Locking mechanism for segmented stator core

Abstract

A stator core assembly for an axial flux motor for an automotive vehicle, comprising: a cylindrical housing defining a central axis; first and second disc-shaped insulating frames axially spaced apart from one another and located within the housing, each of the first and second insulating frames including a circular outer ring, a circular inner ring, and a plurality of radial spokes extending between the outer ring and the inner ring and circumferentially spaced apart about the central axis; and a plurality of segmented core portions extending axially between the first and second insulating frames, circumferentially spaced apart about and supported by the first and second insulating frames, wherein a radial spoke is located between each pair of adjacent segmented core portions, and at least one radial spoke extends through each axial end of each of the plurality of segmented core portions.

Description

Technical Field

[0001] This disclosure relates to an axial flux motor for automobiles, and more specifically, to a stator core for an axial flux motor, the stator core including a locking mechanism to prevent the stator core from falling off. Background Technology

[0002] An electric motor is a machine that converts electrical energy into mechanical energy through the action of a magnetic field generated in its coils. Electric motors produce rotational or circular motion. The central part of an electric motor is a cylinder called the armature or rotor. The rotor is the rotating part of the motor. An axial flux motor (also called an axial clearance motor or disc motor) is a type of motor geometry in which the gap between the rotor and stator, and the direction of the magnetic flux between them, is parallel to the axis of rotation, rather than radially aligned as in the more common concentric cylindrical geometry of radial clearance motors. In an axial flux motor, the stator is located next to the rotor and holds insulated coils, typically made of copper. When current is applied to the motor, the stator generates a magnetic field that drives the rotor.

[0003] In a segmented stator, the stator core sections, magnetically separated from each other, form the stator. Typically, the stator core sections are supported by a non-magnetic frame. One way a segmented stator core can fail is due to detachment from the stator core section. Due to the high magnetic force across the gap between the stator and rotor, the stator core section may be pulled from the frame towards the rotor. This type of failure is called stator core detachment.

[0004] Therefore, although current segmented stator core assemblies and motors with segmented stator core assemblies have achieved their intended purpose, there is still a need for a new and improved segmented stator core assembly that includes a locking mechanism to prevent stator core sections from falling off. Summary of the Invention

[0005] According to several aspects of this disclosure, a stator core assembly for an automotive axial flux motor includes a rotor assembly and a stator assembly. The stator assembly includes: a cylindrical housing defining a central axis; first and second disc-shaped insulating frames made of a non-magnetic material, axially spaced apart from each other and located within the housing, each of the first and second insulating frames including a circular outer ring, a circular inner ring, and a plurality of radial spokes extending between the outer and inner rings and circumferentially spaced around the central axis; and a plurality of segmented core portions extending axially between the first and second insulating frames, circumferentially spaced around the first and second insulating frames, and supported by the first and second insulating frames, wherein radial spokes are located between each pair of adjacent segmented core portions, and at least one radial spoke extends through each axial end of each of the plurality of segmented core portions.

[0006] According to another aspect, the outer ring, inner ring, and plurality of radial spokes of each of the first and second insulating frames define a plurality of openings within each of the first and second insulating frames, and each of the plurality of segmented core portions includes a first axial end on which a pole shoe is formed and a second axial end on which a pole shoe is formed, the pole shoe formed on the first and second axial ends of each of the plurality of segmented core portions having a shape corresponding to and engaging within the openings in each of the first and second insulating frames.

[0007] According to another aspect, each pole shoe includes at least one radial groove formed therein, a radial spoke of a first insulating frame located within each of at least one groove formed in the pole shoe at the first axial end of each of the plurality of segmented core portions, and a radial spoke of a second insulating frame located within each of at least one groove formed in the pole shoe at the second axial end of each of the plurality of segmented core portions.

[0008] According to another aspect, a radial spoke of the first insulating frame is located between the pole shoes at the first axial ends of each pair of adjacent segmented core portions, and a radial spoke of the second insulating frame is located between the pole shoes at the second axial ends of each pair of adjacent segmented core portions.

[0009] On the other hand, each segmented core portion includes a soft magnetic composite material.

[0010] On the other hand, each segmented core portion includes a stack.

[0011] According to another aspect, each segmented core portion includes a first half and a second half glued together.

[0012] According to another aspect, each radial spoke of the first and second insulating frames and the radial grooves formed in the pole shoes at the first and second axial ends of each of the plurality of segmented core portions are straight.

[0013] According to another aspect, each radial spoke of the first and second insulating frames and the radial grooves formed in the pole shoes at the first and second axial ends of each of the plurality of segmented core portions define a radial axis intersecting with the central axis of the segmented stator core.

[0014] According to another aspect, each radial spoke of the first and second insulating frames and the radial grooves formed in the pole shoes at the first and second axial ends of each of the plurality of segmented core portions define a radial axis that does not intersect with the central axis of the segmented stator core.

[0015] According to another aspect, each radial spoke of the first and second insulating frames and the radial grooves formed in the pole shoes at the first and second axial ends of each of the plurality of segmented core portions are V-shaped.

[0016] According to another aspect, the first and second insulating frames are made of non-magnetic materials.

[0017] Further applicability will become apparent from the description provided herein. It should be understood that the specification and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0018] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0019] Figure 1 This is an exploded view of an axial flux motor according to an exemplary embodiment;

[0020] Figure 2 This is a perspective view of a stator core assembly according to an exemplary embodiment;

[0021] Figure 3 This is an exploded view of the stator core assembly according to an exemplary embodiment;

[0022] Figure 4 This is a perspective view of the segmented core portion according to an exemplary embodiment;

[0023] Figure 5 yes Figure 4 An exploded view of the first and second halves of the segmented core portion shown;

[0024] Figure 6 It is an exploded view of a segmented core section and its corresponding opening within the insulation frame;

[0025] Figure 7 It is already assembled. Figure 6 A perspective view showing the segmented core portion and corresponding openings within the insulating frame;

[0026] Figure 8 It is a perspective view of a stator core assembly with inclined radial grooves and radial spokes;

[0027] Figure 9 yes Figure 8 The perspective view of the stator core assembly shown has the insulation frame and housing removed.

[0028] Figure 10 It is a perspective view of a stator core assembly with V-shaped radial grooves and radial spokes; and

[0029] Figure 11 yes Figure 10 The diagram shows a perspective view of the stator core assembly, with the insulation frame and housing removed. Detailed Implementation

[0030] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses.

[0031] refer to Figure 1 The axial flux motor 10 for automobiles includes a rotor assembly 12 and a stator assembly 14. The rotor assembly 12 may include a single rotor 12 positioned adjacent to the stator assembly 14, or alternatively, the rotor assembly 12 may include two rotors 12, one located on either side of the stator assembly 14, such as... Figure 1 As shown.

[0032] refer to Figure 2 and Figure 3 The stator core assembly 14 includes a cylindrical housing 16 that defines a central axis 18. First and second disc-shaped insulating frames 20, 22 are axially spaced from each other and located within the housing 16. Each of the first and second insulating frames 20, 22 includes a circular outer ring 24, a circular inner ring 26, and a plurality of radial spokes 28 extending between the outer ring 24 and the inner ring 26 and circumferentially spaced around the central axis 18.

[0033] Multiple segmented core portions 30 extend axially between the first and second insulating frames 20 and 22, and are circumferentially spaced around and supported by the first and second insulating frames 20 and 22. (Reference) Figure 3 An exploded view of multiple segmented core portions 30 and first and second insulating frames 20, 22 is shown. The multiple segmented core portions 30 are positioned in a ring pattern. The first and second insulating frames 20, 22 are made of a non-magnetic material to magnetically insulate the multiple segmented core portions from each other. As shown, the stator assembly 14 includes 12 segmented core portions 30. It should be understood that the stator assembly 14 according to this disclosure may include any suitable number of segmented core portions 30.

[0034] refer to Figure 4 Each of the plurality of segmented core portions 30 includes a trapezoidal center rod 32, a first axial end 34, and a second axial end 36. The first axial end 34 and the second axial end 36 of each of the plurality of segmented core portions 30 include a pole shoe 38 formed thereon. Each pole shoe 38 includes at least one radial groove 40 formed therein.

[0035] refer to Figure 5 Each segmented core portion 30 includes a first half 42 and a second half 44 glued together, as indicated by arrow 46. In one exemplary embodiment, each segmented core portion 30 includes a soft magnetic composite material. In another exemplary embodiment, each segmented core portion 30 includes a laminate.

[0036] The outer ring 24, inner ring 26, and plurality of radial spokes 28 of each of the first and second insulating frames 20, 22 define a plurality of openings 48 within each of the first and second insulating frames 20, 22. (Reference) Figure 6 and Figure 7 The pole shoes formed on the first and second axial ends 34, 36 of each of the plurality of segmented core portions 30 have a shape that corresponds to and fits within the openings 48 in each of the first and second insulating frames 20, 22.

[0037] Refer again Figure 3 Each pair of adjacent segmented core portions 30 defines a radial groove 50. In one exemplary embodiment, radial spokes 28 are located between each pair of adjacent segmented core portions 30 within each radial groove 50, and at least one radial spoke 28 extends through each axial end 34, 36 of each of the plurality of segmented core portions 30. A radial spoke 28 of a first insulating frame 20 is located within each radial groove 50 at the first axial end 34 of the plurality of segmented core portions 30, and a radial spoke 28 of a second insulating frame 22 is located within each radial groove 50 at the second axial end 36 of the plurality of segmented core portions 30.

[0038] A radial spoke 28 of the first insulating frame 20 is located within at least one radial groove 40 formed in the pole shoe 38 of the first axial end 34 of each of the plurality of segmented core portions 30. Similarly, a radial spoke 28 of the second insulating frame 22 is located within at least one radial groove 40 formed in the pole shoe 38 of the second axial end 36 of each of the plurality of segmented core portions 30. A radial spoke 28 of the first insulating frame 20 is located between the pole shoes 38 of each pair of adjacent first axial ends 34 of the segmented core portions 30, and a radial spoke 28 of the second insulating frame 22 is located between the pole shoes 38 of each pair of adjacent second axial ends 36 of the segmented core portions 30.

[0039] Refer again Figure 6 Each segmented core portion 30 has a single radial groove 40 formed in the axial surface 52 of the pole shoe 38, separate from a corresponding opening 48 in one of the first and second insulating frames 20, 22. When the segmented core portion 30 is assembled onto the insulating frames 20, 22, a first radial spoke 28A will be located near a first side 38A of the pole shoe 38 of the segmented core portion 30, and a second radial spoke 28B will be located near a second side 38B of the pole shoe 38 of the segmented core portion 30. A third radial spoke 28C will be located within the radial groove 40 formed in the axial surface 52 of the pole shoe 38.

[0040] It should be understood that Figure 6 Exploded diagram and Figure 7The assembly diagram shows a pole shoe 38 formed at the first axial end 34 of the segmented core portion 30 assembled to the first insulating frame 20, or a pole shoe 38 formed at the second axial end 36 of the segmented core portion 30 assembled to the second insulating frame 22. The pole shoes 38 at the first and second axial ends 34 and 36 of the segmented core portion 30 are identical, and the first and second insulating frames 20 and 22 are identical. Figure 4 , Figure 6 and Figure 7 As shown, the axial surface 52 of each pole shoe 38 of each segmented core portion 30 includes a single radial groove 40. It should be understood that more than one radial groove 40 may be formed within the axial surface 52 of each pole shoe 38 of each segmented core portion 30, and each radial groove 40 includes radial spokes 28 extending therein.

[0041] Radial spokes 28 extend through the axial face 52 of each pole shoe 38 formed within a radial groove 40 therein, preventing axial movement of the segmented core portion 30 toward an adjacent rotor assembly 12. Due to the high magnetic force in the gap between the stator 14 and the rotor 12, the glued first and second halves 42, 44 of any of the plurality of segmented core portions 30 may separate, causing one or both of the first and second halves 42, 44 to be pulled toward an adjacent rotor assembly 12. The presence of radial spokes 28 within the radial groove 40 of the pole shoe 38 on each segmented core portion 30 provides a locking mechanism that prevents movement of the first and second halves 42, 44 of the segmented core portion 30 toward one or more adjacent rotors 12.

[0042] Refer again Figure 2 and Figure 7 In one exemplary embodiment, each radial spoke 28 of the first and second insulating frames 20, 22 and the radial groove 40 formed within the pole shoe 38 of the first and second axial ends 34, 36 of each of the plurality of segmented core portions 30 are straight. As shown, each radial spoke 28 of the first and second insulating frames 20, 22 and the radial groove 40 formed within the pole shoe 38 of the first and second axial ends 34, 36 of each of the plurality of segmented core portions 30 define a radial axis 54 intersecting the central axis 18 of the stator core 14. For each of the plurality of segmented core portions 30, the pole shoe 38 is center-aligned with the center rod 32.

[0043] refer to Figure 8 and Figure 9In another exemplary embodiment, each radial spoke 28' of the first and second insulating frames 20', 22' and the radial groove 40' formed in the pole shoe 38' of the first and second axial ends 34', 36' of each of the plurality of segmented core portions 30' are straight, and the radial groove 40' formed in the pole shoe 38' of each of the first and second insulating frames 20', 22' and the first and second axial ends 34', 36' of each of the plurality of segmented core portions 30' are inclined, and define a radial axis 56 that does not intersect with the central axis 18 of the segmented stator core.

[0044] like Figure 9 As shown, each pole shoe 38' of the plurality of segmented core portions 30' includes two radial grooves 40' formed therein, each groove including radial spokes 28' located therein. Furthermore, to accommodate the inclined characteristics of the radial grooves 40' formed within the pole shoe 38', for each of the plurality of segmented core portions 30', the pole shoe 38' is inclined relative to the center rod 32'. This exemplary embodiment provides the motor 10 with less cogging effect.

[0045] refer to Figure 10 and Figure 11 In another exemplary embodiment, the radial grooves 40” formed within the pole shoes 38” of each radial spoke 28” of the first and second insulating frames 20”, 22” and the first and second axial ends 34”, 36” of each of the plurality of segmented core portions 30” are V-shaped. Figure 11 As shown, each of the plurality of segmented core portions 30” includes two radial grooves 40” formed therein, each groove including radial spokes 28” located therein. Furthermore, to accommodate the V-shaped radial grooves 40” formed within the pole shoes 38”, the pole shoes 38” are also V-shaped for each of the plurality of segmented core portions 30”. This exemplary embodiment provides less cogging effect for the motor 10.

[0046] The stator core and the motor having the stator core disclosed herein have several advantages. The presence of radial spokes 28 within the radial grooves 40 of the pole shoes 38 on each segmented core portion 30 provides a locking mechanism that prevents the first and second halves 42, 44 of the segmented core portion 30 from moving toward one or more adjacent rotors 12, thereby preventing the stator core portion 30 from falling off. Furthermore, the inclined or V-shaped radial grooves 40', 40” and radial spokes 28', 28” reduce cogging effects in the motor 10.

[0047] The description in this disclosure is merely exemplary in nature, and any changes that do not depart from the spirit of this disclosure are intended to fall within its scope. Such changes should not be considered as departing from the scheme and scope of this disclosure.

Claims

1. A stator core assembly for an automotive axial flux motor, comprising: A cylindrical outer shell, the cylindrical outer shell defining a central axis; First and second disc-shaped insulating frames, which are axially spaced apart from each other and located within the housing, each of the first and second insulating frames including a circular outer ring, a circular inner ring, and a plurality of radial spokes extending between the outer ring and the inner ring and circumferentially spaced around a central axis, wherein the outer ring, the inner ring, and the plurality of radial spokes of each of the first and second insulating frames define a plurality of openings within each of the first and second insulating frames; as well as Multiple segmented core portions, the segmented core portions extending axially between the first and second insulating frames, circumferentially spaced around the first and second insulating frames and supported by the first and second insulating frames; The radial spokes are located between each pair of adjacent segmented core portions, and each of the plurality of segmented core portions includes a first axial end on which a pole shoe is formed and a second axial end on which a pole shoe is formed, wherein the pole shoe formed on the first axial end and the second axial end of each of the plurality of segmented core portions has a shape that corresponds to and engages with an opening in each of the first and second insulating frames. Each segmented core portion includes a first half and a second half glued together, each pole shoe includes at least one radial groove formed therein, a radial spoke of the first insulating frame is located within each of the at least one groove formed in the pole shoe at the first axial end of each of the plurality of segmented core portions, and a radial spoke of the second insulating frame is located within each of the at least one groove formed in the pole shoe at the second axial end of each of the plurality of segmented core portions.

2. The stator core assembly according to claim 1, wherein, A radial spoke of the first insulating frame is located between the pole shoes at the first axial ends of each pair of adjacent segmented core portions, and a radial spoke of the second insulating frame is located between the pole shoes at the second axial ends of each pair of adjacent segmented core portions.

3. The stator core assembly according to claim 2, wherein, Each segment of the core comprises a soft magnetic composite material.

4. The stator core assembly according to claim 2, wherein, Each segment core portion includes a stack.

5. The stator core assembly according to claim 2, wherein, Each radial spoke of the first and second insulating frames and the radial groove formed in the pole shoe at the first and second axial ends of each of the plurality of segmented core portions are straight.

6. The stator core assembly according to claim 5, wherein, Each radial spoke of the first and second insulating frames and the radial grooves formed in the pole shoes at the first and second axial ends of each of the plurality of segmented core portions define a radial axis that intersects the central axis of the segmented stator core.

7. The stator core assembly according to claim 5, wherein, Each radial spoke of the first and second insulating frames and the radial grooves formed in the pole shoes at the first and second axial ends of each of the plurality of segmented core portions define a radial axis that does not intersect with the central axis of the segmented stator core.

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