A three rotor electric machine structure

Abstract

This invention belongs to the field of rotor motor technology, and particularly relates to a three-rotor motor structure. It can significantly increase the magnetic load of the motor within a limited space, thereby improving the utilization rate of motor materials and space, and thus increasing power density and torque density. It includes a three-rotor motor body; the three-rotor motor body includes a stator housing, a modular stator core A, two modular stator cores B, winding coils, two axial flux rotors B, and a radial flux rotor A; the modular stator core A is located between the two modular stator cores B, and the winding coils are wound on the modular stator core A and positioned within the cavity formed by the stator cores A and B; together, they form the wound stator core; the stator housing is installed outside the wound stator core to form a stator assembly; the radial flux rotor A is located between the two axial flux rotors B, and the three together form a rotor assembly; the stator assembly and the rotor assembly are connected and positioned to form the three-rotor motor body.

Description

Technical Field

[0001] This invention belongs to the field of rotor motor technology, and particularly relates to a three-rotor motor structure. Background Technology

[0002] Existing conventional internal rotor and external rotor motors, both domestically and internationally, have various designs, with most having only one air gap surface, located on the outer or inner circle of the stator core. Axial flux dual rotor motors and axial flux dual stator motors have two air gap surfaces. Due to poor core manufacturing processes and inadequate stator winding fixing methods, dual rotor and dual stator motors have been unable to achieve low-cost mass production.

[0003] Problems and disadvantages of existing internal rotor motors and external rotor motors: lower magnetic load, and lower power density under the same heat dissipation conditions. In axial flux dual rotor motors, the core is difficult to manufacture, the winding manufacturing process is poor, and the motor production cost increases exponentially. Summary of the Invention

[0004] This invention addresses the shortcomings of existing technologies by providing a three-rotor motor structure. This structure can significantly increase the magnetic load of the motor within a limited space, thereby improving the utilization rate of motor materials and space, and thus increasing power density and torque density. This provides a new approach to motor structural design.

[0005] To achieve the above objectives, the present invention adopts the following technical solution, including a three-rotor motor body; the three-rotor motor body includes a stator housing, one modular stator core A, two modular stator cores B, multiple winding coils, two axial flux rotors B, and one radial flux rotor A.

[0006] The stator core A is located between two stator cores B. The winding coil is wound on the stator core A, positioned and assembled in the space formed between the stator core A and the stator core B, and in contact with the top surface of the stator core A. The stator core A, the stator core B, and the winding coil together form a wound stator core. The stator housing is installed outside the wound stator core to form a stator assembly. The stator assembly is fixed as a whole by potting.

[0007] Radial flux rotor A is located between two axial flux rotors B. One radial flux rotor A and two axial flux rotors B work together to form a rotor assembly.

[0008] The stator assembly and rotor assembly are connected and positioned as the main body of a three-rotor motor.

[0009] Furthermore, the stator core A is a circular core composed of one or more stator core blocks A; the stator core block A is composed of multiple silicon steel sheets stacked together.

[0010] Furthermore, when the stator core block A is made of oriented silicon steel sheets, the stator core block A is composed of at least three stator core blocks A spliced ​​together; the winding plane of the winding coil is perpendicular to the plane of the annular core of the stator core block A.

[0011] Furthermore, the modular stator core B comprises multiple stator core blocks B, each stator core block B having an L-shaped cross-section. The L-shaped structure includes perpendicular horizontal and vertical sections. The bottom of the horizontal section is fixedly connected to a base plate one perpendicular to it, and the bottom of the vertical section is fixedly connected to a base plate two perpendicular to it. The width of base plate one is greater than the width of the horizontal section, and the width of base plate two is greater than the width of the vertical section. (Base plate one and base plate two may or may not be connected.) This allows the two sides of the L-shaped structure to form base plate grooves with their corresponding base plates.

[0012] Furthermore, the stator core block B is sintered from soft magnetic material SMC.

[0013] Furthermore, in the modular stator core B: multiple stator core blocks B are arranged side by side, and a cavity is formed between two adjacent stator core blocks B. Each cavity corresponds to a winding coil, and the two sides of the winding coil are respectively located in a cavity of the corresponding modular stator core B; the plane on which the base plates of two adjacent stator core blocks B are located forms the radial magnetic flux air gap surface of the motor; the longitudinal part is in contact with the modular stator core A; the plane on which each base plate is located constitutes the axial magnetic flux air gap surface.

[0014] Furthermore, the contact points between the winding coil and the stator core A and stator core B are provided with insulation protection.

[0015] Furthermore, in the wound stator core: multiple positioning grooves are formed on the circumference; the positioning grooves are composed of a set of mirror-arranged stator core blocks B and the winding coils on both sides of the stator core blocks B; wherein, the two core blocks B in the set of stator core blocks B are core blocks in two-piece stator cores B; for example, the first core block and the second core block.

[0016] The inner wall of the stator housing is provided with protrusions at intervals equal to the number of positioning grooves (that is, the number of protrusions equal to the number of windings). Each protrusion corresponds to a positioning groove. When the stator housing is installed on the stator core with windings, the protrusions are located in the positioning grooves to achieve mechanical positioning. The protrusions are in contact with the surface of the stator core A, transferring the heat generated by the motor stator to the housing. The slots between the protrusions are in contact with the winding coils through insulating material.

[0017] Furthermore, a heat dissipation structure is provided on the outer wall of the stator housing. This heat dissipation structure includes, but is not limited to, liquid cooling channels and air-cooled heat dissipation fins.

[0018] Furthermore, the radial flux rotor A adopts a radial flux motor rotor structure, and the axial flux rotor B includes a rotor core, a permanent magnet, and a mating surface; and the radial flux rotor A and the axial flux rotor B are assembled into a rotor assembly through the mating surface.

[0019] Furthermore, the outer surfaces of the permanent magnets on the two-axial flux rotor B and the permanent magnets on the radial flux rotor A have the same polarity.

[0020] Compared with the prior art, the present invention has the following advantages: The present invention breaks through the design constraints of traditional motors and can significantly increase the magnetic load of the motor by increasing the air gap area within a limited space volume, thereby improving the utilization rate of motor materials and motor space, and thus improving power density and torque density, providing a new solution for high-power, low-cost and low-weight applications.

[0021] In this invention, the stator winding is in direct contact with the inner surface of the housing, which greatly increases the heat dissipation area of ​​the motor winding, reduces the thermal resistance of the stator, and improves the heat dissipation effect of the motor.

[0022] Compared to dual-rotor axial flux motors, this invention breaks the limitation that motor power cannot be increased by increasing the axial length of the iron core in dual-rotor axial flux motors. The three-rotor motor structure of this invention can increase the output power of radial flux by increasing the length of the iron core. Therefore, this invention has significant advantages over dual-rotor axial flux motors.

[0023] The invention features a stator core A with extremely high silicon steel sheet utilization and almost no waste during production, significantly reducing the cost of motor cores. The core B uses SMC soft magnetic material, which allows for the application of molded windings (flat copper wire) without changing the motor structure, further improving the flexibility of motor design and production, and providing a new solution for high power density motors. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. The scope of protection of the present invention is not limited to the following description.

[0025] Figure 1-1 This is a structural diagram of stator core block A of a three-rotor modular core A.

[0026] Figure 1-2 This is a method of stacking multiple silicon steel sheets in stator core block A.

[0027] Figure 1-3 This is the second method of stacking multiple silicon steel sheets of stator core block A.

[0028] Figure 2 This is a structural diagram of the three rotor block iron core A after being assembled into a whole (i.e., a schematic diagram of the circular iron core).

[0029] Figure 3-1 This is a schematic diagram of the stator core block B structure.

[0030] Figure 3-2 This is a schematic diagram of stator core block B. Figure 2 .

[0031] Figure 4-1 This is a schematic diagram of the splicing of the three-rotor modular iron core A / B and the winding section.

[0032] Figure 4-2 This is a schematic diagram of the splicing of the three-rotor modular iron core A / B and the winding section. Figure 2 .

[0033] Figure 5 This is a schematic diagram of the structure after the three rotors with winding stator cores are spliced ​​together as a whole.

[0034] Figure 6-1 This is a schematic diagram of the structure of a three-rotor motor housing that facilitates heat dissipation.

[0035] Figure 6-2 This is a schematic diagram of the structure of a three-rotor motor housing designed to facilitate heat dissipation. Figure 2 .

[0036] Figure 7 This is a schematic diagram of a three-rotor stator assembly.

[0037] Figure 8 This is a schematic diagram of rotor A structure of a three-rotor motor.

[0038] Figure 9-1 This is a schematic diagram of rotor B and rotor assembly of a three-rotor motor.

[0039] Figure 9-2 This is a schematic diagram of rotor B and rotor assembly for a three-rotor motor. Figure 2 .

[0040] Figure 10 This is an exploded view of a three-rotor motor structure.

[0041] In the diagram, 1 is surface three, 2 is surface one, 3 is surface four, 4 is surface two, 5 is superposition direction one, 6 is superposition direction two, 7 is base plate one, 8 is base plate two, 9 is horizontal part, 10 is vertical part, 11 is base plate groove, 12 is first iron core block, 13 is winding coil, 14 is second iron core block, 15 is cavity, 16 is top surface of stator iron core A, 17 is radial magnetic flux air gap surface, 18 is axial magnetic flux air gap surface one, 19 is axial magnetic flux air gap surface two, 20 is positioning groove, 21 is stator housing, 22 is protrusion, 23 is rotor A, 24 is permanent magnet of rotor A, 25 is permanent magnet of rotor B, 26 is rotor iron core of motor rotor B, 27 is mating surface, 28 is rotor B, and 32 is stator assembly. Detailed Implementation

[0042] This invention provides a high-permeability modular iron core structure, a soft magnetic material modular iron core structure, and a heat-dissipating three-rotor motor housing structure. It achieves a three-rotor motor structure, changing the traditional structure where motor windings are embedded in stator slots, and realizing the goal of having three air gap surfaces in a single motor. Together, these constitute the three-rotor motor structure.

[0043] Example 1: As Figures 1-1 to 1-3 The structure of the high-permeability modular iron core A.

[0044] 1: The number of modular iron cores A, N≥2. If oriented silicon steel sheets are used, N≥3 is required to achieve the best performance.

[0045] 2: Each segment of the core A (i.e., stator core block A) is part of the entire circular core 33. There are many methods for splicing and positioning, which will not be elaborated here.

[0046] 3: For example Figures 1-1 to 1-3 As shown, the stacking direction of the silicon steel sheets of the modular iron core A can be any direction as shown in either stacking direction 1 (5) or stacking direction 2 (6).

[0047] 4: If the goal of the modular iron core A is to achieve higher performance (increase the core permeability and increase the winding space), then the direction of high permeability of the oriented silicon steel sheet is the tangent direction of the core circle.

[0048] 5: The first surface 2 and the second surface 4 of the modular iron core A can be curved or flat depending on the design and manufacturing process of the motor iron core, without affecting the realization of the motor structure.

[0049] Example 2: As Figures 3-1 to 3-2 As shown, this illustrates the structural form of the soft magnetic material block stator core B.

[0050] 1: The core is made of SMC, a soft magnetic material that is easy to process into irregular shapes, by pressing and sintering.

[0051] 2: The planes shown on the base plate 7 and base plate 8 in the modular core B (i.e., stator core block B) can be connected or disconnected without affecting the realization of the motor structure.

[0052] 3: The plane shown in horizontal section 9 is installed opposite to the plane of the other block iron core B at the same position; the plane shown in bottom plate 7 of the two block iron cores B together form the radial magnetic flux air gap surface of the motor.

[0053] Due to the difficulties in fixing and installing winding 13, it is not easy to produce the iron core as a complete ring structure. Figure 1-1 The third side 1 and Figure 1-3The plane containing the superposition direction 26 is the splicing surface with other modular iron cores A. Surface 12 is in close contact with the protrusion 22 of the housing to achieve dimensional positioning and heat dissipation of the motor stator. The planes shown on the second and fourth sides of surfaces 4, 4, and their opposite sides are in close contact with the plane shown on the upper longitudinal part 10 of iron core B; the plane shown on the middle longitudinal part of iron core B forms the axial magnetic flux air gap surface, and the bottom plate 7 forms the radial magnetic flux air gap surface.

[0054] Example 3: As Figure 4-1 , 4-2 As shown, the winding coil 13 is the motor winding, and its contact position with the block cores A and B is protected by insulating material; the winding coil 13 is placed in the space formed by the block cores A and B and is in close contact with the top surface 16; in the block stator core B: multiple stator core blocks B are arranged side by side, and a cavity 15 is formed between two adjacent stator core blocks B. Each cavity corresponds to a winding coil, and the two sides of the winding coil are respectively located in a cavity of the corresponding block stator core B.

[0055] Example 4: Figure 5 As shown in the diagram, the three rotors with wound stator cores are spliced ​​together to form a complete axial flux air gap surface 18, axial flux air gap surface 19, and radial flux air gap surface 17.

[0056] The protrusion 22 on the housing is in close contact with the positioning groove 20: while achieving mechanical positioning, the heat generated by the motor stator is transferred to the housing via the positioning groove-protrusion. The positioning groove 20 is composed of a set of mirror-arranged stator core blocks B and the winding coils on both sides of the stator core blocks B; wherein, the two core blocks B in the set of stator core blocks B are core blocks in two-piece stator core blocks B; for example, the first core block 12 and the second core block 14.

[0057] Example 5: Figure 6-1 , 6-2 As shown, the outer wall of the casing can be designed as a liquid cooling channel, air-cooled heat dissipation fins, or other heat dissipation structures.

[0058] The protrusion should be the same length as or similar to the positioning groove (contact surface of the interlocking iron core A) and be able to make close contact (both are curved surfaces or both are flat surfaces).

[0059] Example 6: As Figure 7 As shown, the three-rotor stator assembly 32 is assembled from multiple sets of modular iron core A, modular iron core B, coils, and housing.

[0060] The stator assembly 32 can be fixed as a whole by potting after assembly to increase overall rigidity and improve the heat dissipation capacity of the motor stator.

[0061] Example 7: As Figures 8-9-2As shown, the structure of rotor A 23 of the three-rotor motor is similar to that of the rotor of a conventional radial flux motor, and permanent magnets 24 of rotor A of the three-rotor motor are installed on rotor A 23.

[0062] The three-rotor motor rotor B 28 includes a rotor core 26 and a rotor permanent magnet 25. There are multiple mating methods at the mating surface 27 between the three-rotor motor rotor A and rotor B, all of which can realize the three-rotor motor structure described in this invention.

[0063] The three-rotor assembly of the present invention is characterized in that: the outer surface 29 of the permanent magnet of one rotor B, the outer surface 31 of the permanent magnet of another rotor B, and the outer surface 30 of the permanent magnet of rotor A have the same polarity.

[0064] Example 8: As Figure 10 As shown, the main body of the three-rotor motor of the present invention consists of a stator housing 21, multiple block stator cores A, two N block stator cores B, N coils, two axial flux rotors B, and one radial flux rotor A.

[0065] The stator and rotor of the three-rotor motor of the present invention have multiple connection and positioning methods to ensure the positioning between the stator core and the rotor core. All of these methods can achieve the structure described in the present invention. Therefore, they are not shown in the schematic diagram and are not included in the scope of protection of the present invention.

[0066] In the figure, the radial flux rotor A is the inner rotor (the rotor permanent magnet faces outward). With slight structural changes, it can be transformed into an outer rotor (the rotor permanent magnet faces inward). Combined with the housing structure, a three-rotor motor structure can also be realized, which is also within the scope of protection of this invention.

[0067] In addition, the winding of the present invention is directly fixed on the composite iron core A, and the winding plane of the winding is perpendicular to the plane of the circle where the composite iron core A is spliced; the inner wall of the housing has the same number of protrusions as the winding, which directly contact the surface of the composite iron core A; and the slots between the protrusions contact the winding through insulating material.

[0068] It is understood that the above specific description of the present invention is only for illustrating the present invention and is not limited to the technical solutions described in the embodiments of the present invention. Those skilled in the art should understand that modifications or equivalent substitutions can still be made to the present invention to achieve the same technical effect; as long as the use needs are met, they are all within the protection scope of the present invention.

Claims

1. A three rotor machine structure comprising a three rotor machine body; characterized by: The main body of the three-rotor motor includes a stator housing (21), a single-piece stator core A, two single-piece stator cores B, multiple winding coils (13), two axial flux rotors B (28), and one radial flux rotor A (23). Among them, the modular stator core A is located between two modular stator cores B, the winding coil is wound on the modular stator core A, positioned and assembled in the space formed between the modular stator core A and the modular stator core B, and in contact with the top surface (16) of the modular stator core A; the modular stator core A, the modular stator core B and the winding coil together form a wound stator core; the stator housing is installed outside the wound stator core to form a stator assembly (32); the stator assembly (32) is fixed as a whole by potting; A radial flux rotor A (23) is located between two axial flux rotors B (28), and one radial flux rotor A (23) and two axial flux rotors B (28) cooperate to form a rotor assembly; The stator assembly (32) is connected to the rotor assembly and positioned as the main body of a three-rotor motor; The stator core B comprises multiple stator core blocks B, each stator core block B having an L-shaped structure with an L-shaped longitudinal section. The L-shaped structure includes a horizontal section (9) and a vertical section (10) that are perpendicular to each other. The bottom of the horizontal section (9) is fixedly connected to a base plate one (7) that is perpendicular to it, and the bottom of the vertical section (10) is fixedly connected to a base plate two (8) that is perpendicular to it. The width of the base plate one (7) is greater than the width of the horizontal section (9), and the width of the base plate two (8) is greater than the width of the vertical section (10). This results in the two sides of the L-shaped structure forming base plate grooves (11) with the corresponding base plates. In the modular stator core B: multiple stator core blocks B are arranged side by side, and a cavity (15) is formed between two adjacent stator core blocks B. Each cavity corresponds to a winding coil (13), and the two sides of the winding coil (13) are respectively located in a cavity of the corresponding modular stator core B. The plane on which the bottom plates of two adjacent stator core blocks B are located forms the radial magnetic flux air gap surface of the motor. The longitudinal part (10) is in contact with the modular stator core A. The plane on which each bottom plate (8) is located constitutes the axial magnetic flux air gap surface. In the winding stator core: a positioning groove (20) is formed on the circumference; the positioning groove (20) is composed of a set of mirror-arranged stator core blocks B and the winding coils on both sides of the stator core blocks B; The inner wall of the stator housing (21) is provided with the same number of protrusions (22) as the positioning grooves (20). Each protrusion (22) corresponds to a positioning groove (20). When the stator housing (21) is installed on the stator core with windings, the protrusions (22) are located in the positioning grooves (20) to achieve mechanical positioning. The protrusions (22) are in contact with the surface of the block stator core A, transferring the heat generated by the motor stator to the housing. The slots between the protrusions (22) are in contact with the winding coils through insulating material.

2. A three rotor electric machine structure according to claim 1, characterized in that: The stator core A is a circular ring core assembled from multiple stator core blocks A; the stator core block A is composed of multiple silicon steel sheets stacked together.

3. A three-rotor electric machine structure according to claim 2, characterized in that: When the material of the stator core block A is selected as oriented silicon steel sheet, the spliced ​​stator core A is composed of at least three stator core blocks A spliced ​​together; the winding plane of the winding coil is perpendicular to the plane where the annular core of the spliced ​​stator core A is located.

4. A three-rotor motor structure according to claim 1, characterized in that: The stator core block B is made of soft magnetic material SMC sintered together.

5. A three-rotor electric machine structure according to claim 1, characterized in that: The contact points between the winding coil (13) and the block stator core A and block stator core B are provided with insulation protection.

6. The three-rotor motor structure according to claim 1, characterized in that: The outer wall of the stator housing (21) is provided with a heat dissipation structure.

7. The three-rotor motor structure according to claim 1, characterized in that: The radial flux rotor A (23) adopts a radial flux motor rotor structure, and the axial flux rotor B (28) includes the rotor core (26) of the axial flux rotor B, the permanent magnet (25) of the axial flux rotor B, and the mating surface (27); and the radial flux rotor A (23) and the axial flux rotor B (28) are assembled into a rotor assembly through the mating surface (27); The outer surfaces of the permanent magnets on the two-axial flux rotor B (28) and the permanent magnets on the radial flux rotor A (23) have the same polarity.

Images