Rotor having keys arranged in straight line in vertical direction and method of manufacturing the same

1 . A rotor comprising:

a stacked core comprising a plurality of lamination sheets stacked one on top of another, each of the lamination sheets comprising a plurality of lamination segments arranged in a circle,

wherein the stacked core has an upper layer lamination segment coupled to a lower layer lamination segment with a phase difference of a first angle θ 1 with respect to a center of the stacked core,

wherein the lamination segments that are stacked one on top of another each have a first key and a second key, wherein each of the first keys is arranged in a straight line on an inner surface of the stacked core and each of the second keys is arranged in a straight line on the inner surface of the stacked core so that the first keys and the second keys are inserted into a key way of a motor shaft in an axial direction,

wherein each of the lamination segments has a substantially identical shape and substantially identical pattern except for the first and second keys, and the substantially identical shape and the substantially identical pattern are arranged to be repeated in each of the lamination segments with an interval of a second angle θ 2 with respect to the center,

wherein the lamination segments each comprise upper layer and lower layer coupling portions repeatedly disposed at intervals of the second angle θ 2 in a circumferential direction,

wherein there is a third angle θ 3 between the first keys and the second keys, and

wherein the third angle θ 3 is equal to 180°.

2 . The rotor according to claim 1 , wherein the lamination segments each further comprise through holes repeatedly disposed at intervals of the second angle θ 2 in the circumferential direction.

3 . The rotor according to claim 2 , wherein, in the stacked core, the through holes in the lamination segments stacked one on top of another are arranged in a straight line so as to define an insertion hole.

4 . The rotor according to claim 3 , further comprising a permanent magnet inserted into the insertion hole in the stacked core.

5 . The rotor according to claim 1 , wherein the upper layer and lower layer coupling portions of each of the lamination segments are interlocking tabs configured to couple the upper layer lamination segment to the lower layer lamination segment.

6 . The rotor according to claim 5 , wherein the interlocking tabs are groove and protrusion configurations.

7 . The rotor according to claim 1 , wherein, in a state in which an end of the upper layer lamination segment is arranged to correspond to a continuous portion of the lower layer lamination segment, the upper layer lamination segment is coupled to the lower layer lamination segment using the upper layer and lower layer coupling portions, thereby retaining coupling, without a separate coupling mechanism, between the lamination segments as arranged in the circle.

8 . A rotor comprising:

a stacked core comprising a plurality of lamination sheets stacked one on top of another, each of the lamination sheets comprising a plurality of lamination segments arranged in a circle,

wherein the stacked core has an upper layer lamination segment coupled to a lower layer lamination segment with a phase difference of a first angle θ 1 with respect to a center of the stacked core,

wherein the lamination segments that are stacked one on top of another each have a first key and a second key, wherein each of the first keys is arranged in a straight line on an inner surface of the stacked core and each of the second keys is arranged in a straight line on the inner surface of the stacked core so that the first keys and the second keys are inserted into a key way of a motor shaft in an axial direction,

wherein each of the lamination segments has a substantially identical shape and a substantially identical pattern except for the first and second keys, and the substantially identical shape and the substantially identical pattern are arranged to be repeated in each of the lamination segments with an interval of a second angle θ 2 with respect to the center,

wherein the lamination segments each comprise upper layer and lower layer coupling portions repeatedly disposed at intervals of the second angle θ 2 in a circumferential direction,

wherein the first keys and the second keys are arranged at an angle θ key , each of the lamination sheets comprises two keys at intervals of 180° in the circumferential direction,

wherein the angle θ key of an sth lamination segment is determined based on

θ

key

=

360

⁢

°

n

×

(

s

-

1

-

s

-

1

-

mod

⁡

(

s

-

1

,

n

)

n

×

(

1

-

m

p

)

)

,

and

wherein θ key is an angle indicating where the key is located when the sth lamination segment is stacked in a stacking barrel, s is an order of the lamination segment being stacked, mod(s−1, n) is a function representing a remainder when ‘s−1’ is divided by ‘n’, m is an integer that determines the phase difference between each layer (1≤m<p), and p is a number of slots in each lamination segment (p).

9 . The rotor according to claim 8 , wherein the lamination segments each further comprise through holes repeatedly disposed at intervals of the second angle θ 2 in the circumferential direction.

10 . The rotor according to claim 9 , wherein, in the stacked core, the through holes in the lamination segments stacked one on top of another are arranged in a straight line so as to define an insertion hole.

11 . The rotor according to claim 10 , further comprising a permanent magnet inserted into the insertion hole in the stacked core.

12 . The rotor according to claim 8 , wherein the upper layer and lower layer coupling portions of each of the lamination segments are interlocking tabs configured to couple the upper layer lamination segment to the lower layer lamination segment.

13 . The rotor according to claim 8 , wherein, in a state in which an end of the upper layer lamination segment is arranged to correspond to a continuous portion of the lower layer lamination segment, the upper layer lamination segment is coupled to the lower layer lamination segment using the upper layer and lower layer coupling portions, thereby retaining coupling, without a separate coupling mechanism, between the lamination segments as arranged in the circle.

14 . A rotor comprising:

a stacked core comprising a plurality of lamination sheets stacked one on top of another, each of the lamination sheets comprising a plurality of lamination segments arranged in a circle,

wherein the stacked core has an upper layer lamination segment coupled to a lower layer lamination segment with a phase difference of a first angle θ 1 with respect to a center of the stacked core,

wherein the lamination segments that are stacked one on top of another each have a first key and a second key, wherein each of the first keys is arranged in a straight line on an inner surface of the stacked core and each of the second keys is arranged in a straight line on the inner surface of the stacked core so that the first keys and the second keys are inserted into a key way of a motor shaft in an axial direction,

wherein each of the lamination segments has a substantially identical shape and a substantially identical pattern except for the first and the second keys, and the substantially identical shape and the substantially identical pattern are arranged to be repeated in each of the lamination segments with an interval of a second angle θ 2 with respect to the center,

wherein the lamination segments each comprise upper layer and lower layer coupling portions repeatedly disposed at intervals of the second angle θ 2 in a circumferential direction,

wherein the lamination sheets each comprise the lamination segments having the substantially identical shape repeated in the substantially identical pattern at every second angle θ 2 with respect to the center except for the keys protruding from the inner surface of the stacked core,

wherein the first angle θ 1 and the second angle θ 2 are determined based on

θ

1

=

360

⁢

°

n

×

p

1

×

m

=

θ

2

×

m

and

θ

2

=

360

⁢

°

n

×

p

1

,

and

wherein n is a number of lamination segments constituting one lamination sheet, p 1 is a number of times (p 1 ≥2) that the shape of the lamination segments and the substantially identical pattern, except for the keys, are repeated in each of the lamination segments, and m is an integer greater than or equal to 1 and smaller than p 1 .

15 . The rotor according to claim 14 , wherein the lamination segments each further comprise through holes repeatedly disposed at intervals of the second angle θ 2 in the circumferential direction.

16 . The rotor according to claim 15 , wherein, in the stacked core, the through holes in the lamination segments stacked one on top of another are arranged in a straight line so as to define an insertion hole.

17 . The rotor according to claim 16 , further comprising a permanent magnet inserted into the insertion hole in the stacked core.

18 . The rotor according to claim 14 , wherein the upper layer and lower layer coupling portions of each of the lamination segments are interlocking tabs configured to couple the upper layer lamination segment to the lower layer lamination segment.

19 . The rotor according to claim 14 , wherein, in a state in which an end of the upper layer lamination segment is arranged to correspond to a continuous portion of the lower layer lamination segment, the upper layer lamination segment is coupled to the lower layer lamination segment using the upper layer and lower layer coupling portions, thereby retaining coupling, without a separate coupling mechanism, between the lamination segments as arranged in the circle.

20 . The rotor according to claim 14 ,

wherein there is a third angle θ 3 between the first keys and the second keys, and

wherein the third angle θ 3 is equal to 180°.