Automatically increase and decrease power torque, generate electricity and charge, high energy density, coreless permanent magnet motor

Abstract

This invention is entitled "A High-Energy-Density Ironless Permanent Magnet Motor with Automatically Increased Power, Torque, and Power Generation and Charging." It belongs to the field of power motor technology. Its main features are: The stator's ironless windings are distributed along the circumference of an ironless, polymer-made precision-cast stator frame, which is directly and spaced apart and sheathed onto a stator-type housing or stator-type structural housing; the rotor's ironless permanent magnets are distributed along the circumference of an ironless, polymer-made precision-cast rotor frame, which is directly hingedly fixed to the main shaft; and the housing comprises two stator-type housings or rotor-type housings on either side and a rotor-type structure or stator-type structural housing in the middle. It boasts a high power per unit weight exceeding 7 kW / kg, a torque density of 25 Nm / kg, and a high magnetic field energy density of 500 to 25,000 rpm. This motor features a simple structure, high power density, high torque density, high magnetic field energy density, low cost, and excellent performance. It can be widely used in the transportation power sector as an ironless, coreless permanent magnet motor with automatically increased power, torque, and power generation and charging, and high energy density.

Description

Technical Field

[0001] The present invention belongs to the technical field of power motors and relates to a power motor for transportation equipment, which is suitable for vehicles, ships, aircraft, and general power multi-purpose permanent magnet power motors. Specifically, it is a high-energy-density ironless permanent magnet motor that automatically increases and decreases power torque for power generation and charging. Background Art

[0002] Currently, the motor market is dominated by power motors with traditional structures. However, the structural types of power motors have been changing since 2011, mainly centered around Professor Wang Ziqi's invention patent: a permanent magnet super-energy power motor with variable frequency speed regulation for vehicle and ship traction AC and DC (Patent No.: ZL201110295188.3) and a multifunctional permanent magnet super-strong super-energy drive motor with automatic power increase and decrease torque, power generation and charging (Patent No.: 201310290881.0). These structural types are changing with the goal of small size, light weight, high power density, high torque density, and high magnetic field energy density. Although many permanent magnet motor structures have appeared on the market in recent years, the problem of large size caused by traditional structure and design concepts still exists. The use of traditional motor types also causes problems of low power density, low torque density, and low magnetic field energy density, which hinders the improvement of power density, torque density, and magnetic field energy density. Summary of the Invention

[0003] The purpose of the present invention is to provide a high energy density coreless permanent magnet motor that automatically increases and decreases power torque for power generation and charging, which has the characteristics of simple structure, high power density, high torque density, high magnetic field energy density and no iron core.

[0004] The technical solution of the present invention is: a high-energy-density ironless permanent magnet motor with automatic power increase and decrease torque, power generation and charging, including a stator winding, a stator frame, a rotor permanent magnet, a rotor frame, a main shaft, a bearing assembly, a gland and a casing, characterized in that: the stator frame is an ironless polymer material precision casting stator frame, the stator winding is a stator ironless winding, the stator ironless winding is distributed along the circumference of the ironless polymer material precision casting stator frame, the ironless polymer material precision casting stator frame is directly and spaced apart and sleeved on the stator type shell or the inner wall of the stator type structure shell; the rotor frame is an ironless polymer material precision casting rotor frame, The rotor permanent magnets are coreless permanent magnets, which are distributed along the circumference of the coreless polymer precision-cast rotor frame. The coreless polymer precision-cast rotor frame is directly hinged and fixed on the main shaft. The coreless polymer precision-cast stator frame is adjacent to the coreless polymer precision-cast rotor frame. The casing includes stator-type shells or rotor-type shells on both sides and a stator-type structural shell or rotor-type structural shell in the middle. The coreless polymer precision-cast stator frame is located in the stator-type shell or stator-type structural shell, and the coreless polymer precision-cast rotor frame is located in the rotor-type shell or rotor-type structural shell.

[0005] The casings described in the technical solution of the present invention are connected by a bolt assembly; a junction box is provided on the stator-type casing and the stator-type structural casing.

[0006] The rotor skeleton described in the technical solution of the present invention is an ironless polymer precision-cast rotor frame located in the middle of the main shaft, and the ironless polymer precision-cast rotor frame is hinged and fastened to the main shaft; an ironless polymer precision-cast stator frame is provided on each side, and the ironless polymer precision-cast stator frame is directly and spaced apart and mounted on the inner wall of the stator-type shell; the casing includes stator-type shells on both sides and a rotor-type structural shell in the middle; this is a permanent magnet motor structure with stators on both sides of the rotor.

[0007] The ironless polymer precision-cast stator frame described in the technical solution of the present invention is located in the middle of the main shaft, and an ironless polymer precision-cast rotor frame is provided on each side. The ironless polymer precision-cast rotor frame is hinged and fastened to the main shaft; the casing includes rotor-type shells on both sides and a stator-type structural shell in the middle, and the ironless polymer precision-cast stator frame is directly and spaced apart and mounted on the inner wall of the stator-type structural shell; this is a permanent magnet motor structure with rotors on both sides of the stator.

[0008] The technical solution of the present invention comprises three groups of coreless polymer precision-cast stator frames, one of which is located in the middle of the main shaft, and the other two groups are located on both outer sides of the main shaft. The three groups of coreless polymer precision-cast stator frames are directly mounted on the stator-type shells on both sides and the inner wall of the stator-type structural shell in the middle. The rotor skeleton is an iron-coreless polymer precision-cast rotor frame, and there are two groups of them, which are located on both sides of the iron-coreless polymer precision-cast stator frame in the middle of the main shaft and on the inner sides of the two outer iron-coreless polymer precision-cast stator frames. The iron-coreless polymer precision-cast rotor frame is hingedly fastened to the main shaft. The casing comprises stator-type shells on both sides, a stator-type structural shell in the middle, and a rotor-type structural shell between the stator-type structural shell and the stator-type shells on both sides.

[0009] The ironless polymer material precision casting stator frame described in the technical solution of the present invention includes an outer circular frame, a middle circular frame, an ironless polymer material precision casting frame heat dissipation channel, an ironless polymer material precision casting frame moment-enhancing reinforcement structure, and connecting straight rods radially connected therebetween; the outer circular frame, the middle circular frame and the connecting straight rods are provided with ironless polymer material precision casting frame structure holes; the center of the ironless polymer material precision casting frame moment-enhancing reinforcement structure forms a second main shaft structure sleeve; a winding coil compartment is formed between the outer circular frame, the middle circular frame and two adjacent connecting straight rods.

[0010] The coreless polymer material precision casting rotor frame described in the technical solution of the present invention includes an outer circular frame, a middle circular frame, an ironless polymer material precision casting frame moment-enhancing and reinforcing structure, and connecting straight rods radially connected therebetween; the outer circular frame, the middle circular frame and the connecting straight rods are provided with ironless polymer material precision casting frame structural holes; the center of the ironless polymer material precision casting frame moment-enhancing and reinforcing structure forms an ironless rotor shaft sleeve opening, and the ironless rotor shaft sleeve opening is provided with a keyway assembly.

[0011] The rotor coreless permanent magnet polymer material precision casting packaging plate described in the technical solution of the present invention includes an outer circular frame, a middle circular frame, and connecting straight rods radially connected therebetween; the outer circular frame, the middle circular frame and the connecting straight rods are provided with coreless polymer material precision casting frame structure holes.

[0012] The stator coreless winding described in the technical solution of the present invention is a stator coreless radial winding or a stator coreless axial winding; the stator coreless radial winding or the stator coreless axial winding is wound into an ironless polymer material precision casting stator frame, and a winding coil gap of 1 to 3 mm is formed between the windings.

[0013] The rotor coreless permanent magnet described in the technical solution of the present invention is assembled in the ironless polymer precision cast rotor frame, and is encapsulated in the ironless polymer precision cast rotor frame and the rotor coreless permanent magnet is clamped and fastened into one with a rotor coreless permanent magnet polymer precision cast packaging plate; a keyway is provided on the main shaft, and the keyway and the keyway assembly are hinged with the ironless polymer precision cast rotor frame and the rotor coreless permanent magnet as a whole, and then hinged with the bearing assembly and the pressure cover to form a whole.

[0014] The stator coreless winding is installed in the middle of the motor's axial direction, and the rotor coreless permanent magnets are set at both ends of the air gap. The axial deflection deformation of the rotor coreless is calculated, and the rotor coreless permanent magnet is subjected to a unilateral force, which can avoid the uneven thickness of the air gap. The coreless permanent magnets at both ends are very magnetic and can directly form an axial magnetic circuit at both ends. The coreless structure has no iron loss and is more efficient. It is a double air gap structure with high torque density. Its structure has two rotor coreless permanent magnets on the outside and two stator coreless windings in the middle. The internal cooling air path between the stator coreless winding and the rotor coreless permanent magnet can improve the heat dissipation efficiency. Under high torque density, a higher power torque density can be obtained, which is the secondary structure of the present invention.

[0015] The combined structure features three stators and two rotors, multiple sets of stator ironless windings, and multiple sets of rotor ironless permanent magnets. This structure offers high torque density and simple design and assembly. The magnetic poles on either side of the rotor ironless permanent magnets can be arranged with identical or different properties, resulting in different magnetic fields and rotor yoke magnetic circuits. The opposite-pole arrangement eliminates the rotor yoke magnetic circuit, making the rotor ironless permanent magnets thinner and saving material. Similarly, the absence of the stator ironless winding yoke magnetic circuit allows the stator ironless winding to be thinner and reduce losses. The same-pole arrangement results in thicker rotor ironless permanent magnets with greater moment of inertia, allowing the stator ironless winding to have a high slot fill rate in small slots. The stator ironless winding is simple in design and offers high winding utilization. Each phase is independent, resulting in high efficiency, and can also be combined with power and torque for significant energy recovery.

[0016] Polymer materials are widely used in the machinery industry. The so-called "plastics replacing steel" and "plastics replacing iron" have become key areas of research and applied science in materials science. This broadens the range of materials available, transforming traditional mechanical products from being unsafe, heavy, and energy-intensive to being safe, lightweight, durable, and economical. Polyoxymethylene (POM) replaces nonferrous metals such as zinc, copper, and aluminum in the automotive industry, and is widely used in the manufacture of various gears, bearings, cams, nuts, various pump bodies, guide rails, and other mechanical components. It also replaces cast iron and steel stampings. Polyoxymethylene is an optimal choice for the present invention's POM-based applications in the ironless polymer stator frame, the ironless polymer rotor frame, and the ironless polymer permanent magnet packaging.

[0017] The beneficial effects of the present invention are: 1. When in use, the magnetic field of the independent coreless permanent magnet of the present invention can reach a high magnetic density; 2. The superposition of dual use and multiple use can save the usage of permanent magnet steel. Since the price of rare earth permanent magnets is high, the cost of the permanent magnet motor can be reduced by reducing the usage, and the high performance of the permanent magnet can compensate for the lack of its usage, thereby reducing the cost problem; 3. The volume of the air gap is large, and the linear wind friction has no tortuous path and the cooling speed is fast, which is beneficial to the requirements of the permanent magnet motor for the working environment, and can accelerate the uniform diffusion of heat between the winding and the permanent magnet, eliminating the risk of demagnetization and failure of the permanent magnet; 4. The combination of the rotor coreless permanent magnet and the coreless polymer material precision casting rotor frame are pressed by the rotor coreless permanent magnet polymer material precision casting packaging plate The edge-filling and clamping process firmly secures the permanent magnets and will not break under conditions of intense movement or large temperature differences. The axial magnetic field type does not cause alternating fluctuations in the rotating air gap energy of the toothed field. The partial derivative of energy with respect to position is torque. The axial magnetic field eliminates the periodic variation of energy and fluctuations in torque. 5. An intermediate axial rotor iron-coreless permanent magnet structure, an intermediate axial stator iron-coreless winding structure, multiple groups of stator iron-coreless windings and multiple groups of rotor iron-coreless permanent magnet structures are set. The rotor iron-coreless permanent magnet structure type is set to a variety of structures such as arc pole type, circular pole type and polymorphic pole type. This structure has a certain protective effect on overload of the permanent magnet motor, so there is no problem of overload demagnetization, and the electromagnetic load and magnetic field density can be adjusted automatically.

[0018] Compared with traditional motors, the coreless permanent magnet motor of the present invention has the following performance advantages. First, it is highly efficient and energy-saving. The motor has a high power factor, no iron loss, no magnetic damping, and high efficiency. Application examples have shown that a 7-kilowatt ironless permanent magnet motor saves 45% of fuel compared to a 14-kilowatt traditional diesel generator. Second, it is lightweight and material-saving. It is small in size and weighs only 35% of a traditional motor. Application examples have shown that a 7-kilowatt ironless permanent magnet motor can save 80% of steel, 100% of silicon steel sheets, and 50% of copper. Third, it has good speed regulation performance. The speed of the permanent magnet motor remains constant with the power supply frequency, which can simplify the variable frequency speed regulation control system, with a wide speed regulation range and high precision. It is easy to make a multi-pole, low-speed, high-power motor, and can eliminate additional equipment for direct drive. Fourth, it has strong reliability. The motor has a low operating temperature rise, and the ironless winding is precision-cast and insulated with polymer materials, which has good environmental adaptability and reliable operation. Compared with traditional motors, coreless permanent magnet motors have excellent energy-saving and material-saving performance. Compared with current permanent magnet motors, they are more efficient, lighter and more stable.

[0019] The present invention has the characteristics of simple structure, high power density, high torque density, high magnetic field energy density, low cost and good effect. It can be widely promoted and used in the field of transportation equipment power to automatically increase and decrease power torque, generate electricity and charge high energy density coreless permanent magnet motors. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a cross-sectional view of Example 1 of the present invention.

[0021] Figure 2 This is an axial structure diagram of Example 1 of the present invention.

[0022] Figure 3 This is a cross-sectional view of Example 2 of the present invention.

[0023] Figure 4 This is an axial structure diagram of Example 2 of the present invention.

[0024] Figure 5 This is a cross-sectional view of Example 3 of the present invention.

[0025] Figure 6 This is an axial structure diagram of Example 3 of the present invention.

[0026] Figure 7 This is a structural diagram of the coreless polymer material precision casting stator frame of the present invention.

[0027] Figure 8 This is a structural diagram of the stator coreless winding of the present invention.

[0028] Figure 9 This is a structural cross-sectional view of the stator coreless axial winding of the present invention.

[0029] Figure 10 This is a cross-sectional view of the structure of the coreless radial winding of the stator of the present invention.

[0030] Figure 11 This is a structural diagram of the coreless polymer material precision casting rotor frame of the present invention.

[0031] Figure 12 This is a structural diagram of the polymer material precision casting packaging plate of the rotor coreless permanent magnet of the present invention.

[0032] Figure 13 This is a cross-sectional view of the rotor coreless permanent magnet structure of the present invention.

[0033] Figure: 1. Stator housing; 2. Ironless polymer precision-cast stator frame; 3. Ironless radial stator winding; 4. Heat dissipation channel of the ironless polymer precision-cast frame; 5. Torque-enhancing structure of the ironless polymer precision-cast frame; 6. Ironless polymer precision-cast rotor frame; 7. Rotor ironless permanent magnets; 8. Rotor ironless permanent magnet polymer precision-cast packaging plate; 9. Main shaft; 10. Bearing assembly and gland; 11. Keyway; 12. Terminal box; 13. Bolt holes for the first structure; 14. Socket for the first main shaft structure; 15. Rotor housing; 16. Concave tongue-and-groove; 17. Concave tongue-and-groove; 18. Bolt assembly; 19. Stator housing; 20. Rotor housing; 21. Bolt holes for the second structure; 22. 1. Structural holes for the ironless polymer precision casting frame; 23. Winding coil compartment; 24. Second spindle structural sleeve; 25. Winding coil gap; 26. Winding coil outlet; 27. Ironless rotor shaft sleeve opening; 28. Keyway assembly; 29. Stator ironless axial winding frame; 30. Stator ironless winding bracket; 31. Stator ironless axial winding; 32. Third spindle structural sleeve. DETAILED DESCRIPTION

[0034] The present invention will be further described below in conjunction with the accompanying drawings and examples.

[0035] like Figures 1 to 13As shown, the present invention includes a stator coreless winding, an ironless polymer material precision casting stator frame 2, a rotor coreless permanent magnet 7, an ironless polymer material precision casting rotor frame 6, a rotor coreless permanent magnet polymer material precision casting packaging plate 8, a main shaft 9, a bearing assembly and a gland 10, a bolt assembly 18, a junction box 12, and a casing. Among them, the ironless polymer material precision casting stator frame 2 includes an outer circular frame, a middle circular frame, an ironless polymer material precision casting frame moment enhancement and reinforcement structure 5, and radially connected connecting straight rods therebetween. The outer circular frame, the middle circular frame and the connecting straight rods are provided with ironless polymer material precision casting frame structure holes 22. The center of the ironless polymer material precision casting frame moment enhancement and reinforcement structure 5 forms a second main shaft structure sleeve 24. A winding coil compartment 23 is formed between the outer circular frame, the middle circular frame and the two adjacent connecting straight rods. The ironless polymer material precision casting stator frame 2 is directly installed on the inner wall of the stator type shell 1 or the stator type structure shell 19. The coreless polymer precision-cast rotor frame 6 comprises an outer frame, a middle frame, an ironless polymer precision-cast frame moment-enhancing structure 5, and radially connecting rods therebetween. The outer frame, middle frame, and connecting rods are provided with ironless polymer precision-cast frame structural holes 22. The center of the ironless polymer precision-cast frame moment-enhancing structure 5 forms an ironless rotor sleeve opening 27, which is provided with a keyway assembly 28. The rotor coreless permanent magnet precision-cast polymer packaging plate 8 comprises an outer frame, middle frame, and radially connecting rods therebetween. The outer frame, middle frame, and connecting rods are provided with ironless polymer precision-cast frame structural holes 22. The stator coreless winding is either an ironless radial winding 3 or an ironless axial winding 31. The ironless radial winding 3 or the ironless axial winding 31 is wound into the winding coil compartment 23 of the ironless polymer precision-cast stator frame 2 or the ironless polymer precision-cast rotor frame 6, and is distributed along the circumference of the ironless polymer precision-cast stator frame 2. The rotor coreless permanent magnets 7 are distributed along the circumference of the ironless polymer precision-cast rotor frame 6 and assembled to the ironless polymer precision-cast rotor frame 6. They are hinged to the rotor coreless permanent magnet polymer precision-cast encapsulation plate 8, encapsulated in the ironless polymer precision-cast rotor frame 6, and secured to the rotor coreless permanent magnets 7 by a press-fitting, inlaying, and clamping mechanism. The ironless polymer precision-cast rotor frame 6 is directly hinged and secured to the main shaft 9. A keyway 11 is provided on the main shaft 9. The keyway 11 and the keyway assembly 28 are hinged with the coreless polymer material precision casting rotor frame 6 and the rotor coreless permanent magnet 7, and then hinged with the bearing assembly and the pressure cover 10 to form a whole.The housing consists of two stator-type housings 1 or rotor-type housings 20 on either side, and a central rotor-type structural housing 15 or stator-type structural housing 19. The ironless polymer-cast stator frame 2 is located within the stator-type housing 1 or stator-type structural housing 19, while the ironless polymer-cast rotor frame 6 is located within the rotor-type housing 20 or rotor-type structural housing 15. The housings are connected via a bolt assembly 18; a terminal box 12 is provided on the stator-type housing 1 and / or the stator-type structural housing 19. The ironless radial stator winding 3 is wound directly around the left and right slot compartments of the ironless polymer-cast stator frame 2. The winding ends are longer at the top and shorter at the bottom, resulting in a simple process and a high slot fill rate. The stator coreless axial winding 31 is wound directly around the stator coreless axial winding frame 29 on both sides of the ironless polymer precision-cast stator frame 2. The stator coreless winding support 30 serves as a protective wall, and the winding ends are wide at the top and narrow at the bottom, resulting in a simple process and a high slot fill rate. The ends of the stator coreless radial winding 3 and the stator coreless axial winding 31 do not run in the same direction, but the current direction in the slots is consistent, and the potential shape formed by the windings is consistent. The stator coreless radial winding 3 or the stator coreless axial winding 31 is installed in the stator housing 1 or the stator structural housing 19. An air gap is designed between the stator coreless winding and the rotor coreless permanent magnets, with a designed distance of no less than 0.5 to 1.5 mm, to facilitate heat dissipation.

[0036] Example 1 Figure 1-2 、 Figure 7-13 As shown. Embodiment 1 of the present invention includes a stator housing 1, an ironless polymer material precision casting stator frame 2, a stator ironless radial winding 3, an ironless polymer material precision casting frame heat dissipation channel 4, an ironless polymer material precision casting frame moment reinforcement structure 5, an ironless polymer material precision casting rotor frame 6, a rotor ironless permanent magnet 7, a rotor ironless permanent magnet polymer material precision casting packaging plate 8, a main shaft 9, a bearing assembly and a gland 10, a keyway 11, a junction box 12, a first structural bolt hole 13, a first main shaft structure Structural sleeve opening 14, rotor-type structural shell 15, concave tongue-and-groove 16, convex tongue-and-groove 17, bolt assembly 18, ironless polymer material precision casting frame structural hole 22, winding coil compartment 23, second main shaft structural sleeve opening 24, winding coil gap 25, winding coil outlet 26, ironless rotor shaft sleeve opening 27, keyway assembly 28, stator ironless axial winding frame 29, stator ironless winding bracket 30, stator ironless axial winding 31. This is the permanent magnet motor structure type with stators on both sides of the rotor.

[0037] Main process flow: The present invention first selects axial winding, and secondarily selects radial winding. In the stator coreless axial winding frame 29 and the stator coreless winding bracket 30, a stator coreless axial winding 31 or a stator coreless radial winding 3 is prepared. The stator coreless axial winding 31 or the stator coreless radial winding 3 is formed into an integral body of the coreless polymer material precision-cast stator frame 2, and is prepared and pressed into a calibration position on the inner wall of the stator shell 1.

[0038] The prepared rotor coreless permanent magnet 7 is assembled on the coreless polymer precision casting rotor frame 6, and is hinged to the rotor coreless permanent magnet polymer precision casting packaging plate 8 through the coreless polymer precision casting frame structure hole 22. The coreless polymer precision casting rotor frame 6 and the rotor coreless permanent magnet 7 are pressed, inlaid, clamped and fastened into one.

[0039] The main shaft 9 passes through the first main shaft structure sleeve 14 and the second main shaft structure sleeve 24 of the stator type housing 1. The convex tongue-and-groove 17 of the stator type housing 1 and the concave tongue-and-groove 16 of the rotor type structural housing 15 together form a sealing structure fastening between various types of housings of permanent magnet motors. The winding coil outlet 26 is connected to the terminal box 12 of the stator type housing 1.

[0040] Then pass through the coreless rotor sleeve opening 27 of the rotor-type structural housing 15, install the integral component of the coreless polymer material precision casting rotor frame 6 and the rotor coreless permanent magnet 7, and fasten them together with the keyway 11 and the keyway assembly 28 hinge.

[0041] The winding coil continues to pass through the first main shaft structure sleeve 14 and the second main shaft structure sleeve 24 on the stator type housing 1. The convex tongue-and-groove 17 of the stator type housing 1 and the concave tongue-and-groove 16 of the rotor type structure housing 15 are combined to form a sealing structure between various types of housings of permanent magnet motors, and the winding coil outlet end 26 is connected to the terminal box 12 of the stator type housing 1.

[0042] The keyway 11 and keyway assembly 28 on the main shaft 9 are hingedly connected to the ironless polymer precision-cast rotor frame 6 and the ironless permanent magnet 7. They are then hingedly connected to the bearing assembly and gland 10 to form a single unit. Bolt assemblies 18 pass through the first structural bolt holes 13 to hinge and secure the ironless permanent magnet motor, completing the overall process for the stator motor structure on both sides of the rotor.

[0043] The stator coreless radial winding 3 is wound around the coreless polymer precision-cast stator frame 2 via the winding coil compartment 23. The winding coil gap 25 has a gap of 1-3 mm, forming an integral component of the stator coreless radial winding 3. The coreless polymer precision-cast frame heat dissipation channel 4 is an integral part of the coreless polymer precision-cast stator frame 2, providing a channel for airflow and cooling. The coreless polymer precision-cast frame torque-enhancing reinforcement structure 5 is also an integral part of the coreless polymer precision-cast stator frame 2, providing a torque-enhancing, integral reinforcement structure. The coreless polymer precision-cast stator frame 2 forms an integral part of the stator coreless winding 3, which is press-fitted to the inner wall of the stator housing 1 at a designated location. The coreless polymer precision-cast rotor frame 6 is the carrier for assembling the rotor coreless permanent magnets 7. It is the skeleton component of the rotor coreless permanent magnets and the structural framework for mounting the permanent magnets. The coreless polymer precision-cast rotor ironless permanent magnet polymer precision-cast packaging plate 8 is hinged through the coreless polymer precision-cast frame structural holes 22. The coreless polymer precision-cast rotor frame 6 and the rotor coreless permanent magnets 7 are encapsulated by the pressure-filled, clamped, and fastened together into one piece. They are then installed in the rotor-shaped structural housing 15. The main shaft 9 is the main shaft of the permanent magnet motor. The keyway 11 and keyway assembly 28 on the main shaft 9 are hinged together with the coreless polymer precision-cast rotor frame 6 and the rotor coreless permanent magnets 7 to form a single piece. Together with the bearing assembly and gland 10, they form an important part of the permanent magnet motor's motion starter. The main shaft 9 passes through the first and second main shaft sleeves 14 and 24 of the stator housing 1, and the coreless rotor shaft sleeve 27 of the rotor housing 15, hinged to a keyway assembly 28. The rotor housing 15 has a concave tongue-and-groove 16 integrated with the stator housing 1, and a convex tongue-and-groove 17 integrated with the stator housing 1. The rotor housing 15 is secured and sealed via first structural bolt holes 13 and bolt assemblies 18. The winding coil leads 26 are compressed into the terminal box 12 according to phase.

[0044] Example 2 Figure 3-4 、 Figure 7-13As shown. Embodiment 2 of the present invention includes an ironless polymer material precision casting stator frame 2, an ironless stator radial winding 3, an ironless polymer material precision casting frame heat dissipation channel 4, an ironless polymer material precision casting frame moment reinforcement structure 5, an ironless polymer material precision casting rotor frame 6, an ironless rotor permanent magnet 7, an ironless rotor permanent magnet polymer material precision casting packaging plate 8, a main shaft 9, a bearing assembly and a gland 10, a keyway 11, a terminal box 12, a third main shaft structure sleeve 32, a concave tongue-and-groove 16, a convex tongue-and-groove 17, and a bolt assembly 1. 8. Stator type structural housing 19, rotor type housing 20, second structure bolt hole 21, ironless polymer material precision casting frame structure hole 22, winding coil compartment 23, second main shaft structure sleeve 24, winding coil gap 25, winding coil outlet 26, ironless rotor shaft sleeve opening 27, keyway assembly 28, stator ironless axial winding frame 29, stator ironless winding bracket 30, stator ironless axial winding 31, third main shaft structure sleeve 32. This is the permanent magnet motor structure type with rotors on both sides of the stator.

[0045] Main process flow: The present invention prefers axial windings and radial windings. In the stator coreless axial winding frame 29 and the stator coreless winding bracket 30, a stator coreless axial winding 31 or a stator coreless radial winding 3 is prepared. The stator coreless axial winding 31 or the stator coreless radial winding 3 is formed into an integral part of the coreless polymer material precision cast stator frame 2, and is prepared and pressed into a calibration position on the inner wall of the stator-type structural shell 19.

[0046] The prepared rotor coreless permanent magnet 7 is assembled on the coreless polymer precision casting rotor frame 6, and is hinged to the rotor coreless permanent magnet polymer precision casting packaging plate 8 through the coreless polymer precision casting frame structure hole 22. The coreless polymer precision casting rotor frame 6 and the rotor coreless permanent magnet 7 are pressed, inlaid, clamped and fastened into one.

[0047] The main shaft 9 passes through the coreless rotor sleeve opening 27 on the rotor-type housing 20, and the concave tongue-and-groove 16 of the stator-type structural housing 19 and the convex tongue-and-groove 17 of the rotor-type housing 20 are combined to form a sealing structure fastening between various types of housings of permanent magnet motors, and the winding coil outlet end 26 is connected to the terminal box 12 of the stator-type structural housing 19.

[0048] Then pass through the third main shaft structure sleeve 32 and the second main shaft structure sleeve 24 of the stator type structural shell 17, install the integral components of the ironless polymer material precision casting rotor frame 6 and the rotor ironless permanent magnet 7, and fasten them together with the keyway 11 and the keyway assembly 28 hinge.

[0049] Continue to pass through the third main shaft structure sleeve 32 and the second main shaft structure sleeve 24 on the rotor type housing 20, and the convex tongue and groove 17 of the rotor type housing 20 and the concave tongue and groove 16 of the stator type structural housing 19 are combined to form a sealing structure between various types of housings of permanent magnet motors, and the winding coil outlet end 26 is connected to the terminal box 12 of the stator type structural housing 19.

[0050] The keyway 11 and keyway assembly 28 on the main shaft 9 are hingedly connected to the ironless polymer precision-cast rotor frame 6 and the ironless permanent magnet 7. They are then hingedly connected to the bearing assembly and gland 10 to form a single unit. Bolt assemblies 18 pass through the first structural bolt holes 13 to hinge and secure the ironless permanent magnet motor, completing the overall process for the rotor motor structure on both sides of the central stator.

[0051] Example 3 Figure 5-6 、 Figure 7-13 As shown. Embodiment 3 of the present invention includes a stator housing 1, an ironless polymer material precision casting stator frame 2, a stator ironless core winding 3, an ironless polymer material precision casting frame heat dissipation channel 4, an ironless polymer material precision casting frame moment reinforcement structure 5, an ironless polymer material precision casting rotor frame 6, a rotor ironless core permanent magnet 7, a rotor ironless core permanent magnet polymer material precision casting packaging plate 8, a main shaft 9, a bearing assembly and a gland 10, a keyway 11, a terminal box 12, a first structure bolt hole 13, a first main shaft structure sleeve 14, and a rotor housing 15. , concave tongue and groove 16, convex tongue and groove 17, bolt assembly 18, stator type structural shell 19, ironless polymer material precision casting frame structure hole 22, winding coil compartment 23, second main shaft structure sleeve 24, winding coil gap 25, winding coil outlet 26, ironless rotor shaft sleeve mouth 27, keyway assembly 28, stator ironless axial winding frame 29, stator ironless winding bracket 30, stator ironless axial winding 31, this is a three-stator two-rotor type permanent magnet motor structure type or a multi-stator multi-rotor type permanent magnet motor structure type.

[0052] Main process flow: The present invention first selects axial winding, and secondarily selects radial winding. In the stator coreless axial winding frame 29 and the stator coreless winding bracket 30, a stator coreless axial winding 31 or a stator coreless radial winding 3 is prepared. The stator coreless axial winding 31 or the stator coreless radial winding 3, which is integrated with the coreless polymer material precision-cast stator frame 2, is prepared and pressed into the calibration position on the inner wall of the stator type shell 1 and the stator type structural shell 19.

[0053] The prepared rotor coreless permanent magnet 7 is assembled on the coreless polymer precision casting rotor frame 6, and is hinged to the rotor coreless permanent magnet polymer precision casting packaging plate 8 through the coreless polymer precision casting frame structure hole 22. The coreless polymer precision casting rotor frame 6 and the rotor coreless permanent magnet 7 are pressed, inlaid, clamped and fastened into one.

[0054] The main shaft 9 passes through the first main shaft structure sleeve 14 and the second main shaft structure sleeve 24 of the stator type housing 1. The convex tongue-and-groove 17 of the stator type housing 1 and the concave tongue-and-groove 16 of the rotor type structural housing 15 together form a sealing structure fastening between various types of housings of permanent magnet motors. The winding coil outlet 26 is connected to the terminal box 12 of the stator type housing 1.

[0055] Then pass through the coreless rotor sleeve opening 27 of the rotor-type structural housing 15, install the integral component of the coreless polymer material precision casting rotor frame 6 and the rotor coreless permanent magnet 7, and fasten them together with the keyway 11 and the keyway assembly 28 hinge.

[0056] Continue to pass through the first main shaft structure sleeve 14 and the second main shaft structure sleeve 24 on the stator type structure housing 19, and the convex tongue and groove 17 of the stator type structure housing 19 and the concave tongue and groove 16 of the rotor type structure housing 15 are combined to form a sealing structure between various types of housings of permanent magnet motors, and the winding coil outlet end 26 is connected to the terminal box 12 of the stator type structure housing 19.

[0057] Continue to pass through the coreless rotor sleeve opening 27 of the rotor-type structural housing 15, install the coreless polymer material precision casting rotor frame 6 and the rotor coreless permanent magnet 7 as an integral component, and fasten the keyway 11 and the keyway assembly 28 together with the hinge.

[0058] The winding coil continues to pass through the first main shaft structure sleeve 14 and the second main shaft structure sleeve 24 on the stator type housing 1. The convex tongue-and-groove 17 of the stator type housing 1 and the concave tongue-and-groove 16 of the rotor type structure housing 15 are combined to form a sealing structure between various types of housings of permanent magnet motors, and the winding coil outlet end 26 is connected to the terminal box 12 of the stator type housing 1.

[0059] The keyway 11 and keyway assembly 28 on the main shaft 9 are hinged with the coreless polymer material precision casting rotor frame 6 and the rotor coreless permanent magnet 7, and then hinged with the bearing assembly and the pressure cover 10 to form a whole.

[0060] The bolt assembly 18 passes through the first structural bolt hole 13 to hinge and fasten the coreless permanent magnet motor into one piece, completing the overall process of preparing the permanent magnet motor structure type with three stators and two rotors or the permanent magnet motor structure type with multiple stators and multiple rotors. The process flow of the multi-stator and multi-rotor motor structure type is the same.

[0061] The working principle of the present invention is as follows:

[0062] The working principle is basically the same as that of a traditional motor. A three-phase current is passed through the stator coreless axial winding 31 or the stator coreless radial winding 3 fixed to the motor. After the current is passed through, a rotating magnetic field is formed in the stator coreless axial winding 31 or the stator coreless radial winding 3 of the motor. Since permanent magnets are installed on the rotor coreless permanent magnet 7, the magnetic poles of the permanent magnets are fixed. According to the principle that like poles attract and opposite poles repel, the rotating magnetic field generated in the stator coreless axial winding 31 or the stator coreless radial winding 3 will drive the rotor coreless permanent magnet 7 to rotate. The working principle of the stator coreless axial winding 31 or the stator coreless radial winding 3 can be understood in the way of magnetic potential equivalence. The end directions of the vertically embedded axial winding and the horizontally embedded radial winding of the stator coreless axial winding 31 or the stator coreless radial winding 3 are inconsistent, the direction of the current in each slot is consistent, and the shape of the potential formed by the winding is also the same, so the stator coreless axial winding 31 or the stator coreless radial winding 3 are equivalent.

[0063] The pole arc coefficient has a great influence on the torque pulsation. When the pole arc electrical angle is appropriate, the torque fluctuation value is minimized, which can suppress the torque pulsation. The combination of the permanent magnets of the arc magnetic pole type, circular magnetic pole type, and multi-shaped magnetic pole type rotor coreless permanent magnets 7 belongs to the polymer material precision casting packaging plate 8 edge pressing and filling clamping process, which firmly fastens the permanent magnets. This setting is equivalent to narrowing the slot, minimizing the torque fluctuation value, and suppressing the torque pulsation.

[0064] The stator has an iron-coreless axial winding 31. The axial winding is directly wound around the upper and lower slots of the iron core. The winding ends are very short, the process is simple, and the slot fill rate is high. The cogging torque changes with the periodic magnetic resistance of the position. When the magnetic potential of the permanent magnet rotor passes through all positions, the magnetic field alternates in size and generates torque. The cogging torque will not generate torque pulsation at this time.

[0065] The stator coreless axial winding 31 axial armature winding induces back electromotive force, which reduces the harmonic components and weakens the harmonic torque, including harmonics other than the fundamental wave. It is equivalent to several harmonic motors generating torque, and the superposition of harmonic torque will not form torque pulsation.

[0066] The rotor has no iron core permanent magnet 7 of arc pole type, circular pole type and polymorphic pole type. Setting the sector surface as arc pole type can reduce the module of the tooth slot. The pole arc coefficient of the permanent magnet in the radial section of the circular pole type and the polymorphic pole type is inconsistent. These two types can achieve the ultimate effect. The tooth slot torque waveform amplitude is different, the phase is the same, and the torque amplitude superposition is extremely high, which mainly achieves the effect of "phase deviation".

[0067] Reactive operation, coasting, and vector energy recovery are converted from the power motor to a generator, generating power feedback, and the recovered energy can be controlled according to the design.

[0068] The present invention is significantly different from similar motors currently available on the market, in which: the stator coreless axial winding 31 used in the permanent magnet motor of the present invention is mostly a radial winding structure on the market, which is relatively complex, and the heat dissipation area of the radial built-in structure of the rotor is too large, and the eddy current circulation cooling effect is relatively poor. This solution adopts the stator coreless axial winding 31, and the axial structure setting effect is better, the air gap volume and space are large, which is conducive to heat dissipation, cost control and convenient maintenance; the arc magnetic pole type, circular magnetic pole type, and polymorphic magnetic pole type rotor coreless permanent magnet 7 are of arc magnetic pole type with a sector surface, which can reduce the module of the tooth slot. The circular magnetic pole type and the polymorphic magnetic pole type have inconsistent pole arc coefficients of the permanent magnet in the radial cross section. These two types can achieve the ultimate effect, and their tooth slot torque waveform amplitudes are different, the phases are the same, and the torque amplitude superposition is extremely high, mainly to achieve the effect of "staggered phase".

[0069] High power density is achieved primarily by targeting high power density and high torque density, reducing wind friction losses, and selecting high-quality high-speed bearings. The high torque density achieves a high reluctance torque ratio, generating harmonic torque through controlled injection of multiple harmonics, thereby concentrating high magnetic field energy per unit volume. This high torque density is achieved by aligning the motor's magnetic field with an axial magnetic field, which expands axially. The ironless permanent magnets have a large fan-shaped expansion area. The reserved air gap is large, and the airflow is directed in a straight line, eliminating eddy currents and heat accumulation. This increases magnetic energy density and provides a large energy exchange space, resulting in a torque density improvement of over 25% compared to conventional motors. Arc, circular, and polymorphic pole patterns are available, and these pole-shaped configurations offer low torque ripple noise and a torque density of up to 25 NM / kg. This is the fundamental operating principle of the high power density, high torque density, and high magnetic energy density of the ironless, high-energy-density permanent magnet motor, which automatically increases and decreases power and torque for power generation and charging.

[0070] This setting can achieve the following beneficial effects: its high power per unit weight can reach more than 7kw / kg, and the torque density is 25Nm / kg; the magnetic field energy density is high; it can be designed to be 500-25,000 rpm; it has the characteristics of simple structure, high power density, high torque density, high magnetic field energy density, low cost and good effect, and can be widely promoted and used in the field of transportation power to automatically increase and decrease power torque, generate electricity and charge high energy density coreless permanent magnet motors.

Claims

1. A high energy density ironless permanent magnet motor with automatic power increase and decrease torque generation and charging, used for vehicles, ships, aircraft, general power multi-purpose permanent magnet power motor, comprising a stator winding, a stator frame, a rotor permanent magnet, a rotor frame, a main shaft (9), a bearing assembly and a gland (10) and a housing, characterized in that: The stator frame is a coreless polymer precision casting stator frame (2), the stator winding is a coreless stator winding, the coreless stator winding is distributed along the circumference of the coreless polymer precision casting stator frame (2), and the coreless polymer precision casting stator frame (2) is directly and spacedly mounted on the stator shell (20) or the stator structure shell (19); the rotor frame is a coreless polymer precision casting rotor frame (6), the rotor permanent magnet is a coreless rotor permanent magnet (7), the coreless rotor permanent magnet (7) is distributed along the circumference of the coreless polymer precision casting rotor frame (6), and the coreless polymer precision casting rotor frame (6) is directly and spacedly mounted on the stator shell (20) or the stator structure shell (19). The polymer material precision casting rotor frame (6) is directly hinged and fixed on the main shaft (9); the iron-core polymer material precision casting stator frame (2) is adjacent to the iron-core polymer material precision casting rotor frame (6); the housing includes two stator-type shells (1) or rotor-type shells (20) on both sides and a rotor-type structure shell (15) or stator-type structure shell (19) in the middle, the iron-core polymer material precision casting stator frame (2) is located inside the stator-type shell (1) or stator-type structure shell (19), and the iron-core polymer material precision casting rotor frame (6) is located outside the rotor-type shell (20) or rotor-type structure shell The shell (15) is provided with a coreless polymer material precision casting stator frame (2), which includes an outer circular frame, a middle circular frame, a coreless polymer material precision casting frame heat dissipation channel (4), a coreless polymer material precision casting frame moment reinforcement structure (5), and connecting straight rods connected radially therebetween; the outer circular frame, the middle circular frame and the connecting straight rods are provided with coreless polymer material precision casting frame structure holes (22); a winding coil compartment (23) is formed between the outer circular frame, the middle circular frame and two adjacent connecting straight rods; the coreless polymer material precision casting rotor frame (6) includes an outer circular frame, a middle circular frame, An iron-coreless polymer material precision casting frame moment-enhancing structure (5) and connecting straight rods radially connected therebetween; an outer circular frame, a middle circular frame and the connecting straight rods are provided with iron-coreless polymer material precision casting frame structure holes (22); the rotor iron-coreless permanent magnet polymer material precision casting packaging plate (8) comprises an outer circular frame, a middle circular frame and connecting straight rods radially connected therebetween; an iron-coreless polymer material precision casting frame structure holes (22) are provided on the outer circular frame, the middle circular frame and the connecting straight rods; the rotor iron-coreless permanent magnet (7) is of arc magnetic pole type, circular magnetic pole type or polymorphic magnetic pole type.

2. The high energy density coreless permanent magnet motor with automatic power increase and decrease torque generation and charging according to claim 1 is characterized in that: The housing is connected via a bolt assembly (18); a junction box (12) is provided on the stator-type housing (1) and the stator-type structural housing (19).

3. A high energy density coreless permanent magnet motor with automatic power increase and decrease torque generation and charging according to claim 1 or 2, characterized in that: The rotor frame is an ironless polymer precision casting rotor frame (6), which is located in the middle of the main shaft (9). The ironless polymer precision casting rotor frame (6) is hinged and fastened to the main shaft (9); an ironless polymer precision casting stator frame (2) is provided on each side, and the ironless polymer precision casting stator frame (2) is directly spaced and sleeved on the stator type housing (1); the housing includes the stator type housings (1) on both sides and a rotor type structural housing (15) in the middle.

4. A high energy density coreless permanent magnet motor with automatic power increase and decrease torque generation and charging according to claim 1 or 2, characterized in that: The ironless polymer material precision casting stator frame (2) is located in the middle of the main shaft (9), and an ironless polymer material precision casting rotor frame (6) is provided on each side, and the ironless polymer material precision casting rotor frame (6) is hinged and fastened to the main shaft (9); the casing includes rotor-type shells (20) on both sides and a stator-type structure shell (19) in the middle, and the ironless polymer material precision casting stator frame (2) is directly spaced and sleeved on the stator-type structure shell (19).

5. The high energy density ironless permanent magnet motor with automatic power increase and decrease torque generation and charging according to claim 1 or 2, characterized in that: The iron-free polymer material precision casting stator frame (2) comprises three groups, one of which is located in the middle of the main shaft (9), and the other two groups are respectively located on the two outer sides of the main shaft (9). The three groups of iron-free polymer material precision casting stator frames (2) are respectively directly mounted on the stator-type housings (1) on both sides and the stator-type structural housing (19) in the middle. The rotor skeleton is an iron-free polymer material precision casting rotor frame (6), which comprises two groups, respectively located on both sides of the iron-free polymer material precision casting stator frame (2) in the middle of the main shaft (9) and on the inner sides of the two outer iron-free polymer material precision casting stator frames (2). The iron-free polymer material precision casting rotor frame (2) is hingedly fastened to the main shaft (9). The housing comprises stator-type housings (1) on both sides, a stator-type structural housing (19) in the middle, and a rotor-type structural housing (15) between the stator-type structural housing (19) and the stator-type housings (1) on both sides.

6. The high energy density coreless permanent magnet motor with automatic power increase and decrease torque generation and charging according to claim 1 or 2, characterized in that: The center of the coreless polymer material precision casting frame moment-increasing and reinforcing structure (5) forms a second main shaft structure sleeve (24).

7. The high energy density ironless permanent magnet motor with automatic power increase and decrease torque generation and charging according to claim 1 or 2, characterized in that: The center of the coreless polymer material precision casting frame moment-increasing and reinforcing structure (5) forms an ironless rotor shaft sleeve opening (27), and a keyway assembly (28) is provided on the ironless rotor shaft sleeve opening (27).

8. The high energy density coreless permanent magnet motor with automatic power increase and decrease torque generation and charging according to claim 1 or 2, characterized in that: The stator coreless winding is a stator coreless radial winding (3) or a stator coreless axial winding (31); the stator coreless radial winding (3) or the stator coreless axial winding (31) is wound and installed in an ironless polymer material precision casting stator frame (2), and a winding coil gap (25) of 1 to 3 mm is formed between the windings.

9. The high energy density coreless permanent magnet motor with automatic power increase and decrease torque generation and charging according to claim 1 or 2, characterized in that: The rotor coreless permanent magnet (7) is assembled on the coreless polymer precision casting rotor frame (6), hinged on the rotor coreless permanent magnet polymer precision casting packaging plate (8), packaged in the coreless polymer precision casting rotor frame (6) and the rotor coreless permanent magnet (7) is clamped and fastened into one; the main shaft (9) is provided with a keyway (11), the keyway (11) and the keyway assembly (28) are hinged with the coreless polymer precision casting rotor frame (6) and the rotor coreless permanent magnet (7), and then are hinged with the bearing assembly and the pressure cover (10) to form a whole.

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