Rotor interlocking elements and method for their manufacturing
Methods and systems are disclosed for reducing ripple torque associated with internal bridges arranged within one or more barriers of a rotor lamination stack and increasing mechanical strength when the rotor lamination stack is configured without internal bridges. In one example, a rotor lamination stack includes at least one interlocking element arranged in one or more barriers. In another example, the at least one interlocking elements may be fabricated individually and independent of the rotor lamination stack or by employing the rotor lamination stack as a mold.
1 . A motor system, comprising:
a rotor comprising a generally cylindrical rotor body with an inner surface and an outer surface, the rotor being arranged from a rotor lamination stack that includes a magnetic portion comprising a plurality of segments and a non-magnetic portion comprising a plurality of empty regions and a plurality of interlocking elements wherein each of the plurality of interlocking elements are arranged in a part of one of the plurality of empty regions where a portion of the empty region is adjacent to at least one side of the interlocking element;
a stator with a plurality of stator windings electrically coupled to a control circuit of a plurality of circuits including at least one transistor; and
an inverter electrically coupled to an electrical power source wherein executable instructions are configured, stored, and executed in at least one memory by at least one processor of the inverter to apply a current to the plurality of stator windings.
2 . The motor system of claim 1 , wherein each of the plurality of empty regions is generally arc-shaped and comprises two peripheral ends and a middle portion, the two peripheral ends extending toward the outer surface of the rotor.
3 . The motor system of claim 1 , wherein:
the motor system is a synchronous reluctance motor (SRM) system;
the plurality of interlocking elements comprises at least one lateral interlocking element arranged within one or more empty regions of the plurality of empty regions.
4 . The motor system of claim 2 , wherein one lateral interlocking element is positioned within a peripheral end of an empty region included in the plurality of empty regions.
5 . The motor system of claim 3 , wherein one of the centered interlocking element and the middle interlocking element are positioned within a middle portion of an empty region included in the plurality of empty regions.