Axial field motor and its stator cooling structure and manufacturing method

Abstract

The application provides an axial magnetic field motor stator, a cooling structure and a manufacturing method thereof. The cooling structure comprises a stator shell, the stator shell comprises an upper metal plate, an intermediate partition plate and a lower metal plate which are spliced along an axial direction, a plurality of core mounting holes are arranged on the stator shell in a circumferential direction, each core mounting hole penetrates the upper metal plate, the intermediate partition plate and the lower metal plate in sequence, a yokeless core is mounted in the core mounting hole and exposes two ends on both sides of the stator shell, a coil is sleeved on the yokeless core, the yokeless core exposes two ends on both sides of the stator shell, and the coil is sleeved on the two ends, an upper flow channel is arranged on a splicing surface of the upper metal plate and the intermediate partition plate, a lower flow channel is arranged on a splicing surface of the lower metal plate and the intermediate partition plate, and an intermediate hole is arranged on the intermediate partition plate and communicates the upper flow channel and the lower flow channel. The coil circumferential space is not occupied, the coil slot filling rate is improved, the forming difficulty is reduced, and the manufacturability is realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of stator cooling, in particular to an axial magnetic field motor without yoke core and a stator cooling structure and manufacturing method thereof. BACKGROUND

[0002] The axial magnetic field motor is also known as a disc type motor, which has the advantages of small size, high torque density, high power density and high efficiency, and is widely used in electric vehicles, general industry and other fields. The motor includes a housing, a stator and a rotor, and the stator and the rotor are arranged inside the housing. During operation of the motor, heat is generated inside the stator. For safety and efficiency reasons, the heat needs to be removed.

[0003] Currently, cooling fluid is used to remove heat through the stator, but due to space and insulation problems, some non-insulating cooling fluids can only pass through the stator through a well-designed cooling path, such as CN216056503U discloses a disc type motor stator easy to dissipate heat, which utilizes cooling paths arranged between the core windings and the radial inner and outer sides of the core windings, the cooling paths include inner ring flow channels, outer ring flow channels and water cooling channels, and the cooling fluid flows back and forth between the inner ring flow channels and the outer ring flow channels through the water cooling channels. Although the cooling effect can be achieved, there are the following defects:

[0004] First, the heat generated by the core needs to be transmitted to the cooling fluid through the coil, i.e. the core is far away from the cooling path, making the core interior poor in heat dissipation.

[0005] Second, the cooling path occupies the coil circumferential space, reducing the occupancy rate of the slot winding.

[0006] Third, each coil is separated by a water cooling channel, which is not conducive to the connection of the coils to form a winding.

[0007] Fourth, the cooling path includes inner ring flow channels, outer ring flow channels and water cooling channels, so the cooling path is complex and difficult to cast. SUMMARY

[0008] To solve the above problems, the present application provides an axial magnetic field motor and a stator cooling structure and manufacturing method thereof, which directly wrap the core and do not occupy the coil circumferential space, improve the coil slot fill rate, and reduce the molding difficulty to achieve manufacturability.

[0009] According to one object of the present application, the present application provides an axial magnetic field motor stator cooling structure, comprising:

[0010] A stator housing comprises an upper metal plate, an intermediate partition plate and a lower metal plate which are spliced together along an axial direction, and a plurality of core mounting holes are arranged on the stator housing in a circumferential direction, each of the core mounting holes penetrating the upper metal plate, the intermediate partition plate and the lower metal plate in sequence;

[0011] A plurality of yokeless cores are mounted in the core mounting holes and exposed at both sides of the stator housing;

[0012] A plurality of coils are sleeved on the yokeless cores, and the yokeless cores are sleeved with coils on both ends exposed at both sides of the stator housing;

[0013] An upper flow channel is arranged on the spliced surface of the upper metal plate and the intermediate partition plate, a lower flow channel is arranged on the spliced surface of the lower metal plate and the intermediate partition plate, and an intermediate hole is arranged on the intermediate partition plate and communicates with the upper flow channel and the lower flow channel.

[0014] As a preferred embodiment, an upper flow channel opening groove is arranged on the upper metal plate, the intermediate partition plate covers the upper flow channel opening groove to form the upper flow channel, a lower flow channel opening groove is arranged on the lower metal plate, and the intermediate partition plate covers the lower flow channel opening groove to form the lower flow channel.

[0015] As a preferred embodiment, the intermediate hole is connected with and communicates with the upper flow channel opening groove and the lower flow channel opening groove.

[0016] As a preferred embodiment, a sealing glue is arranged between the intermediate partition plate and the upper metal plate, and between the intermediate partition plate and the lower metal plate.

[0017] As a preferred embodiment, the intermediate partition plate is a flexible material plate, and the upper metal plate and the lower metal plate are heat-conducting metal plates.

[0018] As a preferred embodiment, an upper accommodating portion is arranged on the outer side of the upper metal plate away from the intermediate partition plate, a lower accommodating portion is arranged on the outer side of the lower metal plate away from the intermediate partition plate, and the coils located at the axial two sides of the yokeless cores are arranged in the upper accommodating portion and the lower accommodating portion respectively.

[0019] As a preferred embodiment, the application further comprises:

[0020] A plurality of slot wedges are arranged on the axial two sides of the yokeless cores respectively, each of the slot wedges is inserted between two adjacent yokeless cores, and the coils are abutted between the slot wedges and the stator housing.

[0021] As a preferred embodiment, an insulating heat-conducting member is arranged between the yokeless cores and the coils.

[0022] And / or, the coil and the stator housing are provided with an insulating heat conducting member.

[0023] According to another object of the present application, the present application further provides an axial magnetic field motor, which comprises the axial magnetic field motor stator cooling structure of the above-mentioned embodiment, and further comprises two rotors, which are air-gaply kept on the axial two sides of the yokeless core.

[0024] According to another object of the present application, the present application further provides a manufacturing method of an axial magnetic field motor stator cooling structure, which comprises the following steps:

[0025] a. providing a stator housing, which is provided with a plurality of core mounting holes arranged in a circumferential direction, and which comprises an upper metal plate, an intermediate partition plate and a lower metal plate, the core mounting holes penetrating through the upper metal plate, the intermediate partition plate and the lower metal plate in sequence, the upper metal plate being provided with an upper joint part, the upper joint part being provided with an upper flow channel, the lower metal plate being provided with a lower joint part, the lower joint part being provided with a lower flow channel, and the intermediate partition plate being provided with a plurality of intermediate holes;

[0026] b. splicing the intermediate partition plate between the upper joint part and the lower joint part, so that the intermediate holes are communicated with the upper flow channel and the lower flow channel;

[0027] c. inserting a yokeless core into the core mounting hole;

[0028] d. sleeving a coil on the axial two sides of the yokeless core, and keeping the coil on the axial two sides of the stator housing.

[0029] Compared with the prior art, the technical scheme has the following advantages:

[0030] The stator housing is kept on the middle section of the yokeless core, and the two coils sleeved on the yokeless core are kept on the axial two sides of the stator housing, so that the upper flow channel and the lower flow channel arranged in the stator housing can be in contact with the yokeless core and the coil for heat exchange at the same time, and the cooling effect is effectively improved.

[0031] Since the two coils sleeved on the yokeless core are kept on the axial two sides of the stator housing, the coils on the same side are connected and form a winding, which, compared with the conventional coil arranged between the core and the stator cooling structure, avoids the increase of the circumferential space design and the defect problem of low slot winding occupancy.

[0032] The stator shell is a split structure, so as to facilitate processing to form the upper flow channel and the lower flow channel, and then the upper metal plate, the intermediate partition plate and the lower metal plate are spliced, so as to realize manufacturability and reduce casting difficulty. By arranging the intermediate hole on the intermediate partition plate, the cooling medium can be circulated between the upper flow channel and the lower flow channel, and the upper flow channel and the lower flow channel are arranged along the yokeless core in the axial direction, so as to increase the heat exchange area, improve the flowability, and further enhance the cooling performance.

[0033] The application will be further described below in combination with the drawings and examples. BRIEF DESCRIPTION OF DRAWINGS

[0034] Figure 1 It is a structural schematic view of the axial magnetic field motor stator cooling structure of the application.

[0035] Figure 2 It is a front view of the stator shell of the application.

[0036] Figure 3 It is a sectional view along A-A direction. Figure 2

[0037] Figure 4 It is a structural schematic view of the intermediate partition plate of the application.

[0038] Figure 5 It is a structural schematic view of the upper metal plate of the first embodiment of the application.

[0039] Figure 6 It is a structural schematic view of the lower metal plate of the first embodiment of the application.

[0040] Figure 7 It is a principle diagram of the combination of the upper flow channel and the lower flow channel of the first embodiment of the application.

[0041] Figure 8 It is a structural schematic view of the upper metal plate of the second embodiment of the application.

[0042] Figure 9 It is a structural schematic view of the lower metal plate of the second embodiment of the application.

[0043] Figure 10 It is a principle diagram of the combination of the upper flow channel and the lower flow channel of the second embodiment of the application.

[0044] Figure 11 It is a structural schematic view of the upper metal plate of the third embodiment of the application.

[0045] Figure 12 It is a structural schematic view of the lower metal plate of the third embodiment of the application.

[0046] Figure 13 ​The third embodiment schematic diagram of the combination of the upper flow channel and the lower flow channel of the present application;

[0047] Figure 14 The third embodiment structural schematic diagram of the combination of the upper flow channel and the lower flow channel of the present application;

[0048] Figure 15 The exploded view of the axial magnetic field motor of the present application;

[0049] Figure 16 The cross-sectional view along the gap of the core mounting hole in the axial magnetic field motor of the present application;

[0050] Figure 17 The cross-sectional view along the center of the core mounting hole in the axial magnetic field motor of the present application;

[0051] Figure 18 The structural schematic diagram of another embodiment of the stator shell of the present application;

[0052] Figure 19 The schematic diagram of the eddy current path in the stator of the present application. DETAILED DESCRIPTION

[0053] The following description is provided to enable any person skilled in the art to practice the present application. The preferred embodiments described below are only examples of the present application, and other obvious modifications can be made by those skilled in the art. The basic principles defined in the following description can be applied to other embodiments, modifications, improvements, equivalents and other technical solutions without departing from the spirit and scope of the present application.

[0054] First embodiment

[0055] As shown in Figures 1 to 3 The axial magnetic field motor stator cooling structure comprises:

[0056] A stator shell 110, which comprises an upper metal plate 111, an intermediate partition plate 112 and a lower metal plate 113 spliced in the axial direction, and a plurality of core mounting holes 110a are arranged on the stator shell 110 in the circumferential direction, each of which penetrates the upper metal plate 111, the intermediate partition plate 112 and the lower metal plate 113 in turn;

[0057] A plurality of yokeless cores 120 are installed in the core mounting holes 110a and expose both ends on both sides of the stator shell 110;

[0058] A plurality of coils 130 are sleeved on the yokeless cores 120, and coils 130 are sleeved on both ends of the yokeless cores 120 exposed on both sides of the stator shell 110.

[0059] The upper metal plate 111 is provided with an upper flow channel 111a on the surface which is spliced with the intermediate partition plate 112, the lower metal plate 113 is provided with a lower flow channel 113a on the surface which is spliced with the intermediate partition plate 112, and the intermediate partition plate 112 is provided with an intermediate hole 112a which communicates the upper flow channel 111a and the lower flow channel 113a.

[0060] When the yokeless core 120 is inserted into the core mounting hole 110a, the stator casing 110 is held at the middle section of the yokeless core 120, and the two coils 130 which are sleeved on the yokeless core 120 are held at the axial two sides of the stator casing 110, so that the upper flow channel 111a and the lower flow channel 113a arranged in the stator casing 110 can simultaneously contact and exchange heat with the yokeless core 120 and the coils 130, effectively improving the cooling effect. In addition, since the two coils 130 which are sleeved on the yokeless core 120 are held at the axial two sides of the stator casing 110, the coils 130 on the same side are connected and form a winding, which, compared with the traditional coil arrangement between the core and the stator cooling structure, avoids the increase of the circumferential space design and the defect problem of low slot occupancy rate of the winding. In addition, the stator casing 110 is a split structure, so as to facilitate the processing of the upper flow channel 111a and the lower flow channel 113a, and then the upper metal plate 111, the intermediate partition plate 112 and the lower metal plate 113 are spliced, realizing the manufacturability and reducing the casting difficulty. Moreover, by providing the intermediate hole 112a on the intermediate partition plate 112, the cooling medium can circulate between the upper flow channel 111a and the lower flow channel 113a, and the upper flow channel 111a and the lower flow channel 113a are arranged axially along the yokeless core 120, increasing the heat exchange area, improving the flowability, and further enhancing the cooling performance.

[0061] As Figures 2 to 6 , Figure 8 , Figure 9 , Figure 11 , Figure 12 and Figure 15As shown, the upper metal plate 111 has opposite upper joint portions 1112 and upper accommodating portions 1111, and a plurality of upper core mounting portions 1113 penetrating the upper joint portions 1112 and the upper accommodating portions 1111, the lower metal plate 113 has opposite lower joint portions 1132 and lower accommodating portions 1131, and a plurality of lower core mounting portions 1133 penetrating the lower joint portions 1132 and the lower accommodating portions 1131, the intermediate partition plate 112 is provided with a plurality of intermediate core mounting portions 1123 and a plurality of intermediate holes 112a, and the intermediate core mounting portions 1123 are arranged at intervals with the intermediate holes 112a. After the intermediate partition plate 112 is jointed between the upper joint portions 1112 and the lower joint portions 1132, the upper core mounting portions 1113, the intermediate core mounting portions 1123 and the lower core mounting portions 1133 correspond to form core mounting holes 110a, and the intermediate holes 112a are communicated with the upper flow channel 111a and the lower flow channel 113a.

[0062] Specifically, the upper metal plate 111, the intermediate partition plate 112 and the lower metal plate 113 are substantially in the form of a sheet to assemble the disc-shaped stator housing 110, i.e. the axial dimension of the stator housing 100 is small, so as to embody the characteristic of small axial dimension of the axial magnetic field motor. The intermediate partition plate 112 is the thinnest and can be made of metal or non-metal material, and the outer contour of the stator housing 110 can be circular or square, etc., and a through hole is formed in the center of the stator housing 110 for arranging the rotating shaft 300 and the bearing 400, referring to Figure 15 In addition, the shapes of the upper core mounting portions 1113, the intermediate core mounting portions 1123 and the lower core mounting portions 1133 are consistent, all in the form of a trapezoid, and correspond to form the trapezoidal core mounting holes 110a to adapt to the trapezoidal yokeless core 120, referring to Figure 2 and Figure 15 , wherein the upper base of the trapezoidal core mounting hole 110a is arranged inward, and the lower base of the trapezoidal core mounting hole 110a is arranged outward.

[0063] More specifically, the upper metal plate 111 is provided with an upper flow channel opening slot 111a0, the intermediate partition plate 112 covers the upper flow channel opening slot 111a0 to form the upper flow channel 111a, the lower metal plate 113 is provided with a lower flow channel opening slot 113a0, and the intermediate partition plate 112 covers the lower flow channel opening slot 113a0 to form the lower flow channel 113a.

[0064] The upper flow channel opening slot 111a0 is processed on the upper splicing part 1112 of the upper metal plate 111 exposed outside, and the lower flow channel opening slot 113a0 is processed on the lower splicing part 1132 of the lower metal plate 113 exposed outside, and then the intermediate partition plate 112 is spliced between the upper metal plate 111 and the lower metal plate 113 to form the upper flow channel 111a and the lower flow channel 113a. The intermediate hole 112a is connected with the upper flow channel opening slot 111a0 and the lower flow channel opening slot 113a0 respectively and communicates the upper flow channel opening slot 111a0 and the lower flow channel opening slot 113a0. In addition, the upper metal plate 111, the intermediate partition plate 112 and the lower metal plate 113 can also be formed by stamping, which reduces the difficulty of casting and facilitates the cleaning of the exposed upper flow channel opening slot 111a0 and lower flow channel opening slot 113a0. Compared with the traditional built-in water channel, the inner wall of the water channel formed by processing is rough and cannot be cleaned, which is easy to cause blockage and other problems.

[0065] Reference Figure 3 The intermediate partition plate 112 is connected between the upper metal plate 111 and the lower metal plate 113, and the sealing connection includes setting sealing glue, sealing ring or welding. Taking the upper metal plate 111 and the intermediate partition plate 112 as an example, the intermediate partition plate 112 and the upper splicing part 1112 of the upper metal plate 111 are provided with sealing glue to ensure the sealing between the two and avoid leakage of cooling medium (including cooling water, cooling oil or cooling gas).

[0066] The intermediate partition plate 112 is a flexible material plate, such as a rubber plate, and the upper metal plate 111 and the lower metal plate 113 are heat-conducting metal plates, which improve their support and heat exchange capacity.

[0067] Reference Figure 1 The upper metal plate 111, the intermediate partition plate 112 and the lower metal plate 113 are arranged along the axial direction of the yokeless core 120, the upper accommodating part 1111 is used to arrange the coil 130, the upper flow channel 111a arranged on the upper splicing part 1112 can cool the coil 130 in the upper accommodating part 1111, and similarly, the lower flow channel 113a arranged on the lower splicing part 1132 can cool the coil 130 in the lower accommodating part 1131, and the upper flow channel 111a and the lower flow channel 113a can simultaneously cool the yokeless core 120, which reasonably utilizes the space and effectively ensures the cooling capacity of the coil 130 and the yokeless core 120.

[0068] It should be noted that the upper flow channel 111a and the lower flow channel 113a are separated by the intermediate partition plate 112 and are communicated only through the intermediate hole 112a, so that the cooling medium can fully pass through the upper flow channel 111a and the lower flow channel 113a, and the cooling effect is improved.

[0069] As shown in Figure 1 and Figure 15 The axial magnetic field motor stator cooling structure 100 further comprises:

[0070] A plurality of slot wedges 140 are arranged on the axial sides of the yokeless core 120, respectively, each of the slot wedges 140 is inserted between two adjacent yokeless cores 120, and the coil 130 is abutted between the slot wedge 140 and the stator housing 110.

[0071] Specifically, the circumferential sides of the yokeless core 120 are arranged in the core insertion grooves 121, respectively, and the slot wedges 140 are radially inserted into the core insertion grooves 121 of the adjacent two yokeless cores 120, so as to fix the coil 130 between the slot wedge 140 and the stator housing 110.

[0072] Referring to Figure 1 and Figure 3 The upper accommodating portion 1111 and the lower accommodating portion 1131 are both embedded grooves, so that the coil 130 can be embedded in the upper accommodating portion 1111 and the lower accommodating portion 1131, and the coil 130 is abutted between the embedded groove bottom and the slot wedge 140. Wherein the yokeless core 120, the slot wedge 140 and the axial side of the stator housing 110 are substantially flush, and there is a gap between the coil 130 and the side wall of the embedded groove, which can be used to fill the potting glue, that is, the upper accommodating portion 1111 and the lower accommodating portion 1131 are filled with potting glue, so as to fix the stator housing 110, the coil 130 and the yokeless core 120.

[0073] In addition, the wiring portion 131 of the coil 130 is located on the radial outer side of the coil 130, and the wiring portion 131 is located in the gap between the coil 130 and the side wall of the embedded groove, and the wiring between the coils 130 on the same side can be performed in the gap. Specifically, the coil 130 can be sleeved on each yokeless core 120 one by one, and then the wiring between the coils 130 is performed between the coil 130 and the embedded groove side wall, so that the coil 130 can be connected to form a winding. Of course, the coils 130 on the same side can be connected as a whole through the wiring portion 131, and then wired together to the yokeless core 120.

[0074] As shown in Figure 1As shown, an insulating heat-conducting member is arranged between the yokeless core 120 and the coil 130, which can be a ceramic sheet or insulating paper, so as to ensure the insulation and heat conduction between the two, avoid eddy current loss, and affect the operation performance of the motor. Specifically, the insulating paper can be wrapped around the outer periphery of the yokeless core 120, and then the coil 130 is sleeved outside the insulating paper, so as to realize the insulation between the yokeless core 120 and the coil 130. It should be noted that the axial end faces of the yokeless core 120 are air gap faces, and the insulating paper should avoid shielding.

[0075] The coil 130 and the stator housing 110 can also be provided with an insulating heat-conducting member, which is arranged between the coil 130 and the embedding groove bottom, so as to realize the insulation between the coil 130 and the stator housing 110.

[0076] Second embodiment

[0077] The axial magnetic field motor stator cooling structure of the second embodiment is different from that of the first embodiment in that Figures 4 to 6 The upper flow channel 111a includes an upper main flow channel 111a1 and an upper branch flow channel 111a2, the upper main flow channel 111a1 is arranged in communication with the upper branch flow channel 111a2 at one end and in communication with an external water channel at the other end, and the upper branch flow channel 111a2 is arranged around the yokeless core 120 and forms a flow channel notch 1110a inside the yokeless core 120;

[0078] The lower flow channel 113a includes a lower main flow channel 113a1 and a lower branch flow channel 113a2, the lower main flow channel 113a1 is arranged in communication with the lower branch flow channel 113a2 at one end and in communication with an external water channel at the other end, and the lower branch flow channel 113a2 is arranged around the yokeless core 120 and forms a flow channel notch 1110a inside the yokeless core 120;

[0079] The intermediate hole 112a is in communication with the upper branch flow channel 111a2 and the lower branch flow channel 113a2 on the side of the flow channel notch 1110a.

[0080] The upper and lower sub-flow passages 111a2 and 113a2 are multiple in number, the upper main flow passage 111a1 is connected with an external water passage, and the cooling medium introduced from the external water passage is introduced into the multiple upper sub-flow passages 111a1, and then the cooling medium is introduced into the lower sub-flow passages 113a2 through the intermediate holes 112a of the upper sub-flow passages 111a1 respectively, and then flows into the lower main flow passage 113a1, and finally is discharged through the external water passage connected with the lower main flow passage 113a1. The upper flow passage 111a and the lower flow passage 113a are arranged axially and spaced apart along the yokeless core 120, and the upper sub-flow passages 111a2 and the lower sub-flow passages 113a2 are arranged around the yokeless core 120 respectively, so as to increase the heat exchange area and make the cooling medium pass through the upper flow passage 111a and the lower flow passage 113a uniformly, thereby improving the cooling effect.

[0081] As shown in Figure 4 and Figure 6 , the upper sub-flow passages 111a2 are connected with the lower sub-flow passages 113a2 through the two intermediate holes 112a at both ends of the flow passage notch 1110a respectively, the upper main flow passage 111a1 is connected with the upper sub-flow passages 111a2 outside the yokeless core 120, and the lower main flow passage 113a1 is connected with the lower sub-flow passages 113a2 outside the yokeless core 120.

[0082] The upper main flow passage 111a1 is located on the radial outside of the yokeless core 120, the lower main flow passage 113a1 is also located on the radial outside of the yokeless core 120, the upper sub-flow passages 111a2 and the lower sub-flow passages 113a2 are arranged axially and spaced apart, and the upper sub-flow passages 111a2 and the lower sub-flow passages 113a2 are arranged around the yokeless core 120 respectively, and in addition, the flow passage notch 1110a is located on the radial inside of the yokeless core 120, thereby increasing the heat exchange area of the upper sub-flow passages 111a2 and the lower sub-flow passages 113a2 with the yokeless core 120 respectively, and improving the cooling performance.

[0083] As shown in Figure 5 and Figure 6 , the upper main flow passage 111a1 includes a water inlet 111a11 and a water inlet loop 111a12, the water inlet loop 111a12 is arranged around the outside of the yokeless core 120, the water inlet 111a11 is connected with the water inlet loop 111a12 and the outer wall of the upper metal plate 111, and the upper sub-flow passages 111a2 are connected with the water inlet loop 111a12.

[0084] The lower main flow channel 113a1 includes a water outlet 113a11 and a water outlet loop 113a12, the water outlet loop 113a12 is arranged outside the yokeless core 120, and the water outlet 113a11 connects the water outlet loop 113a12 and the outer wall of the lower metal plate 113, and the lower branch flow channel 113a2 is connected to the water outlet loop 113a12.

[0085] The water inlet 111a11 and the water outlet 113a11 are used to communicate with the external water channel, including connecting external water pipes and the like to communicate with the external water channel. The water inlet 111a11 is used to introduce the cooling medium, and the water outlet 113a11 is used to discharge the cooling medium, and as a preferred, when the intermediate partition plate 112 is spliced between the upper metal plate 111 and the lower metal plate 113, the water inlet 111a1 and the water outlet 113a1 are arranged opposite to each other, facilitating the centralized external pipeline and management. The water inlet loop 111a12 and the water outlet loop 113a12 are loops connected in sequence.

[0086] Continuing to refer to Figure 5 and Figure 6 The upper branch flow channel 111a2 includes a water inlet branch 111a21, an outer core upper branch 111a22, and an inter-core upper branch 111a23, the water inlet branch 111a21 is connected between the water inlet loop 111a12 and the outer core upper branch 111a22, both ends of the outer core upper branch 111a22 are connected to the inter-core upper branch 111a23, the inter-core upper branch 111a23 is arranged between two adjacent yokeless cores 120, and the flow channel gap 1110a is formed between the two inter-core upper branches 111a23 inside the yokeless core 120.

[0087] The lower branch flow channel 113a2 includes a water outlet branch 113a21, an outer core lower branch 113a22, and an inter-core lower branch 113a23, the water outlet branch 113a21 is connected between the water outlet loop 113a12 and the outer core lower branch 113a22, both ends of the outer core lower branch 113a22 are connected to the inter-core lower branch 113a23, and the inter-core lower branch 113a23 is arranged between two adjacent yokeless cores 120, and the flow channel gap 1110a is formed between the two inter-core lower branches 113a23 inside the yokeless core 120.

[0088] The upper and lower flow channels 111a2 and 113a2 are in plurality, and are arranged in intervals after the intermediate partition plate 112 is spliced between the upper and lower metal plates 111 and 113, so that each of the yokeless cores 120 is arranged around the flow channel, and the cooling medium is uniformly passed through.

[0089] As shown in Figure 5 the flow channel gap 1110a is formed between the upper branch 111a23 between the adjacent two cores on the inner side of the yokeless core 120. Figure 6 As shown in Figure 6 the flow channel gap 1110a is formed between the upper branch 111a23 between the adjacent two cores on the inner side of the yokeless core 120.

[0090] As shown in Figures 4 to 7 the cooling medium is introduced through the water inlet 111a11, then flows along the water inlet loop 111a12, and through the water inlet branch 111a21 to the outer core upper branch 111a22 connected thereto, and then the cooling medium in the outer core upper branch 111a22 flows to the upper branch 111a23 between the two cores connected thereto, and then flows through the intermediate hole 112a to the corresponding lower branch 113a23 between the cores, and then the cooling medium in the lower branch 113a23 between the cores flows through the outer core lower branch 113a22 in sequence, until it flows into the water outlet loop 113a21, and finally is collected and discharged from the water outlet 113a11. The reasonable design of the cooling flow channel path not only increases the heat exchange area and improves the flowability of the cooling medium, but also avoids the design limitation of the cooling path, which causes part of the heat to be not discharged in time or causes a large temperature gradient, thereby causing adverse effects on the stator or failing to make the motor achieve satisfactory output capacity.

[0091] As shown in Figure 18 the flow channel gap 1110a is provided with a flow interruption seam 1110a1, which penetrates the stator housing 110 in the axial direction, and communicates the core mounting hole 110a and the inner side wall of the stator housing 110, and each of the core mounting holes 110a corresponds to a flow interruption seam 1110a1, which extends in the radial direction to block the stator eddy current path 1001, as shown in Figure 19Further, each of the cores 120 generates a stator eddy current path 1001 composed of a plurality of elliptical loop paths arranged from inside to outside, and the flow breaking gap 1110a1 refers to a gap provided in the radial direction and penetrating the stator housing 110 in the axial direction, which breaks each elliptical loop path, thereby reducing the eddy current loss. In addition, a closed loop can be additionally provided on the inner side wall of the stator housing 110, the closed loop can be a closed loop of metal material, and an insulating member can be additionally provided between the stator housing 110 and the closed loop to ensure the structural strength and achieve the insulation effect.

[0092] Third embodiment

[0093] The axial magnetic field motor stator cooling structure of the third embodiment is different from that of the second embodiment in that, referring to Figures 8 to 10 The upper flow channel 111a includes a plurality of upper branch water paths 111a3 extending in the radial direction, the upper branch water paths 111a3 are arranged between adjacent yokeless cores 120 and leave upper ports 111a31 on the inner side of the yokeless cores 120, and adjacent two upper branch water paths 111a3 are separated from each other on the inner side of the yokeless core 120 to form a blocking space 1110b;

[0094] The lower flow channel 113a includes a plurality of lower branch water paths 113a3 extending in the radial direction, the lower branch water paths 113a3 are arranged between adjacent yokeless cores 120 and leave lower ports 113a31 on the inner side of the yokeless cores 120, and adjacent two lower branch water paths 113a3 are separated from each other on the inner side of the yokeless core 120 to form a blocking space 1110b;

[0095] The intermediate partition plate 112 is provided with an intermediate hole 112a, and the intermediate hole 112a communicates the upper ports 111a31 of the upper branch water paths 111a3 and the lower ports 113a31 of the lower branch water paths 113a3 on the inner side of the yokeless core 120.

[0096] When the intermediate partition plate 112 is spliced between the upper metal plate 111 and the lower metal plate 113, the upper branch water paths 111a3 and the lower branch water paths 113a3 correspond one by one. By providing the blocking space 1110b, the corresponding upper branch water paths 111a3 and lower branch water paths 113a3 are communicated through the intermediate hole 112a. The upper ports 111a31 and the lower ports 113a31 are located on the inner side of the yokeless core 120 in the radial direction, which ensures the heat exchange area and improves the cooling performance.

[0097] Referring to Figure 8 and Figure 9The upper flow channel 111a further comprises a water inlet 111a11 and a water inlet loop 111a12, the water inlet loop 111a12 is arranged around the outside of the yokeless core 120, and the water inlet 111a11 connects the water inlet loop 111a12 and the outside wall of the upper metal plate 111, and the upper water branch channel 111a3 is connected to the water inlet loop 111a12.

[0098] The lower flow channel 113a further comprises a water outlet 113a11 and a water outlet loop 113a12, the water outlet loop 113a12 is arranged around the outside of the yokeless core 120, and the water outlet 113a11 connects the water outlet loop 113a12 and the outside wall of the lower metal plate 113, and the lower water branch channel 113a3 is connected to the water outlet loop 113a12.

[0099] As shown in Figures 8 to 10 , the cooling medium is introduced through the water inlet 111a11, then flows along the water inlet loop 111a12, and passes through a plurality of inter-core upper branch channels 111a3, the cooling medium in the inter-core upper branch channel 111a3 flows into the inter-core lower branch channel 113a3 through the intermediate hole 112a, and then flows into the water outlet loop 113a12, and finally is collected and discharged from the water outlet 113a11. Reasonable design of the cooling flow path not only increases the heat exchange area and improves the flowability of the cooling medium, but also avoids the design limitation of the cooling path, which causes part of the heat to be discharged in time or causes a large temperature gradient, thereby causing adverse effects on the stator or failing to make the motor achieve satisfactory output capacity.

[0100] To reduce eddy current loss, a flow interruption gap 1110a1 can also be provided on the blocking space 1110b. For specific content, please refer to the flow interruption gap 1110a1 of the second embodiment, which will not be repeated here.

[0101] Fourth embodiment

[0102] The axial field motor stator cooling structure of the fourth embodiment is different from that of the second embodiment, as shown in Figures 11 to 14 , the upper flow channel 111a comprises an upper main flow channel 111a1, a first upper sub-flow channel 111a4 and a second upper sub-flow channel 111a5, the upper main flow channel 111a1 communicates with the first upper sub-flow channel 111a4, and the second upper sub-flow channel 111a5 is independently arranged, the first upper sub-flow channel 111a4 and the second upper sub-flow channel 111a5 are arranged around the yokeless core 120 and form a flow channel gap 1110a inside the yokeless core 120;

[0103] The lower flow channel 113a includes a lower main flow channel 113a1, a first lower sub-flow channel 113a4, and a second lower sub-flow channel 113a5, the lower main flow channel 113a1 communicates with the first lower sub-flow channel 113a4, the second lower sub-flow channel 113a5 is independently arranged, and the first lower sub-flow channel 113a4 and the second lower sub-flow channel 113a5 are arranged around the yokeless core 120 and form flow channel notches 1110a inside the yokeless core 120;

[0104] The intermediate partition plate 112 is provided with an intermediate hole 112a arranged on both sides of the flow channel notch 1110a, the first upper sub-flow channel 111a4 and the second lower sub-flow channel 113a5 communicate through the intermediate hole 112a, the second upper sub-flow channel 111a5 and the first lower sub-flow channel 113a4 communicate through the intermediate hole 112a, and the second upper sub-flow channel 111a5 and the second lower sub-flow channel 113a5 communicate through the intermediate hole 112a.

[0105] The upper main flow channel 111a1 is used to guide the cooling medium to the first upper sub-flow channel 111a4 connected thereto, and then the first upper sub-flow channel 111a4 guides the cooling medium to the second lower sub-flow channel 113a5 through the intermediate hole 112a, the second lower sub-flow channel 113a5 guides the cooling medium to the second upper sub-flow channel 111a5 through the intermediate hole 112a, the second upper sub-flow channel 111a5 guides the cooling medium to the first lower sub-flow channel 113a4 through the intermediate hole 112a, and finally the cooling medium is discharged through the lower main flow channel 113a1.

[0106] It can be seen that the first upper sub-flow channel 111a4, the second lower sub-flow channel 113a5, the second upper sub-flow channel 111a5, and the first lower sub-flow channel 113a4 are sequentially connected. When the intermediate partition plate 112 is spliced between the upper metal plate 111 and the lower metal plate 113, the first upper sub-flow channel 111a4, the second lower sub-flow channel 113a5, the second upper sub-flow channel 111a5, and the first lower sub-flow channel 113a4 are sequentially connected in the circumferential direction and are partially staggered and extended in sequence, so as to ensure that the water channels are arranged around each yokeless core 120 and ensure the cooling effect.

[0107] Reference Figure 11 and Figure 12 The second upper sub-flow channel 111a5 includes a plurality of independent ones, and the first upper sub-flow channel 111a4 includes a plurality of independent ones. Similarly, the second lower sub-flow channel 113a5 includes a plurality of independent ones, and the first lower sub-flow channel 113a4 includes a plurality of independent ones.

[0108] Specifically, the first upper branch flow passages 111a4 are two in number and are connected to two ends of the upper main flow passage 111a1 respectively, and the second lower branch flow passages 113a5 are four in number, each of the first upper branch flow passages 111a4 corresponding to two of the second lower branch flow passages 113a5, so that the first upper branch flow passages 111a4 are connected to the second upper branch flow passages 111a5 through one of the second lower branch flow passages 113a5 on each side.

[0109] With reference to the foregoing Figure 11 and Figure 12 , the first upper branch flow passages 111a4 include a first water inlet branch 111a41, a first outer core upper branch 111a42 and a first inter-core upper branch 111a43, the first water inlet branch 111a41 being connected between the upper main flow passage 111a1 and the first outer core upper branch 111a42, the first outer core upper branch 111a42 being connected to two of the first inter-core upper branches 111a43, and the first inter-core upper branches 111a43 being arranged between two adjacent yokeless cores 120;

[0110] The second upper branch flow passages 111a5 include a second outer core upper branch 111a52 and a second inter-core upper branch 111a53, the second outer core upper branch 111a52 being connected to three of the second inter-core upper branches 111a53, and the second inter-core upper branches 111a53 being arranged between two adjacent yokeless cores 120;

[0111] The first lower branch flow passages 113a4 include a first water outlet branch 113a41, a first outer core lower branch 113a42 and a first inter-core lower branch 113a43, the first water outlet branch 113a41 being connected between the lower main flow passage 113a1 and the first outer core lower branch 113a42, the first water outlet branch 113a41 being connected to the center of the first outer core lower branch 113a42, the first outer core lower branch 113a42 being connected to four of the first inter-core lower branches 113a43, and the first inter-core lower branches 113a43 being arranged between two adjacent yokeless cores 120;

[0112] The second lower branch flow passages 113a5 include a second outer core lower branch 113a52 and a second inter-core lower branch 113a53, the second outer core lower branch 113a52 being connected to two of the second inter-core lower branches 113a53, and the second inter-core lower branches 113a53 being arranged between two adjacent yokeless cores 120.

[0113] The upper main flow channel 111a1 includes a water inlet 111a11 and a water inlet loop 111a12, the water inlet loop 111a12 is arranged around the outside of the yokeless core 120, the water inlet 111a11 connects the water inlet loop 111a12 and the outside wall of the upper metal plate 111, and the first upper sub-flow channel 111a4 is connected to the water inlet loop 111a12.

[0114] The lower main flow channel 113a1 includes a water outlet 113a11 and a water outlet loop 113a12, the water outlet loop 113a12 is arranged around the outside of the yokeless core 120, the water outlet 113a11 connects the water outlet loop 113a12 and the outside wall of the lower metal plate 113, and the first lower sub-flow channel 113a4 is connected to the water outlet loop 113a12.

[0115] The water inlet loop 111a12 and the water outlet loop 113a12 are semi-annular loops, and the arc is about 90°. The water inlet loop 111a12 and the water outlet loop 113a12 are arranged in a circumferential direction, and the water outlet loop 113a12 is offset by 90° relative to the water inlet loop 111a12, so that the center line of the two first water inlet branches 111a41 is perpendicular to the center line of the two first water outlet branches 113a41. In this way, the cooling medium introduced by the first water inlet branch 111a41 is divided into two paths, and the path angle of each path on the stator housing 110 is 90°, which can make the cooling medium pass uniformly and improve the cooling effect.

[0116] As shown in Figures 11 to 14 The cooling medium is introduced through the water inlet 111a11, then flows along the water inlet loop 111a12 and through the two first water inlet branches 111a41 to the first upper sub-flow channel 111a4 connected thereto, then the first upper sub-flow channel 111a4 introduces the cooling medium to the second lower sub-flow channel 113a5 through the intermediate hole 112a, the second lower sub-flow channel 113a5 introduces the cooling medium to the second upper sub-flow channel 111a5 through the intermediate hole 112a, the second upper sub-flow channel 111a5 introduces the cooling medium to the first lower sub-flow channel 113a4 through the intermediate hole 112a, and finally the cooling medium is discharged through the lower main flow channel 113a1. Reasonable design of the cooling flow path not only increases the heat exchange area and improves the flowability of the cooling medium, but also avoids the design limitation of the cooling path, which causes part of the heat to be discharged in time or causes a large temperature gradient, thereby causing adverse effects on the stator or failing to make the motor achieve satisfactory output capacity.

[0117] Fifth embodiment

[0118] As shown in Figures 15 to 17As shown, the axial magnetic field motor further comprises two rotors 200, which are air gap maintained on the axial two sides of the yokeless core 120.

[0119] Due to the axial magnetic field motor adopting the axial magnetic field motor stator cooling structure 100 of the above-mentioned embodiments, the axial magnetic field motor has the beneficial effects of the axial magnetic field motor stator cooling structure 100 of the above-mentioned embodiments.

[0120] Continuing to refer to Figure 12 and Figure 17 , the axial magnetic field motor further comprises a rotating shaft 300 and at least one bearing 400, the rotating shaft 300 is arranged through the center of the stator housing 110, the rotating shaft 300 and the stator housing 110 are provided with the bearing 400, the rotor 200 is fixed on the rotating shaft 300, and the rotor 200 and the stator 100 are air gap maintained.

[0121] As shown in Figure 15 , the rotor 200 comprises a rotor disc 210 and a plurality of magnetic steels 220, the plurality of magnetic steels 220 are circumferentially and interval arranged on the rotor disc 210, and the magnetic steels 220 are air gap maintained with the yokeless core 120. When the magnetic steels 220 are arranged on the rotor disc 210, the magnetic steels 220 slightly protrude from the surface of the rotor disc 210 to air gap cooperate with the core 130.

[0122] The rotor 200 further comprises a plurality of pressing plates 230, one pressing plate 230 is arranged between two adjacent magnetic steels 220, the pressing plate 230 is fixed in the magnetic steel accommodating groove through fasteners, and the pressing plate 230 is adapted to the circumferential side surface of the magnetic steel 220 through the inclined surface, so as to axially and circumferentially position the magnetic steel 220.

[0123] The magnetic steel 220 is radially stacked by a plurality of silicon steel sheets, and a flux breaking surface is formed between two adjacent silicon steel sheets. The flux breaking surface can block the magnetic steel eddy current path, so as to achieve the effect of suppressing eddy current loss.

[0124] The magnetic steel 220 is trapezoidal, the number of the magnetic steel 220 is consistent with the number of the yokeless core 120, and the upper base of the trapezoidal magnetic steel 220 is arranged inward, and the lower base of the trapezoidal magnetic steel 220 is arranged outward. That is, the width of the plurality of silicon steel sheets 221 constituting the magnetic steel 220 increases from inside to outside along the radial direction.

[0125] As shown in Figure 15As shown, the number of the stator 100 is one, and the number of the rotor 200 is two, and the two rotors 200 are air gaply kept on the axial two sides of the stator 100 to form a single-stator double-rotor axial magnetic field motor. Of course, different numbers can be obtained to form a single-stator single-rotor axial magnetic field motor or a double-stator single-rotor axial magnetic field motor.

[0126] Sixth embodiment

[0127] As Figures 1 to 3 shown, the manufacturing method of the axial magnetic field motor stator cooling structure is used to manufacture the axial magnetic field motor stator cooling structure 100 of any one of the first to third embodiments, and the method comprises the following steps:

[0128] a. Provide a stator housing 110, wherein a plurality of circumferentially spaced core mounting holes 110a are arranged on the stator housing 110, the stator housing 110 comprises an upper metal plate 111, an intermediate partition plate 112 and a lower metal plate 113, the core mounting holes 110a sequentially penetrate the upper metal plate 111, the intermediate partition plate 112 and the lower metal plate 113, the upper metal plate 111 has an upper splicing part 1112, the upper splicing part 1112 is provided with an upper flow channel 111a, the lower metal plate 113 has a lower splicing part 1132, the lower splicing part 1132 is provided with a lower flow channel 113a, and the intermediate partition plate 112 is provided with a plurality of intermediate holes 112a;

[0129] b. Splice the intermediate partition plate 112 between the upper splicing part 1112 and the lower splicing part 1132 to make the intermediate holes 112a communicate with the upper flow channel 111a and the lower flow channel 113a;

[0130] c. Insert a yokeless core 120 into the core mounting hole 110;

[0131] d. Set a coil 130 on the axial two sides of the yokeless core 120, and make the coil 130 keep on the axial two sides of the stator housing 110.

[0132] The shapes of the upper flow channel 111a and the lower flow channel 113a refer to the first to third embodiments, which are not repeated here. The stator housing 110 is a split structure to facilitate the processing of the upper flow channel 111a and the lower flow channel 113a, and then the upper metal plate 111, the intermediate partition plate 112 and the lower metal plate 113 are spliced, which realizes manufacturability and reduces casting difficulty. At the same time, it is convenient to clean the upper flow channel 111a exposed on the upper splicing part 1112 and the lower flow channel 113a exposed on the lower splicing part 1132.

[0133] In the step b, the intermediate partition plate 112 is sealingly connected between the upper metal plate 111 and the lower metal plate 113 to increase the sealing property. The sealing connection includes setting sealing glue, sealing ring or welding.

[0134] The upper metal plate 111 is provided with an upper core mounting portion 1113, the lower metal plate 113 is provided with a lower core mounting portion 1133, the intermediate partition plate is provided with an intermediate core mounting portion 1123, and in the step b, the upper core mounting portion 1113, the intermediate core mounting portion 1123 and the lower core mounting portion 1133 correspond to form a core mounting hole 110a.

[0135] After the step d, the method further includes:

[0136] A slot wedge 140 is inserted between two adjacent yokeless cores 120, so that the coil 130 abuts between the slot wedge 140 and the stator casing 110.

[0137] The upper metal plate 111 is provided with an upper accommodating portion 1111, and the lower metal plate 113 is provided with a lower accommodating portion 1131. Encapsulating glue is filled in the upper accommodating portion 1111 and the lower accommodating portion 1131 in which the coil 130 is embedded, so as to fix the stator casing 110, the coil 130, the yokeless core 120 and the like.

[0138] The above-mentioned embodiments are only used to illustrate the technical ideas and characteristics of the present application, and the purpose is to enable those skilled in the art to understand the content of the present application and to implement it. The patent application range of the present application cannot be limited by the above-mentioned embodiments only, that is, any equivalent changes or modifications made according to the disclosed spirit of the present application still fall within the patent scope of the present application.

Claims

1. A stator cooling structure (100) for an axial magnetic field motor, characterized in that, include: A stator housing (110) is provided, the stator housing (110) includes an upper metal plate (111), a middle partition plate (112) and a lower metal plate (113) spliced ​​along the axial direction, and the stator housing (110) is provided with a plurality of circumferentially spaced iron core mounting holes (110a), each of the iron core mounting holes passing through the upper metal plate (111), the middle partition plate (112) and the lower metal plate (113) in sequence; A plurality of yokeless iron cores (120) are installed in the iron core mounting holes (110a) and have both ends exposed on both sides of the stator housing (110); A plurality of coils (130) are sleeved on the yokeless iron core (120), and coils (130) are sleeved on both ends of the yokeless iron core (120) exposed on both sides of the stator housing (110); An upper flow channel (111a) is provided on the surface where the upper metal plate (111) and the middle partition plate (112) are joined, and a lower flow channel (113a) is provided on the surface where the lower metal plate (113) and the middle partition plate (112) are joined. An intermediate hole (112a) is provided on the middle partition plate (112) to connect the upper flow channel (111a) and the lower flow channel (113a).

2. The axial magnetic field motor stator cooling structure (100) as described in claim 1, characterized in that, The upper metal plate (111) is provided with an upper flow channel opening groove (111a0), and the middle partition plate (112) covers the upper flow channel opening groove (111a0) to form the upper flow channel (111a). The lower metal plate (113) is provided with a lower flow channel opening groove (113a0), and the middle partition plate (112) covers the lower flow channel opening groove (113a0) to form the lower flow channel (113a).

3. The axial magnetic field motor stator cooling structure (100) as described in claim 2, characterized in that, The intermediate partition plate (112) is provided with an intermediate hole (112a), which is connected to and communicates with the upper flow channel opening groove (111a0) and the lower flow channel opening groove (113a0).

4. The axial magnetic field motor stator cooling structure (100) as described in claim 3, characterized in that, A sealant is provided between the middle partition (112) and the upper metal plate (111), and between the middle partition (112) and the lower metal plate (113).

5. The axial magnetic field motor stator cooling structure (100) as described in claim 1, characterized in that, The middle partition (112) is a flexible material plate, and the upper metal plate (111) and the lower metal plate (113) are thermally conductive metal plates.

6. The axial magnetic field motor stator cooling structure (100) as described in claim 1, characterized in that, The upper metal plate (111) is provided with an upper receiving portion (1111) on the outer side away from the middle partition plate (112), and the lower metal plate (113) is provided with a lower receiving portion (1131) on the outer side away from the middle partition plate (112). The coils (130) located on both sides of the axial direction of the yokeless iron core (120) are respectively disposed in the upper receiving portion (1111) and the lower receiving portion (1131).

7. The axial magnetic field motor stator cooling structure (100) as described in claim 1, characterized in that, Also includes: A plurality of slot wedges (140) are provided on both sides of the axial direction of the yokeless iron core (120). Each slot wedge (140) is inserted between two adjacent yokeless iron cores (120). The coil (130) abuts between the slot wedge (140) and the stator housing (110).

8. The axial magnetic field motor stator cooling structure (100) as described in claim 1, characterized in that, An insulating and heat-conducting component is provided between the yokeless iron core (120) and the coil (130); And / or, an insulating heat-conducting element is provided between the coil (130) and the stator housing (110).

9. An axial magnetic field motor, characterized in that, The axial magnetic field motor includes a stator cooling structure (100) as described in any one of claims 1 to 8, and the axial magnetic field motor further includes two rotors (200), which are air-gaply held on both sides of the yokeless core (120).

10. A method for manufacturing a stator cooling structure for an axial magnetic field motor, characterized in that, Includes the following steps: a. A stator housing (110) is provided, wherein the stator housing (110) is provided with a plurality of circumferentially spaced iron core mounting holes (110a), the stator housing (110) includes an upper metal plate (111), a middle partition plate (112) and a lower metal plate (113), wherein the iron core mounting holes (110a) sequentially penetrate the upper metal plate (111), the middle partition plate (112) and the lower metal plate (113), wherein the upper metal plate (111) has an upper splicing part (1112) and an upper flow channel (111a) is provided on the upper splicing part (1112), wherein the lower metal plate (113) has a lower splicing part (1132) and a lower flow channel (113a) is provided on the lower splicing part (1132), and wherein the middle partition plate (112) is provided with a plurality of intermediate holes (112a); b. The middle partition plate (112) is spliced ​​between the upper splicing part (1112) and the lower splicing part (1132) so that the middle hole (112a) connects the upper flow channel (111a) and the lower flow channel (113a); c. Insert the yokeless iron core (120) into the iron core mounting hole (110a); d. A coil (130) is sleeved on both sides of the axial direction of the yokeless iron core (120), and the coil (130) is held on both sides of the axial direction of the stator housing (110).

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