Axial flux electric machine comprising a mechanically fixed stator core with radially extending segments of sheet metal

Abstract

The invention relates to an axial flux electric machine (1) comprising a ring-shaped stator (2) and two rotor elements (4a, 4b) mounted in such a way that they can rotate relative to the stator (2) about an axis of rotation (3), wherein the first rotor element (4a) is arranged axially adjacent to a first end face (5a) of the stator (2) and the second rotor element (4b) is arranged axially adjacent to a second end face (5b) of the stator (2), and wherein the stator (2) has a plurality of stator cores (6) distributed in a circumferential direction of an annular line extending about the axis of rotation (3), wherein at least one stator core (6) has a plurality of radially extending guide sections (7) stacked on top of one another in the circumferential direction and having a plate-like design, wherein at least a part of the number of guide sections (7) has a holding contour (10a, 10b) on its radially outer side (8) and / or on its radially inner side (9), which holding contour is accommodated in an interlocking manner on at least one bearing area (11, 12) fixed to a housing.

Description

TECHNICAL FIELD

[0001] The present invention relates to an axial flux electric machine, preferably for a drive train of an electric or hybrid electric motor vehicle, comprising an annular stator and two rotor elements mounted in a manner rotatable relative to the stator about a (common) axis of rotation, wherein a first rotor element is arranged axially (along the axis of rotation) adjacent to a first (axial) end face of the stator and a second rotor element is arranged axially adjacent to a second (axial) end face of the stator, and wherein the stator has a plurality of stator cores distributed along a circumferential direction of an annular line extending about the axis of rotation. BACKGROUND

[0002] General axial flux electric machines are known from the background art. For example, WO 2018 / 015293 A1 discloses a stator for an axial flux electric machine having a stator portion formed from a plurality of sheet materials and provided with teeth.

[0003] Further background art is known, for example, from WO 2014 / 166811 A2, which discloses a lightweight axial flux electric machine in which a plurality of stator teeth are connected to each other in end regions via respective ring-like structures and to a housing radially surrounding the stator on the outside. It is thus known to construct the stator cores by means of sheet materials arranged laterally to the stator cores in the axial direction.

[0004] However, a disadvantage of these designs known from the background art is that the mechanical fixing of the stator cores is often insufficient. Furthermore, the magnetic reluctance present in the desired direction is often still relatively large. In addition, eddy currents can form in the magnetic cores due to the alternating current in the windings and the magnetic field from the rotor. At the same time, there is a need for effective cooling of the stator windings and the stator cores for these systems. SUMMARY

[0005] It is therefore an object of the present invention to remedy the disadvantages known from the background art and, in particular, to provide an axial flux electric machine with as stable stator cores as possible, in which, at the same time, the magnetic reluctance in the desired direction is reduced and undesirable eddy currents are avoided. At the same time, effective cooling of the components of the stator is achieved.

[0006] According to the application, this is achieved in that the at least one stator core has a plurality of (magnetically conductive) guide segments which are stacked (layered) on top of one another in the circumferential direction, extend radially and have a plate-like (flat) design, wherein at least a portion of the number of guide segments has a retaining contour on its radially outer side and / or on its radially inner side, which is received in an interlocking manner on at least one bearing area which is fixed to the housing (fixed at the mounting position).

[0007] This results in several advantages. On the one hand, the radially extending guide segments, preferably designed as sheet metal segments, ensure a high mechanical strength against forces in the circumferential direction. At the same time, this extension of the guide segments enables good heat transfer from within the guide segments to the outside, preferably towards the fixing. In addition, the radial arrangement of the guide segments enables a high pole pitch, which is particularly advantageous for high torques. The retaining contour on the guide segments simplifies the fixing of the stator core.

[0008] Further advantageous embodiments are claimed by the dependent claims and are explained in more detail below.

[0009] If the guide segments of the at least one stator core are designed as identical parts, a series production can be realized in a particularly economical manner.

[0010] Preferably, the plurality of stator cores is designed identically. In other embodiments, it is also advantageous if the stator cores are differently designed at least with regard to the retaining contour.

[0011] It is further advantageous if the guide segments of the at least one stator core are connected to two axially spaced first bearing areas on the radially outer side and / or to two axially spaced second bearing areas on the radially inner side in an interlocking manner. This even makes the structural design of the stator more robust.

[0012] The at least one bearing area is preferably ring-shaped / designated as retaining ring.

[0013] It is particularly advantageous if the guide segments of the at least one stator core are fastened and / or prevented from tilting about an axis parallel to the axis of rotation in the circumferential direction, in the radial direction and / or in the axial direction of the axis of rotation via the interlocking with respect to the at least one bearing area.

[0014] In order to realize an interlocking connection between the guide segments and the at least one bearing region, it has proven advantageous to provide the at least one bearing region with an axially protruding retaining lobe which protrudes into an undercut which jointly forms a retaining contour and which opens in the axial direction to the at least one bearing region. The retaining lobe is thus preferably inserted into the retaining contour in such a way that the guide segments are supported on the bearing region in both the radial direction and the axial direction and are prevented from tilting about an axis parallel to the rotational axis of the rotor. Forces acting on the stator core tangentially to the rotational axis together with this bearing produce a torque on the respective stator core.

[0015] For a robust circumferential support of the guide segments, it has proven advantageous for the at least one bearing region to have two axially protruding bearing lobes which are spaced apart in the circumferential direction, the guide segments of the respective stator core together being accommodated between the bearing lobes.

[0016] If the at least one stator core is provided with a cover section composed of a soft magnetic composite material towards one or both circumferential sides of the overall guide segment, the magnetic resistance is further reduced.

[0017] It is further preferred for an electrical insulation to be provided between the respective stator cores themselves and / or between the respective stator cores and the at least one bearing region. In the latter case, it is also advantageous for the insulation to be inserted between the sleeve formed by the guide segments and the fixing element, or for the fixing element to be formed directly from a non-conductive material.

[0018] It is further advantageous in this context for the at least one stator core to taper inwards in the radial direction (reduction in the width / extension in the circumferential direction).

[0019] It is furthermore advantageous for the at least one stator core to comprise a plurality of groups of guide segments which differ from one another in the shaping of their guide segments.

[0020] It has been found to be particularly advantageous in this context for the at least one stator core to have, in addition to a first group of a plurality of first guide segments which are designed identically to one another, a second group of a plurality of second guide segments, wherein the second guide segments have a shorter radial extension than the first guide segments and are arranged stacked towards a first circumferential side of the first guide segments of the first group. This further reduces the magnetic resistance.

[0021] It is likewise advantageous in this regard for a third group of a plurality of third guide segments to be arranged on a second circumferential side of the overall first guide segments which faces away from the first circumferential side, in addition to the second group of a plurality of second guide segments, wherein the third guide segments have a shorter radial extension than the first guide segments.

[0022] It is more conducive to assembling the stator core and the entire stator if at least one stator core is divided into two halves in the circumferential direction. In other preferred embodiments, the stator core is further formed as a single piece / undivided, and on the other hand, the cover segments (more preferably two cover segments in each case) are then divided / halved. This provides the advantage that the windings can be manufactured independently of the stator core, and then the windings and stator core are combined.

[0023] Furthermore, it is advantageous that each stator core is provided with a stator winding, wherein the stator winding forms a plurality of axially adjacent winding loops, and the corresponding winding loops narrow inward in the radial direction relative to their axial side width.

[0024] In other words, according to the present invention, the mechanical fixation of the stator core for an axial flux motor is achieved using a radially extending electrical sheet (guide section). The sheet has a radially outer and / or radially inner profile that allows the stator core to be fixed in an interlocking manner. Optionally, the stator core is covered with an SMC material (SMC = "soft magnetic composite") in the circumferential direction. Attached Figure Description

[0025] The invention will now be described in more detail with reference to the accompanying drawings, in which various exemplary embodiments are also shown.

[0026] In the attached diagram:

[0027] Figure 1 A perspective view of an axial flux motor according to the present invention, cut along the longitudinal direction according to a first exemplary embodiment, is shown, wherein the structure of the axial flux motor can be clearly seen.

[0028] Figure 2 The longitudinal section shows the results according to Figure 1 A detailed view of the axial flux motor in the radially outer region of the stator core, which together form the stator, to illustrate its interlocking reception on the two retaining rings.

[0029] Figure 3 A perspective view of the assembly including the stator core and the stator windings surrounding the stator core is shown.

[0030] Figure 4 A perspective view of the stator core is shown, with a complete radial view of the stator core.

[0031] Figure 5 The diagram shows a view of the stator core from the front side.

[0032] Figure 6 A perspective view of the first metal plate segment inserted into the stator core is shown.

[0033] Figure 7It shows that according to Figure 6 Front view of the first metal section.

[0034] Figure 8 A perspective view of a portion of the stator components is shown in longitudinal section, in which, without the stator windings, multiple stator cores with two axially spaced retaining rings distributed circumferentially can be seen from the radially outer side.

[0035] Figure 9 It shows the relationship with Figure 4 Similar to, having Figure 8 A three-dimensional view of the stator core with the orientation implemented in the process.

[0036] Figure 10 A perspective view of the circumferential region of the retaining ring that receives the stator core is shown, illustrating the retaining protrusion and the supporting protrusion that form an interlock.

[0037] Figure 11 It shows Figure 8 The diagram shown is an exploded view of some of the components.

[0038] Figure 12 A perspective view of an assembly of a stator core and stator windings designed according to a second exemplary embodiment is shown, wherein the stator core has different groups of metal sheet segments.

[0039] Figure 13 A perspective view of an assembly of a stator core and stator winding designed according to a third exemplary embodiment is shown, wherein, according to... Figure 12 Compared to the second exemplary embodiment, it even omits the two covering sections made of SMC material.

[0040] Figure 14 A perspective view of the stator coil arrangement structure is shown, in which multiple stator cores wound with coil windings are arranged in rows along the circumferential direction.

[0041] Figure 15 A detailed perspective view of the coil arrangement in the radial outer region of three adjacent stator cores is shown.

[0042] Figure 16 It shows that according to Figure 14 A front view of the entire coil arrangement structure.

[0043] Figure 17 An exploded perspective view of a sub-assembly comprising a stator core and stator windings according to a fourth exemplary embodiment is shown, wherein the stator core is divided into two axial halves.

[0044] Figure 18 It shows multiple bases Figure 17a partial perspective exploded view of a sub-assembly of the stator of the axial flux electric machine 1, wherein each half of the stator core is fixed to one of the two outer retaining rings; and

[0045] Figure 19 A partial perspective exploded view of a sub-assembly of the stator of the axial flux electric machine 1 is shown, wherein, in contrast to the first exemplary embodiment, only the covering section is divided into two axial halves.

[0046] The drawings are purely schematic and serve only to understand the application. Identical elements are provided with identical reference signs. Furthermore, features of the different exemplary embodiments can in principle be freely combined with one another. DETAILED DESCRIPTION

[0047] Figure 1 A configuration of an axial flux electric machine 1 according to the present application is shown, in terms of a preferred first exemplary embodiment. In its preferred application, the axial flux electric machine 1 is used in the drive of a motor vehicle. Accordingly, the corresponding motor vehicle is realized as a purely electric motor vehicle or as a hybrid motor vehicle.

[0048] As already mentioned in connection with Figure 14 As can be seen, the directional information used in the following refers to the center axis of rotation 3 of the two rotor elements 4a, 4b of the axial flux electric machine 1. Thus, the axial direction is the direction along / parallel to the axis of rotation 3, the radial direction is the direction perpendicular to the axis of rotation 3, and the circumferential direction is the direction along a constant diameter annular line extending coaxially around the axis of rotation 3.

[0049] According to the configuration of the axial flux electric machine 1, it has a substantially annular stator 2 which rotates entirely in the circumferential direction Figure 1 Of course, it is also possible to dispense with the individual stator teeth 6 from the composition of the stator 2. As can be seen, the stator 2 has a thickness (axial extension) which is smaller than its radial extension (radial height / thickness).

[0050] As already mentioned, in addition to the stator 2, the two rotor elements 4a, 4b are also part of the axial flux electric machine 1. The first rotor element 4a is arranged towards the first (axial) end face 5a of the stator 2.

[0051] The second (axial) end face 5b of the stator 2, which axially faces away from the first end face 5a, is provided with a second stator element 4b. The rotor elements 4a, 4b are each realized in essentially the same way. Both rotor elements 4a, 4b each have a disc-shaped body 23 and a plurality of magnets 24 (permanent magnets) distributed in the circumferential direction, which are arranged on the axial side of the rotor elements 4a, 4b facing the stator 2. The rotor elements 4a, 4b can also be configured in different ways; for example, they extend radially between flux guide elements shaped like a slice of pie. The rotor elements 4a, 4b are mounted in a typical manner in such a way that they can be rotated relative to the stator 2 about the axis of rotation 3.

[0052] In the overall consideration of Figures 1 to 5 , Figure 8 , Figure 9 and Figure 11 , the stator 2 is equipped with a plurality of stator cores 6 distributed in the circumferential direction of the axis of rotation 3. The stator cores 6 are each realized as identical parts to one another. Each stator core 6 serves to accommodate a stator winding 21 having a plurality of winding loops 22 (see Figure 15 ) arranged side by side in the axial direction. The stator cores 6 and the stator windings 21 generally form stator coils 25 / coil arrangements. As can be seen in Figures 14 to 16 , the stator coils 25 are arranged uniformly and are distributed continuously in the circumferential direction. The stator coils 25 taper in the radial direction towards their inner side. Each stator coil 25, i.e. each stator core 6 and each stator winding 21, thus has a reduced extension in the circumferential direction as seen in its radial direction.

[0053] In the overall consideration of Figures 4 to 7 , it can also be seen that each stator core 6 has a plurality of first guide sections 7 designed as sheet metal sections, which is why these first guide sections 7 are referred to below as first sheet metal sections 7. According to the invention, each stator core 6 has a plurality of first sheet metal sections 7 aligned / running in the radial direction of the axis of rotation 3. Each first sheet metal section 7 in turn extends along the entire radial length of the stator core 6 or even directly forms a radial end of the stator core 6. In Figure 6 and Figure 7 , the first sheet metal sections 7 are shown by way of example. The plurality of first sheet metal sections 7 are stacked on top of one another in the circumferential direction to form a laminated core and are electrically insulated from one another such that only minimal eddy currents occur as a result of changes in the magnetic field, as can be seen in Figure 4 and Figure 5 , and are each insulated from one another in a typical manner by means of an intermediate insulating layer, which is not further shown here for the sake of clarity.

[0054] The first sheet segment 7 is provided with a retaining contour 10a, 10b both towards its radially outer side 8 and towards its radially inner side 9, which are each connected to a bearing area in the form of a retaining ring 11, 12 of the stator 2 in an interlocking manner.

[0055] The first sheet segment 7 is realized entirely as identical parts and each has a specified retaining contour 10a, 10b Figure 7 ). Each retaining contour 10a, 10b is formed by a radially extending portion, which forms two undercuts 14a, 14b towards its axial sides. The first retaining contour 10a is formed as the radially outer side 8 of the stator core 6; the second retaining contour 10b is formed as the radially inner side 9 of the stator core 6. The axially open undercuts 14a, 14b in opposite directions are each fixed to the retaining rings 11, 12. In Figure 8 , Figure 10 and Figure 11 , the interlocking fixing of the first retaining contour 10a on a portion of the two first retaining rings 11 is shown. However, in this context it should be pointed out that the interlocking fixing of the second retaining contour 10b on the second retaining rings 12 on the radially inner side 9 is realized in the same manner.

[0056] In Figure 10 , a first retaining ring 11 is shown as an example for the retaining rings 11, 12. This first retaining ring 11 has an annular band-like area 26, which extends continuously in the circumferential direction. From the band-like area 26, a plurality of retaining lugs 13 and bearing lugs 15a, 15b protrude in the axial direction. The retaining lugs 13 are associated with each stator core 6. Two bearing lugs 15a, 15b are also associated with each retaining lug 13. As observed, the first bearing lug 15a is arranged immediately adjacent to the retaining lug 13 in the circumferential direction towards the first circumferential side 16a; as observed, the second bearing lug 15b is arranged immediately adjacent to the retaining lug 13 in the circumferential direction towards the second circumferential side 16b.

[0057] In this context, it should be pointed out that the retaining rings 11, 12 in the exemplary embodiment have merely exemplary character for the sake of completeness and, therefore, in other embodiments, retaining areas 11, 12 are also formed which are designed differently, however, always realize the fixing of the stator core. In addition, in other embodiments, the first sheet segment 7 is also only partially provided with retaining contours 10a, 10b, which are further attached to the retaining areas 11, 12.

[0058] In Figure 8In the middle, it can be seen that a retaining protrusion 13 of one first retaining ring 11 is inserted into the first undercut 14a such that the stator core 6 is fixed in the radial direction. Furthermore, a retaining protrusion 13 of one first retaining ring 11 abuts against the first undercut 14a in the axial direction. Retaining protrusions 15a, 15b, which are positioned slightly more radially outward relative to the retaining protrusions 13, abut against the set of first sheet metal segments 7 in the circumferential direction. The first bearing protrusion 15a thereby bears the first sheet metal segments 7 toward the first circumferential side 16a, while the second bearing protrusion 15b bears the first sheet metal segments 7 toward the second circumferential side 16b. Complementary to this fastening of the stator core 6 to one first retaining ring 11, the fastening of the stator core 6 (over a portion of the second undercut 14b) to the other first retaining ring 11 is achieved. Both first retaining rings 11 are designed as identical parts and are rotated 180° relative to one another (relative to the radially extending axis).

[0059] Corresponding to the fastening of the stator core 6 to the two first retaining rings 11, the stator core 6 is fastened to the two second retaining rings 12. In this context, it should be noted that the retaining protrusions 13 of the second retaining rings 12 are not arranged radially inside the bearing protrusions 15a, 15b of the second retaining rings 12, but rather radially outside the bearing protrusions of the second retaining rings. In addition, the strip-like regions 26 extend away from the retaining protrusions 13, and the bearing protrusions 15a, 15b are radially inward, rather than radially outward.

[0060] The retaining rings 11, 12 are also formed (by the free cutouts 28) such that the corresponding stator windings 21 radially extend in the circumferential direction between the bearing protrusions 15a, 15b of different stator cores 6. This becomes clear in the addition of the stator windings 21 in Figure 8 In the middle, it can be seen that a retaining protrusion 13 of one first retaining ring 11 is inserted into the first undercut 14a such that the stator core 6 is fixed in the radial direction. Furthermore, a retaining protrusion 13 of one first retaining ring 11 abuts against the first undercut 14a in the axial direction. Retaining protrusions 15a, 15b, which are positioned slightly more radially outward relative to the retaining protrusions 13, abut against the set of first sheet metal segments 7 in the circumferential direction. The first bearing protrusion 15a thereby bears the first sheet metal segments 7 toward the first circumferential side 16a, while the second bearing protrusion 15b bears the first sheet metal segments 7 toward the second circumferential side 16b. Complementary to this fastening of the stator core 6 to one first retaining ring 11, the fastening of the stator core 6 (over a portion of the second undercut 14b) to the other first retaining ring 11 is achieved. Both first retaining rings 11 are designed as identical parts and are rotated 180° relative to one another (relative to the radially extending axis).

[0061] Referring back to Figure 2 It can further be seen that an insulating layer 27, preferably a plastic element or an insulating paper, is positioned between the individual first sheet metal segments 7 and the retaining rings 11, 12 such that the retaining rings 11, 12 are insulated from the stator cores 6. Alternatively, the bearing regions / bearing elements 11, 12 can also be partially or entirely made of a non-conductive material such that an electrical insulation is provided between the individual stator cores 6 and the stator cores 6 are also insulated from, for example, the motor housing.

[0062] In a first exemplary embodiment, the respective stator core 6 has, in addition to the set / group of first sheet segments 7, two cover segments 17a, 17b, each of which adjoins a circumferential side 16a, 16b of the group of first sheet segments 7. In this embodiment, each cover segment 17a, 17b forms a pole shoe segment and is made of a soft magnetic composite material. The first cover segment 17a is applied to the first circumferential side 16a of the group of first sheet segments 7, while the second cover segment 17b is applied to the second circumferential side 16b of the group of first sheet segments 7.

[0063] In Figures 12 to 13 , two further exemplary embodiments are shown, according to which the stator core 6 can be designed in different ways. According to Figure 12 a second exemplary embodiment, not only a first set of first guide segments / first sheet segments 7 is now provided in the respective stator core 6. A second set of second guide segments / second sheet segments 18 and a third set of third guide segments / third sheet segments 19 are also provided. The second sheet segments 18 are arranged directly against the first sheet segments 7 towards the first circumferential side 16a. The third sheet segments 19 are arranged directly against the first sheet segments 7 towards the second circumferential side 16b. The second sheet segments 18 and the third sheet segments 19 are identical in this embodiment / designated as identical parts.

[0064] However, the second sheet segments 18 and the third sheet segments 19 are shorter in the radial direction than the first sheet segments 7. The second sheet segments 18 and the third sheet segments 19 are essentially realized as first sheet segments 7 halved at a certain radial height. It is also possible to use more than two sheet segments 7, 18, 19 which are stepped in different ways, for example to reproduce the wedge shape of the stator core 6 more precisely. Thus, each second sheet segment 18 and each third sheet segment 19 now has a first retaining contour 10a towards its radially outer side 8; on its radially inner side, the sheet segments 18, 19 are separated and do not form an undercut. The respective second sheet segments 18 and third sheet segments 19 are covered towards the radially inner side 9 by the cover segments 17a, 17b.

[0065] The sheet segments 7, 18, 19 of the various exemplary embodiments are each made of an electrical sheet material.

[0066] According to Figure 13The third exemplary embodiment illustrates that, in principle, the cover sections 17a, 17b can also be omitted and, as a result, the stator winding 21 can be wound directly around the respective first sheet section 7, second sheet section 18 and third sheet section 19 without the cover sections 17a, 17b.

[0067] In conjunction with Figures 17 to 19 alternative assembly steps of the stator 2 according to the application are illustrated in conjunction with further exemplary embodiments. As shown in Figure 18 According to the fourth exemplary embodiment, the respective stator core 6 is divided into two halves 20a, 20b in the axial direction. Each half 20a, 20b is associated with a first retaining ring 11 radially outwardly and with a second retaining ring 12 radially inwardly toward a common axial side and is first connected to these retaining rings 11, 12. The second half 20b is associated with a further first retaining ring 11 and a further second retaining ring 12 and is thus first connected to the further first retaining ring 11 and the further second retaining ring 12. Subsequently, the winding 21 is positioned axially between these partial assemblies and the partial assemblies are pushed toward one another in the circumferential direction such that the halves 20a, 20b are inserted into the respective stator winding 21.

[0068] In this context, Figure 19 It is shown in that, in principle, only the cover sections 17a, 17b can also be halved and correspondingly inserted into the stator winding 21 from different sides in the axial direction. The sheet sections 7, 18, 19 are then preferably each realized as a single piece. Figure 19 The stator core 6 is thus depicted in which the laminate core is continuous and only the cover sections 17a, 17b are segmented. This offers the advantage that the laminate core is continuous to achieve good magnetic conduction. With regard to assembly, this offers the advantage that the coil 21 and the stator core 6 can be prefabricated independently of one another and then only the individual parts are joined together. With this manufacturing sequence, the optional pole shoes 29 on the cover sections 17a, 17b do not interfere with the assembly.

[0069] In other words, according to the application, it is proposed that the sheet material 8, 18, 19 extends radially and is optionally laterally covered in the circumferential direction with SMC (cover sections 17a, 17b). Furthermore, the sheet material 8, 18, 19 preferably has a contour 10a, 10b on the radially outer side and / or on the radially inner side which enables the respective stator core 6 to be fixed in an interlocking manner.

[0070] Figure 4A single stator core 6 is shown without windings. The stator core 6 comprises a central region composed of iron sheet material 7 stacked in a circumferential direction, wherein the individual sheet layers 7 are electrically insulated from each other. Each sheet 7 extends approximately in a radial direction and in an axial direction (forming a corresponding surface approximately perpendicular to the circumferential direction) respectively.

[0071] In the circumferential direction, the stacked sheets 7 can be enclosed by a material having good magnetic permeability but poor electrical conductivity, for example SMC = Soft Magnetic Composite. These material sections 17a, 17b are shown as wedge-shaped portions which rest on the stack of sheets 7 on both sides 16a, 16b in the circumferential direction and form, for example, pole shoes 29 Figure 4 ).

[0072] Furthermore, the sheets 7 from the central region have contours 10a, 10b at the outer and / or inner end in the radial direction, which serve to fix / hold the core 6 in an interlocking manner.

[0073] Figure 5 The same construction is shown, but in a plan view from the axial direction, instead of a 3D illustration. Figure 6 A single sheet 7 is shown in a 3D illustration. Figure 7 A single sheet 7 according to its use in the iron core 6 is shown in a plan view in the circumferential direction. The radial inward contour 10b for interlocking fixation as well as the radial outward contour 10a can also be seen.

[0074] Figure 10 An exemplary design of the retaining rings 11, 12 with contours 13, 15a, 15b for receiving and fixing the single stator core 6 via the contours 10a, 10b in the radially extending sheets 7 in the individual stator core 6 is shown. In the embodiment shown here, the contours 13, 15a, 15b of the retaining rings 11, 12 protrude into a cavity inside the windings 21. In order not to impede the winding route, the retaining rings 11, 12 also have free cutouts 28 for the windings 21.

[0075] Figure 9 The stator core 6 is again shown, which is oriented approximately to the retaining ring 11, so that the contours 11, 15a, 15b from the retaining ring 11 can engage with the contours 10a, 10b from the sheets 7 of the stator core 6.

[0076] Figure 8 A left retaining ring and a right retaining ring 11 are shown, the contours of which engage with the contours of the stator core 6. The stator core 6 is arranged between the retaining rings 11. Optionally, but not specifically shown, there is an electrical insulation between the contours on the retaining rings 11 and the contours on the stator core 6, for example in the form of plastic elements or insulating paper. Figure 11 A left retaining ring and a right retaining ring 11 are shown, the contours of which engage with the contours of the stator core 6. The stator core 6 is arranged between the retaining rings 11. Optionally, but not specifically shown, there is an electrical insulation between the contours on the retaining rings 11 and the contours on the stator core 6, for example in the form of plastic elements or insulating paper.Figure 8 The same arrangement as in

[0077] Figure 3 and Figure 12 Each shows an example of a single stator tooth 6, 25 with a single tooth winding 21. The two designs of stator tooth 25 differ in the stacking height in the circumferential direction of the laminated core and the different radial height. Figure 13 A stator core 6 is shown with a winding 21, but without SMC side portions 17a, 17b.

[0078] Figure 14 A plurality of separate stator cores 6 is shown with single tooth windings 21, which are arranged annularly to form a stator ring, but are not yet further fixed by mechanical components, for example retaining rings. Figure 15 A detailed view of Figure 14 can be seen. The fixing profiles 10a on the sheet 7 can be seen, which in the embodiment shown here are located inside the winding 21.

[0079] Figure 16 The same design as in Figure 14 is shown, but as a plan view in the axial direction. The fixing profiles 10a on the sheet 7 of the individual stator teeth 6 can be seen. These profiles are shown on both the radially outer and the radially inner side, wherein these profiles can also be provided only on the inner side or only on the outer side or in another combined manner, as long as mechanical fixing is ensured.

[0080] Figure 1 A stator 2 for an axial flux machine 1 is shown together with the rotor disks 4a, 4b. The stator 2 is composed of a plurality of separate stator teeth 6 which are fixed by means of retaining rings 11, 12. A total of four retaining rings 11, 12 (two on the inside and two on the outside) are shown. The retaining rings 11, 12 are preferably designed both on the inside and on the outside, so that the individual sheets 7 of the individual stator teeth 6 are loaded with tension.

[0081] From Figure 1 it can be seen that the fixing can be arranged by means of retaining rings 11, 12 and engaging profiles in such a way that they hardly increase the axial length of the machine 1. Here, this is achieved by the engaging profiles located inside the winding 21 and the radial walls 26 of the retaining rings 11, 12 which are arranged axially in the space of the pole shoes 29.

[0082] Figure 2 A cross-section is shown through the stator 2, and the rotor 4a, 4b and an exemplary insulation 27 between the retaining ring 11 and the sheet 7 of the stator core 6.

[0083] Figures 17 to 19 Alternative designs are shown for different assembly sequences: in Figure 17 the split stator teeth 6 are joined after the winding of the coils, for example on winding supports not shown. In Figure 18 the split stator teeth 6 are pre-assembled to form a stator half with the retaining rings 11, 12. Furthermore, the windings 21 are positioned in the torus and / or mounted or mechanically fixed. Then, the stator halves and arranged windings 21 are joined together. In Figure 19 the SMC side portions 17a, 17b are joined subsequently. This offers the advantage that the following properties can be combined: - centrally located, unsplit sheets 7, 18, 19, which are advantageous for the magnetic flux and mechanical stability; - pre-fabricated windings 21, wherein only the cores are joined subsequently; - SMC side portions 17a, 17b with pole shoe profiles 29.

[0084] As an alternative to the Figure 19 the unsplit SMC side portions 17a, 17b can also be used by employing the following joining sequence: - joining the SMC side portions 17a, 17b into the windings 21 before joining the laminated core; - arranging the SMC side portions 17a, 17b against the windings 21 in the circumferential direction; - joining the laminated core between the SMC side portions 17a, 17b.

[0085] In all of the above figures, the windings are shown in an exemplary manner. For example, no connections are shown, and also no winding supports or insulations, which can of course be additionally required for the manufacturing process and / or the function of the motor 1.

[0086] Legend of the figures

[0087] 1 axial flux motor 2 stator 3 axis of rotation 4a first rotor element 4b second rotor element 5a first end face 5b second end face 6 stator core 7 first guide section / first sheet section 8 outer side 9 inner side 10a first retaining profile 10b second retaining profile 11 first retaining ring 12 second retaining ring 13 retaining lug 14a first undercut 14b second undercut 15a first support lug 15b second support lug 16a first circumferential side 16b second circumferential side 17a first cover section 17b second cover section 18 second guide section / second sheet section 19 third guide section / third sheet section 20a first half 20b second half 21 stator winding 22 winding ring 23 main body 24 magnet 25 stator coil 26 strip region 27 insulation layer 28 free cutout 29 pole shoe.

Claims

1. An axial flux motor (1) comprising an annular stator (2) and two rotor elements (4a, 4b) mounted in a manner rotatable relative to the stator (2) about a rotation axis (3), wherein, A first rotor element (4a) is arranged axially adjacent to a first end face (5a) of the stator (2), and a second rotor element (4b) is arranged axially adjacent to a second end face (5b) of the stator (2), wherein the stator (2) has a plurality of stator cores (6) distributed in a circumferential direction along an annular line extending about the rotation axis (3), characterized in that at least one stator core (6) has a plurality of radially extending guide sections (7) stacked on top of each other in a circumferential direction and having a plate-like design, wherein at least a portion of the guide sections (7) The guide section has retaining profiles (10a, 10b) on its radially outer side (8) and / or radially inner side (9), the retaining profiles being interlocked and received on at least one support region (11, 12), the at least one support region being fixed to the housing; the at least one support region (11, 12) has an axially projecting retaining protrusion (13) that protrudes into undercut portions (14a, 14b), the undercut portions together forming the retaining profiles (10a, 10b) and opening axially toward the at least one support region (11, 12).

2. The axial flux motor (1) according to claim 1, characterized in that, The guide sections (7) of the at least one stator core (6) are designed to be the same.

3. The axial flux motor (1) according to claim 1, characterized in that, The guide section (7) of the at least one stator core (6) is interlocked to two axially spaced first support regions (11) on the radially outer side (8) and interlocked to two axially spaced second support regions (12) on the radially inner side (9).

4. The axial flux motor (1) according to any one of claims 1 to 3, characterized in that, The guide section (7) of the at least one stator core (6) is secured in the circumferential, radial, and axial directions and / or prevented from tilting about an axis parallel to the rotation axis (3) via interlocking with respect to the at least one support region (11, 12).

5. The axial flux motor (1) according to any one of claims 1 to 3, characterized in that, The at least one stator core (6) is provided with a covering section (17a, 17b) facing one circumferential side (16a, 16b) of the entire guide section (7) or facing both circumferential sides (16a, 16b) of the entire guide section, the covering section being made of soft magnetic composite material.

6. The axial flux motor (1) according to any one of claims 1 to 3, characterized in that, Electrical insulation elements are provided between each stator core (6) itself and / or between each stator core (6) and the at least one support region (11, 12).

7. The axial flux motor (1) according to any one of claims 1 to 3, characterized in that, In addition to having a first group of multiple first guide sections (7) designed to be identical to each other, the at least one stator core (6) also has a second group of multiple second guide sections (18), wherein the second guide sections (18) have a radial extension shorter than the first guide sections (7) and are stacked toward the first circumferential side (16a) of the first guide sections (7) of the first group.

8. The axial flux motor (1) according to claim 7, characterized in that, In addition to the multiple second guide sections (18) of the second group, multiple third guide sections (19) of the third group are arranged on the second circumferential side (16b) of the entire first guide section (7) facing away from the first circumferential side (16a), wherein the third guide section (19) has a radial extension that is shorter than the first guide section (7).

9. The axial flux motor (1) according to any one of claims 1 to 3, characterized in that, The at least one stator core (6) is divided into two halves (20a, 20b) along the axial direction.

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