containing the permanent magnets. In this case the radius is the same as of the metal sheets of FIG. 2.

(28) Since the radial dimensions of the different types of metal sheets according to FIG. 2-6 differ it is possible to manufacture them with a progressive stamping die. The metal sheets are interlocked. This is done during the stamping of the stack in the progressive die.

(29) One possibility for using a progressive stamping die is that in a first step the metal sheets for the second axial subsection 22 are produced, with the bores 9 only, see FIG. 6, then in a second step the metal sheets for the first axial section 1 are produced from metal sheets from the first step, i.e. the recesses 3 are added and the shaft insertion hole 5 is enlarged to diameter 6, see FIG. 2. In a third step the metal sheets for the first axial sub-subsection 211 are produced from metal sheets from the second step, i.e. the parts outside the recesses 3 are cut away, see FIG. 4.

(30) To obtain the holder plate 23, see FIG. 3, one has to take a metal sheet after the first (FIG. 6) and make six cutouts to receive the approximately hexagonal shape with a radial dimension 12, see FIG. 3, which radial dimension 12 radially ends approximately in the middle of the recesses 3 to be able to hold the permanent magnets 20.

(31) Another possibility to use progressive stamping is that in a first step the metal sheets for the second axial subsection 22 are produced, see FIG. 6, then in a second step the metal sheets for the second axial sub-subsection 212 are produced from metal sheets from the first step, i.e. the approximately hexagonal form with reduced radial dimension 8 is produced, see FIG. 5, then in an optional third step metal sheets for the first axial sub-subsection 211 are produced from metal sheets from the second step, i.e. the shaft insertion hole 5 is enlarged from diameter 7 to diameter 6, see the result in FIG. 4.

(32) The metal sheets are interlocked. This is done during the stamping of the stack in the progressive die.

(33) FIG. 7 shows a longitudinal section of the IPM rotor of FIG. 1 according to lines A-A in FIG. 2, now with an oil pump 13 mounted on the rotor. The oil pump 13 has a hollow cylindric portion which is closed on its lower side except for an opening 14 through which oil can get inside the oil pump 13. The cylindric portion has the same inner diameter as the adjacent portion of the shaft insertion hole 5 with its diameter 7. Inside the oil pump 13, emerging from its bottom, is an asymmetric guiding element 15. The hollow cylindric portion opens up into a flat circular ring with similar dimensions as the metal sheets of the second subsection 22 (see FIG. 6). The circular ring lies flat on the free face side of the second axial (sub)section 2 or 22, respectively. This has the advantage that the oil pump 13 can be mounted to the rotor with the same fixation means which are used to fix different parts of the rotor together. Here the fixation means are bolts 16 with heads 17 on the side of the second axial section 2, which bolts 16 are secured by rivets 18 on the side of the first axial section 1. The heads 17 press the circular ring of the oil pump 13 against the free face side of the second axial subsection 22.

(34) On the free face side of the first axial section 1 there is a circular ring plate 19 which is part of the rotor and which secures the permanent magnets 20 in their place in the recesses 3. The circular ring plate 19 is also secured by the bolts 16 and rivets 18. The circular ring plate 19 is made of non-magnetic material.

(35) FIG. 8 shows a perspective view of the IPM rotor of FIG. 7. One can see the heads 17 of the bolts 16 and the hexagonal form of the first axial subsection 21.

(36) FIG. 9 shows a side view of the IPM rotor of FIG. 7.

(37) FIG. 10 shows a top view of the IPM rotor of FIG. 7. Since the shaft is not yet pressed into the shaft insertion hole 5 one can see the asymmetric guiding element 15 inside the oil pump 13.

(38) A possible embodiment of a refrigerant compressor with a rotor according to the invention is shown in FIG. 11. The refrigerant compressor has a hermetically sealed housing 25, as well as a drive unit disposed in the interior of the housing 25, having a piston/cylinder unit 26 for cyclical compression of a refrigerant, and an electric motor for drive of the piston/cylinder unit 26. The electric motor comprises a stator 24 and a rotor within the stator, the IPM rotor comprising a first and a second axial section 1,2 and the IPM rotor being connected with the shaft 27 and the shaft 27 being connected to the piston/cylinder unit 26. At its base the drive unit is connected to the hermetically sealed housing 25 via spring elements 28.

LIST OF REFERENCE SYMBOLS

(39) 1 first axial section 2 second axial section 3 recess for a permanent magnet 4 axis of the rotor 5 shaft insertion hole 6 diameter of shaft insertion hole 5 7 diameter of shaft insertion hole 5 8 reduced radial dimension 9 bore for fixation means 10 corner of metal sheet 11 enlarged portion 12 radial dimension 13 oil pump 14 opening 15 asymmetric guiding element 16 bolt (fixation means) 17 head of bolt 16 18 rivet 19 circular ring plate 20 permanent magnet 21 first axial subsection of second axial section 2 22 second axial subsection of second axial section 2 23 holder plate 24 stator 25 housing 26 piston/cylinder unit 27 shaft 29 spring element 211 first axial sub-subsection of first axial subsection of second axial section 2 212 second axial sub-subsection of first axial subsection of second axial section 2