Stator assembly and axial flux wheel motor having the same

Abstract

The application provides a stator assembly and an axial flux wheel motor with the same, and the stator assembly comprises: a housing assembly, the housing assembly has a containing cavity; and a stator winding unit, the stator winding unit is arranged in the containing cavity, and the stator winding unit is multiple, a first cooling flow channel is formed between adjacent stator winding units, a second cooling flow channel is formed between the stator winding unit and the containing cavity, and the housing assembly is provided with an inlet and an outlet which are connected with the first cooling flow channel and the second cooling flow channel. According to the technical scheme of the application, the stator winding unit is arranged in the containing cavity of the housing assembly, and the stator winding unit is multiple, so that the mechanical strength of the stator assembly is enhanced, the sealing effect of the stator assembly and the heat dissipation and cooling effect of the stator winding unit are ensured, and the problem of high heat of the motor caused by the improvement of the torque density of the axial flux motor in the prior art is solved.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and more specifically, to a stator assembly and an axial flux hub motor having therein. Background Technology

[0002] With the rapid development of new energy vehicle technology, the performance requirements for in-wheel motors are becoming increasingly stringent. This increased performance inevitably leads to a larger in-wheel motor size, but the internal space of new energy vehicle wheels is very limited, making the contradiction between performance and size increasingly prominent. Axial flux motors, due to their axial magnetic field design, have shorter axial dimensions, higher torque density, higher power density, lighter weight, and higher efficiency compared to traditional radial flux motors. Furthermore, they can inherit the control methods of radial flux motors, making them more suitable for in-wheel motors in new energy vehicles. However, the increased torque density of axial flux motors also brings problems such as high load and high heat generation. Therefore, solving the heat dissipation and cooling problem of axial flux in-wheel motors has become one of the important issues in improving their reliability. Summary of the Invention

[0003] The main objective of this invention is to provide a stator assembly and an axial flux hub motor having the same, so as to solve the problem of high heat generation in existing axial flux motors caused by the increase in torque density.

[0004] To achieve the above objectives, according to one aspect of the present invention, a stator assembly is provided, comprising: a housing assembly having a receiving cavity; stator winding units disposed within the receiving cavity, wherein there are multiple stator winding units, a first cooling channel is formed between adjacent stator winding units, and a second cooling channel is formed between the stator winding units and the receiving cavity, and the housing assembly is provided with an inlet and an outlet communicating with the first cooling channel and the second cooling channel.

[0005] Furthermore, the housing assembly includes: a first clamping plate; a second clamping plate, the second clamping plate being disposed at a distance from the first clamping plate; an outer housing ring, the outer housing ring being connected to both the first and second clamping plates, and having an inlet and an outlet disposed at intervals along the circumferential direction of the outer housing ring, with the inlet and outlet being 180° apart in the circumferential direction of the outer housing ring; and an inner housing ring, the inner housing ring being disposed at a distance from the outer housing ring, and being connected to both the first and second clamping plates, with the first and second clamping plates forming a receiving cavity between the outer and inner housing rings.

[0006] Furthermore, the stator winding unit includes a stator core and a stator winding, with multiple stator cores and stator windings. Multiple stator windings are mounted around multiple stator cores. Grooves are provided at both ends of each stator core. Multiple reinforcing ribs are provided on the side of the first clamping plate and the second clamping plate facing the stator core, and the multiple reinforcing ribs are provided in a one-to-one correspondence with the multiple grooves.

[0007] Furthermore, the stator assembly includes: a first sealing plate disposed on the outside of the first clamping plate; and a second sealing plate disposed on the outside of the second clamping plate, wherein a sealing cavity is formed between the first sealing plate and the first clamping plate and between the second sealing plate and the second clamping plate.

[0008] Furthermore, the first clamping plate facing the first sealing plate and the second clamping plate facing the second sealing plate are each provided with multiple positioning grooves. The stator assembly also includes a stator tooth shoe assembly, which is disposed in the sealing cavity. The stator tooth shoe assembly includes multiple pairs of stator tooth shoe pairs, which are spaced apart. Each pair of stator tooth shoe pairs is formed by two stator tooth shoes being arranged opposite each other. The multiple stator tooth shoes are arranged one-to-one with the multiple positioning grooves.

[0009] Furthermore, the stator toothed shoe includes a first component segment and a second component segment, the first end of the second component segment is connected to the second end of the first component segment, the second component segment and the first component segment are arranged at an angle, and the second end of the second component segment forms a hook portion.

[0010] Furthermore, both the first clamping plate and the second clamping plate are provided with a plurality of first protrusions, which are spaced apart and are grounded against the stator winding. The first protrusions are used to limit the stator winding.

[0011] Furthermore, the outer ring of the housing includes an annular body and a third protrusion. The third protrusion is protrudingly disposed on the annular body. A first clamping plate is connected to the annular body and is disposed on one side of the third protrusion. A second clamping plate is connected to the annular body and is disposed on the other side of the third protrusion.

[0012] Furthermore, the inner ring of the housing is provided with two second protrusions, which are arranged at a distance of 180° from the outer circumference of the inner ring of the housing. The two second protrusions are in direct contact with the stator windings and are used to restrict the circulation of coolant between the inner ring of the housing and the stator windings.

[0013] According to another aspect of the present invention, an axial flux hub motor is provided, including a stator assembly, wherein the stator assembly is as described above.

[0014] By applying the technical solution of this invention, the stator winding units are arranged in the receiving cavity of the housing assembly. There are multiple stator winding units, a first cooling channel is formed between adjacent stator winding units, and a second cooling channel is formed between the stator winding units and the receiving cavity. An inlet and an outlet connecting the first cooling channel and the second cooling channel are provided in the housing assembly, thereby enhancing the mechanical strength of the stator assembly, ensuring the sealing effect of the stator assembly and the heat dissipation and cooling effect of the stator winding units, and solving the problem of high motor heat generation caused by the increase of torque density in axial flux motors in the prior art. Attached Figure Description

[0015] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0016] Figure 1 A schematic diagram of the structure of a first embodiment of a stator assembly according to the present invention is shown;

[0017] Figure 2 A schematic diagram of the structure of a first embodiment of the stator winding unit according to the present invention is shown;

[0018] Figure 3 A schematic diagram of a second embodiment of a stator assembly according to the present invention is shown;

[0019] Figure 4 A schematic diagram of the structure of a first embodiment of the stator core according to the present invention is shown;

[0020] Figure 5 A schematic diagram of a second embodiment of the stator core according to the present invention is shown;

[0021] Figure 6 A schematic diagram of a second embodiment of the stator winding unit according to the present invention is shown;

[0022] Figure 7 A schematic diagram of an embodiment of the stator core and the first clamping plate according to the present invention is shown;

[0023] Figure 8 A schematic diagram of an embodiment of the stator gear shoe assembly and its cooperation with the first clamping plate according to the present invention is shown;

[0024] Figure 9 A schematic diagram of an embodiment of the stator toothed shoe according to the present invention is shown;

[0025] Figure 10 A schematic diagram of a structure according to an embodiment of the first sealing plate of the present invention is shown;

[0026] Figure 11 A schematic diagram of the structure of an embodiment of the outer ring according to the present invention is shown;

[0027] Figure 12 A schematic diagram of the structure of an embodiment of the inner ring according to the present invention is shown;

[0028] Figure 13 A schematic diagram of an embodiment of the stator gear assembly according to the present invention is shown;

[0029] Figure 14A schematic diagram of an embodiment of the stator tooth pair according to the present invention is shown.

[0030] The above figures include the following reference numerals:

[0031] 1. Housing assembly; 10. First clamping plate; 20. Second clamping plate;

[0032] 30. Outer ring of the casing; 31. Inlet; 32. Outlet; 33. Annular body; 34. Third protrusion;

[0033] 40. Inner ring of the casing; 41. Second protrusion;

[0034] 50. Stator winding unit; 51. Stator core; 511. Groove; 52. Stator winding; 53. Busbar; 531. U-phase lead; 532. V-phase lead; 533. W-phase lead;

[0035] 60. First sealing plate; 70. Second sealing plate;

[0036] 80. Stator toothed shoe assembly; 81. Stator toothed shoe; 811. First component section; 812. Second component section. Detailed Implementation

[0037] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0038] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0039] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0040] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0041] Combination Figures 1 to 14 As shown, according to a specific embodiment of this application, a stator assembly is provided.

[0042] Specifically, the stator assembly includes a housing assembly 1 and a stator winding unit 50. The housing assembly 1 has a receiving cavity, and the stator winding unit 50 is disposed in the receiving cavity. There are multiple stator winding units 50. A first cooling channel is formed between adjacent stator winding units 50, and a second cooling channel is formed between the stator winding unit 50 and the receiving cavity. The housing assembly 1 is provided with an inlet 31 and an outlet 32 ​​that connect the first cooling channel and the second cooling channel.

[0043] By applying the technical solution of this embodiment, the stator winding unit 50 is disposed in the receiving cavity of the housing assembly 1. There are multiple stator winding units 50, and a first cooling channel is formed between adjacent stator winding units 50. A second cooling channel is formed between the stator winding unit 50 and the receiving cavity. An inlet 31 and an outlet 32 ​​connecting the first cooling channel and the second cooling channel are provided in the housing assembly 1. This enhances the mechanical strength of the stator assembly, ensures the sealing effect of the stator assembly and the heat dissipation and cooling effect of the stator winding unit, and solves the problem of high motor heat generation caused by the increase of torque density in axial flux motors in the prior art.

[0044] like Figure 1 As shown, the housing assembly 1 includes a first clamping plate 10, a second clamping plate 20, an outer housing ring 30, and an inner housing ring 40. The second clamping plate 20 is spaced apart from the first clamping plate 10. The outer housing ring 30 is connected to both the first clamping plate 10 and the second clamping plate 20. An inlet 31 and an outlet 32 ​​are spaced apart along the circumferential direction of the outer housing ring 30, with a circumferential distance of 180° between the inlet 31 and the outlet 32. The inner housing ring 40 is spaced apart from the outer housing ring 30 and is connected to both the first clamping plate 10 and the second clamping plate 20. A receiving cavity is formed between the first clamping plate 10, the second clamping plate 20, the outer housing ring 30, and the inner housing ring 40. This arrangement is beneficial for enhancing the heat dissipation and cooling effect on the stator winding unit, thereby improving the overall performance of the motor.

[0045] like Figure 2 , Figure 4 and Figure 7 As shown, the stator winding unit 50 includes stator cores 51 and stator windings 52. Multiple stator cores 51 and stator windings 52 are mounted around multiple stator cores 51. Grooves 511 are formed at both ends of each stator core 51. Multiple reinforcing ribs are provided on the side of the first clamping plate 10 and the second clamping plate 20 facing the stator core 51, with each reinforcing rib corresponding to one of the grooves 511. By providing reinforcing ribs, the overall mechanical strength of the stator assembly is significantly enhanced. Since the reinforcing ribs do not occupy the space between the stator core 51 and the rotor, the electromagnetic air gap is reduced, which is beneficial for further reducing the size, increasing the torque density of the motor, and improving the overall performance of the motor.

[0046] In another specific embodiment of this application, the stator assembly further includes a busbar 53, which is connected to the outgoing lines of a plurality of stator windings 52 to form a neutral point. The U-phase lead 531, the V-phase lead 532 and the W-phase lead 533 are respectively connected to each stator winding 52.

[0047] Furthermore, the stator assembly includes a first sealing plate 60 and a second sealing plate 70. The first sealing plate 60 is disposed on the outer side of the first clamping plate 10, and the second sealing plate 70 is disposed on the outer side of the second clamping plate 20. A sealing cavity is formed between the first sealing plate 60 and the first clamping plate 10, and between the second sealing plate 70 and the second clamping plate 20. This arrangement further ensures the overall sealing effect of the stator assembly. Specifically, the first sealing plate 60 and the second sealing plate 70 are made of non-magnetic and non-conductive carbon fiber material. The thinness of this sealing material results in a smaller electromagnetic air gap, which is beneficial for further reducing the volume and increasing the torque density of the motor.

[0048] The first clamping plate 10 facing the first sealing plate 60 and the second clamping plate 20 facing the second sealing plate 70 are both provided with multiple positioning grooves. The stator assembly also includes a stator tooth shoe assembly 80, which is disposed within the sealing cavity. The stator tooth shoe assembly 80 includes multiple pairs of stator tooth shoes, which are spaced apart. Each pair of stator tooth shoes is formed by two stator tooth shoes 81 arranged opposite each other. The multiple stator tooth shoes 81 are correspondingly arranged with multiple positioning grooves. This arrangement improves the installation stability of the stator tooth shoe assembly 80 within the first clamping plate 10 and the second clamping plate 20, and further enhances the overall mechanical strength of the stator assembly.

[0049] like Figure 9As shown, the stator gear shoe 81 includes a first component segment 811 and a second component segment 812. The first end of the second component segment 812 is connected to the second end of the first component segment 811. The second component segment 812 and the first component segment 811 are arranged at an included angle, and the second end of the second component segment 812 forms a hook. The stator gear shoe 81 is die-cast from a soft magnetic composite material.

[0050] Furthermore, both the first clamping plate 10 and the second clamping plate 20 are provided with multiple first protrusions, which are spaced apart and abut against the stator winding 52. The first protrusions are used to limit the stator winding 52. Specifically, the stator winding 52 is a flat wire winding. The first protrusions are used to restrict the flat wire winding to the axial position of the motor, ensuring that a second cooling channel is formed between the flat wire winding and the receiving cavity, thereby ensuring the cooling effect on the stator winding unit 50 and solving the problem of high motor heat generation caused by the increase in torque density of axial flux motors in the prior art.

[0051] Combination Figure 1 , Figure 3 and Figure 11 As shown, the outer ring 30 of the housing includes an annular body 33 and a third protrusion 34. The third protrusion 34 is projected onto the annular body 33. A first clamping plate 10 is connected to the annular body 33 and is located on one side of the third protrusion 34. A second clamping plate 20 is connected to the annular body 33 and is located on the other side of the third protrusion 34. This arrangement improves the reliability of the connection between the first clamping plate 10, the second clamping plate 20, and the outer ring 30 of the housing.

[0052] Furthermore, the inner ring 40 of the housing is provided with two second protrusions 41, which are arranged at a distance of 180° from the outer circumference of the inner ring 40 of the housing. Figure 12 As shown, the two second protrusions 41 are in direct contact with the stator winding 52, and these protrusions restrict the circulation of coolant between the inner ring 40 of the housing and the stator winding 52. Specifically, after entering through the inlet 31 of the outer ring 30 of the housing, the coolant flows upward through the flat wire winding and the inner ring 40 of the housing, and simultaneously enters the gap between the flat wire winding and the inner ring 40 of the housing through the gap between the flat wire windings, flowing upward to the outlet 32 ​​of the outer ring 30 of the housing. This further ensures the cooling effect on the stator winding unit 50, and the cooling effect is better, solving the problem of high motor heat generation caused by the increase in torque density of axial flux motors in the prior art.

[0053] According to another specific embodiment of this application, an axial flux hub motor is provided, including a stator assembly, which is the stator assembly described in the above embodiments. Because the motor uses the stator assembly described in the above embodiments, the mechanical strength of the axial flux motor stator and the sealing effect on the stator are enhanced.

[0054] According to another specific embodiment of this application, a vehicle is provided, including an axial flux hub motor, which is the axial flux hub motor described in the above embodiment. Using the axial flux hub motor described in the above embodiment results in a smaller motor size, higher torque density, and solves the problem of high heat generation in the stator assembly, making it more suitable for the higher requirements of new energy vehicles.

[0055] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0056] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0057] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0058] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A stator assembly, characterized in that, include: A housing assembly (1) having a receiving cavity; Stator winding unit (50), the stator winding unit (50) is disposed in the receiving cavity, there are multiple stator winding units (50), a first cooling channel is formed between adjacent stator winding units (50), a second cooling channel is formed between the stator winding unit (50) and the receiving cavity, and the housing assembly (1) is provided with an inlet (31) and an outlet (32) connecting the first cooling channel and the second cooling channel. The housing assembly (1) includes: First clamp (10); The second clamping plate (20) is disposed at a distance from the first clamping plate (10); The outer ring (30) of the housing is connected to the first clamping plate (10) and the second clamping plate (20). The inlet (31) and the outlet (32) are provided at intervals along the circumferential direction of the outer ring (30), and the inlet (31) and the outlet (32) are 180° apart in the circumferential direction of the outer ring (30). The inner ring (40) of the housing is spaced apart from the outer ring (30) of the housing, and the inner ring (40) of the housing is connected to the first clamping plate (10) and the second clamping plate (20). The first clamping plate (10), the second clamping plate (20), the outer ring (30) of the housing, and the inner ring (40) of the housing form the receiving cavity. The stator winding unit (50) includes a stator core (51) and a stator winding (52), and there are multiple stator cores (51) and multiple stator windings (52), with multiple stator windings (52) being mounted around multiple stator cores (51); The stator assembly includes: The first sealing plate (60) is disposed on the outside of the first clamping plate (10); The second sealing plate (70) is disposed on the outside of the second clamping plate (20), and a sealing cavity is formed between the first sealing plate (60) and the first clamping plate (10) and between the second sealing plate (70) and the second clamping plate (20); The outer ring (30) of the housing includes an annular body (33) and a third protrusion (34). The third protrusion (34) is protrudingly disposed on the annular body (33). The first clamping plate (10) is connected to the annular body (33) and is disposed on one side of the third protrusion (34). The second clamping plate (20) is connected to the annular body (33) and is disposed on the other side of the third protrusion (34). The inner ring (40) of the housing is provided with two second protrusions (41). The two second protrusions (41) are arranged at a distance of 180° from the outer circumference of the inner ring (40). The two second protrusions (41) are in direct contact with the stator winding (52). The two second protrusions (41) are used to restrict the circulation of coolant between the inner ring (40) of the housing and the stator winding (52). The first clamping plate (10) facing the first sealing plate (60) and the second clamping plate (20) facing the second sealing plate (70) are each provided with multiple positioning grooves. The stator assembly further includes: A stator tooth shoe assembly (80) is disposed in the sealed cavity. The stator tooth shoe assembly (80) includes multiple pairs of stator tooth shoe pairs, which are spaced apart. Each pair of stator tooth shoe pairs is formed by two stator tooth shoes (81) arranged opposite to each other. The multiple stator tooth shoes (81) are arranged one-to-one with the multiple positioning grooves. The stator toothed shoe (81) includes a first component segment (811) and a second component segment (812). The first end of the second component segment (812) is connected to the second end of the first component segment (811). The second component segment (812) and the first component segment (811) are arranged at an angle, and the second end of the second component segment (812) forms a hook.

2. The stator assembly according to claim 1, characterized in that, Each of the stator cores (51) has grooves (511) at both ends. The first clamping plate (10) and the second clamping plate (20) are provided with multiple reinforcing ribs on the side facing the stator core (51). The multiple reinforcing ribs are provided in a one-to-one correspondence with the multiple grooves (511).

3. The stator assembly according to claim 2, characterized in that, Both the first clamping plate (10) and the second clamping plate (20) are provided with a plurality of first protrusions, which are spaced apart. The first protrusions are grounded against the stator winding (52) and are used to limit the stator winding (52).

4. An axial flux hub motor, characterized in that, Includes a stator assembly, said stator assembly being the stator assembly according to any one of claims 1-3.

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