A block-spliced ​​axial flux stator structure

Abstract

The present invention provides a block-spliced ​​axial magnetic flux stator structure, comprising a stator bracket; a stator core is sleeved on the outer wall of the stator bracket, and a Hall circuit board and a wire outlet slot are sequentially connected to one side of the stator bracket; a coil is wound on the stator core, and a plurality of Hall sensors are provided on the outer wall of the stator core; the stator core is composed of six block cores, with the block cores distributed in two layers axially and three parts circumferentially. The stator core of the present invention adopts a block-spliced ​​structure and is formed by SMC press molding, which enhances the designability of the core structure. By splicing the block cores, winding can be achieved on a machine, greatly improving the processability of this type of armature; the stator core can be machined in grooves on the inner and outer rings to arrange the coils, making the radial size of the armature more compact, which is beneficial for reducing the size of the motor casing and improving the power density of the motor.

Description

Technical Field

[0001] The invention relates to a block-spliced ​​axial magnetic flux stator structure, belonging to the technical field of permanent magnet synchronous motor stator structures. Background Art

[0002] Axial flux permanent magnet synchronous motors, also known as disc permanent magnet motors, have advantages such as compact structure, high power density, and high efficiency. Their applications include automotive systems, manufacturing systems, household appliances, power tools, aerospace, and other fields. The single stator-dual rotor structure, with its balanced stator and rotor forces and good structural stability, is one of the most widely used typical topologies of axial flux motors. The ring-yoke winding stator structure has the advantages of short end length and high torque density, making it a key structure for high-performance single-stator-dual-rotor motors. However, the fixed structure design and manufacturing process of the ring-yoke core, as well as the connection and fixation of the windings, are key and difficult issues in the design and manufacturing of motors with this structure. These factors lead to poor stability, integration, and process feasibility of single-stator-dual-rotor axial flux motors. Therefore, to a certain extent, the design of the stator structure is a key factor in determining the product maturity of motors with this structure. Summary of the Invention

[0003] In order to solve the above technical problems, the present invention provides a block-spliced ​​axial flux stator structure, which improves the structural stability, integration and process feasibility of the single-stator-dual-rotor axial flux motor.

[0004] The present invention is achieved through the following technical solutions.

[0005] The present invention provides a block-spliced ​​axial magnetic flux stator structure, comprising a stator bracket; a stator core is sleeved on the outer wall of the stator bracket, and a Hall circuit board and an outlet slot are sequentially connected to one side of the stator bracket; a coil is wound around the stator core, and a plurality of Hall sensors are provided on the outer wall of the stator core; the stator core is composed of six block cores, which are distributed axially in two layers and circumferentially in three parts.

[0006] The segmented iron cores are fixedly connected by glue, and are connected to the stator bracket by bolts through twisted holes in the radial direction, positioned by a pressure plate in the axial direction, and fixed to the stator bracket by a first screw.

[0007] The stator bracket includes a first de-weighting groove and a key slot hole sleeved in the first de-weighting groove, and the first de-weighting groove and the key slot hole are connected by a second de-weighting groove; multiple groups of symmetrically arranged support columns are provided on both sides of the outer wall of the first de-weighting groove, and hinged hole bolt threaded holes located on the first de-weighting groove are provided between the symmetrically arranged support columns; one end of the support column is provided with a bracket positioning boss, and the end face of the support column is provided with a threaded hole and a wire outlet slot threaded hole.

[0008] The Hall circuit board is connected to the stator bracket by adhesive.

[0009] The wire outlet slot is connected to the stator bracket via a second screw.

[0010] A relative positioning boss and a relative positioning groove are provided on the inner side wall of each segmented iron core, and the segmented iron cores are positioned by the mutual relative positioning bosses and relative positioning grooves.

[0011] Adjacent positioning grooves and adjacent positioning bosses are respectively provided at both ends of each segmented iron core, and the segmented iron cores are positioned by the mutual adjacent positioning grooves and adjacent positioning bosses.

[0012] The inner side walls of the segmented iron core are each provided with bolt through holes, and the outer side walls are provided with a plurality of Hall installation slots.

[0013] The segmented iron core is provided with wide teeth and narrow teeth at intervals to form narrow winding grooves and wide winding grooves, and a bracket positioning groove is provided on the inner side wall of any wide tooth. Three Hall installation grooves spaced 30° apart are provided on the outer wall of each segmented iron core, one of the Hall installation grooves is located on the outer wall of the wide tooth, and the other two Hall installation grooves are respectively located on the outer walls of different narrow teeth.

[0014] The Hall lead wire of the Hall sensor and the coil lead wire of the coil are led out together and welded on the Hall circuit board, and are led out through the lead slot.

[0015] The beneficial effects of the present invention are:

[0016] 1. The stator core adopts a block-type splicing structure and is made by SMC pressing, which enhances the designability of the core structure. In addition, by splicing the block core, winding can be achieved on the machine, greatly improving the processing technology of this type of armature;

[0017] 2. The stator core can be machined with grooves on the inner and outer rings to arrange the coils, making the radial size of the armature more compact, which is beneficial to reducing the size of the motor casing and improving the power density of the motor;

[0018] 3. The Hall effect sensor can be arranged in a slot on the end face of the stator core, which makes the Hall effect positioning accuracy high. A Hall effect circuit board is set up and the leads are unified, making the Hall effect lead wire easy to install, so the armature has a higher degree of integration.

[0019] 4. A stator bracket placed in the inner ring of the stator core is used to support the armature structure, which has the advantages of high positioning accuracy, high support strength, simple and compact structure;

[0020] 5. The coil lead wire is led out through a wire groove, which has the advantages of reliable and standardized routing and compact space. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a structural schematic diagram of the present invention;

[0022] Figure 2 It is the irascible figure of the present invention;

[0023] Figure 3 It is a schematic assembly diagram of a longitudinal section of the present invention;

[0024] Figure 4 It is a schematic structural diagram of the first segmented iron core of the present invention;

[0025] Figure 5 It is a schematic structural diagram of the second segmented iron core of the present invention;

[0026] Figure 6 1 is a schematic structural diagram of a stator support of the present invention;

[0027] In the figure: 1-first screw, 2-pressure plate, 3-coil, 4-stator core, 41-first segmented core, 42-second segmented core, 411-relative positioning groove, 412-bolt through hole, 413-relative positioning boss, 414-adjacent positioning groove, 415-Hall mounting groove, 416-wide winding groove, 417-bracket positioning groove, 418-adjacent positioning boss, 419-narrow winding groove, 4110-wide tooth, 5-Hall sensor, 6-bolt for hinged hole, 7-stator bracket, 71-support column, 72-threaded hole for hinged hole bolt, 73-bracket positioning boss, 74-first de-weighting groove, 75-key slot hole, 76-second de-weighting groove, 77-threaded hole, 78-threaded hole for outlet slot, 8-Hall circuit board, 9-outlet slot, 10-second screw, 11-coil lead wire, 12-Hall lead wire. DETAILED DESCRIPTION

[0028] The technical solution of the present invention is further described below, but the scope of protection claimed is not limited to the description.

[0029] Example 1

[0030] like Figures 1 to 6 The structure shown is a block-jointed axial magnetic flux stator, comprising a stator bracket 7; a stator core 4 is sleeved on the outer wall of the stator bracket 7, and a Hall circuit board 8 and an outlet slot 9 are sequentially connected to one side of the stator bracket 7; a coil 3 is wound around the stator core 4, and a plurality of Hall sensors 5 are provided on the outer wall of the stator core 4; the stator core 4 is composed of six block cores, which are distributed axially in two layers and circumferentially in three parts.

[0031] The first segmented iron core 41 (consisting of three segmented iron cores) and the second segmented iron core 42 (consisting of three segmented iron cores) are fixedly connected by glue. The stator iron core 4 is radially connected to the stator bracket 7 by bolts 6 through twisted holes, and is positioned axially by the pressure plate 2 and fixed to the stator bracket 7 by the first screw 1.

[0032] The stator bracket 7 includes a first de-weighting groove 74 and a key slot hole 75 sleeved in the first de-weighting groove 74, and the first de-weighting groove 74 and the key slot hole 75 are connected by a second de-weighting groove 76; a plurality of groups of symmetrically arranged support columns 71 are provided on both sides of the outer wall of the first de-weighting groove 74, and a hinged hole bolt threaded hole 72 located on the first de-weighting groove 74 is provided between the symmetrically arranged support columns 71; one end of the support column 71 is provided with a bracket positioning boss 73, and the end face of the support column 71 is provided with a threaded hole 77 and a wire outlet slot threaded hole 78.

[0033] The Hall circuit board 8 is connected to the stator bracket 7 by adhesive.

[0034] The wire outlet slot 9 is connected to the stator bracket 7 via a second screw 10 .

[0035] A relative positioning boss 413 and a relative positioning groove 411 are provided on the inner side wall of each segmented core. The segmented cores are positioned by the relative positioning bosses 413 and the relative positioning grooves 411 .

[0036] Adjacent positioning grooves 414 and adjacent positioning bosses 418 are respectively provided at both ends of each segmented core. The segmented cores are positioned by the mutual adjacent positioning grooves 414 and adjacent positioning bosses 418 .

[0037] The inner sidewalls of the segmented iron core are each provided with bolt through holes 412 , and the outer sidewalls are provided with a plurality of Hall installation slots 415 .

[0038] The segmented iron core is provided with wide teeth 4110 and narrow teeth at intervals to form narrow winding grooves 419 and wide winding grooves 416, and a bracket positioning groove 417 is provided on the inner side wall of any wide tooth 4110. Three Hall installation grooves 415 with an interval of 30° are provided on the outer wall of each segmented iron core, one of the Hall installation grooves 415 is located on the outer wall of the wide tooth 4110, and the other two Hall installation grooves 415 are respectively located on the outer walls of different narrow teeth.

[0039] The Hall lead wire 12 of the Hall sensor 5 and the coil lead wire 11 of the coil 3 are led out together and welded on the Hall circuit board 8 , and then led out through the wire outlet slot 9 .

[0040] Example 2

[0041] The present invention is a block-spliced ​​axial flux motor stator structure. The ring yoke stator structure adopts a block-type iron core, which can be spliced ​​into two or three equally divided parts with open windings. The two or three parts are wound separately and then spliced ​​together to form the entire armature assembly. It has the advantages of high overall structural integration, good structural stability, high positioning accuracy, good processability and low manufacturing cost.

[0042] The stator cores 4 can be spliced ​​separately and wound on a machine before being assembled together, which makes winding simple and the processing efficiency high.

[0043] The segmented core is made of soft magnetic composite material (SMC), which facilitates the molding of various detailed features of the segmented core and improves the designability of the core.

[0044] At the location where the threaded hole bolt 6 is installed, in order to leave enough space for the coil 3, a wide tooth 4110 and a narrow tooth structure are adopted. When dividing the blocks, the bolt through hole 412 is axially divided into two halves to facilitate SMC pressing and molding.

[0045] On each of the segmented cores that are axially and circumferentially matched or connected, relative positioning grooves 411 and relative positioning bosses 413 are provided to ensure the mutual positioning accuracy between the blocks, thereby ensuring the manufacturing accuracy of the segmented cores after splicing.

[0046] Hall installation slots 415 are designed on the end faces of each segmented core. This slotting ensures high positioning accuracy for the Hall sensor 5. To maintain the compact outer diameter of the armature while maintaining magnetic conductivity, slots (narrow winding slots 419 and wide winding slots 416) are also created on the inner and outer diameters of the stator core 4. Coil 3 is embedded within the stator core 4, further compacting the overall armature dimensions.

[0047] The grooves, bosses and slots on the stator core 4 can all be formed by (SMC) pressing in one step, without the need for secondary processing, thus ensuring the consistency of the processed stator core 4.

[0048] In order to ensure the integrity of the winding slots (narrow winding slots 419 and wide winding slots 416) after the two stator cores 4 are spliced ​​together, and to avoid the situation where multiple teeth need to be spliced ​​into a whole stator core 4 before winding, which reduces the armature processing efficiency, when the stator core 4 is circumferentially cut, it is necessary to cut from the middle of a certain slot, and in order to ensure the strength and processability of a single stator core 4, it is necessary to avoid cutting the tooth part (wide teeth 4110 and narrow teeth).

[0049] After winding, the coil 4's inlet and outlet terminals in each winding slot (narrow winding slot 419 and wide winding slot 416) are welded together in outlet slots 9. The neutral point is welded to a single mounting wire, while the remaining three phases are led out using three separate wires. Coil lead wires 11 are uniformly arranged and tied together within outlet slots 9, ensuring reliable, standardized routing and compact space.

[0050] The stator bracket 7 is of spoke type, with radially arranged support columns 71 evenly distributed axially. The support columns 71 must have sufficient strength and positioning accuracy to ensure the concentricity of the stator core 4 and the keyway hole 75, and a certain supporting strength.

[0051] Example 3

[0052] The stator core 4 consists of a three-lobed first segment core 41 and a three-lobed second segment core 42. The first segment cores 41 are positioned by relative positioning bosses 413 and relative positioning grooves 411, and are glued together. The stator core 4 is provided with evenly distributed winding grooves, the coil 3 is fixed in the winding grooves, and the coil lead wires 11 are fixed and led out by the lead-out grooves 9. The lead-out grooves 9 are fixed to the stator bracket 7 by second screws 10. The stator core 4 is installed on the stator bracket 7, radially fixed by the tapped hole bolts 6, and axially positioned by the pressure plate 2 and fixed by the first screw 1. The Hall sensor 5 is installed in the Hall mounting groove 415 of the first segment core 41 and the second segment core 42. The Hall circuit board 8 is fixed to the stator bracket 7 by glue. The Hall lead wires 12 are welded to the Hall circuit board 8 and uniformly converted and led out through the lead-out grooves 9.

[0053] The first segmented core 41 and the second segmented core 42 are both made of SMC pressed into shape, and their structures are mirror-symmetrical to each other. In order to facilitate the installation of the threaded hole bolts 6, wide winding grooves 416 and narrow winding grooves 419 are provided, and mutually cooperating relative positioning grooves 411, adjacent positioning grooves 414 or relative positioning bosses 413, adjacent positioning bosses 418 are provided between the relative or adjacent segmented cores for positioning. The bolt through hole 412 is provided on the wide tooth 4110 between the two narrow winding grooves 419, and the bolt through holes 412 divided into semicircles are respectively placed on the first segmented core 41 and the second segmented core 42.

[0054] The inner ring of the wide teeth 4110 is provided with a bracket positioning groove 417 for positioning with the stator bracket 7, ensuring concentricity of the stator core 4. A Hall installation groove 415 is provided for installing and positioning the Hall sensor 5. The positional accuracy of one end surface of the Hall installation groove 415 ensures the positioning accuracy of the Hall sensor 5.

[0055] The stator bracket 7 is a spoke-type bracket, with six support columns 71 arranged radially and evenly distributed axially. These columns are arranged in pairs, with threaded holes 72 for mounting and fixing the threaded hole bolts 6 between the two parallel support columns 71. The support columns 71 must be sufficiently strong. A bracket positioning boss 73 is provided on the top of the support column 71 to cooperate with the bracket positioning groove 417 on the stator core 4 to ensure concentricity between the stator core 4 and the inner hole. A first de-weighting groove 74 and a second de-weighting groove 76 are provided to reduce the weight of the structure. Threaded holes 77 and outlet slot threaded holes 78 are provided to mount the outlet slot 9 and the pressure plate 2. A keyway hole 75 is provided to secure the stator core 4.

[0056] Example 4

[0057] The assembly process of the present invention is as follows:

[0058] 1. The first segmented core 41 and the second segmented core 42 are spliced ​​into three parts by gluing, each part is spliced ​​by machine to form a complete winding slot and complete the winding. Then, the three wound parts are spliced ​​together by gluing to form the entire stator core 4;

[0059] 2. Install the complete stator core 4 on the stator bracket 7, and fix it with bolts 6 and the pressure plate 2 through the twisted holes, then complete the winding of the three slots at the circumferential joint, install the Hall sensor 5 and the Hall circuit board 8, and the Hall lead wire 12 of the Hall sensor 5 is led out together with the coil lead wire 11, welded to the Hall circuit board 8, and finally the lead wire is converted by the Hall circuit board 8 and led out together with the three-phase line; 3. Finally, all the coil lead wires 11 of the coil 3 and the Hall lead wire 12 led out together with the coil lead wire 11 are passed through the mounting holes of the outlet slot 9, and are connected in series with the installation wire in the outlet slot 9 according to the series-parallel relationship of the electromagnetic design, and the installation wire is arranged and fixed in the outlet slot 9 to complete the armature assembly.

Claims

1. A block-jointed axial flux stator structure, comprising a stator bracket (7), characterized in that: A stator core (4) is sleeved on the outer wall of the stator bracket (7), and a Hall circuit board (8) and a wire outlet slot (9) are sequentially connected to one side of the stator bracket (7); a coil (3) is wound on the stator core (4), and a plurality of Hall sensors (5) are provided on the outer wall of the stator core (4); the stator core (4) is composed of six block cores, and the block cores are distributed in two layers axially and three parts circumferentially; The stator bracket (7) includes a first de-weighting groove (74) and a key slot hole (75) sleeved in the first de-weighting groove (74), and the first de-weighting groove (74) and the key slot hole (75) are connected via a second de-weighting groove (76); multiple groups of symmetrically arranged support columns (71) are provided on both sides of the outer wall of the first de-weighting groove (74), and threaded holes (72) for hinged holes and bolts located on the first de-weighting groove (74) are provided between the symmetrically arranged support columns (71); one end of the support column (71) is provided with a bracket positioning boss (73), and the end face of the support column (71) is provided with a threaded hole (77) and a threaded hole (78) for an outlet groove.

2. The block-jointed axial flux stator structure according to claim 1, characterized in that: The segmented iron cores are fixedly connected by glue, are radially connected to the stator bracket (7) by bolts (6) through twisted holes, are axially positioned by a pressure plate (2), and are fixed to the stator bracket (7) by a first screw (1).

3. The block-jointed axial flux stator structure according to claim 1, characterized in that: The Hall circuit board (8) is connected to the stator bracket (7) via adhesive.

4. The block-jointed axial flux stator structure according to claim 1, characterized in that: The wire outlet slot (9) is connected to the stator bracket (7) via a second screw (10).

5. The block-jointed axial flux stator structure according to claim 1, characterized in that: A relative positioning boss (413) and a relative positioning groove (411) are provided on the inner side wall of each segmented iron core, and the segmented iron cores are positioned by the relative positioning bosses (413) and the relative positioning grooves (411).

6. The block-jointed axial flux stator structure according to claim 1, characterized in that: Adjacent positioning grooves (414) and adjacent positioning bosses (418) are respectively provided at both ends of each segmented iron core, and the segmented iron cores are positioned by the mutual adjacent positioning grooves (414) and adjacent positioning bosses (418).

7. The block-jointed axial flux stator structure according to claim 1, characterized in that: Bolt through holes (412) are provided on the inner side walls of the segmented iron core, and a plurality of Hall installation slots (415) are provided on the outer side walls.

8. The block-jointed axial flux stator structure according to claim 1, characterized in that: The segmented iron core is provided with wide teeth (4110) and narrow teeth at intervals to form narrow winding grooves (419) and wide winding grooves (416), and a bracket positioning groove (417) is provided on the inner side wall of any wide tooth (4110); three Hall installation grooves (415) spaced 30 degrees apart are provided on the outer wall of each segmented iron core, one of the Hall installation grooves (415) is located on the outer wall of the wide tooth (4110), and the remaining two Hall installation grooves (415) are respectively located on the outer walls of different narrow teeth.

9. The block-jointed axial flux stator structure according to claim 1, characterized in that: The Hall lead wire (12) of the Hall sensor (5) and the coil lead wire (11) of the coil (3) are led out together and welded on the Hall circuit board (8), and are led out through the wire outlet slot (9).

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