An axial flux motor stator and a manufacturing method thereof

Abstract

The present invention relates to an axial flux motor stator and a manufacturing method thereof. The axial flux motor stator includes a fixed support assembly, a segmented iron core, and a stator coil. The fixed support assembly includes an upper plate, a lower plate, and a connecting cylinder. One end of the connecting cylinder is fixedly connected to the lower plate, and the other end is detachably connected to the upper plate. A lower mounting groove is formed on the lower plate, and corresponding upper mounting grooves are formed on the upper plate one by one. Both ends of the segmented iron core are respectively inserted into the upper mounting groove and the lower mounting groove, and the stator coil is wound around the side surface of the segmented iron core; each segmented iron core includes an intermediate component and iron core segments fixedly connected to both side surfaces of the intermediate component respectively. Implementing the embodiments of the present invention has the following beneficial effects: The segmented iron core of this axial flux motor stator is manufactured by a combined method, and at the same time, two materials, silicon steel sheet and SMC, are used. Its electromagnetic performance is higher than that of using only SMC material, and the iron core utilization rate is higher than that of using only laminated iron core.

Description

Technical Field

[0001] The present invention relates to the technical field of motor stators, and particularly to an axial-flux motor stator and a manufacturing method thereof. Background Art

[0002] The stator core of an axial-flux motor is divided into an integral core and a segmented core, and generally the segmented core is mainly used. At present, the segmented core is generally formed by stacking silicon steel sheets with various different cross-sectional sizes or by integrally molding SMC (Soft Magnetic Composites). For the method of laminating silicon steel sheets with various different cross-sectional sizes, since a large number of types of silicon steel sheets with different specifications are required, a large number of molds with different specifications are needed, increasing the process difficulty; for the method of integrally molding with SMC, although it can meet the requirements of structural molding, the electromagnetic properties of the SMC material are poor, the magnetic permeability is not high and the loss is large.

[0003] For example, in a manufacturing method of a segmented core described in CN111756125A, the segmented core in this invention is formed by stacking silicon steel sheets with various different cross-sectional sizes and then splicing with two SMC soft magnetic sleeves to form the outer shape of the segmented core. Then, multiple segmented cores are spliced into a complete stator core through a fixture. Although this method can effectively fix the segmented core and meet the performance requirements, the structural components are too complex, and silicon steel sheets with various different cross-sectional sizes are required, resulting in a large process difficulty.

[0004] For example, in a manufacturing method of a segmented core described in CN111181261A, the bottom plate, stator teeth and magnetic conduction blocks of the segmented core in this invention can be produced and manufactured separately, and then assembled into an axial-flux motor stator. The stator teeth can be formed by laminating multiple layers of silicon steel sheets or integrally molding with SMC materials. This method reduces the production difficulty of the stator core, but the gaps between the segmented cores are distributed in a fan shape, the gaps are too large, and the process density of the motor is low. Summary of the Invention

[0005] In view of this, it is necessary to provide an axial-flux motor stator and a manufacturing method thereof to solve the technical problems in the prior art that the manufacturing process of the stator manufactured by laminating silicon steel sheets is complex, and the electromagnetic performance of the stator made by integrally molding with SMC is poor.

[0006] The present invention provides an axial flux motor stator, which includes a fixed support assembly, segmented iron cores, and stator coils. The fixed support assembly includes an upper plate, a lower plate, and a connecting cylinder. One end of the connecting cylinder is fixedly connected to the lower plate, and the other end is detachably connected to the upper plate. A lower mounting groove is formed on the lower plate, and corresponding upper mounting grooves are formed on the upper plate. Both ends of the segmented iron cores are respectively inserted into the upper mounting grooves and the lower mounting grooves, and the stator coils are wound around the sides of the segmented iron cores; each segmented iron core includes an intermediate component and iron core segments fixedly connected to both side surfaces of the intermediate component.

[0007] Further, both ends of the segmented iron cores are fan-shaped, and the shapes and sizes of the upper mounting grooves and the lower mounting grooves respectively match both ends of the segmented iron cores.

[0008] Further, the cross-section of the intermediate component is an isosceles triangle, the cross-section of the iron core segment is a rectangle, and the iron core segment fits against the side where the waist of the isosceles triangle is located and is fixedly connected to the intermediate component.

[0009] Further, the intermediate component and the iron core segment are bonded or riveted.

[0010] Further, the connecting cylinder is of a cylindrical structure, and corresponding circular upper through holes and lower through holes are formed on the upper plate and the lower plate, and both ends of the connecting cylinder communicate with the upper through hole and the lower through hole respectively.

[0011] Further, the lower mounting grooves are arranged in a circle and are equidistantly arranged around the connecting cylinder.

[0012] Further, the iron core segment is composed of a plurality of stacked silicon steel sheets.

[0013] Further, the material of the intermediate component is SMC.

[0014] Further, connecting holes are formed on the upper plate and the lower plate for connecting with the motor housing.

[0015] The present invention also provides a manufacturing method of an axial flux motor stator, which includes the following steps: S1. Stack silicon steel sheets to obtain iron core segments, and integrally form an intermediate component using SMC material; S2. Attach and install the iron core segments on both sides of the intermediate component, and perform pre-fastening by bonding or riveting to obtain segmented iron cores; S3. Wind stator coils on the segmented iron cores, and then perform potting treatment on them to obtain a wound iron core; S4. Assemble the fixed support assembly so that both ends of the wound iron core are inserted into the upper mounting grooves and the lower mounting grooves to obtain an axial flux motor stator.

[0016] Compared with the prior art, the segmented iron core of the axial-flux motor stator of the present invention is composed of a combination of a core segment laminated with silicon steel sheets of the same cross-sectional size and a structural member integrally formed by SMC. The difficult-to-machine outer shape is segmented, and a complex structural outer shape is obtained through a combined form. Since the silicon steel sheets use the same cross-sectional size, only one mold for silicon steel sheets is required, which greatly reduces the manufacturing cost of silicon steel sheets. Moreover, the segmented iron core has a simple structure, reducing the manufacturing process difficulty of the segmented iron core.

[0017] In addition, the segmented iron core is manufactured by a combined method and uses two materials, silicon steel sheets and SMC. Its electromagnetic performance is higher than that of using only SMC material, and the iron core utilization rate is higher than that of using only laminated iron cores.

[0018] The above description is only an overview of the technical solution of the present invention. In order to be able to more clearly understand the technical means of the present invention and implement it in accordance with the content of the specification, the preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. The specific implementation manners of the present invention are given in detail by the following embodiments and their accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The drawings described herein are used to provide a further understanding of the present invention and form a part of this application. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0020] Figure 1 is an exploded view of the axial-flux motor stator provided by the present invention;

[0021] Figure 2 is Figure 1 the exploded view of the segmented iron core in

[0022] Figure 3 is a flowchart of the manufacturing method of the axial-flux motor stator provided by the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0023] The following specifically describes the preferred embodiments of the present invention in conjunction with the accompanying drawings. The accompanying drawings form a part of this application and are used together with the embodiments of the present invention to explain the principles of the present invention, and are not used to limit the scope of the present invention.

[0024] Please refer to Figure 1 and Figure 2 , the axial-flux motor stator of the present invention includes a fixed support assembly, a segmented iron core 2, and a stator coil 3. The stator coil 3 is wound around the segmented iron core 2 to form a winding iron core, and the fixed support assembly is used to connect and fix the winding iron core.

[0025] The fixed support component includes an upper plate 11, a lower plate 12, and a connecting cylinder 13. One end of the connecting cylinder 13 is fixedly connected to the lower plate 12, and the other end is detachably connected to the upper plate 11. A lower installation groove is formed on the lower plate 12, and corresponding upper installation grooves are formed on the upper plate 11. Both ends of the segmented iron core 2 are respectively inserted into the upper installation groove and the lower installation groove, and the fixed support component clamps the segmented iron core 2 from both ends. The stator coil 3 is wound around the side of the segmented iron core 2 and forms a winding iron core together with the segmented iron core 2. Connecting holes are formed on the upper plate 11 and the lower plate 12 for connecting with the motor housing.

[0026] In this embodiment, in order to facilitate the installation of the rotor, the connecting cylinder 13 preferably adopts a cylindrical structure, and corresponding circular upper through holes and lower through holes are formed on the upper plate 11 and the lower plate 12. Both ends of the connecting cylinder 13 communicate with the upper through hole and the lower through hole respectively, forming a cylindrical cavity. In order to obtain better electrical performance, the lower installation grooves are arranged in a circle and are equally spaced around the connecting cylinder 13. That is, the distances from each lower installation groove to the connecting cylinder 13 are equal, and the distances between adjacent two lower installation grooves are also equal. Since the upper installation grooves and the lower installation grooves correspond to each other, the upper installation grooves are also arranged in a circle and are equally spaced around the connecting cylinder 13.

[0027] In order to make the gaps between adjacent two segmented iron cores 2 uniform, the cross-section of the segmented iron core 2 preferably adopts a fan-shaped structure and is arranged around the connecting cylinder 13. Correspondingly, the upper installation groove and the lower installation groove are also fan-shaped, and the sizes respectively match the two ends of the segmented iron core 2, so that the two ends of the segmented iron core 2 can be exactly installed in the upper installation groove and the lower installation groove.

[0028] In order to reduce the manufacturing process difficulty of the segmented iron core 2, in this embodiment, each segmented iron core 2 includes an intermediate component 21 and iron core segments 22 fixedly connected to both side surfaces of the intermediate component 21 respectively. The cross-section of the intermediate component 21 is an isosceles triangle, the cross-section of the iron core segment 22 is a rectangle, and the iron core segment 22 fits against the side surface where the waist of the isosceles triangle is located and is fixedly connected to the intermediate component 21. This fixed connection method can adopt bonding or riveting.

[0029] In this embodiment, the intermediate component 21 is integrally formed by SMC, and the iron core segments 22 are composed of a plurality of stacked silicon steel sheets. By combining silicon steel sheets and SMC, better electromagnetic performance and iron core utilization rate can be obtained.

[0030] Please refer to Figure 3 , the manufacturing method of the stator of this axial flux motor, includes the following steps: S1. Stack silicon steel sheets to obtain the iron core segments 22, and integrally form the intermediate component 21 by using SMC material.

[0031] S2. Install the iron core segments 22 against both sides of the intermediate component 21 and perform pre-fastening by bonding or riveting to obtain the segmented iron core.

[0032] S3. Wind the stator coil 3 around the segmented iron core, and then perform potting treatment on it to obtain a wound iron core.

[0033] S4. Assemble and fix the support component so that both ends of the wound iron core are inserted into the upper mounting groove and the lower mounting groove to obtain the stator of the axial flux motor of the present invention.

[0034] Implementing the embodiments of the present invention has the following beneficial effects: The segmented iron core of the stator of the axial flux motor of the present invention is composed of a combination of a core segment laminated with silicon steel sheets of the same cross-sectional size and an SMC integral structure member. The difficult-to-process outer shape is segmented, and a complex structural outer shape is obtained through a combined form. Since the silicon steel sheets use the same cross-sectional size, only one mold for silicon steel sheets is required, which greatly reduces the manufacturing cost of silicon steel sheets. Moreover, the segmented iron core has a simple structure, reducing the manufacturing process difficulty of the segmented iron core.

[0035] Furthermore, the segmented iron core is manufactured by a combined method and uses two materials, silicon steel sheets and SMC. Its electromagnetic performance is higher than that of using only SMC material, and the iron core utilization rate is higher than that of using only laminated iron cores.

[0036] As described above, the above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention should be covered by the protection scope of the present invention.

Claims

1. An axial flux motor stator, characterized in that, It includes: A fixed support component, a segmented iron core, and a stator coil. The fixed support component includes an upper plate, a lower plate, and a connecting cylinder. One end of the connecting cylinder is fixedly connected to the lower plate, and the other end is detachably connected to the upper plate. A lower mounting groove is formed on the lower plate, and corresponding upper mounting grooves are formed on the upper plate. Both ends of the segmented iron core are respectively inserted into the upper mounting groove and the lower mounting groove, and the stator coil is wound around the side surface of the segmented iron core; Each of the segmented iron cores includes an intermediate component and iron core segments fixedly connected to both side surfaces of the intermediate component; The iron core segments are composed of a plurality of silicon steel sheets stacked with the same cross-sectional size, and the material of the intermediate component is SMC; The cross-section of the intermediate component is an isosceles triangle, the cross-section of the iron core segment is a rectangle, and the iron core segment fits against the side surface where the waist of the isosceles triangle is located and is fixedly connected to the intermediate component.

2. The axial flux motor stator according to claim 1, characterized in that, Both ends of the segmented iron core are fan-shaped, and the shapes and sizes of the upper mounting groove and the lower mounting groove respectively match both ends of the segmented iron core.

3. The axial flux motor stator according to claim 2, characterized in that, The intermediate component is bonded or riveted to the iron core segment.

4. The axial flux motor stator according to claim 1, characterized in that, The connecting cylinder is of a cylindrical structure, and corresponding circular upper through holes and lower through holes are formed on the upper plate and the lower plate, and both ends of the connecting cylinder communicate with the upper through hole and the lower through hole respectively.

5. The axial flux motor stator according to claim 4, characterized in that, The lower mounting grooves are arranged in a circle and are equidistantly arranged around the connecting cylinder.

6. The axial flux motor stator according to claim 1, characterized in that, Connecting holes are formed on the upper plate and the lower plate for connecting with the motor housing.

7. A manufacturing method of the axial flux motor stator according to any one of claims 1-6, characterized in that, It includes the following steps: S1. Stack silicon steel sheets to obtain the iron core segments, and integrally form the intermediate component using SMC material; S2. Install the iron core segments against both sides of the intermediate component and pre-fasten them by bonding or riveting to obtain the segmented iron core; S3. Wind the stator coil on the segmented iron core, and then perform potting treatment on it to obtain the wound iron core; S4. Assemble the fixed support component so that both ends of the wound iron core are inserted into the upper mounting groove and the lower mounting groove to obtain the axial flux motor stator.

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