Hybrid stator core segment for axial flux motor

Abstract

This invention discloses a hybrid stator core segment for an axial flux motor. An axial flux motor is provided, comprising a shaft, at least one rotor connected to the shaft, and a stator. The stator includes a stator core and conductive wires. The stator core is segmented and annular, and includes a central opening through which the shaft extends to at least one rotor. The stator core includes a hybrid segment. The hybrid segment includes a soft magnetic composite material component and laminated delaminations. The laminated delaminations include two inclined laminated delaminations, wherein the distance between the two inclined laminated delaminations increases radially along the radially extending centerline of the hybrid segment. Conductive wires are wound on the hybrid segment.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to stators of axial flux motors, and more particularly, to stator core segments in axial flux motors. BACKGROUND

[0002] The information provided in this section is intended to summarize the context of the present disclosure. To the extent that the work of the current inventors, and the descriptions in this section, as they pertain to the prior art, are not expressly identified as such, they are neither expressly nor impliedly admitted to be prior art with respect to the present disclosure.

[0003] Electric motors convert electrical energy into mechanical work by producing torque, while electric generators convert mechanical work into electrical energy. Electric vehicles and hybrid vehicles employ electric motors / generators, such as induction and permanent magnet motors / generators, for propulsion and harvesting of brake energy. While the present discussion primarily refers to motors, the principles described herein also apply to generators.

[0004] An electric motor can include a rotor and a stator. The rotor includes permanent magnets and rotates relative to the stator. The rotor is connected to a rotor shaft that rotates with the rotor. The rotor is separated from the stator by an air gap. The stator includes conductors in the form of wire windings. When current passes through the wire windings, a magnetic field having an associated magnetic flux is produced. As the magnetic field acts on the permanent magnets of the rotor, power is transferred through the air gap. As a result, electrical energy is converted into mechanical energy to rotate the rotor shaft. In electric vehicles, the rotor is used to transmit torque through a gear set via a rotating shaft to drive the wheels of the vehicle.

[0005] Two types of electric motors are radial flux motors and axial flux electric motors. In a radial flux motor, the rotor and stator are typically positioned in a concentric or nested configuration such that when the stator is energized, a magnetic flux is produced that extends radially from the stator to the rotor. The electrically conductive windings of the stator are typically arranged parallel to the axis of rotation, resulting in a magnetic field that is oriented in a radial direction from the axis of rotation along the rotor shaft. In an axial flux motor, a magnetic field parallel to the axis of rotation is produced by electrically conductive wire windings of a corresponding stator. The magnetic flux produced in an axial flux motor extends parallel to the axis of rotation of the rotor shaft. Axial flux motors tend to be smaller, lighter, and produce more power than radial flux motors. SUMMARY

[0006] An axial flux motor is provided and includes a shaft, at least one rotor connected to the shaft, and a stator. The stator includes a stator core and electrically conductive wire. The stator core is segmented and annular and includes a central opening through which the shaft extends to the at least one rotor. The stator core includes a hybrid segment. The hybrid segment includes a soft magnetic composite component and a laminated layer block. The laminated layer block includes two tilted laminated layer blocks, where a distance between the two tilted laminated layer blocks increases radially along a radially extending centerline of the hybrid segment. The electrically conductive wire is wound on the hybrid segment.

[0007] In other features, the hybrid segment is a first hybrid segment. The stator core includes a hybrid segment. The hybrid segment includes the first hybrid segment. Each of the hybrid segments includes a soft magnetic composite component and a laminated layer block.

[0008] In other features, the laminated layer block of each of the hybrid segments includes two tilted laminated layer blocks, where a distance between the two tilted laminated layer blocks of each of the hybrid segments increases radially along a respective radially extending centerline of the first hybrid segment.

[0009] In other features, the hybrid segment includes one or more non-tilted laminated layer blocks extending at least one of: parallel to the radially extending centerline or radially along the radially extending centerline.

[0010] In other features, the one or more non-tilted laminated layer blocks include a single non-tilted laminated layer block extending radially inward from a radially outermost edge of the hybrid segment toward the two tilted laminated layer blocks along the radially extending centerline.

[0011] In other features, an axial width of the layers of the two tilted laminated layer blocks is the same as an axial width of the layers of the one or more non-tilted laminated layer blocks.

[0012] In other features, the hybrid segment includes a non-tilted laminated layer block extending at least one of: parallel to the radially extending centerline or radially along the radially extending centerline.

[0013] In other features, an axial width of the layers of the two tilted laminated layer blocks is the same as an axial width of the layers of the one or more non-tilted laminated layer blocks.

[0014] In other features, the non-tilted laminated layer block includes: two non-tilted laminated layer blocks extending to a radially outermost edge of the hybrid segment; and a single non-tilted laminated layer block extending radially inward from the two non-tilted laminated layer blocks toward the two tilted laminated layer blocks.

[0015] In other features, the axial width of the layers of the two tilted laminated layer blocks is the same.

[0016] In other features, an axial flux motor is provided and includes a shaft, at least one rotor, and a stator. The at least one rotor is connected to the shaft. The stator includes a stator core and electrically conductive wire. The stator core is segmented and annular and includes a central opening through which the shaft extends to the at least one rotor. The stator core includes a hybrid segment. The hybrid segment includes a soft magnetic composite component and a laminated layered insert including laminated layered blocks. A radially innermost one of the laminated layered blocks extends to a radially innermost edge of the hybrid segment. A radially outermost one of the laminated layered blocks extends to a radially outermost edge of the hybrid segment. The electrically conductive wire is wound on the hybrid segment.

[0017] In other features, the hybrid segment is a first hybrid segment. The stator core includes a hybrid segment. The hybrid segment includes the first hybrid segment. Each of the hybrid segments includes a soft magnetic composite component and a laminated layered block.

[0018] In other features, the hybrid segment includes one or more laminated layered blocks disposed between a radially innermost one of the laminated layered blocks and a radially outermost one of the laminated layered blocks.

[0019] In other features, the hybrid segment includes two laminated layered blocks disposed between a radially innermost one of the laminated layered blocks and a radially outermost one of the laminated layered blocks.

[0020] In other features, the laminated layers of one of the laminated layered blocks are the same axial width.

[0021] In other features, the laminated layers of each of the laminated layered blocks are the same axial width.

[0022] In other features, the laminated layered blocks are different axial widths.

[0023] In other features, one or more of the laminated layered blocks extend axially to an axially outermost edge of the hybrid segment.

[0024] In other features, the laminated layered blocks are arranged in a stepped configuration. The soft magnetic composite component has a stepped axially innermost surface that matches a dimension of an axially outermost surface dimension of the laminated layered blocks.

[0025] In other features, an axially innermost one of the laminated layered blocks is a smaller axial width than the laminated layered blocks disposed between the radially innermost one of the laminated layered blocks and a radially outermost one of the laminated layered blocks. An axially outermost one of the laminated layered blocks is a larger axial width than the laminated layered blocks disposed between the radially innermost one of the laminated layered blocks and the radially innermost one of the laminated layered blocks.

[0026] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0027] The present disclosure will become more fully understood from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0028] Figure 1 is a perspective view of an example axial flux motor including a stator core and two rotors;

[0029] Figure 2 is a perspective view of an example segmented stator core;

[0030] Figure 3 is a perspective view of an example stator core segment having soft magnetic composite (SMC) molded teeth and pole shoes;

[0031] Figure 4 is a perspective view of an example stator core tooth including stacked laminated layers having different widths;

[0032] Figure 5 is a perspective view of an example stator core segment having a hybrid structure in which the teeth and pole shoes include SMC material and corresponding portions of laminated segmented blocks;

[0033] Figure 6 is a side view of an example of a stator core segment including tilted laminated segmented blocks and non-tilted laminated segmented blocks according to the present disclosure;

[0034] Figure 7 is a side view of an example of a stator core segment including tilted laminated segmented blocks and non-tilted laminated segmented blocks according to the present disclosure;

[0035] Figure 8 is a side view of an example of a stator core segment according to the present disclosure including stacked laminated segmented blocks having respective widths and collectively extending to a radially inner peripheral edge and an outer peripheral edge;

[0036] Figure 9 is a plot of efficiency curves showing a difference in efficiency between a first motor including stator core segments formed only of SMC material and a second motor including hybrid stator core segments;

[0037] Figure 10 is a top view of a portion of a vehicle including an axial flux motor according to the present disclosure; and

[0038] Figure 11 is a functional block diagram of a vehicle system including an axial flux motor according to the present disclosure.

[0039] In the drawings, reference numerals can be repeated among the figures to identify similar and / or identical elements. DETAILED DESCRIPTION

[0040] Figure 1 An example of an axial flux motor 100 is shown. The axial flux motor 100 has a first rotor 110 and a second rotor 120, both of which are connected to a rotor shaft 130 and configured to rotate about the rotor shaft 130. The examples disclosed herein are applicable to this type of axial flux motor and other axial flux motors. For example, while two rotors are shown, the axial flux motor can include one or more rotors. The first rotor 110 and the second rotor 120 are both annular, with a centrally disposed hole 118. The rotor shaft 130 passes through the centrally disposed hole 118 and defines a rotation axis 132 about which the rotors 110, 120 rotate. The rotation axis 132 can extend along and / or include a longitudinal centerline of the rotor shaft 130.

[0041] A stator 140 is axially disposed between the rotors 110, 120 and is annular. The stator 140 is fixed and stationary, while the first rotor 110 and the second rotor 120 rotate with the rotor shaft 130 during operation. The first rotor 110 faces a first side 142 of the stator 140 and defines a first air gap 144 therebetween. The second rotor 120 faces a second side 146 of the stator 140 and defines a second air gap 148 therebetween.

[0042] While the axial flux motor 100 is shown as having a central single stator 140 and two external rotors 110, 120, the examples disclosed herein are also applicable to other configurations. Some example axial flux motor configurations include (i) two stators and a single rotor, or (ii) a single stator and two or more rotors. The axial motor can include respective housings, and the corresponding rotors, stators, and shafts can be disposed within the housings. The housings can be fixed to a vehicle frame, and the shafts can be coupled to one or more axles of a corresponding vehicle, a gear box (e.g., a reduction gear box), another shaft, etc.

[0043] Each of the rotors 110, 120 can have the same design and face the stator 140 in opposite directions. Each of the rotors 110, 120 includes permanent magnets 112 attached to a rotor body 114. The permanent magnets 112 can have alternating polarity. Each permanent magnet 112 defines a channel 116 therebetween, which can extend radially along the face of the corresponding rotor. In this way, the permanent magnets 112 and the channels 116 can together define a plurality of magnetic poles.

[0044] The stator 140 includes a stator core comprising stator core segments (referred to herein as "segments") 150 around which electrically conductive windings (or wound wires) 152 are wound. The stator 140 defines slots 156 between adjacent ones of the stator core segments 150. The stator 140 can be fixed and stationary. The slots 156 can be configured to receive the electrically conductive windings 152, which can be wound in and through the slots 156. As an example, the windings 152 can comprise copper and / or copper alloys.

[0045] The rotor shaft 130 can pass through a centrally disposed hole 154 in the stator 140 and be supported by bearings that align the rotor 110, 120 relative to the stator 140 while allowing the rotor shaft 130 to rotate. The electrically conductive windings 152 of the stator 140 can be formed of copper and / or other electrically conductive materials. The electrically conductive windings 152 are configured to generate a magnetic field when an electric current is applied to interact with the magnetic field of the permanent magnets 112. Different regions of the stator 140 can be selectively energized to exert a rotational force on the rotor 110, 120, causing the rotor 110, 120 and the rotor shaft 130 to rotate relative to the rotational axis 132.

[0046] The axial flux motor 100 provides a high torque output and is thus suitable for high torque applications, including for use in electric or hybrid vehicles. In such a variant, a housing enclosing the motor 100 can be attached to a vehicle frame, and at least one output from an end of the rotor shaft 130 can be coupled to a reduction gearbox or directly to a vehicle drive wheel.

[0047] Figure 2 An example of a segmented stator core 200 is shown, which includes segments 220 disposed on a stator disk 230. The segmented stator core 200 can replace Figure 1 the stator 140 and enclose the rotor shaft 202. The segments 220 are generally trapezoidal and are at least partially formed of soft magnetic composite material (SMC). One or more of the segments 220 can be configured as shown in Figures 3-5 In some embodiments, the segments 220 are each configured as shown in one or more of the figures in Figures 3-5 The gaps between the segments 220 are referred to as channels 232 and are defined by the sides of the segments 220. As shown, the segments 220 can include recessed regions 226 configured to receive at least one electrically conductive wire that is wound around the segments 220 to provide windings 234. The wires can be wound around at least a portion of an exterior 236 of each of the segments 220. The SMC material can be readily manufactured into a variety of complex shapes to provide at least portions of the segments 220. The segments 220 can include pole pieces 224.

[0048] Figures 3-8 A stator core segment and portions thereof are shown, which can replaceFigures 1-2 one or more of segments 150, 220. Figure 3 An example stator core segment 300 is shown having SMC molded teeth 302 and pole shoes 304, 306. The stator core segment 300 can be formed in two parts, for example, (i) a first part 308 including a first axial portion 310 of the first pole shoe 304 and teeth 302, and (ii) a second part 312 including a second axial portion 314 of the second pole shoe 306 and teeth 302. The first part 308 can be adhered to the second part 312. More specifically, the first axial portion 310 can be adhered to the second axial portion 314. The entire stator core segment can be formed from SMC, or alternatively, a first portion of the stator core segment 300 can be formed from SMC, while another portion can be formed from and / or include laminated metal layers and / or one or more laminated sub-lamination blocks.

[0049] Figure 4 An example stator core tooth 400 is shown that includes stacked laminated layers 410 having different widths. The laminated layers 410 of magnetic material can each include a ferromagnetic material, such as a magnetic steel. The ferromagnetic material of each of these layers 410 can be isolated from one another by an insulating coating. As an example, each of the layers 410 can include a layer of magnetic material coated with an insulating and / or dielectric material. The insulating material is disposed between two adjacent layers of magnetic material. As shown, the laminated layers 410 can be laminated steel sheets that are stacked, pressed, stamped, annealed, and / or adhered to one another during a manufacturing process to form a laminated stator core tooth. When multiple laminated stator core teeth are assembled, these teeth provide magnetizable magnetic poles.

[0050] Each of the layers 410 of the tooth 400 has a respective and different set of dimensions, with each set including a different length and width. Each of these layers 410 can have the same thickness. As an example, a first layer 412 has a first size defined by its length, width, and height (e.g., thickness), while a second layer 414 has a second size defined by its length, width, and height. The second size of the second layer 414 is smaller than the first size of the first layer 412. Because each of these layers 400 has a different size, the manufacturing of the tooth 400 requires a much more complex manufacturing process than the manufacturing of a tooth formed entirely from SMC material. Figure 3

[0051] For axial flux motors, it is easier to manufacture a stator core segment using SMC material than to manufacture a stator core segment using laminated layers. However, motor efficiency is impacted because SMC exhibits higher core losses than laminated magnetic steel layers. In contrast to an axial flux motor including a stator core having laminated magnetic steel sub-lamination teeth, an axial flux motor including a stator core having SMC formed teeth also has lower torque capability.​

[0052] Figure 5 An example stator core segment 500 is shown having a hybrid construction, where the teeth 502 and pole shoes 504, 506 include SMC and a laminated layered stack 508. The teeth 502 include a first axial portion 510 and a second axial portion 512. The laminated layered stack 508 includes laminated layered blocks, where each laminated layered block includes a stack of laminated layers. Each laminated layer of a laminated layered block has the same or similar dimensions as each other laminated layer in the laminated layered block. In the example shown, each laminated layered block has a different width. An example width W of one of the laminated layered blocks is shown. By including the laminated layered stack 508, the segment 500 exhibits less loss and higher efficiency than the segment 300 of Figure 3 As an example, the percentage of the total volume of the segment 500 that includes laminated layered blocks can be 45%.

[0053] Examples set forth herein include an axial flux motor including a stator core having hybrid segments. The hybrid segments include SMC material and a stack of laminated magnetic steel layers, referred to as laminated layered blocks. Figures 6-8 A number of hybrid examples are shown. The more laminated content of each segment, the less core loss and the better the motor operates. The hybrid examples are designed to maximize the number of laminated content for a given envelope of the segment and thereby maximize operational efficiency.

[0054] Figure 6 An example of a stator core segment 600 is shown that includes tilted laminated blocks 602, 604 and a non-tilted (or centerline-extended) laminated block 606. The tilted laminated blocks 602, 604 are angled relative to a centerline 608. The centerline 608 extends radially and through the center of the segment 600. Each of the tilted laminated blocks 602, 604 extends to an annular outer edge and thus shares an annular outer edge with the annular outer edge of the segment. For example, the annular outer edge 610 of the tilted laminated block 602 is the annular outer edge of the segment 600. Similarly, the annular outer edge 612 of the tilted laminated block 604 is another annular outer edge of the segment 600. The non-tilted laminated block 606 extends along the centerline 608 and is centered in the annular direction on the centerline 608. The non-tilted laminated block 606 extends from a radial outer edge 620 of the segment 600 to inner annular edges 622, 624 of the tilted laminated blocks 602, 604.

[0055] The width of each of blocks 602, 604, and 606 can be the same. The length of each of blocks 602, 604 can be the same and longer than the length of block 606. Width is measured in the annular direction. Length is measured radially. The width W and length L of tilted laminated block 604 are shown as examples. The depth of blocks 602, 604, and 606 can also be the same. Depth is measured in the axial direction. The width and depth of blocks 602, 604, and 606 can be the same to reduce manufacturing complexity.

[0056] Segment 600 also includes SMC components 630, 632, 634. SMC components 630, 632, 634 are triangular. SMC component 630 is disposed between the radially inner edge 636 of non-tilted laminated block 606 and inner annular edges 622, 624. SMC components 632, 634 are disposed between inner annular edges 622, 624. SMC components 632, 634 have radially outer edges 640, 642 that extend along radially outer edge 620. Each of SMC components 630, 632, 634 can be formed of SMC material and as described herein. As shown, radially outer edge (or outer peripheral edge) 620 can be arcuate and / or have a plurality of linear edges. Each of laminated segmented blocks 602, 604, 606 extends to a linear edge. Laminated segmented blocks 602, 604, 606 can have an outer radial edge that is shaped to match the shape of a corresponding portion of radially outer edge 720.

[0057] SMC components referred to herein can be formed of SMC powder, which can be covered with an electrically insulating layer on its surface. The SMC powder can include iron powder having fine particles that can be molded using a press to provide a predetermined shape. The particles can be coated with an insulating material. Pressure from the press causes the particles to bind together. These powders are consolidated by pressing or solidification to form soft magnetic components. Thus, such SMC material can be easily formed into a variety of different and complex shapes, like Figures 5-8 the generally trapezoidal and triangular shapes shown.

[0058] The size and shape of segment 600, blocks 602, 604, 606, and SMC components 630, 632, 634 can vary depending on the application. The size and shape of blocks 602, 604, 606 and SMC components 630, 632, 634 can vary to maximize the ratio between the total volume of blocks 602, 604, 606 and the total volume of SMC components 630, 632, 634. As an example, the percentage of laminated segmented material relative to the total volume of segment 600 can be 76% or other percentage.

[0059] Segment 600 can not include pole shoes. In one embodiment, the stator core teeth are formed similar to segment 600 and include axially disposed pole shoes. The pole shoes can be partially formed of SMC material. Similar to the example of Figure 5 Segments 600, 604, 606 can extend axially into the pole shoes. Although segment 600 is shown as including only two slanted laminated blocks and only one non-slanted laminated block, segment 600 can include more slanted laminated blocks and / or more non-slanted laminated blocks.

[0060] Figure 7 An example of a stator core segment 700 is shown similar to the stator core segment of Figure 6 However, instead of including two slanted laminated blocks and a single non-slanted laminated block, stator core segment 700 includes two slanted laminated blocks 702, 704 and a plurality of non-slanted laminated blocks 706, 708, 710. A centerline extends between laminated blocks 708, 710 and through the center of laminated block 706, which is disposed between and in contact with slanted laminated blocks 702, 704 and non-slanted laminated blocks 708, 710. Laminated blocks 708, 710 are in contact with each other and with laminated blocks 702, 704, respectively, and can be replaced with a single laminated block.

[0061] The width of each of blocks 702, 704, 706, 708, and 710 can be the same. The length of each of blocks 702, 704 can be the same and longer than the length of blocks 706, 708, and 710. The length of blocks 706, 708, and 710 can be the same. The depth of blocks 702, 704, 706, 708, and 710 can be the same. Width is measured in the annular direction. Length is measured radially. Depth is measured in the axial direction. The width and depth of blocks 702, 704, 706, 708, and 710 can be the same to reduce manufacturing complexity.

[0062] Each of laminated blocks 702, 704, 708, 710 extends to a linear edge of a radially outer edge (or outer peripheral edge) 720 of segment 700. Radially outer edge 720 can be arcuate. Laminated blocks 702, 704, 708, 710 can have an outer radial edge shaped to match the shape of a corresponding portion of radially outer edge 720.

[0063] Section 700 also includes SMC components 730, 732, 734, 736, 738. SMC components 730, 732, 734, 736, 738 are triangular. SMC component 730 is disposed between and adhered to the angled lamination layered blocks 702, 704 and the non-angled lamination layered block 706. SMC components 732, 734 are disposed between and adhered to the angled lamination layered blocks 702, 704 and the non-angled lamination layered blocks 706, 708, 710. SMC components 736, 738 are disposed between and adhered to the angled lamination layered blocks 702, 704 and the non-angled lamination layered blocks 708, 710. SMC components 736, 738 have radially outer edges 740, 742 that extend along the radially outer edge 720. Each of the SMC components 730, 732, 734, 736, 738 can be formed of SMC material and as described herein. As an example, the percentage of lamination layered material relative to the overall volume of section 700 can be 86% or other percentage.

[0064] Section 700 can not include pole shoes. In one embodiment, the stator core teeth are formed similar to section 700 and include axially disposed pole shoes. The pole shoes can be partially formed of SMC material. Similar to Figure 5 As an example, blocks 702, 704, 706, 708, 710 can extend axially into the pole shoes. Although section 700 is shown as including only two angled lamination layered blocks and only three non-angled lamination layered blocks, section 700 can include more angled lamination layered blocks and / or more non-angled lamination layered blocks.

[0065] Figure 8 An example of a stator core section 800 is shown that includes stacked lamination layered blocks 802, 804, 806, 808 having respective widths and collectively extending to a radially inner perimeter edge 810 and a radially outer perimeter edge 812. The lamination layered blocks 802, 804, 806, 808 are configured to provide a stepped structure as shown. Widths W1-W4 are shown for lamination blocks 802, 804, 806, 808, respectively. As shown, the width W1 of block 802 is less than the width W2 of block 804, which is less than the width W3 of block 806. The width W4 of block 808 is greater than width W3. Although blocks 802, 804, 806, 808 are shown as having particular widths relative to the annular outer angled edges 820, 822 of section 800, the widths of blocks 802, 804, 806, 808 can be less than or greater than the widths shown relative to the distance between angled edges 820, 822. In one embodiment, the widths W1-W4 increase such that the lamination layered blocks extend to the angled edges 820, 822.

[0066] As shown in the figure, the radial inner peripheral edge 810 and the radial outer peripheral edge 812 can each be linear, arc-shaped, and / or formed by linear edges. The radial inner edge of the laminated layer block 802 can match the shape of the radial inner peripheral edge 810. The radial outer edge of the laminated layer block 808 can match the shape of the radial outer peripheral edge 812. As an example, the percentage of the laminated layer material relative to the total volume of segment 800 can be 75% or other percentages.

[0067] Segment 800 includes two SMC components 830 and 832. SMC components 830 and 832 include a linear axial outermost edge and a stepped axial innermost edge, which match the stepped axial outer dimensions of laminated blocks 802, 804, 806, and 808. SMC components 830 and 832 are adhered to the axial outermost surfaces of laminated blocks 802, 804, 806, and 808.

[0068] Segment 800 may not include pole shoes. In one embodiment, the stator core teeth are formed similarly to segment 800 and include axially disposed pole shoes. The pole shoes may be partially formed of SMC material. Similar to Figure 5 For example, blocks 802, 804, 806, and 808 may extend axially into the pole shoe. Although segment 800 is shown as comprising four laminated blocks, the segment may include more or fewer laminated blocks.

[0069] Figure 9 An efficiency graph is shown, illustrating the increase in efficiency when using a hybrid segment with an increased ratio of laminated structure volume to total structure volume. The graph includes a first curve 900 and a second curve 902. The first curve 900 is an example efficiency curve for a first motor comprising a first stator core including a segment formed of SMC material, wherein the segment does not include laminated delaminated blocks. An example of a first stator core is made of a material similar to... Figure 3 The stator core formed by the segment shown is illustrated. The second curve 902 is an example efficiency curve for a second motor including a second stator core with a hybrid segment. This hybrid segment comprises SMC material and laminated delaminated blocks. An example of a second stator core is formed from a material similar to... Figure 5 The stator core is formed by the segments shown. Each of the efficiency curves 900 and 902 correlates the percentage of efficiency with a relative torque measured, for example, in Newton-meters (Nm). Efficiency curves 900 and 902 are for a specific motor speed (e.g., 3500 revolutions per minute (rpm)). The higher the efficiency of the stator core, the higher the output torque at the same supply voltage and current levels. Figures 6-8 As shown, the stator core ratio formed by segments Figure 3 and 5 The stator core shown is more efficient.

[0070] The above example involves minimizing the number of laminated layers on different sides within a segment of the stator core. While achieving this, the volume of laminated layers included in a given total volume of the segment is maximized, thereby maximizing operational efficiency.

[0071] Figures 6-8 Each of the laminated layers comprises layers (or sheets). These sheets may comprise ferromagnetic materials, and each sheet may have at least one insulating layer or coating disposed therebetween. Suitable ferromagnetic materials for laminated stator core segments include magnets. The insulating materials interleaved between adjacent layers may comprise nonmagnetic materials. The insulating materials may comprise (i) siloxane materials, such as silicone varnishes, and / or (ii) metal-organic and / or inorganic insulating materials, which may comprise silicate layers, oxide layers, phosphate layers, and equivalents and / or combinations thereof.

[0072] As shown in the figure, each sheet of each laminated block has a substantially identical footprint to the other sheets of the same laminated block. For example, taking into account manufacturing tolerances and variations, each sheet of each laminated block can have substantially the same dimensions, including the same width, length, and thickness. These sheets can have a rectangular annular cross-section. As an example, each sheet can have a thickness ranging from greater than or equal to 0.1 mm to less than or equal to about 0.5 mm. As an example, the total volume of the mixed segment filled with the laminated blocks can range from greater than or equal to about 10% by volume to less than or equal to about 90% by volume.

[0073] As an example, the laminated blocks of a segment can be formed in parallel with the formation of the corresponding SMC component. The laminated blocks can then be adhered to the SMC component. As another example, the laminated blocks of a segment can be formed and arranged relative to each other, and the SMC component can then be formed around them to fill the gaps between the laminated blocks and the areas within the outer envelope of the segment that are not filled with laminated blocks.

[0074] Figures 6-8 The formation of each of the SMC components may include one or more precursors using SMC material. Precursors may include, for example, ferromagnetic powder particles and optionally a matrix material, such as a polymeric resin. The precursor may be introduced into a mold and fill the area between and / or around the laminated interlayers disposed therein. For example, the precursor may be densified by applying compressive force to the mold. In some aspects, the applied pressure may be greater than or equal to about 1000 MPa. Additional heat and / or photochemical radiation may be applied to react the matrix material, such as through polymerization or crosslinking. In some variations, adhesives or glues may be used at the interfaces between the laminated interlayers to enhance adhesion of the molded SMC material.

[0075] The precursor may include particles defining a magnetic core, which is surrounded by one or more insulating shells in the shell region. The magnetic material in the core may be ferromagnetic and includes iron (e.g., iron or ferrite powder) or other magnetizable materials or alloys, including, for example, iron alloys containing silicon, nickel, and / or phosphorus. Other examples include rare earth metal compounds, such as those containing samarium (Sm), neodymium (Nd), samarium cobalt (SmCo 1:5), samarium cobalt (SmCo 2:17), and neodymium iron boron (NdFeB). Other examples of suitable magnetic particles include AlNiCo alloys. The average particle size of the magnetic particles may be greater than or equal to 50 micrometers to less than or equal to 250 micrometers. As an example, the particle size may be 100 micrometers. The core region including the magnetic material may be surrounded by one or more insulating layers. The insulating layers may include non-magnetic materials, such as siloxane materials, silicone varnish materials, or metal-organic or inorganic insulating materials. Inorganic insulating materials may include, for example, silicate layers, oxide layers, phosphate layers, and equivalents and combinations thereof. The insulating shell may have a total thickness greater than or equal to 10 nanometers (nm) to less than or equal to about 1 millimeter (mm). As an example, the insulating shell may have a total thickness greater than or equal to 10 nm to less than or equal to 800 micrometers.

[0076] In addition, the adhesive layer can be used as a matrix to help individual particles adhere to each other, as needed. As an example, the adhesive or matrix may include thermosetting or thermoplastic polymers, such as elastomers or polytetrafluoroethylene, or alternatives to ceresin wax.

[0077] Relatively high compression pressure is used to compress and solidify the precursor SMC powder to form molded SMC material. It should be noted that the molded SMC material is not sintered during densification and compression.

[0078] In this way, the molded SMC material can be integrally formed around a laminated insert comprising multiple laminated layers, the laminated insert being non-releasably located within the molded SMC material. Thus, the laminated insert and the molded SMC material together form a single, integral hybrid tooth and / or segment. Advantageously, the ability to have the exterior of the molded hybrid tooth and / or segment to form complex shapes, such as… Figures 5-8 As shown (e.g., a basic trapezoidal cross-sectional shape). As illustrated, the hybrid segment may define an outer surface and include two pole shoes that together define an annular outer recessed region. As mentioned above, the recessed region is configured to receive wound wire conductors (or windings). The hybrid teeth and / or segments may have a variety of other shapes and configurations for receiving at least a portion of one or more conductor windings. The hybrid teeth and segments of the stator core configured as disclosed herein can have complex shapes, while advantageously providing improved performance by reducing eddy currents and hysteresis due to the presence of integrated laminated core inserts.

[0079] Although vehicle examples are described below, this application is also applicable to non-vehicle implementations. This application is applicable to other axial flux motor applications. It should be understood that these concepts apply not only to electric axial flux motors that generate mechanical energy from electrical energy, but also to axial flux generators that can generate electrical energy from mechanical energy.

[0080] Figure 10 A portion 1000 of a vehicle 1001 (referred to as a vehicle system) including axial flux motors 1004 and 1005 is shown. The vehicle system includes a control module 1002, multiple axial flux motors 1004 and 1005, a front axle 1006, a rear axle 1008 and 1009, a user input device 1010, and a steering device (e.g., a steering wheel) 1012. The control module 1002 controls the distribution of output torque to the axles 1006 and 1008 based on torque requests. As an example, a torque request may be provided by the driver via the user input device 1010 (e.g., the accelerator pedal) or via another input device (e.g., the steering angle (e.g., the angle of the steering wheel)). The distribution of output torque is indicated by dashed line 1016, and inputs from the user input device 1010 and the steering device 1012 are indicated by arrows 1017 and 1018. The control module 1002 may implement the algorithms disclosed herein. In the example shown, the axial flux motor 1005 is connected to the rear axles 1008 and 1009 via the differential transfer case 1020. Axles 1006, 1008, and 1009 are connected to the drive tires 1030.

[0081] Figure 11 A vehicle system 1100 is shown, comprising one or more axial flux motors 1103. The vehicle system 1100 can be connected to... Figure 10 The vehicle system operates and / or is configured similarly. Vehicle system 1100 may include a chassis control module 1104 and a torque source, such as one or more axial flux motors 1103 and one or more engines (an engine 1108 is shown). Vehicle system 1100 may also include vehicle sensors 1110 and memory 1112. Chassis control module 1104 can control the distribution of output torque to the axles of vehicle 1102 via the torque source. Chassis control module 1104 can control the operation of propulsion system 1113, which includes axial flux motors 1103 and one or more engines 1108.

[0082] Sensor 1110 may include a steering sensor 1120 (e.g., a steering wheel sensor), a vehicle speed sensor 1122, an accelerometer 1124, an accelerator pedal sensor 1126, a yaw rate sensor 1128, and other sensors 1130. The chassis control module 1104 controls the torque source based on the output of the sensors 1110.

[0083] The memory 1112 may store vehicle status 1140, tire forces 1142, driver inputs 1144, actuator constraints 1146, and other parameters and data 1148. Vehicle status 1140 may include longitudinal, lateral, and vertical forces. Tire forces 1142 may indicate tire capacity levels. Driver inputs 1144 may indicate accelerator pedal position, steering wheel angle, and / or other driver inputs. Actuator constraints 1146 may include the maximum output torque of torque sources (or how much output torque each torque source can produce). Engine 1108 may include a starter motor 1150, a fuel system 1152, an ignition system 1154, and a throttle system 1156.

[0084] Vehicle 1102 may also include a Body Control Module (BCM) 1160, a Telematics Module 1162, a Braking System 1163, a Navigation System 1164, an Infotainment System 1166, an Air Conditioning System 1170, other actuators 1172, other devices 1174, and other vehicle systems and modules 1176. Modules and systems 1104, 1160, 1162, 1164, 1166, 1170, and 1176 can communicate with each other via a Controller Area Network (CAN) bus 1178 and / or other suitable communication interfaces. A power supply 1180 may be included to power the BCM 1160 and other systems, modules, devices, and / or components. The power supply 1180 may include one or more batteries and / or other power sources.

[0085] The telematics module 1162 may include a transceiver 1182 and a telematics control module 1184. The BCM 1160 can control modules and systems 1162, 1163, 1164, 1166, 1170, 1176, and other actuators, devices, and systems (e.g., actuator 1172 and device 1174). This control may be based on data from sensor 1110.

[0086] The preceding description is illustrative in nature and is in no way intended to limit this disclosure, its application, or use. The broad teachings of this disclosure can be implemented in many forms. Therefore, while this disclosure includes specific examples, its true scope should not be so limited, as other modifications will become apparent upon examination of the drawings, specification, and appended claims. It should be understood that one or more steps in the method may be performed in a different order (or simultaneously) without altering the principles of this disclosure. Furthermore, although each of these embodiments has been described above as having certain features, any one or more of those features described with respect to any embodiment of this disclosure may be implemented in any embodiment of other embodiments and / or combined with features of any embodiment of other embodiments, even if such combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and substitution of one or more embodiments for each other remains within the scope of this disclosure.

[0087] Spatial and functional relationships between components (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “joined,” “linked,” “adjacent,” “right next to,” “on top of,” “above,” “below,” and “set on.” Unless explicitly described as “direct,” when describing a relationship between a first component and a second component in the foregoing disclosure, the relationship can be a direct relationship in which no other intermediate components exist between the first and second components, or an indirect relationship in which one or more intermediate components (spatially or functionally) exist between the first and second components. As used herein, the phrase “at least one of A, B, and C” should be interpreted as using the non-exclusive logic “OR” to represent logic (A or B or C) and should not be interpreted as representing “at least one of A, at least one of B, and at least one of C.”

[0088] In the accompanying drawings, the direction of the arrow, as indicated by the arrowhead, typically represents the flow of information (e.g., data or instructions) of interest to the illustration. For example, when components A and B exchange various types of information, but the information transmitted from component A to component B is relevant to the illustration, the arrow may point from component A to component B. This unidirectional arrow does not imply that no other information is transmitted from component B to component A. Furthermore, for information transmitted from component A to component B, component B may send a request for the information to component A or receive an acknowledgment.

[0089] In this application, including the following definitions, the term "module" or "controller" may be replaced by the term "circuit". The term "module" may refer to, be a part of, or include: application-specific integrated circuit (ASIC); digital, analog, or mixed-signal analog / digital discrete circuit; digital, analog, or mixed-signal analog / digital integrated circuit; combinational logic circuit; field-programmable gate array (FPGA); processor circuitry (shared, dedicated, or grouped) that executes code; memory circuitry (shared, dedicated, or grouped) that stores code executed by the processor circuitry; other suitable hardware components that provide the described functionality; or some or all of the foregoing, such as in a system-on-a-chip.

[0090] This module may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces that connect to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functionality of any given module in this disclosure may be distributed across multiple modules connected via the interface circuits. For example, multiple modules may allow for load balancing. In another example, a server (also referred to as a remote or cloud) module may perform some functions on behalf of a client module.

[0091] As used above, the term "code" can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuitry" covers a single processor circuitry that executes some or all of the code from multiple modules. The term "group processor circuitry" covers a processor circuitry that, in conjunction with additional processor circuitry, executes some or all of the code from one or more modules. References to multiple processor circuitry cover multiple processor circuitry on a discrete die, multiple processor circuitry on a single die, multiple cores of a single processor circuitry, multiple threads of a single processor circuitry, or a combination thereof. The term "shared memory circuitry" covers a single memory circuitry that stores some or all of the code from multiple modules. The term "group processor circuitry" covers a memory circuitry that, in conjunction with additional memory, stores some or all of the code from one or more modules.

[0092] The term "memory circuit" is a subset of the term "computer-readable medium." As used herein, the term "computer-readable medium" does not cover transient electrical or electromagnetic signals propagated through a medium (e.g., via a carrier wave); therefore, the term "computer-readable medium" can be considered tangible and non-transient. Non-limiting examples of non-transient tangible computer-readable media are non-volatile memory circuits (e.g., flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (e.g., static random access memory circuits or dynamic random access memory circuits), magnetic storage media (e.g., analog or digital magnetic tape or hard disk drives), and optical storage media (e.g., CDs, DVDs, or Blu-ray discs).

[0093] The apparatus and methods described in this application can be implemented, in part or in whole, by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The function blocks, flowchart components, and other elements described above serve as software specifications that can be translated into computer programs through the routine work of a skilled technician or programmer.

[0094] A computer program includes processor-executable instructions stored on at least one non-transitory tangible computer-readable medium. A computer program may also include or depend on stored data. A computer program may encompass a basic input / output system (BIOS) for interacting with the hardware of a special-purpose computer, device drivers for interacting with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0095] Computer programs may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JS Object Notation), (ii) assembly code, (iii) object code generated from source code by a compiler, (iv) source code executed by an interpreter, (v) source code compiled and executed by a just-in-time (JIT) compiler, and so on. As an example only, source code may be written using the syntax of languages ​​including: C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, Javascript®, HTML5 (Hypertext Markup Language version 5), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.

Claims

1. An axial flux motor, comprising: axis; At least one rotor connected to the shaft; and Stator, which includes: Stator core, among which, The stator core is segmented and annular, and includes a central opening through which the shaft extends to the at least one rotor. The stator core includes a hybrid section. The hybrid section comprises multiple soft magnetic composite material components and multiple laminated blocks, and The plurality of laminated blocks include two inclined laminated blocks, wherein the distance between the two inclined laminated blocks increases radially along the radially extending centerline of the hybrid segment, and Conductive wires wound around the mixing section; In this configuration, inclined laminated blocks are angled relative to a centerline that extends radially and passes through the center of the segment. Each of the inclined laminated blocks extends to the outer edge of the annular ring and thus shares the outer edge of the annular ring with the outer edge of the segment. Non-inclined laminated blocks extend along the centerline and are centered in the annular direction on the centerline. The non-inclined laminated blocks extend from the radial outer edge of the segment to the inner annular edge of the inclined laminated blocks. The soft magnetic composite material component is disposed between the radial inner edge of the non-inclined laminated blocks and the inner annular edge of the inclined laminated blocks.

2. The axial flux motor according to claim 1, wherein, The mixing section is the first mixing section; The stator core includes multiple hybrid sections; The plurality of hybrid segments includes the first hybrid segment; and Each of the plurality of hybrid segments includes a plurality of soft magnetic composite material components and a plurality of laminated delamination blocks.

3. The axial flux motor of claim 2, wherein each of the plurality of hybrid sections comprises two inclined laminated blocks, wherein the distance between the two inclined laminated blocks of each of the plurality of hybrid sections increases radially along the respective radially extending centerline of the first hybrid section.

4. The axial flux motor according to claim 1, wherein, The hybrid segment includes one or more non-tilted laminated blocks that extend in at least one of the following ways: parallel to the radial extension centerline or radially along the radial extension centerline.

5. The axial flux motor according to claim 4, wherein, The one or more non-tilted laminated blocks include a single non-tilted laminated block that extends radially inward from the outermost radial edge of the mixing segment along the radially extending centerline to the two tilted laminated blocks.

6. The axial flux motor according to claim 4, wherein, The axial width of the layers in the two inclined laminated blocks is the same as the axial width of the layers in the one or more non-inclined laminated blocks.

7. The axial flux motor according to claim 1, wherein, The hybrid segment includes a plurality of non-tilted laminated blocks that extend in at least one of the following ways: parallel to the radial extension centerline or radially along the radial extension centerline.

8. The axial flux motor according to claim 7, wherein, The axial width of the layers in the two inclined laminated blocks is the same as the axial width of the layers in the one or more non-inclined laminated blocks.

9. The axial flux motor according to claim 7, wherein, The plurality of non-tilted laminated blocks include: Two non-tilted laminated blocks extend to the outermost radial edge of the hybrid segment; and A single non-tilted laminated block extends radially inward from the two non-tilted laminated blocks toward the two tilted laminated blocks.

10. The axial flux motor according to claim 1, wherein, The two inclined laminated blocks have the same axial width.

Images