Axial motor, axial motor rotor and preparation method of rotor

Abstract

The invention provides an axial motor, an axial motor rotor and a preparation method of the rotor. The axial motor comprises a rotor, a stator and a rotating shaft, the rotor is fixedly connected with the rotating shaft, the rotating shaft is sleeved with the stator, and the stator and the rotor are coaxially installed and arranged in the axial direction; the rotor comprises a plurality of permanent magnets and a rotor disc, the rotor disc comprises a first disc body and a second disc body which are coaxial and fixedly connected, the first disc body is a carbon fiber disc, and the permanent magnets are uniformly distributed in the circumferential direction of the first disc body or the second disc body. According to the invention, the carbon fiber is used on the motor rotor part, so that the mass and rotational inertia of the rotor are greatly reduced, and the response speed of the axial motor can be improved.

Description

Technical Field

[0001] The present application relates to the field of motor technology, and in particular to an axial motor, an axial motor rotor, and a method for preparing the rotor. Background Art

[0002] Axial flux permanent magnet synchronous motors can output large torque in the flattened space of the wheel hub due to their unique structural characteristics. Rare earth permanent magnets can also effectively improve the output characteristics of the motor, and the axial flux permanent magnet synchronous motor can improve the output capacity of the motor by superimposing the number of disks. Compared with the traditional radial motor structure, the axial flux motor has unique structural characteristics. Its air gap magnetic field distribution is planarized, and the stator and rotor are arranged in sequence along the axial direction. Axial flux motors can form different topological structures according to the diversity of the number and arrangement of stators and rotors, such as multi-disc structure, dual-stator single rotor structure, dual-rotor single stator structure, and single stator single rotor structure.

[0003] The output torque of the axial flux motor has a strong correlation with the air gap between the rotor and the stator. The smaller the air gap, the greater the working output torque, but at the same time, the magnetic force between the stator and the rotor will also be greater, which places greater requirements on the fixation reliability and structural strength of the stator and rotor. Summary of the invention

[0004] In a first aspect, an embodiment of the present application provides an axial motor, the axial motor comprising a rotor, a stator and a rotating shaft, wherein the rotor is fixedly connected to the rotating shaft, the stator is sleeved on the rotating shaft, and the stator and the rotor are coaxially mounted and arranged in an axial direction;

[0005] Wherein, the rotor includes permanent magnets and a rotor disk, the rotor disk includes a first disk body and a second disk body that are coaxial and fixedly connected, the first disk body is a carbon fiber disk, the number of the permanent magnets is multiple, and they are evenly distributed along the circumference of the first disk body or the second disk body.

[0006] A second aspect of an embodiment of the present application provides an axial motor, the axial motor comprising a rotor, a first stator, a second stator and a rotating shaft, the rotor being fixedly connected to the rotating shaft, the first stator and the second stator being respectively sleeved on the rotating shaft, the first stator, the rotor and the second stator being coaxially mounted and arranged in sequence along the axial direction, and the first stator and the second stator being arranged on both sides of the rotor;

[0007] The rotor comprises permanent magnets and a rotor disk, a radial surface of the rotor disk is provided with a plurality of permanent magnets evenly distributed along the circumferential direction, and the rotor disk is a carbon fiber disk.

[0008] A third aspect of an embodiment of the present application provides an axial motor rotor, which includes a rotating shaft, a rotor disk and a permanent magnet; the rotor disk is arranged circumferentially along the side of the rotating shaft, the rotating shaft and the rotor disk are both made of carbon fiber material, and the two are an integrated structure, and the permanent magnet is fixedly connected to the rotor disk.

[0009] A fourth aspect of the embodiments of the present application provides an axial motor, comprising a stator and a rotor as described in any one of the above embodiments, wherein the permanent magnets of the stator and the rotor are aligned and magnetically matched to drive the rotor to rotate.

[0010] A fifth aspect of an embodiment of the present application provides a method for preparing an axial motor rotor, the method comprising: fixing a permanent magnet by a mold; wrapping the permanent magnet by carbon cloth laying or winding to form a rotating shaft and a rotor disk of an integrated structure.

[0011] The beneficial effect of the present application is: different from the prior art, the present application proposes an axial motor with a carbon fiber stiffness-reinforced rotor. By using carbon fiber on the motor rotor parts, the mass and moment of inertia of the rotor are greatly reduced, thereby improving the response speed of the axial motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0013] Figure 1 It is an overall schematic diagram of an embodiment of the axial motor of the present application;

[0014] Figure 2 yes Figure 1 A schematic cross-sectional view of the structure of the axial motor at AA in the embodiment;

[0015] Figure 3 yes Figure 1 Schematic diagram of the exploded structure of the axial motor in the embodiment;

[0016] Figure 4 yes Figure 1 Schematic diagram of the structure of the middle and lower cover;

[0017] Figure 5 yes Figure 3 A schematic diagram of the structure of the second disk;

[0018] Figure 6 is an overall schematic diagram of another embodiment of the axial motor of the present application;

[0019] Figure 7 yes Figure 6 A schematic cross-sectional view of the structure of the axial motor at position BB in the embodiment;

[0020] Figure 8 yes Figure 6 Schematic diagram of the exploded structure of the axial motor in the embodiment;

[0021] Fig. 9 yes Figure 8 Schematic diagram of the structure of the middle rotor;

[0022] Fig.10 yes Fig. 9 Schematic diagram of the cross-section of the structure of the middle rotor at CC;

[0023] Fig.11 It is an overall schematic diagram of an embodiment of the axial motor rotor of the present application;

[0024] Fig.12 is a front view of an embodiment of an axial motor rotor of the present application;

[0025] Fig.13 is an overall schematic diagram of another embodiment of the axial motor rotor of the present application;

[0026] Fig.14 yes Fig.13 A schematic cross-sectional view of the structure of the axial motor rotor at DD in the embodiment;

[0027] Fig.15 is a structural schematic diagram of yet another embodiment of the axial motor of the present application;

[0028] Fig.16 It is a schematic flow chart of an embodiment of a method for preparing an axial motor rotor of the present application. DETAILED DESCRIPTION

[0029] The present application is further described in detail below in conjunction with the accompanying drawings and examples. It is particularly noted that the following examples are only used to illustrate the present application, but are not intended to limit the scope of the present application. Similarly, the following examples are only some embodiments of the present application rather than all embodiments, and all other embodiments obtained by those of ordinary skill in the art without making creative work are within the scope of protection of the present application.

[0030] The terms "first", "second", "third" in this application are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Thus, the features defined as "first", "second", "third" can expressly or implicitly include at least one of the features. In the description of this application, the meaning of "multiple" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined. In the embodiments of this application, all directional indications (such as up, down, left, right, front, back...) are only used to explain the relative position relationship, movement, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication also changes accordingly. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device comprising a series of steps or units is not limited to the steps or units listed, but optionally also includes steps or units that are not listed, or optionally also includes other steps or units inherent to these processes, methods, products or devices.

[0031] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0032] Axial flux permanent magnet synchronous motors can output large torque in the flattened space of the hub due to their unique structural characteristics, and the axial flux permanent magnet synchronous motor can increase the output capacity of the motor by superimposing the number of discs. Compared with the traditional radial motor structure, the axial flux motor has unique structural characteristics. Its air gap magnetic field distribution is planarized, and the stator and rotor are arranged in sequence along the axial direction. Axial flux motors can form different topological structures according to the diversity of the number and arrangement of stators and rotors, such as multi-disc structure, dual-stator single rotor structure, dual-rotor single stator structure, and single stator single rotor structure.

[0033] The output torque of the axial flux motor has a strong correlation with the air gap between the rotor and the stator. The smaller the air gap, the greater the working output torque, but at the same time, the magnetic force between the stator and the rotor will also be greater, which places greater requirements on the fixation reliability and structural strength of the stator and rotor.

[0034] In conventional technical solutions, most axial motor rotors are made of metal, which are machined into grooves and bonded to hard magnets. However, due to the small air gap and large axial force, the thickness of the metal parts cannot be too thin to avoid local deformation under force and interference with the stator. Thick metal parts will increase in weight, and the overall moment of inertia of the rotor will increase, thus affecting the response rate of the motor.

[0035] In view of this, the present application provides an axial motor embodiment as described below, which can reduce the weight and moment of inertia of the rotor without losing the overall stiffness by using high modulus carbon fiber materials on the motor rotor parts.

[0036] See also Figure 1 , Figure 2 and Figure 3 , Figure 1 is a schematic diagram of the overall structure of an embodiment of the axial motor of the present application, Figure 2 yes Figure 1 A schematic cross-sectional view of the structure of the axial motor at AA in the embodiment, Figure 3 yes Figure 1 Schematic diagram of the exploded structure of the axial motor in the embodiment.

[0037] It should be noted that the axial motor 10 in this embodiment includes but is not limited to a frame cover 110, a stator 120, a rotor 130 and a rotating shaft 140. The rotating shaft 140 passes through the stator 120 and the rotor 130. The rotor 130 is fixedly connected to the rotating shaft 140. The stator is sleeved on the rotating shaft 140. The stator 120 and the rotor 130 are coaxially installed and arranged in the axial direction. In this embodiment, the axial motor 10 is an oblate shape as a whole. The frame cover 110 includes a lower cover 111, a middle frame 112 and an upper cover 113. The lower cover 111, the middle frame 112 and the upper cover 113 are fixedly connected by bolts on the outside and form a containing space for containing the stator 120 and the rotor 130. The middle frame 112 is sleeved on the outside of the stator 120. The upper end of the upper cover 113 has a threaded hole for fixing, and a wrench avoidance position is left on the side.

[0038] The rotor 13 includes a permanent magnet 131 and a rotor disk, and the rotor disk includes a first disk body 133 and a second disk body 132 that are coaxial and fixedly connected, wherein the first disk body 133 can be a carbon fiber disk, and the number of permanent magnets 131 can be multiple and uniformly distributed around the radial surface of the first disk body 133 or the second disk body 132 (i.e., circumferentially).

[0039] Optionally, the first plate body 133 and the second plate body 132 may be fixedly connected by gluing.

[0040] Optionally, the material of the rotating shaft 140 may be aluminum alloy or a lighter metal material, so as to reduce the moment of inertia while ensuring the rigidity.

[0041] Optionally, the rotating shaft 140 is made of carbon fiber, and the rotating shaft 140 and the first disk body 133 can be integrally formed.

[0042] Optionally, see Figure 4 , Figure 4 yes Figure 1 Schematic diagram of the structure of the middle and lower cover. An annular boss 114 is provided at the center of the lower cover 111, and the stator 120 is sleeved on the annular boss 114 and fixedly connected. The annular boss 114 is used to realize the positioning of the stator 120. For example, the stator 120 is bonded to the annular boss 114 by glue. The middle frame 112 and the stator 120 and the stator 120 and the lower cover 111 are filled with potting glue for better heat transfer.

[0043] Optionally, a gap is left between the upper cover and the rotor 130 described in 113, and carbon fiber discs of different thicknesses can be arranged to cope with different stress conditions. Specifically, the rotor disc may include a plurality of the first disc bodies of different thicknesses, and one of the plurality of the first disc bodies may be selectively arranged in the gap.

[0044] Optionally, the stator 120 includes a stator core 121, an insulating paper 122 and a coil 123. The stator core 121 is wrapped with the insulating paper 122 and then the coil 123 is wound. The detailed structural features of the stator 120 are within the scope of understanding of those skilled in the art and will not be described in detail here.

[0045] Optionally, the axial motor 100 further includes an angular contact bearing 150 and a deep groove ball bearing 160, and the single angular contact bearing 150 is transitionally matched with the bearing seat on the lower cover 111. The rotating shaft 140 is provided with a bearing seat for installing the deep groove ball bearing 160 to enhance the support stiffness.

[0046] Optionally, see Figure 5 , Figure 5 yes Figure 3 In this embodiment, a fixing groove for installing a permanent magnet is provided on the second disk 132, and the shape of the fixing groove matches the shape of the permanent magnet 31. The permanent magnet 131 is embedded in the fixing groove, and the permanent magnet 131 is fixedly connected to the second disk 132 by bonding.

[0047] Optionally, in this embodiment, the second disk body 132 is made of metal or alloy for magnetic flux. For example, the second disk body 132 is made of low-carbon steel. Since carbon steel has a high moment of inertia, this embodiment only provides a second disk body 132 with a very thin thickness, which is fixedly connected with the first disk body 133 to jointly bear the axial force. The first disk body 133 made of carbon fiber can enhance the rigidity.

[0048] See also Figure 6 , Figure 7 and Figure 8 , Figure 6 is an overall schematic diagram of another embodiment of the axial motor of the present application, Figure 7 yes Figure 6 A schematic cross-sectional view of the structure of the axial motor at position BB in the embodiment, Figure 8 yes Figure 6 Schematic diagram of the exploded structure of the axial motor in the embodiment. Optionally, the axial motor 20 in this embodiment includes but is not limited to a housing 210, a first stator 221, a second stator 222, a rotor 230 and a rotating shaft 240, the rotor 230 is fixedly connected to the rotating shaft 240, the first stator 221 and the second stator 222 are respectively rotatably connected to the rotating shaft 240, the first stator 221, the rotor 230 and the second stator 222 are coaxially installed and arranged in sequence along the axial direction, and the first stator 221 and the second stator 222 are arranged on both sides of the rotor 230.

[0049] Optionally, the shell 210 includes a first shell 211 and a second shell 212, the first stator 221 and the second stator 222 are fixedly connected to the first shell 211 and the second shell 212 respectively, the first shell 211 and the second shell 212 cooperate to form a accommodating space, and the rotor 230, the first stator 221 and the second stator 222 are arranged in the accommodating space.

[0050] Optionally, the rotor 230 includes permanent magnets 231 and a rotor disk 232 . A plurality of permanent magnets 231 are arranged on a radial surface of the rotor disk 232 and are evenly distributed around the circumference (ie, in the circumferential direction) of the radial surface. The rotor disk 232 is a carbon fiber disk.

[0051] Optionally, the axial motor 20 further includes a bearing 250 , and the bearing 250 includes a first bearing 251 and a second bearing 252 . The first stator 221 and the second stator 222 are rotatably connected to the rotating shaft 240 via the first bearing 251 and the second bearing 252 , respectively.

[0052] Optionally, the rotating shaft 240 includes a first rotating shaft 241 and a second rotating shaft 242 , and the first rotating shaft 241 and the second rotating shaft 242 are flange shafts fixedly connected to the center of the carbon rotor disk 232 for connecting to an external component to be driven to output torque.

[0053] See also Fig. 9 and Fig.10 , Fig. 9 yes Figure 8 Schematic diagram of the structure of the middle rotor. Fig.10 yes Fig. 9The schematic cross-sectional view of the structure of the middle rotor at CC, optionally, a mounting groove 233 for mounting a permanent magnet is provided on the rotor disk 232, the shape of the mounting groove 233 is adapted to the shape of the permanent magnet 231, and the permanent magnet 231 is embedded in the mounting groove 233 of the rotor disk 232. Optionally, the mounting groove 233 of the rotor disk 232 is a through groove, and the permanent magnet 231 is sealed up and down by epoxy resin glue after being embedded in the mounting groove 233 of the rotor disk 232, to ensure that the permanent magnet will not be pulled off by the axial magnetic force; this solution is less likely to fail in the case of a double-stator single-rotor motor type, because the axial pulling forces applied to the magnets cancel each other out.

[0054] See also Fig.11 and Fig.12 , Fig.11 is an overall schematic diagram of an embodiment of the axial motor rotor of the present application, Fig.12 It is a front view of an embodiment of the axial motor rotor of the present application. Optionally, the rotor 330 includes a rotating shaft 331, a rotor disk 332 and a permanent magnet 333; the rotor disk 332 is arranged along the side circumference of the rotating shaft 331, the rotating shaft 331 and the rotor disk 332 are both made of carbon fiber, and the two are an integrated structure, and the permanent magnet 333 is fixedly connected to the rotor disk 332. The carbon fiber rotor of this solution has a high modulus and low weight, and can be applied in various forms of axial motors.

[0055] Optionally, the permanent magnet 333 is embedded in the rotor disk 332. Specifically, the permanent magnet can be exposed or completely embedded in the rotor.

[0056] See also Fig.13 and Fig.14 , Fig.13 is an overall schematic diagram of another embodiment of the axial motor rotor of the present application, Fig.14 yes Fig.13 The schematic cross-sectional view of the structure of the axial motor rotor at DD in the embodiment. Optionally, the rotor 330 in this embodiment may include a rotating shaft 331, a rotor disk 332, a permanent magnet 333 and a metal embedded part 334; the rotor disk 332 is arranged circumferentially along the side of the rotating shaft 331, and the rotating shaft 331 and the rotor disk 332 are both made of carbon fiber, and the two are an integrated structure, and the permanent magnet 333 is fixedly connected to the rotor disk 332. Optionally, a metal embedded part 334 is reserved at one end of the rotating shaft, and the metal embedded part 334 may be provided with an internal thread. Optionally, a joint position may be reserved at one end of the rotating shaft, and the joint position is used to connect to an external component to be driven to output torque. The carbon fiber rotor of this scheme has a high modulus and low weight, and can be applied to the structures of various axial motors.

[0057] See also Fig.15 , Fig.15It is a structural schematic diagram of another embodiment of the axial motor of the present application. Optionally, the axial motor 40 in this embodiment may include a stator 420 and a rotor, the rotor includes a rotating shaft 431, a rotor disk 432, and a permanent magnet 433, the rotor disk 432 is arranged along the side circumference of the rotating shaft 431, the rotating shaft 431 and the rotor disk 432 are both made of carbon fiber, and the two are an integral structure, and the permanent magnet 433 is fixedly connected to the rotor disk 432. The stator 420 and the permanent magnet 433 of the rotor are aligned magnetically to drive the rotor to rotate.

[0058] See also Fig.16 , Fig.16 The figure is a flow chart of an embodiment of a method for preparing an axial motor rotor of the present application. The method includes but is not limited to the following steps.

[0059] Step S10, fixing the permanent magnet by a mold.

[0060] Step S20, wrapping the permanent magnet by carbon cloth laying or winding method to form a rotating shaft and a rotor disk with an integrated structure.

[0061] In this step, the carbon cloth laying or winding method can form the shaft end part in one go, leaving only the metal embedded bolt part or joint position at the end.

[0062] The axial motor rotor obtained by the preparation method in this embodiment can improve the rotor stiffness and reduce the mass by using carbon fiber materials, thereby improving the response speed of the axial motor.

[0063] The above descriptions are only some embodiments of the present invention, and are not intended to limit the protection scope of the present invention. Any equivalent device or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. An axial motor, characterized in that: It comprises a rotor, a stator and a rotating shaft, wherein the rotor is fixedly connected to the rotating shaft, the stator is sleeved on the rotating shaft, and the stator and the rotor are coaxially installed and arranged in an axial direction; Wherein, the rotor includes permanent magnets and a rotor disk, the rotor disk includes a first disk body and a second disk body that are coaxial and fixedly connected, the first disk body is a carbon fiber disk, the number of the permanent magnets is multiple, and they are evenly distributed along the circumference of the first disk body or the second disk body.

2. The axial motor according to claim 1, characterized in that: The second disk body is provided with a fixing groove for mounting a permanent magnet, the shape of the fixing groove is matched with the shape of the permanent magnet, and the permanent magnet is embedded in the fixing groove.

3. The axial motor according to claim 1, characterized in that: The second disk body is made of metal or alloy.

4. The axial motor according to claim 1, characterized in that: The rotating shaft is made of carbon fiber, and the rotating shaft is integrally formed with the first disk body.

5. The axial motor according to claim 2, characterized in that: Also includes bearings and frame covers; The bearing is installed between the rotating shaft and the stator; The frame cover includes an upper cover, a middle frame and a lower cover, wherein the upper cover, the middle frame and the lower cover are fixedly connected by bolts to form a receiving space for receiving the rotor and the stator, and the middle frame is sleeved on the outside of the stator.

6. The axial motor according to claim 5, characterized in that: An annular boss is arranged at the center of the lower cover, the stator is sleeved on the annular boss and fixedly connected, and the annular boss is used to realize the positioning of the stator.

7. The axial motor according to claim 6, characterized in that: A gap is left between the upper cover and the rotor, and the rotor disk includes a plurality of first disk bodies with different thicknesses, and one of the plurality of first disk bodies can be selectively arranged in the gap.

8. An axial motor, characterized in that: The invention comprises a rotor, a first stator, a second stator and a rotating shaft, wherein the rotor is fixedly connected to the rotating shaft, the first stator and the second stator are respectively sleeved on the rotating shaft, the first stator, the rotor and the second stator are coaxially installed and arranged in sequence along the axial direction, and the first stator and the second stator are arranged on both sides of the rotor; The rotor comprises permanent magnets and a rotor disk, a radial surface of the rotor disk is provided with a plurality of permanent magnets evenly distributed along the circumferential direction, and the rotor disk is a carbon fiber disk.

9. The axial motor according to claim 8, characterized in that: The carbon fiber disc is provided with an installation groove for installing a permanent magnet, the shape of the installation groove is adapted to the shape of the permanent magnet, and the permanent magnet is embedded in the installation groove.

10. The axial motor according to claim 9, characterized in that The mounting groove is a through groove.

11. The axial motor according to claim 8, characterized in that The rotating shaft is made of carbon fiber, and the rotating shaft and the rotor disk are integrally formed.

12. The axial motor according to claim 8, characterized in that It also includes a bearing, a first shell and a second shell. The first stator and the second stator are fixedly connected to the first shell and the second shell respectively, and are rotatably connected to the rotating shaft through a bearing. The first shell and the second shell cooperate to form a accommodating space. The rotor, the first stator and the second stator are arranged in the accommodating space.

13. A rotor for an axial motor, characterized in that: It includes a rotating shaft, a rotor disk and a permanent magnet; the rotor disk is arranged circumferentially along the side of the rotating shaft, the rotating shaft and the rotor disk are both made of carbon fiber material, and the two are an integrated structure, and the permanent magnet is fixedly connected to the rotor disk.

14. The rotor according to claim 13, characterized in that The permanent magnet is embedded in the rotor disk.

15. An axial motor, characterized in that: It comprises a stator and the rotor as claimed in claim 13 or 14, wherein the permanent magnets of the stator and the rotor are aligned and magnetically matched to drive the rotor to rotate.

16. A method for preparing an axial motor rotor, characterized in that: The preparation method comprises: Fixing the permanent magnet by the mold; The permanent magnet is wrapped by carbon cloth laying or winding to form an integrated rotating shaft and rotor disk.

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