A connection structure of a statorless disc generator coil disc

Abstract

This invention discloses a connection structure for a statorless disc generator coil, including a coil flange located at the center of the coil and a speed increaser flange located at the output end of the speed increaser. At least two sector-shaped bosses are evenly distributed around the center of the speed increaser flange on the end face of the speed increaser flange. Sector-shaped grooves matching the shape, position, number, and size of the sector-shaped bosses are provided on the mating end face of the coil flange. All sector-shaped bosses are embedded in the sector-shaped grooves to form radial and tangential constraints. At least two anti-shear pin holes are also paired on the speed increaser flange and the coil flange, and anti-shear pins are fitted into the anti-shear pin holes. This solution can effectively transmit torque, reduce bolt shear force, ensure high-speed rotational stability, and enhance impact resistance.

Description

Technical Field

[0001] This invention relates to the field of motor technology, specifically to a connection structure for the coil disc of a statorless disc generator. Background Technology

[0002] In an axial flux generator integrated into the wheel hub of a two-wheeled electric vehicle, the coil disc needs to be tightly connected to the output flange of the planetary gear speed increaser via its central flange, and rotate at high speed accordingly. Traditional connection methods often use simple stop-type positioning and bolt fastening. For example, utility model patent CN222029797U discloses a disc generator, wheel, and vehicle. The disc generator is housed within a brake connected to the wheel hub. The brake includes a brake drum and a back plate. The brake drum is fixedly connected to the wheel hub and can rotate with it. The back plate is fixedly connected to the vehicle body. The disc generator includes a stator assembly and a rotor assembly. The stator assembly is fixedly mounted on the back plate. The stator assembly is arc-shaped and includes a stator core and stator windings disposed on the stator core. The rotor assembly is fixedly connected to the brake drum and can rotate with it. The rotor assembly is annular and includes a rotor core and several magnets disposed on the rotor core. Because the stator assembly is arc-shaped and fan-shaped, it will not conflict with the parts on the back plate. This allows the disc generator to not only adapt to the installation space of the brake, but also ensure the output power of the disc generator, thereby effectively realizing the vehicle's own power generation and meeting the vehicle's power demand.

[0003] However, in the actual operation of two-wheeled electric vehicles, frequent rapid acceleration and braking (sudden stops) generate huge inertial impact torques and alternating loads. Relying solely on bolts to withstand shear forces can easily lead to bolt loosening, fatigue fracture, or fretting wear on the connection surface. This can cause the coil disc to wobble at high speeds, lose dynamic balance, generate abnormal noise, and even damage the coil insulation, seriously threatening the reliability and lifespan of the generator. Therefore, there is an urgent need for a flange connection structure that can significantly improve connection rigidity, stability, and impact resistance. Summary of the Invention

[0004] To address the problems mentioned in the background technology, this solution provides a special connection structure for connecting the coil flange and the speed increaser flange of a statorless disc generator inside the wheel hub of a two-wheeled electric vehicle. This structure effectively transmits torque, reduces bolt shear force, and ensures high-speed rotational stability and impact resistance.

[0005] The technical solution adopted by the present invention to solve its technical problem is as follows: a connection structure of a statorless disc generator coil disc, including a coil disc flange located at the center of the coil disc and an increaser flange located at the output end of the increaser. At least two fan-shaped bosses are provided on the end face of the increaser flange, evenly distributed around the center of the increaser flange. A fan-shaped groove matching the shape, position, number and size of the fan-shaped bosses is provided on the mating end face of the coil disc flange. All the fan-shaped bosses are embedded in the fan-shaped grooves to form radial and tangential constraints. At least two anti-shear pin holes are also provided in pairs on the increaser flange and the coil disc flange, and anti-shear pins are fitted on the anti-shear pin holes.

[0006] Furthermore, the axis of the anti-shear pin is parallel to the rotation axis of the coil disc flange and the speed increaser flange.

[0007] Furthermore, the number of the fan-shaped bosses and fan-shaped grooves is preferably four or six, but it can also be three or eight, etc.

[0008] Furthermore, the number of anti-shear pin holes on both the speed increaser flange and the coil disc flange is preferably two, and the two anti-shear pin holes are symmetrically distributed around the center of the speed increaser flange and the coil disc flange.

[0009] Furthermore, the anti-shear pin hole is provided on the sector-shaped boss and sector-shaped groove.

[0010] Furthermore, the sector-shaped boss and the sector-shaped groove adopt a clearance fit or a transition fit, and the anti-shear pin and the anti-shear pin hole adopt an interference fit.

[0011] Furthermore, the coil disc flange and the speed increaser flange are also provided with bolt connection holes, and the coil disc flange and the speed increaser flange are connected by fastening bolts.

[0012] Furthermore, both the speed increaser flange and the coil disc flange are made of aluminum alloy or alloy steel.

[0013] The beneficial effects of this invention are: 1. High rigidity and high stability: Through the dual design of "concave-convex interlocking structure (fan-shaped boss-groove)" and "anti-shear pin", multi-path transmission of torque and impact load is achieved. The boss-groove mainly bears tangential force and part of radial force, while the anti-shear pin specifically bears shear force, which greatly reduces the shear load on the fastening bolts, significantly enhances the overall rigidity of the connection, and effectively suppresses the edge sway of the coil at high speed.

[0014] 2. Excellent impact resistance: The huge reverse inertial impact torque generated by sudden braking or stopping can be reliably transmitted and dispersed through the concave-convex interlocking structure and anti-shear pins, avoiding instantaneous loosening or damage of the connection parts and ensuring dynamic stability.

[0015] 3. Good centering: The concave-convex interlocking structure has a self-positioning function during assembly, which can ensure the rapid and accurate centering of the two flanges, improving assembly efficiency and quality.

[0016] 4. Compact and reliable structure: The ingenious design eliminates the need for additional large components, making it particularly suitable for installation in the limited space inside the wheel hub. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the flange connection part of the speed increaser of the present invention; Figure 2 This is a schematic diagram of the coil disc flange connection part of the present invention; Figure 3 This is a cross-sectional schematic diagram of the overall connection structure of the present invention. Detailed Implementation

[0018] The present invention will be further described below with reference to embodiments. It is worth noting that these specific embodiments are merely representative embodiments of the present invention, and the specific methods, apparatuses, conditions, materials, etc., exemplified are not intended to limit the present invention or the corresponding specific embodiments.

[0019] A connection structure for the coil disc of a statorless disc generator, such as Figures 1-3 As shown, the device includes a coil disc flange 2 located at the center of the coil disc and a speed increaser flange 1 located at the output end of the speed increaser. Both the speed increaser flange 1 and the coil disc flange 2 are made of aluminum alloy or alloy steel. The speed increaser flange 1 and the coil disc flange 2 are respectively provided with a first bolt connection hole 13 and a second bolt connection hole 23. The coil disc flange 2 and the speed increaser flange 1 are connected by fastening bolts. At least two fan-shaped bosses 11 are evenly distributed around the center of the speed increaser flange 1 on the end face. In this embodiment, four fan-shaped bosses 11 symmetrical about the center are machined on its end face. On the mating end face of the coil flange 2, there is a fan-shaped groove 21 that matches the shape, position, number and size of the fan-shaped boss 11. All the fan-shaped bosses 11 are embedded in the fan-shaped groove 21 to form radial and tangential constraints. At least two first anti-shear pin holes 12 are also provided on the speed increaser flange 1, and at least two second anti-shear pin holes 22 are also provided on the coil flange 2. Each first anti-shear pin hole 12 and each second anti-shear pin hole 22 are paired with each other, and anti-shear pins 3 are fitted on the first anti-shear pin holes 12 and the second anti-shear pin holes 22.

[0020] Furthermore, the axis of the anti-shear pin 3 is parallel to the rotational axis of the coil flange 2 and the speed increaser flange 1.

[0021] Furthermore, the number of the fan-shaped protrusions 11 and fan-shaped grooves 21 can also be three, six, or eight, etc.

[0022] Furthermore, the number of the first anti-shear pin hole 12 and the second anti-shear pin hole 22 on the speed increaser flange 1 and the coil disc flange 2 is preferably two, and the two first anti-shear pin holes 12 and the second anti-shear pin holes 22 are symmetrically distributed around the center of the speed increaser flange 1 and the coil disc flange 2.

[0023] Furthermore, the first anti-shear pin hole 12 and the second anti-shear pin hole 22 are respectively disposed on the fan-shaped boss 11 and the fan-shaped groove 21.

[0024] During assembly in this embodiment, firstly, gently tap one end of each of the two anti-shear pins 3 into the first anti-shear pin hole 12. Then, align the fan-shaped groove 21 of the coil disc flange 2 with the fan-shaped boss 11 of the speed increaser flange 1 for engagement. Simultaneously, insert the other end of the anti-shear pin 3 into the second anti-shear pin hole 22. After the end faces of the speed increaser flange 1 and the coil disc flange 2 are in contact, use four high-strength hexagonal socket head cap bolts to pass through the first bolt connection hole 13 and the second bolt connection hole 23, and tighten the nuts with the specified torque for fixation. The fan-shaped boss 11 and the fan-shaped groove 21 adopt a small-clearance transition fit, while the anti-shear pin 3 and the first anti-shear pin hole 12 and the second anti-shear pin hole 22 adopt an interference fit or a tight fit.

[0025] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. Any simple equivalent changes and modifications made in accordance with the scope of the patent application and the description of the invention shall still fall within the scope of the patent of the present invention.

Claims

1. A connection structure for the coil disc of a statorless disc generator, characterized in that, The device includes a coil disc flange located at the center of the coil disc and a speed increaser flange located at the output end of the speed increaser. At least two sector-shaped bosses are evenly distributed around the center of the speed increaser flange on the end face of the speed increaser flange. A sector-shaped groove matching the shape, position, number, and size of the sector-shaped bosses is provided on the mating end face of the coil disc flange. All the sector-shaped bosses are embedded in the sector-shaped grooves to form radial and tangential constraints. At least two anti-shear pin holes are also paired on the speed increaser flange and the coil disc flange, and anti-shear pins are fitted on the anti-shear pin holes.

2. The connection structure of the statorless disc generator coil disc according to claim 1, characterized in that, The number of sector-shaped bosses and sector-shaped grooves are both four or six.

3. The connection structure of the statorless disc generator coil disc according to claim 1, characterized in that, The number of shear pin holes on both the speed increaser flange and the coil disc flange is two.

4. The connection structure of the statorless disc generator coil disc according to claim 3, characterized in that, The two shear pin holes are symmetrically distributed at the center of the speed increaser flange and the coil disc flange.

5. The connection structure of the statorless disc generator coil disc according to claim 1, characterized in that, The axis of the anti-shear pin is parallel to the rotation axis of the coil flange and the speed increaser flange.

6. The connection structure of the statorless disc generator coil disc according to claim 1, characterized in that, The sector-shaped boss and the sector-shaped groove are fitted with a clearance fit or a transition fit.

7. The connection structure of the statorless disc generator coil disc according to claim 1, characterized in that, The anti-shear pin and the anti-shear pin hole are fitted with an interference fit.

8. The connection structure of the statorless disc generator coil disc according to claim 1, characterized in that, Both the speed increaser flange and the coil disc flange are made of aluminum alloy or alloy steel.

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