An integrated weak magnetic resistance hub motor

Abstract

The present invention discloses an integrated weak magnetic resistance hub motor, which comprises a shaft body, a housing, a rotor assembly and a stator assembly. The housing includes an inner rim, an outer rim and a spoke made of a metal material. The spoke is fixedly installed with the inner rim to form an installation space, the outer rim is fixedly installed with the spoke, and the outer rim is hermetically connected with the inner rim; both the inner rim and the spoke are rotatably connected with the shaft body; the rotor assembly and the stator assembly are located in the installation space, and the rotor assembly is fixedly installed on the housing; the stator assembly is fixedly installed on the shaft body. The present invention does not require a separate motor housing. When the tire size is determined, the outer diameters of the rotor and the stator can be increased, thereby improving the motor efficiency; the present invention adopts a structure in which the motor stator, rotor and hub are highly integrated, and the outer diameters of the stator and rotor are maximally increased to achieve the design of low-speed and high-torque of the hub motor and reduce the weight of the hub motor.

Description

Technical Field

[0001] The present invention belongs to the technical field of hub motors, and in particular relates to an integrated weak magnetic resistance hub motor. Background Art

[0002] Currently, in-wheel hub motors are gaining increasing popularity. Existing in-wheel hub motors generally consist of a motor and a rim mounted on the motor, with a tire mounted on the rim. Since the motor itself also includes a motor housing, the presence of the rim and motor housing results in a smaller outer diameter of the rotor and stator when determining tire size, resulting in low motor efficiency. Furthermore, since both the rim and motor housing are made of metal, the overall weight of the in-wheel hub motor and rim after installation is relatively heavy. Furthermore, the motor housing needs to be installed during motor installation, and the motor housing and rim need to be installed when the motor is assembled to the rim, increasing the number of operations. The rim's structure also makes tire installation and removal difficult, potentially damaging the tire and rim structures.

[0003] The above information disclosed in this background technology is only used to increase the understanding of the background technology of this application. Therefore, it may contain information that does not constitute the prior art known to ordinary technicians in this field. Summary of the Invention

[0004] The present invention proposes an integrated weak magnetic resistance hub motor to solve the technical problems of low motor efficiency, heavy weight and difficult assembly caused by the existing hub motor comprising a housing and being assembled with a rim through the housing.

[0005] In order to achieve the above invention / design purpose, the present invention adopts the following technical solutions:

[0006] An integrated weak magnetic resistance hub motor, comprising:

[0007] Axis;

[0008] The outer shell includes an inner rim, an outer rim, and spokes made of metal, the spokes being fixedly mounted on the inner rim to form an installation space, the outer rim being fixedly mounted on the spokes, and the outer rim and the inner rim being sealed; the inner rim and the spokes being rotatably connected to the shaft;

[0009] a rotor assembly, located in the installation space, wherein the rotor assembly is fixedly mounted on the housing;

[0010] The stator assembly is located in the installation space, and the stator assembly is fixedly installed on the shaft.

[0011] The integrated weak magnetic resistance hub motor as described above, wherein the inner rim includes a circular portion and an annular portion connected to the circular portion, the spoke is opposite to the circular portion and fixedly installed with the annular portion, and the annular portion is hermetically connected to the outer rim.

[0012] The integrated weak magnetic resistance hub motor as described above, wherein the annular portion is provided with an annular assembly portion, the outer diameter of the annular assembly portion is smaller than the outer diameter of the annular portion, the outer rim is sleeved on the annular assembly portion, and the spoke is connected to the annular assembly portion.

[0013] The integrated weak magnetic resistance hub motor as described above, wherein a plurality of first V-shaped protrusions are provided on the inner side of the annular portion, V-shaped grooves are formed between the first V-shaped protrusions, the rotor assembly includes a rotor yoke, a plurality of second V-shaped protrusions are provided on the rotor yoke, the second V-shaped protrusions are adapted to the V-shaped grooves, a plurality of magnet mounting grooves are provided in the second V-shaped protrusions, and permanent magnets are installed in the magnet mounting grooves; the spoke is fixedly installed on the first V-shaped protrusions.

[0014] The integrated weak magnetic resistance hub motor as described above, wherein the stator assembly includes a stator bracket, a stator, a winding, a capacitor ring and a stator fixing disk, the stator is fixed on the outer ring of the stator bracket, the capacitor ring is fixed on the inner ring of the stator bracket, and the stator fixing disk is fixed on the stator bracket to limit the capacitor ring and the stator on the stator bracket.

[0015] The integrated weak magnetic resistance hub motor as described above, wherein the stator includes a plurality of open-mouth stator magnetic conduction rings and closed-mouth stator magnetic conduction rings, the open-mouth stator magnetic conduction rings and the closed-mouth stator magnetic conduction rings are arranged alternately, and the open mouths and the closed mouths are connected to form a winding winding space; the magnetic conduction performance of the open-mouth stator magnetic conduction ring is greater than that of the closed-mouth stator magnetic conduction ring; the height of the outer edge of the open-mouth stator magnetic conduction ring is lower than the height of the outer edge of the closed-mouth stator magnetic conduction ring.

[0016] The integrated weak magnetic resistance hub motor as described above, wherein the winding is a flat wire winding or a flat strip winding;

[0017] The flat wire winding includes a plurality of U-shaped flat wires, the U-shaped flat wires are inserted into the winding space, and the free ends of the U-shaped flat wires are welded;

[0018] The flat-strip winding is an integrated winding sintered by 3D printing technology, or the flat-strip winding is a semi-cast and semi-welded flat-strip winding; the semi-cast and semi-welded flat-strip winding includes two groups of cast-layer windings. The first group of cast-layer windings includes a number of U-shaped flat strips formed by casting, and the number of U-shaped flat strips are inserted into the winding space. The second group of cast-layer windings includes the connecting ends of a number of U-shaped flat strips formed by casting, and the connecting ends of the U-shaped flat strips of the second group of cast-layer windings are welded to the free ends of the number of U-shaped flat strips of the first group of cast-layer windings according to the winding method.

[0019] For the integrated weak magnetic resistance hub motor as described above, a brake drum is formed on the circular part of the inner rim.

[0020] For the integrated weak magnetic resistance hub motor as described above, the stator bracket includes a cooler, and the pipeline connected to the cooler is led out through the central cavity of the shaft body; the motor includes a temperature sensor for detecting the temperature of the winding, and controls the flow rate and / or temperature of the refrigerant in the cooling pipeline according to the temperature detected by the temperature sensor; the wires connected to the temperature sensor, the winding, and the capacitor ring are all led out through the central cavity of the shaft body.

[0021] For the integrated weak magnetic resistance hub motor as described above, the motor includes a resolver, the resolver is located in the central cavity of the shaft body, the rotating shaft of the resolver is fixedly connected to the outer shell, and the resolver is used to detect the corresponding angle between the rotor assembly and the stator assembly; and / or, the motor includes a tire balance sensor, the sensing part of the tire balance sensor is installed on the shaft body, and the magnet part of the tire balance sensor is installed on the outer shell.

[0022] Compared with the prior art, the advantages and positive effects of the present invention are:

[0023] The integrated reluctance wheel hub motor of the present invention includes a shaft body, a housing, a rotor assembly, and a stator assembly. The housing includes an inner rim, an outer rim, and spokes made of metal. The spokes are fixedly installed with the inner rim to form an installation space. The outer rim is fixedly installed with the spokes, and the outer rim is hermetically connected to the inner rim. Both the inner rim and the spokes are rotatably connected to the shaft body. The rotor assembly is located within the installation space and is fixedly installed on the housing. The stator assembly is located within the installation space and is fixedly installed on the shaft body. In the present invention, the installation space for installing the stator assembly and the rotor assembly is formed by the inner rim and the spokes made of metal, and the inner rim and the outer rim are hermetically connected to form a rim. Therefore, the rim and the spokes of the wheel hub motor of the present invention form the housing of the motor, eliminating the need for a separate motor housing. Given a fixed tire size, the outer diameters of the rotor and stator can be increased, thereby improving the motor efficiency. The present invention adopts a highly integrated structure of the motor stator, rotor, and wheel hub, maximizing the outer diameters of the stator and rotor to achieve the design of a low-speed, high-torque wheel hub motor and reducing the weight of the wheel hub motor. In the present invention, the inner and outer rims are designed independently. When removing the tire, the outer rim can be removed first, followed by the tire. At the same time, it can ensure that the spokes and the inner rim form a closed motor housing, without damaging the internal sealing of the wheel hub motor, preventing damage to the rim and tire during tire removal, and making tire removal more convenient and efficient.

[0024] After reading the specific embodiments of the present invention in conjunction with the accompanying drawings, other features and advantages of the present invention will become clearer. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following will briefly introduce the drawings required for use in the embodiments. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0026] Figure 1 is an external view of the wheel hub motor in a specific embodiment of the present invention.

[0027] Figure 2 is an external view of the wheel hub motor in a specific embodiment of the present invention.

[0028] Figure 3 is an exploded view of the wheel hub motor in a specific embodiment of the present invention.

[0029] Figure 4 is a cross-sectional view of the wheel hub motor in a specific embodiment of the present invention.

[0030] Figure 5 is an exploded view of the housing in a specific embodiment of the present invention.

[0031] Figure 6It is a cross-sectional view of a housing according to a specific embodiment of the present invention.

[0032] Figure 7 Schematic diagram of a rotor assembly according to a specific embodiment of the present invention.

[0033] Figure 8 It is a schematic diagram of the assembly of the rotor assembly and the inner rim according to a specific embodiment of the present invention.

[0034] Figure 9 It is a schematic diagram of the assembly of the rotor assembly and the spokes according to a specific embodiment of the present invention.

[0035] Figure 10 It is a cross-sectional view of a stator assembly according to a specific embodiment of the present invention.

[0036] Figure 11 It is an exploded view of the stator assembly according to a specific embodiment of the present invention.

[0037] Figure 12 is an enlarged view of the stator assembly.

[0038] Figure 13 This is a comparison chart of open-mouth stator magnetic rings and closed-mouth stator magnetic rings.

[0039] Figure 14 It is a flat line diagram.

[0040] Figure 15 yes Figure 14 Schematic diagram of the cross-sectional shape of the welding strip.

[0041] Figure 16 This is another flat line diagram.

[0042] Figure 17 yes Figure 16 Schematic diagram of the cross-sectional shape of the welding strip.

[0043] Figure 18 It is a cross-sectional diagram of the stator and winding.

[0044] Figure 19 It is a schematic diagram of semi-cast and semi-welded flat strip winding.

[0045] Figure 20 It is a schematic diagram of the cooling system.

[0046] In the figure,

[0047] 1. Shell;

[0048] 11. Inner rim;

[0049] 111, circular part;

[0050] 112, annular part;

[0051] 1121, annular assembly part;

[0052] 1122. First V-shaped protrusion;

[0053] 1123. V-shaped groove;

[0054] 113. Sealing ring;

[0055] 114. Brake drum;

[0056] 12. Outer rim;

[0057] 13. Wheel spoke;

[0058] 131. V-shaped protrusion;

[0059] 14. Wheel spoke fixing bracket;

[0060] 15. Wheel decorative cover;

[0061] 2. Shaft body;

[0062] 21. Bearing;

[0063] 22. Central cavity;

[0064] 3. Rotor assembly;

[0065] 31. Rotor yoke;

[0066] 311. Second V-shaped protrusion;

[0067] 312. Magnet mounting groove;

[0068] 313. Permanent magnet;

[0069] 4. Stator assembly;

[0070] 41. Stator bracket;

[0071] 411. Pipeline;

[0072] 42. Stator;

[0073] 421. Open-mouth stator magnetic conduction ring;

[0074] 422. Closed-mouth stator magnetic conduction ring;

[0075] 43. Winding;

[0076] 431. Flat wire;

[0077] 4311. Parallel section;

[0078] 4312. Intermediate section;

[0079] 4321. First group of cast layer windings;

[0080] 4322. Second-layer casting winding;

[0081] 44. Capacitance ring;

[0082] 45. Stator fixing plate;

[0083] 5. Drum brake disc;

[0084] 61. Coolant pump;

[0085] 62. Radiator;

[0086] 63. Throttle element;

[0087] 64. Cooler;

[0088] 7. Resolver. Detailed implementation manner

[0089] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0090] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore, should not be construed as a limitation of the present invention.

[0091] In the description of the present invention, it should be noted that unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations. In the description of the implementation manner, specific features, structures, materials, or characteristics can be combined in a suitable manner in any one or more embodiments or examples.

[0092] The terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features.

[0093] In the description of the present invention, unless otherwise specified, "a plurality of" means two or more.

[0094] An integrated reluctance wheel hub motor includes an integrated wheel hub housing, a rotor assembly, a stator assembly, bearings and a shaft body, a drum brake disc, a cooling system, and a motor control system. When the wheel hub motor starts, current passes through the winding coils around the outside of the stator, generating excitation, which interacts with the permanent magnets fixed on the rotor, causing the rotor to rotate, thereby driving the rotation of the wheel hub motor housing. When braking, the brake disc receives a braking signal, driving the hydraulic cylinder inside the brake disc to expand the friction plate, generating friction between the motor housing and the friction plate, and stopping the rotation of the wheel. The wheel hub motor saves materials to the greatest extent, reduces the weight of the wheel hub, weakens the influence of magnetic reluctance, and at the same time improves the efficiency of the wheel hub motor.

[0095] As Figures 1 - 20 shown, an integrated reluctance wheel hub motor includes a housing 1, a shaft body 2, a rotor assembly 3, and a stator assembly 4. The housing 1 is rotatably connected to the shaft body 2. The rotor assembly 3 and the stator assembly 4 are located inside the housing 1. The rotor assembly 3 is connected to the housing 1, and the stator assembly 4 is connected to the shaft body 2.

[0096] As Figures 5 - 6 shown, the housing 1 will be described first as follows:

[0097] The housing 1 includes an inner rim 11, an outer rim 12, and a spoke 13 made of metal. The inner rim 11, the outer rim 12, and the spoke 13 made of metal have the function of shielding the magnetic field, preventing the magnetic field from leaking out, and the entire inside of the wheel hub motor is in a sealed environment.

[0098] The spoke 13 is fixedly installed with the inner rim 11 to form an installation space. The outer rim 12 is fixedly installed with the spoke 13. The inner rim 111 and the spoke 13 are fixedly installed by bolts. The outer rim 12 and the spoke 13 are fixedly installed by bolts. The outer rim 12 is hermetically connected to the inner rim 11, and the installation space inside the entire wheel hub motor is a sealed space.

[0099] Specifically, the inner rim 11 includes a circular part 111 and an annular part 112 connected to the circular part 111. The spoke 13 is circular. The spoke 13 is opposite to the circular part 111 and is fixedly installed with the annular part 112. The annular part 112 is hermetically connected to the outer rim 12.

[0100] A circular fitting portion 1121 is provided at the free end of the annular portion 112. The outer diameter of the circular fitting portion 1121 is smaller than that of the annular portion 112. The outer rim 12 is sleeved on the circular fitting portion 1121, and the wheel spoke 13 is connected to the circular fitting portion 1121. A sealing ring 113 is provided between the outer rim 12 and the inner rim 11. The sealing ring 113 is sleeved on the circular fitting portion 1121. The sealing ring 113 seals between the outer rim 12 and the inner rim 11, so that the installation space is in a sealed state.

[0101] A number of first V-shaped protrusions 1122 are provided on the inner side of the annular portion 112. V-shaped grooves 1123 are formed between the first V-shaped protrusions 1122. The V-shaped grooves 1123 are used to fix the rotor assembly. A number of second V-shaped protrusions 311 are provided on the rotor yoke 31 of the rotor assembly. The second V-shaped protrusions 311 are adapted to the V-shaped grooves 1123, and the second V-shaped protrusions 311 are inserted into the V-shaped grooves 1123.

[0102] The wheel spoke 13 is fixedly installed on the first V-shaped protrusion 1122. Specifically, the wheel spoke 13 is fixedly connected to the first V-shaped protrusion 1122 by bolts. Further, V-shaped protrusions 131 are also provided on the inner side of the wheel spoke 13. The V-shaped protrusions 131 face and are connected to the first V-shaped protrusions 1122. The V-shaped protrusions 131 and the first V-shaped protrusions 1122 are in close contact with the rotor assembly. After the wheel spoke 13 and the inner rim 11 are fixedly connected by bolts, the outer rotor assembly will not rotate relative to or move laterally between the inner rim 11 and the wheel spoke 13.

[0103] The extending directions of the first V-shaped protrusions 1122 and the V-shaped protrusions 131 are both parallel to the axis direction of the shaft body 2.

[0104] The valve of the tire is installed at the edge of the outer rim 12.

[0105] The inner rim 11 and the wheel spoke 13, and the outer rim 12 and the wheel spoke 13 are each fixed with a set of bolts. When the tire mounted on the rim needs to be replaced, the fixing bolts between the outer rim 12 and the wheel spoke 13 can be directly removed without damaging the sealing inside the hub motor. After replacing the tire, the outer rim 12 can be fixed with bolts again.

[0106] In some embodiments, in order to reinforce the wheel spoke 13, a wheel spoke fixing frame 14 can also be provided. The wheel spoke fixing frame 14 is also made of metal. The wheel spoke fixing frame 14 is fixed to or integrally formed with the wheel spoke 13. The outer rim 12 is fixedly installed on the wheel spoke fixing frame 14, and generally the outer rim 12 and the wheel spoke fixing frame 14 are fixed by bolts.

[0107] In some embodiments, the housing 1 of the hub motor includes a wheel decorative cover 15. The wheel decorative cover 15 is made of plastic. A card slot is provided on the wheel spoke 13 or the wheel spoke fixing frame 14 for fixing the wheel decorative cover 15.

[0108] Both the inner rim 11 and the spoke 13 are rotatably connected to the shaft body 2. Specifically, both the inner rim 11 and the spoke 13 are rotatably connected to the shaft body 2 through bearings 21. Both the inner rim 11 and the spoke 13 are connected to the outer ring of the bearing 21, and the inner ring of the bearing 21 is connected to the shaft body 2.

[0109] The rotor assembly 3 is located in the installation space, and the rotor assembly 3 is fixedly installed on the housing 1.

[0110] As Figure 7 shown, the rotor assembly includes an annular rotor yoke 31 and a plurality of second V-shaped protrusions 311 located on the outer surface of the rotor yoke 31. The extending direction of the second V-shaped protrusions 311 is parallel to the axial direction of the rotor yoke 31, that is, parallel to the axial direction of the shaft body 2.

[0111] A plurality of magnet mounting grooves 312 are provided in the second V-shaped protrusions 311, and the extending direction of the magnet mounting grooves 312 is parallel to the axial direction of the shaft body 2. Permanent magnets 313 are installed in the magnet mounting grooves 312. Among them, when two magnet mounting grooves 312 are provided in the second V-shaped protrusions 311, the two magnet mounting grooves 312 are in the second V-shaped protrusions 311 and close to the two sides of the second V-shaped protrusions 311. When three magnet mounting grooves 312 are provided in the second V-shaped protrusions 311, two magnet mounting grooves 312 are in the second V-shaped protrusions 311 and close to the two sides of the second V-shaped protrusions 311, and the other magnet mounting groove 312 is between the two magnet mounting grooves 312 and close to the rotor yoke 31.

[0112] The permanent magnet 313 is embedded in the rotor yoke 31. The advantage is that the permanent magnet 313 can be protected from armature reaction demagnetization and some mechanical stress effects, and a magnetic concentration effect can be obtained.

[0113] As Figure 8 shown, the second V-shaped protrusions 311 of the rotor yoke 31 are adapted to the V-shaped grooves 1123 of the inner rim 11, and the second V-shaped protrusions 311 are inserted into the V-shaped grooves 1123.

[0114] The structural design of the rotor yoke 31 and the housing 1 can not only reduce the overall weight of the in-wheel motor, but also reduce the thickness of the housing and stator assembly, and facilitate the assembly of the inner rim 11 and the spoke 13.

[0115] As Figure 9As shown in the figure, a V-shaped protrusion 131 is also provided inside the spoke 13. The V-shaped protrusion 131 is opposite to and connected with the first V-shaped protrusion 1122. A V-shaped groove is formed between the V-shaped protrusions. When the spoke 13 and the inner rim 11 are assembled, the V-shaped groove of the spoke 13 is connected to the V-shaped groove 1123 of the inner rim 11. Part of the second V-shaped protrusion 311 is inserted into the V-shaped groove 1123 of the inner rim 11, and part of the second V-shaped protrusion 311 is inserted into the V-shaped groove of the spoke 13. The inner rim 11 and the spoke 13 are in close contact with the rotor assembly 3, and the rotor assembly 3 is positioned and clamped with the housing 1 in the rotational direction. After the spoke 13 and the inner rim 11 are fixed by bolts, the rotor assembly 3 will not generate relative rotation or axial movement between the inner rim 11 and the spoke 13.

[0116] The stator assembly 4 is located in the installation space, and the stator assembly 4 is fixedly installed on the shaft body 2.

[0117] As Figures 10 - 13 shown, the stator assembly 4 includes a stator bracket 41, a stator 42, a winding 43, a capacitor ring 44, and a stator fixing disk 45. The stator 42 is fixed to the outer ring of the stator bracket 41, and the capacitor ring 44 is fixed to the inner ring of the stator bracket 41. Steps are provided on both the inner and outer rings of the stator bracket 41 for clamping the capacitor ring 44 and the stator 42. The stator fixing disk 45 is fixed to the stator bracket 41 to limit the capacitor ring 44 and the stator 42 on the stator bracket 41. The stator fixing disk 45 is fixed to the stator bracket 41 by bolts.

[0118] The stator fixing disk 45 and the steps limit the axial movement of the stator 42 and the capacitor ring 44. A clamping groove is also provided on the stator bracket 41 for restricting the stator 42, the capacitor ring 44 and the stator bracket 41 from relative rotation.

[0119] The stator bracket 41 is fixedly connected to the shaft body 2, for example, by a keyway connection method.

[0120] As Figure 12 、 13 shown, the stator 42 includes a plurality of open-ended stator magnetic conductive rings 421 and closed-ended stator magnetic conductive rings 422. The closed-ended stator magnetic conductive rings 422 are coaxially arranged with the open-ended stator magnetic conductive rings 421. The open-ended stator magnetic conductive rings 421 and the closed-ended stator magnetic conductive rings 422 are alternately arranged, bonded and compacted to form the stator 42. A closed-ended stator magnetic conductive ring 422 is arranged between two adjacent open-ended stator magnetic conductive rings 421, and an open-ended stator magnetic conductive ring 422 is arranged between two adjacent closed-ended stator magnetic conductive rings 421. The open ends and the closed ends are connected relatively to form a winding winding space.

[0121] Among them, both the open end and the closed end are rectangular, and the sizes of the open end and the closed end are adapted to each other. This design can effectively increase the slot area and improve the iron core utilization rate.

[0122] The magnetic permeability of the open-ended stator magnetic conduction ring 422 is greater than that of the closed-ended stator magnetic conduction ring 421. The height of the outer edge of the open-ended stator magnetic conduction ring 422 is lower than that of the outer edge of the closed-ended stator magnetic conduction ring 421. A tight air gap is formed between the closed-ended stator magnetic conduction ring 421 and the rotor assembly 3, which can reduce the magnetic resistance. The air gap between the open-ended stator magnetic conduction ring 421 and the rotor assembly 3 is greater than the air gap between the closed-ended stator magnetic conduction ring 421 and the rotor assembly 3. The gap between the open-ended stator magnetic conduction ring 421 and the rotor assembly 3 can reduce the reactive power, reduce the heat loss, weaken the high-order harmonic electromotive force and the high-order tooth harmonic electromotive force, eliminate the screeching sound caused by the magnetic resistance, achieve the effect of weak magnetic resistance, improve the active power, and greatly improve the motor efficiency.

[0123] The winding 43 is a flat wire winding or a flat strip winding.

[0124] The flat wire winding includes a number of U-shaped flat wires 431. The U-shaped flat wires 431 are inserted into the winding space, and the free ends of the U-shaped flat wires are welded according to the winding method.

[0125] Figures 14 - 18 It is a schematic diagram of a flat wire winding. The flat wire 431 is U-shaped, including two parallel segments 4311 and an intermediate segment 4312 connecting the parallel segments. The intermediate segment 4312 is of special-shaped design, and the thickness of the intermediate segment is less than the thickness of the parallel segment 4311. The free ends of the two parallel segments 4311 are welded by welding.

[0126] Figure 14 、 15 is an O-shaped solder tape, Figure 16 、 17 is a C-shaped solder tape.

[0127] The flat wire is inserted into the winding space - the stator magnetic slot in a U-shape, as Figure 18 shown. Each stator magnetic slot contains four flat wires, and the four flat wires are distributed in a "field" shape in the stator magnetic slot.

[0128] During production, first place the U-shaped flat wire in the stator magnetic slot, and then weld the winding on the other side according to the winding method to complete the welding of each wire.

[0129] According to the cross-sectional shape of the winding solder tape, the flat wire winding can be divided into an injection welding method (O-shaped solder tape) and a surface-mounted welding (C-shaped solder tape) method. For the injection welding of the flat wire winding, the solder tape is first wound around the two ends of the U-shaped flat wire, and the height of the solder tape protrudes from the flat wire, making it easier for the solder to be injected into the wound solder tape. The surface-mounted welding of the flat wire winding means that the solder tape is placed at the two ends of the U-shaped flat wire respectively, and then welded directly at the welding points with a welding machine.

[0130] The use of flat wire windings can compress the air gap in the stator magnetic slots, resulting in a higher slot fill factor. Moreover, the contact between the winding and the stator magnetic slots is better, improving the heat dissipation performance.

[0131] Flat strip windings are convenient for automated production, suitable for large-scale production, and more in line with the future development trend.

[0132] The flat strip winding can be an integrated winding sintered using 3D printing technology. During the manufacturing process, the placement of the stator magnetic conduction ring and the sintering of the winding are carried out simultaneously to form an integrated stator winding.

[0133] The flat strip winding can also be a semi-cast and semi-welded flat strip winding.

[0134] As Figure 19 shown, the semi-cast and semi-welded flat strip winding includes two groups of cast layer windings. The first group of cast layer windings 4321 includes several U-shaped flat strips formed by casting. The U-shaped flat strips include a middle section and parallel sections. Several U-shaped flat strips are interspersed in the winding space. The second group of cast layer windings 4322 includes several U-shaped flat strip connection ends formed by casting. The several U-shaped flat strip connection ends of the second group of cast layer windings 4322 and the free ends (the free ends of the parallel sections) of the several U-shaped flat strips of the first group of cast layer windings 4321 are welded together according to the winding method.

[0135] In some embodiments, the middle sections of the U-shaped flat strips of the first group of cast layer windings and the U-shaped flat strip connection ends of the second group of cast layer windings are both cast on high-temperature plates. Then, the first group of cast layer windings and the second group of cast layer windings respectively form a whole. When assembling with the stator, only the two wholes need to be assembled with the stator. The high-temperature plates are located on both sides of the stator. In this way, the assembly operation between the winding and the stator is greatly reduced.

[0136] The above windings need to be processed to increase insulation and then assembled with the stator.

[0137] Two bearings 21 are provided on the shaft body 2. The shaft body 2 is rotationally connected to the housing 1 through the two bearings 21. The shaft body 2 is used to support the stator bracket 41. The shaft body 2 is also used to connect and fix the brake bottom plate of the drum brake disc.

[0138] A brake drum 114 is formed on the circular part of the inner rim 11. The drum brake disc 5 has a conventional brake disc structure, including a brake backing plate, a brake wheel cylinder, friction linings, return springs, a brake drum, an electronic parking brake, and brake shoes. During braking, the brake wheel cylinder of the brake disc bulges, driving the friction linings on both sides of the brake shoes to move outward. After the linings contact the rotating brake drum, the hub is braked by relying on the frictional force. When the vehicle is driving without using the brake, the return spring returns the brake shoes, and the brake shoes are separated from the brake drum, without friction, which can save electric energy and avoid the power loss of the motor. The electronic parking brake includes a built-in DC motor, a cam mechanism, and a linkage device. When the hub needs to be braked for a long time or when the brake wheel cylinder fails, the DC motor inside the electronic parking brake receives a parking signal, the DC motor starts, drives the built-in cam to rotate through gears, makes the friction linings move outward, and the linkage mechanism fixed on both sides of the brake shoes expands the friction linings outward at the same time. After the friction linings contact the rotating brake drum, the hub is braked by relying on the frictional force. The integrated hub motor using a drum brake disc can reduce the weight brought by the braking system, save the external space of the hub, be inexpensive, have high durability, and the electronic parking brake can provide safe and reliable control, making the braking effect more stable.

[0139] The hub motor includes a cooling system, and a refrigerant cooling method can be adopted. The refrigerant can be water, oil, or other cooling media.

[0140] As Figure 20 shown, the stator bracket 41 includes a cooler 64, and the pipeline 411 connected to the cooler 64 is led out through the central cavity 22 of the shaft body 2. The pipeline 411 is used to provide a refrigerant transmission channel. The cooler 64 is used to provide cooling capacity for the stator assembly. Generally, the cooler 64 is located between the stator bracket 41 and the stator assembly. Of course, the cooler 64 can also be located inside the stator bracket 41.

[0141] In order to more precisely adjust the motor temperature, the motor includes a temperature sensor for detecting the winding temperature, and controls the flow rate and / or temperature of the refrigerant in the cooling pipeline according to the temperature detected by the temperature sensor.

[0142] The cooling system includes a coolant pump 61, a radiator 62, a throttle element 63, and a cooler 64 connected in sequence by pipelines. After the coolant is cooled by the radiator 62 outside the hub motor, the power is generated by the coolant pump 61, enters the cooling pipeline in the central cavity 22 of the shaft body 2 and the cooler 64, takes away the heat generated by the windings, and enables the motor to cool down quickly.

[0143] The wires connected to the temperature sensor, the windings, and the capacitor ring are all led out from the central cavity 22 of the shaft body 2.

[0144] The motor includes a rotary transformer 7, which is located in the central cavity of the shaft body 2. The rotating shaft of the rotary transformer 7 is fixedly connected to the housing 1. The rotary transformer 7 is used to detect the corresponding angles of the rotor assembly and the stator assembly.

[0145] The motor includes a tire balance sensor. The sensing portion of the tire balance sensor is mounted on the shaft 2 , and the magnetic portion of the tire balance sensor is mounted on the housing 1 .

[0146] The motor control system includes a power supply, sensors, a controller, and a driver. The power supply consists of an AC power supply converted from a DC power supply via an inverter, as well as a control power supply. The sensors include a resolver and a temperature sensor. The resolver's shaft is fixedly connected to the housing and detects the relative angle between the rotor and stator assemblies. The temperature sensor, mounted on the edge of the stator bracket, monitors temperature changes in the winding coils. When the coil temperature exceeds a set threshold, the coolant pump's operating efficiency is increased, the radiator's fan power is increased, and the throttle element's opening is increased to increase the liquid flow rate in the cooling channel, rapidly reducing the coil temperature. When the coil temperature falls below the set threshold, the coolant pump's operating frequency is reduced, the radiator's fan power is reduced, and the throttle element's opening is decreased to bring the coil temperature within the specified range. This prevents the coil from cooling too low and conserves energy. The controller receives sensor feedback and controls the motor according to a pre-set control algorithm. The driver converts the controller's output signals into acceptable voltage and current signals for the motor.

[0147] The power transmission process of the hub motor is as follows: when starting, the inverter outside the motor converts direct current into alternating current, and the capacitor ring provides additional starting torque, so that the winding on the stator generates an excitation magnetic field. The permanent magnet on the rotor rotates under the action of the magnetic field, driving the rim, spokes and tire fixed to the outer periphery of the rotor to rotate; when going downhill, the alternating current stops supplying power, there is no current excitation in the winding, and the rotor continues to rotate due to inertia. The rotor generates a magnetic field due to rotation, and the winding generates electrical energy through the magnetic field and is transmitted to the energy storage device outside the hub motor; when braking, the hydraulic cylinder of the drum brake disc bulges, driving the friction plate to contact the brake drum of the inner rim, so that the wheel hub stops rotating due to friction.

[0148] The assembly sequence of the integrated wheel hub motor is as follows: 1. Wind the coil winding of the stator and perform insulation treatment, and install suitable permanent magnets on the rotor; 2. Install the bearing and the outer rotor into the inner rim; 3. Install the capacitor ring and the winding on the stator bracket, use the stator fixing plate to press the side of the winding and the capacitor ring tightly, and lock the stator fixing plate and the stator bracket with bolts; 4. Place the completed stator bracket on the shaft body, add gaskets, and place it inside the inner ring of the inner rim, with the gaskets in contact with the bearings; 5. Install the resolver and the temperature sensor respectively, and route all the cables of the sensor, the winding, and the capacitor ring through the central cavity of the shaft body; 6. Install the gaskets inside the inner side of the wheel spoke, then place the double bearings on the gaskets, and fix the inner end cover of the bearing to the bearing with bolts; 7. Install the wheel spoke on the side of the inner rim and press it tightly and align it; 8. Place the wheel decoration cover behind the wheel spoke, use the wheel spoke fixing bracket to hold the wheel decoration cover, and use bolts to fix the wheel spoke fixing cover, the wheel spoke, and the inner rim; 9. Install the sealing ring, install the tire, and fix the outer rim with bolts; 10. Install the drum brake disc on the outside of the axle steel and fix it with bolts.

[0149] The integrated wheel hub motor with the above structure adopts a structure with a high integration of the motor stator and rotor and the wheel hub, maximally increasing the outer diameter of the stator and rotor to achieve the design of low speed and high torque of the wheel hub motor and reducing the weight of the wheel hub motor; also, due to the independent design of the inner and outer rims, the tire will not cause damage to the rim and the tire during disassembly, making the tire disassembly more convenient and fast. Since the wheel hub motor uses an interpenetrating design of the open magnetic conduction ring stator slot and the closed magnetic conduction ring stator slot, the effect of weak magnetic resistance is achieved, and the motor power is improved.

[0150] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, for those of ordinary skill in the art, it is still possible to modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions required to be protected by the present invention.

Claims

1. An integrated weak magnetic resistance hub motor, characterized in that, The hub motor includes: A shaft body; A housing, which includes an inner rim, an outer rim, and spokes made of a metal material. The spokes are fixedly installed with the inner rim to form an installation space. The outer rim is fixedly installed with the spokes, and the outer rim is hermetically connected to the inner rim. Both the inner rim and the spokes are rotatably connected to the shaft body; A rotor assembly, which is located within the installation space and is fixedly installed on the housing; A stator assembly, which is located within the installation space and is fixedly installed on the shaft body; The inner rim includes a circular portion and an annular portion connected to the circular portion. The spokes are opposite to the circular portion and are fixedly installed with the annular portion. The annular portion is hermetically connected to the outer rim. The annular portion is provided with an annular assembly portion, the outer diameter of the annular assembly portion is smaller than the outer diameter of the annular portion, the outer rim is sleeved on the annular assembly portion, and the spokes are connected to the annular assembly portion. A plurality of first V-shaped protrusions are provided on the inner side of the annular portion, and V-shaped grooves are formed between the first V-shaped protrusions. The rotor assembly includes a rotor yoke, and a plurality of second V-shaped protrusions are provided on the rotor yoke. The second V-shaped protrusions are adapted to the V-shaped grooves, and a plurality of magnet mounting grooves are provided in the second V-shaped protrusions, and permanent magnets are installed in the magnet mounting grooves. The spokes are fixedly installed on the first V-shaped protrusions.

2. The integrated weak magnetic resistance hub motor according to claim 1, wherein The stator assembly includes a stator bracket, a stator, a winding, a capacitor ring, and a stator fixing disk. The stator is fixed on the outer ring of the stator bracket, the capacitor ring is fixed on the inner ring of the stator bracket, and the stator fixing disk is fixed on the stator bracket to limit the capacitor ring and the stator on the stator bracket.

3. The integrated weak magnetic resistance hub motor according to claim 2, wherein The stator includes a plurality of open-ended stator magnetic conduction rings and closed-ended stator magnetic conduction rings, which are alternately arranged. The open ends and the closed ends are connected to form a winding winding space. The magnetic conduction performance of the open-ended stator magnetic conduction ring is greater than that of the closed-ended stator magnetic conduction ring. The height of the outer edge of the open-ended stator magnetic conduction ring is lower than the height of the outer edge of the closed-ended stator magnetic conduction ring.

4. The integrated weak magnetic resistance hub motor according to claim 3, characterized in that, The winding is a flat wire winding or a flat strip winding; The flat wire winding includes a plurality of U-shaped flat wires, which are inserted into the winding space, and the free ends of the U-shaped flat wires are welded; The flat strip winding is an integrated winding sintered by 3D printing technology, or the flat strip winding is a semi-cast and semi-welded flat strip winding. The semi-cast and semi-welded flat strip winding includes two groups of cast layer windings. The first group of cast layer windings includes a plurality of U-shaped flat wires formed by casting, and the plurality of U-shaped flat wires are inserted into the winding space. The second group of cast layer windings includes the connecting ends of a plurality of U-shaped flat wires formed by casting. The connecting ends of the U-shaped flat wires of the second group of cast layer windings are welded to the free ends of the U-shaped flat wires of the first group of cast layer windings according to the winding method.

5. The integrated weak magnetic resistance hub motor according to claim 1, wherein A brake drum is formed on the circular portion of the inner rim.

6. The integrated weak magnetic resistance hub motor according to claim 2, characterized in that The stator bracket includes a cooler, and a pipeline connected to the cooler is led out through a central cavity of the shaft body; the motor includes a temperature sensor for detecting the temperature of the winding, and controls the flow rate and / or temperature of the refrigerant in the cooling pipeline according to the temperature detected by the temperature sensor; wires connected to the temperature sensor, the winding, and the capacitor ring are all led out through the central cavity of the shaft body.

7. The integrated weak magnetic resistance hub motor according to claim 1, wherein, The motor includes a resolver, the resolver is located in the central cavity of the shaft body, a rotating shaft of the resolver is fixedly connected to the housing, and the resolver is used for detecting the corresponding angle between the rotor assembly and the stator assembly; and / or, the motor includes a tire balance sensor, an induction part of the tire balance sensor is installed on the shaft body, and a magnet part of the tire balance sensor is installed on the housing.

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