Hub motor

Abstract

A hub motor comprises a rim (10), a first end cover (40), a second end cover (90), a plurality of magnetic steel sheets (80), a fixed shaft (20) and a stator assembly. The rim (10), the end cover I (40), the end cover II (90) and the magnetic steel sheet (80) are matched to form a rotor assembly; a circular ring part (423) of the first end cover (40) penetrates through the rim (10) and is attached to the inner wall of an inner groove (101) of the rim (10). And a flange part I (424) of the circular ring part (423) is detachably connected with a flange part II (901) of the end cover II (90) through a bolt connecting component (902).

Description

A hub motor Technical Field

[0001] The present invention belongs to the technical field of electric vehicle accessories, and in particular relates to a hub motor. Background Art

[0002] Patents CN201920996599.7 and CN202020876366.6 both disclose a waterproof hub motor, which includes a rim with a metal ring welded to the inner wall of the rim. A magnetic steel sheet is glued to the inner wall of the metal ring. The magnetic steel sheet, metal ring, and rim form an outer rotor structure. A stator winding is mounted on a fixed shaft. Internally threaded holes are provided on both sides of the metal ring, and two end caps are fixed by bolts.

[0003] Its disadvantages are as follows:

[0004] 1. Although the end cap and the metal ring are fixed with bolts and sealed with glue, the thickness of the metal ring does not exceed 6mm to save costs. Therefore, the contact area between the metal ring and the end cap is limited, and the gluing effect is poor. Both ends of the metal ring need to be sealed with the end cap. After long-term use, the aging of the glue will cause the waterproofing to fail. Water enters the motor and causes leakage in the stator winding, affecting the safety and service life of the motor.

[0005] 2. Only the rim is stamped and welded from iron plates, a process suitable for thin metal parts. When the hub motor brakes, the brake seat is subject to large circumferential shear forces, requiring a certain thickness. Furthermore, to save costs, the motor end cover, excluding the brake seat, is thinner, resulting in uneven thickness. Uneven thickness prevents the motor end cover from being stamped from thin iron plates, forcing it to be made of cast aluminum, which is more expensive.

[0006] 3. With the demand for wheel hub reduction and cost reduction, rims and end caps are becoming thinner and thinner. Manufacturers can reduce the thickness of rims and end caps to 1.7mm. Correspondingly, the thinner the rim, the greater the risk of deformation due to impact. Too thin end caps will lead to insufficient support strength.

[0007] 4. When an electric vehicle is accelerating or climbing a slope, a high current continuously outputs to the stator winding, causing the temperature inside the wheel hub to rise, resulting in an increase in internal air pressure. Gas will be discharged from the gap between the end cover and the metal ring, and the gap between the fixed shaft and the end cover. After the internal temperature cools down, air from the external environment will be sucked into the wheel hub. At this time, humid air or water from the external environment will enter the interior of the wheel rim.

[0008] 5. The magnetic steel sheet is directly glued to the inner wall of the metal ring, and the metal ring and the rim are welded. The installation base of the magnetic steel sheet is the inner wall of the metal ring, and the installation base of the fixed shaft is the mounting seat on the end cover. When the final assembly is completed, there is a slight deviation between the center axis 1 of the inner wall of the metal ring and the center axis 2 of the mounting seat, resulting in uneven force on both sides of the rim. Although this difference is very subtle, it will still cause wear of the fixed shaft after long-term operation, resulting in failure of the end cover and metal ring and increased possibility of water leakage.

[0009] 6. A wire threading hole is provided on the fixed shaft, through which the lead wire of the stator winding extends out of the wheel hub and is connected to the controller wire of the electric vehicle; the sealing effect of the lead wire and the wire threading hole is general, and water vapor in the environment can easily enter the inside of the wheel hub through the wire threading hole.

[0010] Summary of the Invention

[0011] The object of the present invention is to provide a hub motor with simple structure, good strength, low cost and good waterproof performance.

[0012] The object of the present invention is achieved like this:

[0013] A hub motor, comprising

[0014] The rim is used to carry the tire; the rim is annular, and the circumference of the rim is inwardly recessed to form an inner groove;

[0015] End cap 1, comprising a disc-shaped end cap body, a circular ring portion, and a flange portion 1; the end cap body extends from a first side of the rim and extends from a second side of the rim; the circular ring portion is located in the middle of the rim; the flange portion 1 is located on the first side of the rim;

[0016] End cover 2 is provided on the first side of the rim; end cover 2 is mounted on flange portion 1 of end cover 1; end cover 1 and end cover 2 cooperate to form an inner cavity of the hub;

[0017] A plurality of magnetic steel sheets are arranged on the inner wall of the annular portion of the first end cover; the magnetic steel sheets are connected to the inner wall of the annular portion by adhesive bonding; the rim, the first end cover, the second end cover and the magnetic steel sheets cooperate to form a rotor assembly;

[0018] A fixed shaft passes through the end cover 1 and the end cover 2; bearings are respectively provided in the middle of the end cover 1 and the end cover 2; both ends of the fixed shaft are passed through the bearings;

[0019] A stator assembly is mounted on the fixed shaft.

[0020] Bead seats are provided on both sides of the inner groove;

[0021] Both sides of the bead seat extend upward to form a wheel rim, and the wheel rim is provided with an outer turning edge portion or an inner turning edge portion;

[0022] The side wall of the inner groove is inclined toward the middle of the rim; the included angle b between the side wall of the inner groove and the bottom wall of the inner groove is ≥80 degrees, and the included angle b is <90 degrees.

[0023] Preferably, the rim comprises a metal sheet,

[0024] Both sides of the metal sheet in the width direction are folded upward to form a first bent portion, the metal sheet between the two first bent portions on the left and right forms the bottom wall of the inner groove, and the two first bent portions form the side walls of the inner groove; the bending angle of the first bent portion is greater than 90 degrees;

[0025] The upper side of the first bending portion is folded outward to form a second bending portion;

[0026] The outer side of the second bending portion is further folded upward to form a third bending portion;

[0027] The outer end of the third bent portion is further bent outward or inward to form the wheel rim;

[0028] The metal plate is bent into a circular shape along the length direction and welded end to end to form the rim;

[0029] The thickness of the rim is 1.5 mm to 2 mm.

[0030] Preferably, a transition section 1 is provided between the bottom wall of the inner groove and the side wall of the inner groove, the thickness of the transition section 1 is less than the thickness of the bottom wall, and the thickness of the transition section 1 is less than the thickness of the side wall; the transition section 1 is located at the bend between the side wall and the bottom wall.

[0031] Preferably, when the first bending portion is folded outward, it is first folded downward to form a second transition section, and then folded outward to form the second bending portion;

[0032] The second transition section extends downward and outward; the second bending portion extends outward and upward.

[0033] The end cap 1 includes an end cap body, which is disc-shaped; the outer end of the end cap body extends horizontally toward the end cap 2 to form a circular ring portion;

[0034] The annular portion passes through the rim and fits against the inner wall of the inner groove of the rim; the front end of the annular portion is folded outward to form a flange portion; the inner wall of the annular portion is pasted with the magnetic steel sheet;

[0035] The end cover body and the bent portion 1 of the annular portion are welded to the inner wall of the rim as a whole, and / or the outer edge of the flange portion 1 is welded to the inner wall of the rim as a whole;

[0036] The edge of the end cover 2 is provided with a flange part 2; the flange part 2 and the flange part 1 are detachably connected as a whole through a plurality of bolt connection components, so that the end cover 1 and the end cover 2 are tightly matched.

[0037] Preferably, the edge of the end cover body expands outward to form a retaining ring portion, which is larger than the inner aperture of the inner groove of the rim; the retaining ring portion and the circular ring portion are transitioned by an arc segment, which fits the corner of the inner groove of the rim.

[0038] Preferably, an inner disc seat is provided in the middle of the end cover body;

[0039] The inner disc seat includes a base in the shape of a disc;

[0040] The outer edge of the base is horizontally folded outward to form a brake ring 1;

[0041] The middle portion of the base is folded outward to form a stepped inner ring portion 1 and an inner ring portion 2;

[0042] The middle portion of the end cover body is horizontally folded outward to form a second brake ring, and the second brake ring is sleeved on the outside of the first brake ring and welded into one.

[0043] Preferably, the end cover body and the inner disc seat are both thin iron parts; the thickness of the end cover body and the inner disc seat is 1.5mm to 3mm.

[0044] Preferably, the end cover body is provided with one or more annular reinforcing ribs; the base of the inner disc seat is provided with a plurality of radially arranged strip reinforcing ribs.

[0045] Preferably, the length of the brake ring 1 is greater than that of the brake ring 2; and the brake ring 2 and the bent portion 2 of the end cover body are welded to the annular surface of the brake ring 1.

[0046] Preferably, a plurality of “Π”-shaped connecting strips are provided in the inner groove of the rim, and the bending portions three on both sides of the connecting strips are welded to the corresponding rim wall surfaces.

[0047] Preferably, a bearing is provided in the middle of the end cap 1 and the end cap 2; the fixed shaft is passed through the bearing; a threading hole is provided obliquely on the fixed shaft, and the lead wire of the hub motor extends through the threading hole; the threading hole includes an oblique section, the inner wall of the oblique section is provided with a step portion, and the outer side of the step portion is provided with an internal thread portion; the lead wire includes a plurality of wire cores;

[0048] A threading hole is provided on the fixed shaft of the wheel hub, and the lead wire of the wheel hub motor extends out of the threading hole;

[0049] The lead wires include a plurality of wire cores and outer sheaths; the outer sheaths are covered on the outside of the plurality of wire cores; the outer wall of the outer sheaths and the threading holes are sealed; a gap channel is formed between the wire cores, and one end of the gap channel is connected to the inner cavity of the hub motor;

[0050] The outer end of the lead wire extends upward to the interior of the electric locomotive housing;

[0051] An exhaust joint is installed at the outer end of the lead wire, a separation chamber is provided in the exhaust joint, and a first joint, a second joint and a third joint are provided on the peripheral side of the separation chamber;

[0052] The outer sheath and the wire core are inserted into the first connector, and the outer sheath and the first connector are sealed;

[0053] The wire core passes through the separation chamber and then extends from the second joint; the wire core and the second joint are sealed;

[0054] The gap channels between the wire cores lead to the separation chamber.

[0055] Preferably, the third joint is provided with a gas-permeable and liquid-tight valve component, and the separation chamber is in communication with the external environment via the gas-permeable and liquid-tight valve component.

[0056] Preferably, the exhaust joint comprises a branch joint and a sleeve; the sleeve is wrapped around the outside of the branch joint;

[0057] The separation chamber is provided inside the branch joint, and the first end, second end and third end of the branch joint are provided on the peripheral side of the separation chamber; the outer sheath and the wire core are inserted into the first end, and the outer sheath and the first end are sealed; the wire core extends out of the second end, and an exhaust hole is provided on the third end.

[0058] Preferably, the outer end of the lead wire extends to the inside of the controller of the electric vehicle; after the wire core extends out of the second connector, it is connected to the circuit board of the controller.

[0059] Preferably, the second end is provided with a rubber sleeve body 1, and a plurality of through holes are pre-formed on the rubber sleeve body 1, and the through holes correspond to the wire cores one by one; the wire cores pass through the corresponding through holes.

[0060] Preferably, a tightening ring is provided on the outside of the rubber sleeve body 1; and the envelope wraps the rubber sleeve body 1.

[0061] Preferably, the outer wall of the outer sheath and the threading hole are sealed by glue.

[0062] Preferably, the threading hole includes an oblique section, an inner wall of the oblique section is provided with a step portion, and an outer side of the step portion is provided with an internal thread portion;

[0063] The second rubber sleeve is annular; the second rubber sleeve is sleeved on the outer side of the outer leather sleeve and abuts against the step portion;

[0064] The copper sleeve is sleeved on the outside of the outer leather sleeve and abuts against the second rubber sleeve body; the copper sleeve tightens the outer leather sleeve;

[0065] The nut sleeve is sleeved on the outside of the outer leather sleeve and abuts against the copper sleeve; the nut sleeve is screwed into the internal thread part and presses the rubber sleeve body 2.

[0066] Preferably, the threading hole is obliquely arranged on the fixed shaft; a protective spring is sleeved on the outside of the outer sheath; one end of the protective spring is embedded in the oblique section of the threading hole and fixed, and the other end of the protective spring extends to the outside of the threading hole.

[0067] The end cap 1 includes an insert ring and a shielding ring; the insert ring and the shielding ring are partially overlapped; the insert ring, the shielding ring and the inner wall of the rim are tightly fitted; the matching relationship between the shielding ring, the insert ring and the inner wall of the rim is:

[0068] An insertion cavity is formed between the outer wall of the shielding ring and the inner wall of the rim, and the insert ring is inserted into the insertion cavity; the insert ring and the inner wall of the rim are welded together; the inner wall of the shielding ring is provided with a plurality of magnetic steel sheets;

[0069] Alternatively, the matching relationship between the shielding ring, the insert ring and the inner wall of the rim is: the outer wall of the shielding ring is tightly fitted with the inner wall of the rim; the outer side of the insert ring is tightly fitted with the inner side of the shielding ring, and the inner wall of the insert ring is provided with several magnetic steel sheets.

[0070] An electric vehicle comprises the aforementioned hub motor.

[0071] Compared with the prior art, the present invention has the following outstanding and beneficial technical effects:

[0072] The circular ring portion of the end cover 1 of the present invention passes through the rim and fits against the inner wall of the inner groove of the rim; the flange portion 1 of the circular ring portion and the flange portion 2 of the end cover 2 are detachably connected by a bolt connection component; this design allows the end cover 1 and the end cover 2 to directly seal and cooperate, reducing the independent metal ring in the existing design, and significantly improving the sealing effect; the width of the flange portion 1 and the flange portion 2 can also be set by oneself, providing more areas for glue sealing and higher sealing effect.

[0073] The end cover 1 of the present invention is combined by the end cover body and the inner disc seat, and the brake ring 1 of the inner disc seat and the brake ring 2 of the end cover body are nested and welded; the brake ring 1 and the brake ring 2 are superimposed to form a brake seat, and the thickness of the brake seat can meet the strength requirements. The end cover body and the inner disc seat can both be stamped out of iron plates with a thickness of 1.5mm to 2mm, which significantly reduces the cost.

[0074] The edge of the end cap body of the present invention expands outward to form a retaining ring portion, which is larger than the inner diameter of the groove in the rim. A circular arc segment transitions between the retaining ring portion and the annular portion, which fits the corner of the groove in the rim. The retaining ring portion and flange portion (I) cooperate to clamp the rim, ensuring a tighter fit between the end cap (I) and the rim. Even uneven welding or partial detachment will not cause problems, thus extending the service life.

[0075] The end cap body of this invention is equipped with one or more annular reinforcing ribs; the base of the inner disc seat is provided with several radially arranged strip reinforcing ribs. The forces acting on the hub include radial impact, axial impact, and circumferential shear forces. Radial impact forces are borne and dispersed by the rim, while axial impact forces are primarily borne and dispersed by the end cap body. The annular reinforcing ribs provide better load-carrying efficiency, while circumferential shear forces are primarily borne and dispersed by the inner disc seat. The strip reinforcing ribs provide better load-carrying efficiency and enhanced strength.

[0076] The length of the brake ring 1 of the present invention is greater than that of the brake ring 2; the bent portion 2 of the brake ring 2 and the end cover body are welded to the annular surface of the brake ring 1; when subjected to axial impact force, this design makes the load effect more concentrated on the end cover body, and the stability is better.

[0077] The inner groove of the rim of the present invention is provided with several "Π"-shaped connecting strips, and the bent portions three on both sides of the connecting strips are welded to the corresponding rim wall surfaces; when the rim thickness is relatively thin, the design of the connecting strips can prevent the rim from expanding outward, thereby ensuring the strength of the rim.

[0078] The outer end of the lead wire of the present invention extends upward to the interior of the electric vehicle housing, for example, directly connected to the interior of the controller. These parts are at a relatively high position and generally do not come into contact with water; a branch joint is installed at the outer end of the lead wire, and a separation chamber is provided inside the branch joint; the gas and oil inside the wheel hub can be conducted to the separation chamber through the gap channel between the wire cores, and then released into the external environment through the separation chamber.

[0079] The protective spring of the present invention can effectively prevent the outer sheath from being scratched by the fixed shaft, thereby protecting the inner wire core. BRIEF DESCRIPTION OF THE DRAWINGS

[0080] Figure 1 is a schematic diagram of a hub motor.

[0081] FIG2 is an exploded view of the hub (the stator assembly is not shown).

[0082] FIG3 is a cross-sectional view of the hub (the stator assembly is not shown).

[0083] FIG4 is a schematic diagram of the cooperation between the rim and the end cover.

[0084] FIG5 is a schematic diagram of end cap 1. FIG.

[0085] FIG6 is a partial cross-sectional view of end cover 1. FIG.

[0086] FIG7 is a schematic diagram of the outer end of the lead wire.

[0087] FIG8 is a cross-sectional view of the outer end of the lead wire.

[0088] FIG9 is an exploded view of the outer end of the lead wire.

[0089] FIG10 is a schematic diagram showing the coordination of the fixed shaft and the lead wire.

[0090] FIG11 is a second schematic diagram of the coordination between the fixed shaft and the lead wire.

[0091] FIG12 is a schematic diagram of a rim and an end cap.

[0092] FIG13 is an enlarged view of point A in FIG12 .

[0093] FIG14 is one of the schematic diagrams of the installation of the magnetic steel sheet.

[0094] FIG15 is a second schematic diagram of the installation of the magnetic steel sheet.

[0095] FIG16 is a schematic diagram of the rim of Example 2. FIG.

[0096] FIG17 is a schematic diagram of the rim of Example 3. FIG.

[0097] FIG18 is a schematic structural diagram of the rim of Example 4. FIG.

[0098] FIG19 is a schematic diagram showing the stress state of the rim of Example 4. FIG.

[0099] Figure 20 is one of the schematic diagrams of the coordination of the rim, end cover 1 and end cover 2 of Example 5.

[0100] Figure 21 is the second schematic diagram of the coordination of the rim, end cover 1 and end cover 2 of Example 5.

[0101] Reference numerals in the figure indicate the following: 10 - rim; 20 - fixed shaft; 30 - lead wire; 40 - end cap (1); 50 - connecting bar; 61 - oil seal (1); 62 - oil seal (2); 71 - bearing (1); 72 - bearing (2); 80 - magnetic steel sheet; 90 - end cap (2); 21 - threading hole; 22 - oblique section; 221 - stepped portion; 222 - internal threaded portion; 301 - wire core; 302 - protective spring; 303 - through hole; 304 - rubber sleeve (2); 305 - copper sleeve; 306 - nut sleeve; 307 - outer sleeve; 308 - vent pipe; 309 - valve member; 41 - inner disc seat; 42 - end cap body; 411 - Base; 412 - Brake ring 1; 414 - Inner ring 1; 413 - Strip reinforcement rib; 415 - Inner ring 1; 421 - End cap ring surface; 422 - Annular reinforcement rib; 423 - Circular ring; 424 - Flange 1; 425 - Inner thread 1; 426 - Brake ring 2; 427 - Positioning step; 428 - Groove; 429 - Abutment ring; 430 - Bend 2; 431 - Welding 3; 432 - End cap abutment; 441 - Brake ring 3; 442 - Base 2; 443 - Embedded block; 444 - Mounting hole; 445 - Slot; 446 - Positioning step; 46 - Valve member 2; 491 - retaining ring; 492 - arc segment; 493 - bolt; 494 - positioning flange; 495 - nut; 496 - internal threaded portion (II); 501 - welding portion (I); 901 - flange (II); 902 - bolted connection member; 101 - inner groove; 102 - welding portion (II); 103 - bent portion (I); 110 - corner; 111 - bottom wall of inner groove; 113 - side wall of inner groove; a - inclination angle; 3000 - exhaust connector; 3000A - first connector; 3000B - second connector; 3000C - third connector; 3011 - sleeve; 3011A - first end of sleeve; 3011B - second end of sleeve; 3011C - central hole of sleeve; 3012 - branch connector; 3012A - first end; 3012B - second end; 3012C - third end; 3012D - separation chamber; 3012C1 - exhaust hole; 3013 - air-permeable and liquid-tight valve member; 3013A - hollow hole; 3013B - polymer film layer; 3014 - tightening ring; 3015 - rubber sleeve 1; 3015A - through hole. DETAILED DESCRIPTION

[0102] The present invention will be further described below in conjunction with specific embodiments:

[0103] Embodiment 1, as shown in FIG1-15 , a hub motor includes a rim 10 , an end cap 1 40 , an end cap 2 90 , a plurality of magnetic steel sheets 80 , a fixed shaft 20 , and a stator assembly. The stator assembly is connected to the core of the lead wire. The stator assembly is prior art and will not be expanded in this application.

[0104] The rim 10 is used to carry the tire; the rim is annular, and the circumference of the rim is inwardly recessed to form an inner groove 101;

[0105] End cap 1 40 includes a disc-shaped end cap body 42, an annular portion 423, and a flange portion 1 424; the end cap body extends from a first side of the rim and extends from a second side of the rim; the annular portion 423 is located in the middle of the rim; the flange portion 1 424 is located on the first side of the rim;

[0106] End cap 2 90 is disposed on the first side of the rim; end cap 2 is mounted on flange portion 1 424 of end cap 1; end cap 1 and end cap 2 cooperate to form the inner cavity of the wheel hub; therefore, end cap 1 and end cap 2 mate directly without passing through the rim; the mating portions of end cap 2 and end cap 1 are both flat (i.e., flange portion 1 and flange portion 2 are both flat), providing a better sealing effect when glued.

[0107] A plurality of magnetic steel sheets 80 are arranged on the inner wall of the annular portion 423 of the end cover 1 40; the magnetic steel sheets 80 are connected to the inner wall of the annular portion 423 by gluing; the rim 10, end cover 1 40, end cover 2 90 and the magnetic steel sheets 80 cooperate to form a rotor assembly; after the stator assembly inside the hub is energized, the magnetic steel sheets of the rotor assembly are affected by the magnetic field to generate driving force.

[0108] A fixed shaft 20 passes through the end cover 1 and the end cover 2; bearings are respectively provided in the middle of the end cover 1 and the end cover 2; both ends of the fixed shaft are passed through the bearings;

[0109] The stator assembly is mounted on the fixed shaft 20 .

[0110] Preferably, the outer periphery of the flange portion 424 fits the inner wall of the shoulder of the rim; a certain distance is set between the flange portion 424 and the side wall of the inner groove of the rim; this distance is used to form a screw sleeve portion 425 on the flange portion, and the screw sleeve portion 425 is a structure on the flange portion that protrudes toward the inside of the rim;

[0111] The flange part 1, the outer wall of the annular part 423, the side wall of the groove in the rim, and the inner wall of the shoulder of the rim cooperate with each other to form a transition cavity 104; although the wheel hub manufacturer will set an annular welding part 2 102 between the outer edge of the flange part 1 and the inner wall of the shoulder of the rim; however, due to the working environment that is easily subject to collision during the operation of the rim, there is a risk that the welding part 2 102 will partially fall off; in addition, due to the problem of processing accuracy, there is also the possibility of cold welding in the welding part 2 102, that is, liquid in the external environment may enter the transition cavity 104; therefore, it is necessary to pre-process the transition cavity 104. Electrophoretic plating is also performed inside 04. Therefore, a through-groove is required in the flange portion to connect the transition cavity and the external environment of the wheel hub. During electrophoresis, the electrophoretic liquid enters the transition cavity 104 through the through-groove. After the electrophoresis is completed, the rim only needs to be lifted. The lifting position is generally selected at the air hole 114. The rest of the rim is relatively smooth and difficult to lift stably. Since the through-groove and the air hole on the rim are respectively arranged on different sides of the rim, the air hole and the through-groove are arranged diagonally with respect to the rim. On the vertical rolling plane of the wheel hub, the projection positions of the air hole and the through-groove are 180 degrees apart from each other. When the rim is lifted through the air hole, the through-groove is exactly at the bottom of the corresponding transition cavity 104, allowing the electrophoretic liquid to be discharged smoothly. After drying, a rubber plug is embedded in the notch of the through-groove. The rubber plug seals the through-groove and prevents liquid from entering the transition cavity.

[0112] Preferably, an auxiliary ring is provided on the inner wall of the annular portion 423. The auxiliary ring includes a ring body 804 and a plurality of separators 802 provided on the ring body. The length of the separators is approximately half the length of the magnetic steel sheet. The design of the auxiliary ring enables the magnetic steel sheet 80 to be more firmly adhered to the inner wall of the annular portion 423, and the glue can fully penetrate between each magnetic steel sheet. The magnetic steel sheet is a flat sheet, and the inner wall of the annular portion 423 is curved. Therefore, there is a certain gap between the magnetic steel sheet and the inner wall of the annular portion 423. When the glue is injected, the separators can slightly hinder the flow rate of the glue, so that the glue can better penetrate the gap between the magnetic steel sheet and the inside of the annular portion. The magnetic steel sheet 80 is embedded between two adjacent separators. The width of the separators is 2 to 3 mm. The auxiliary ring is bonded to the inner wall of the annular portion.

[0113] The end cap 1 40 includes an end cap body 42, which is disc-shaped; the outer end of the end cap body 42 extends horizontally toward the end cap 2 90 to form a circular ring portion 423;

[0114] The annular portion 423 passes through the rim 10 and fits against the inner wall of the inner groove 101 of the rim; the front end of the annular portion 423 is folded outward to form a flange portion 424; the inner wall of the annular portion 423 is adhered to the magnetic steel sheet 80;

[0115] The end cap body 42 and the bent portion 103 of the annular portion 423 are welded to the inner wall of the rim as a whole, and / or the outer edge of the flange portion 424 is welded to the inner wall of the rim 10 as a whole; the bent portion 103 forms a welding point;

[0116] The edge of the second end cap 90 is provided with a second flange 901. The second flange 901 and the first flange 424 are detachably connected together via a plurality of bolted connection members 902, ensuring a tight fit between the first and second end caps 40 and 90, significantly enhancing the sealing effect. The width of the first and second flanges can also be customized, providing more area for glue sealing and achieving a more effective seal. Compared to traditional wheel hubs, this embodiment further reduces the risk of magnetic flux leakage and improves external interference resistance.

[0117] Preferably, an inner disc seat 41 is provided in the middle of the end cover body 42;

[0118] The inner disc seat includes a base 411 in the shape of a disc;

[0119] The outer edge of the base 411 is folded outward horizontally to form a brake ring 1 412;

[0120] The middle portion of the base 411 is folded outward to form a stepped inner ring portion 1 414 and an inner ring portion 2 415;

[0121] The middle portion of the end cover body 42 is horizontally folded outward to form a second brake ring 426 . The second brake ring 426 is sleeved onto the outside of the first brake ring 412 and welded together.

[0122] Preferably, the end cover body 42 and the inner disc seat 41 are both thin iron parts; the thickness of the end cover body 42 and the inner disc seat 41 is 1.5mm to 3mm. Brake ring 1 and brake ring 2 are superimposed to form a brake seat, and the thickness of the brake seat can meet the strength requirements. When the end cover body 42 and the inner disc seat 41 are both stamped out of 2mm thick iron plates, the thickness of the brake seat can reach 4mm, thereby meeting the strength requirements; this design makes full use of the assembly of two stamping parts, and the cost reduction effect is significant. The casting process is time-consuming and labor-intensive, while the stamping process is simple and reliable, and the cost difference between the two is huge.

[0123] Preferably, the end cap body 42 is provided with one or more annular reinforcing ribs 422, and the base 411 of the inner disc seat 41 is provided with a plurality of radially arranged strip reinforcing ribs 413. The annular reinforcing ribs 422 and strip reinforcing ribs 413 in this structure not only increase strength but also are more effective for specific loads.

[0124] After analysis, the applicant found that the stress conditions of the hub can be divided into radial impact force, axial impact force and circumferential shear force.

[0125] Radial impact force is generally caused by the wheel hub hitting stones or steps during driving. The radial impact force is borne and dispersed by the rim; therefore, the radial impact force has little effect on the two motor end covers.

[0126] Axial impact force is generally caused by lateral impact on electric vehicles. The impact is mainly borne by the main body of the electric vehicle and has little impact on the wheel hub. The load is mainly carried and dispersed by the end cover body. The design of the annular reinforcement rib makes the load effect better.

[0127] The circumferential shear force is the main force acting on the wheel hub. Every time the brake is applied, the brake drum will exert a circumferential shear force on the brake seat. The inner disc seat is the component that is directly subjected to force, and the design of the strip reinforcement ribs makes the load effect better and the strength better.

[0128] Preferably, the length of brake ring 1 412 is greater than that of brake ring 2 426 . Brake ring 2 426 and the second bend 430 of the end cap body 42 are welded to the annular surface of brake ring 1 412 , forming a weld point at the location of bend 2 430 . This design allows the load to be more concentrated on the end cap body when subjected to axial impact forces, resulting in improved stability. Brake ring 1 412 and brake ring 2 426 are also spot-welded together at their central portions, with the weld point located at weld 3 431 .

[0129] Preferably, the inner groove 101 of the rim 10 is provided with several "Π"-shaped connecting strips 50. The third bends 501 on either side of the connecting strips 50 are welded to the corresponding rim wall surface. For thin rims, such as those with a thickness of 1.7 mm, the addition of the connecting strips can prevent the rim from flaring outward, ensuring rim strength. The third bends 501 form welding points.

[0130] Preferably, a bearing is provided in the middle of the end cover 1 40 and the end cover 2 90; the fixed shaft 20 is inserted into the bearing; a threading hole 21 is provided obliquely on the fixed shaft, and the lead wire 30 of the hub motor extends through the threading hole 21; the threading hole 21 includes an oblique section 22, the inner wall of the oblique section is provided with a step portion 221, and the outer side of the step portion is provided with an internal thread portion 222; the lead wire 30 includes a plurality of wire cores 301;

[0131] A threading hole 21 is provided on the fixed shaft 20 of the wheel hub, and the lead wire 30 of the wheel hub motor extends out of the threading hole 21; the lead wire 30 includes a plurality of wire cores 301 and an outer sheath 307; the outer sheath 307 covers the outside of the plurality of wire cores 301; the outer wall of the outer sheath 307 and the threading hole 21 are sealed; the wire core 301 generally has six wires, three thick wires corresponding to the U, V, and W wires of the stator winding, and three thin wires corresponding to the Hall sensor, etc.; currently, some models also have the electric vehicle controller directly installed on the stator assembly inside the wheel hub, and the power line of the core wire is connected to the battery, and the signal line of the core wire is connected to the external central control device for two-way communication;

[0132] The outer end of the lead wire 30 extends upward to the interior of the electric locomotive housing, thereby avoiding direct exposure to the environment and improving the protection effect;

[0133] An exhaust connector 3000 is installed at the outer end of the lead wire 30. A separation chamber 3012D is provided in the exhaust connector 3000. A first connector 3000A, a second connector 3000B, and a third connector 3000C are provided around the separation chamber 3012D.

[0134] The outer sheath and the wire core are inserted into the first connector 3000A, and the outer sheath and the first connector 3000A are sealed;

[0135] The wire core 301 passes through the separation chamber 3012D and then extends from the second connector 3000B; the wire core 301 and the second connector 3000B are sealed;

[0136] The gap channels between the wire cores 301 lead to the separation chamber 3012D.

[0137] The third joint 3012C is provided with a valve member 3013 which is air-permeable but liquid-tight. The separation chamber 3012D communicates with the external environment through the valve member 3013 which is air-permeable but liquid-tight.

[0138] Preferably, the exhaust connector 3000 includes a branch connector 3012 and a sleeve 3011 ; the sleeve 3011 is wrapped around the outside of the branch connector 3012 ; the first connector 3000A and the first end 3011A of the sleeve form a double seal with the outer sheath 307 .

[0139] The separation chamber 3012D is provided inside the branch connector 3012. A first end 3012A, a second end 3012B, and a third end 3012C are provided around the separation chamber 3012D. The branch connector 3012 can also be configured as a tee or a spherical shape. When the branch connector 3012 is spherical, the first end 3012A, the second end 3012B, and the third end 3012C are located at three holes on the spherical surface.

[0140] The end of the outer sheath is inserted into the first end 3012A and sealed;

[0141] The wire core 301 is inserted into the first end 3012A, passes through the separation chamber 3012D, and then extends from the second end 3012B. The wire core 301 and the second end 3012B are sealed. The wire core 301 is circular, and a gap channel is formed between multiple wire cores 301. One end of the gap channel is connected to the inner cavity of the hub motor, and the other end of the gap channel is connected to the separation chamber 3012D. Air and oil will be trapped in the separation chamber and can no longer pass through the second end 3012B, ensuring that they do not affect the stability of the controller.

[0142] The threading hole 21 is set on the fixed shaft. Since the amount of oil (generally silicone oil, non-conductive) inside the wheel hub is generally small, it will not immerse the fixed shaft; when the wheel hub rotates, the oil will splash into the gap channels between the core wires; the present invention no longer seeks to block the gap channels between the core wires, but chooses to use the gap channels as exhaust channels; the air and a small amount of oil in the wheel hub will be discharged upward along the gap channels, and then processed through the branch joint 3012.

[0143] The air-permeable and liquid-tight valve component 3013 can be purchased on the market. Its core function is to conduct gas to the external environment through a layer of polymer film layer 3013, but prevent liquid from passing through, which can completely prevent oil leakage and prevent water vapor from entering.

[0144] The outer end of the lead wire 30 extends to the inside of the controller of the electric vehicle; after the wire core 301 extends out of the second end 3012B, it is connected to the circuit board of the controller.

[0145] The second end 3012B is provided with a rubber sleeve 1 3015 , and the rubber sleeve 1 3015 is pre-formed with a plurality of through holes 3015A, which correspond one-to-one to the wire cores 301 ; the wire cores 301 pass through the corresponding through holes 3015A.

[0146] The outside of the rubber sleeve 1 3015 is provided with a tightening ring 3014. The tightening ring 3014 can shrink the rubber sleeve 1 3015 so that the rubber sleeve 1 3015 can seal the gap channel between the wire cores 301.

[0147] The outside of the branch joint 3012 is wrapped with a sleeve 3011; the sleeve 3011 also wraps the rubber sleeve 3015 to achieve a complete sealing effect.

[0148] The threading hole 21 includes an oblique section 22, an inner wall of the oblique section is provided with a step portion 221, and an outer side of the step portion is provided with an internal thread portion 222;

[0149] The second rubber sleeve 304 is annular; the second rubber sleeve 304 is sleeved on the outside of the outer sleeve 307 and abuts against the step portion 221;

[0150] The copper sleeve 305 is mounted on the outside of the outer sleeve 307 and abuts against the second rubber sleeve 304; the copper sleeve tightens the outer sleeve 307;

[0151] The nut sleeve 306 is sleeved on the outside of the outer sleeve 307 and abuts against the copper sleeve 305 ; the nut sleeve 306 is screwed into the internal thread portion 222 and presses the second rubber sleeve 304 .

[0152] When the nut sleeve is screwed into the internal thread, it compresses the second rubber sleeve. The front end of the second rubber sleeve rests against the step 221. The second rubber sleeve is deformed by the external force and compresses the outer sleeve 307. This design seals the outer sleeve and the threading hole 21. The copper sleeve secures the outer sleeve 307, ensuring the stability and sealing of the lead wires and preventing water from entering. The nut sleeve and the second rubber sleeve further secure the lead wires to the outside of the wheel hub and improve the sealing performance.

[0153] The threading hole 21 is tilted and arranged on a fixed axis; a protective spring 302 is mounted on the outer side of the outer sheath 307; one end of the protective spring is embedded in the oblique section 22 of the threading hole 21 and fixed, and the other end of the protective spring extends to the outer side of the threading hole 21. The threading hole 21 has burrs that may cut the outer sheath, and the design of the protective spring 302 can isolate the burrs of the threading hole; the protective spring 302 is directly inserted into the threading hole and can be pulled out with greater force. The iron mentioned in this application refers to steel. The rubber parts in this application that are in direct contact with oil are generally made of fluorine-containing rubber. Ordinary rubber will swell, crack, lose elasticity, or even disintegrate if it is in contact with oil for a long time.

[0154] Example 2: This example is basically the same as Example 1, except that the shape of the inner groove 101 of the rim is improved.

[0155] The included angle b between the side wall 113 of the inner groove of the rim and the bottom wall 111 of the inner groove is less than 90 degrees. The included angle b can be set to between 80 degrees and 90 degrees (excluding 90 degrees), and is 85 degrees in this embodiment.

[0156] Therefore, the sidewall 113 of the inner groove is tilted at a certain inward inclination angle a in the middle of the rim. This design causes the rim to tend to squeeze inward when subjected to radial impact force. Due to the presence of the tire, the rim is hindered from squeezing inward, thus enhancing its ability to resist radial impact force.

[0157] Preferably, a plurality of connecting strips 50 are provided in the inner groove 101, and the bent portions 501 on both sides of the connecting strips 50 are welded to the corresponding rim wall surface. Combined with the design of the connecting strips 50, the stability of the rim can be doubly guaranteed, and it is not easy to tilt and deform inward, nor is it easy to tilt and deform outward. The connecting strip 50 is also a stamped iron part, and the bent portions at both ends have a certain elasticity and toughness; although the side walls 113 of the inner groove are tilted inward, the tilt angle is generally small. Therefore, when the connecting strip 50 is installed into the inner groove, the two sides of the connecting strip 50 can be directly squeezed by external force to deform it and enter. The bent portions 501 on both sides of the connecting strip 50 are then welded to the side walls of the rim to form a welding portion. When the rim thickness is thin, for example, when the rim thickness is 1.7 mm, adding the design of the connecting strip can prevent the rim from opening outward and ensure the strength of the rim. The bent portion 501 forms a welding point. Preferably, the connecting strip 50 is shape.

[0158] In this embodiment, a drum brake ring 424 is installed on the end cover 40 .

[0159] The sidewall 113 of the inner groove is inclined toward the center of the rim; the angle b between the sidewall 113 of the inner groove and the bottom wall 111 of the inner groove is ≥ 80 degrees, and the angle b is < 90 degrees, excluding 90 degrees. The inward-inclined structure in this application refers to the sidewall 113 of the inner groove being inclined inward.

[0160] When the wheel hub hits a stone or step during driving, it generates radial impact force, which is then borne and dispersed by the rim. The design of angle b causes the rim to squeeze inward when subjected to radial impact force. Due to the presence of the tire, this inward squeeze of the rim is hindered, making it more resistant to radial impact force.

[0161] Preferably, the rim comprises a metal plate, both sides of the metal plate in the width direction are folded upward to form a first bent portion 104a, the metal plate between the left and right first bent portions 104a forms the bottom wall 111 of the inner groove, and the two first bent portions form the side walls 101 of the inner groove; the bending angle of the first bent portion 104a is greater than 90 degrees;

[0162] The upper side of the first bending portion 104a is folded outward to form a second bending portion 105a;

[0163] The outer side of the second bending portion 105a is further folded upward to form a third bending portion 106a;

[0164] The outer end of the third bent portion 106a is further bent outward or inward to form the wheel rim 103a;

[0165] The metal plate is bent into a circular shape along the length direction and welded end to end to form the rim 10;

[0166] The thickness of the rim is 1.5mm to 2mm; the thickness of the rim can be selected to be 1.6mm, 1.7mm, 1.8mm or 1.9mm. The thinner the rim is, the lower the production cost is, and the weaker the impact resistance is.

[0167] Preferably, the angle b is 81 degrees, 82 degrees, 83 degrees, 84 degrees, 85 degrees, 86 degrees, 87 degrees, 88 degrees or 89 degrees.

[0168] Example 3: This example is essentially the same as Example 1, except that, as shown in Figure 17, the partial structure of this example can be slightly modified to form another embodiment. This example is essentially the same as Example 1, except that the edge of the end cap body 42 is expanded outward to form a retaining ring portion 491. Retaining ring portion 491 is larger than the inner diameter of the rim inner groove 101. A circular arc segment 492 transitions between retaining ring portion 491 and annular portion 423, which conforms to the corner 110 of the rim inner groove 101. The retaining ring portion and flange portion 1 cooperate to clamp the rim, ensuring a tighter fit between end cap 1 and the rim. Even uneven welding or partial detachment will not cause problems, thus extending service life. After end cap 1 is installed on the rim, the retaining ring portion is inserted into end cap 1 using a spinning device to spin the edge of end cap body 42, causing it to expand outward a certain distance, thereby forming retaining ring portion 491.

[0169] The flange portion 424 is formed with a bolt portion 493 extending outward.

[0170] Example 4 is substantially the same as Example 1, except that bead seats 102a are provided on both sides of the inner groove 101 of the rim; both sides of the bead seat 102a extend upward to form a rim 103a, each rim 103a having an outer flange 1031 and an inner flange 1032; a transition section 1001 is provided between the bottom wall of the inner groove 101 and the sidewalls thereof; the thickness of the transition section 1001 is less than that of the bottom wall 111 and less than that of the sidewalls; and the transition section 1001 is located at the bend between the sidewalls and the bottom wall. This design facilitates shaping of the first bend during processing.

[0171] Preferably, when the first bend folds outward, it first folds downward to form transition section 2 1002, and then folds outward to form second bend 106a. Transition section 2 1002 extends downward and outward, while second bend 106a extends outward and upward. This design allows the rim to release a certain amount of impact force at transition section 2 when it is impacted, and then extend the impact force to transition section 2. In fact, as shown in Figure 5, when an impact force is received, the first corner A, second corner B, third corner C, and fourth corner D sequentially bear a certain amount of the impact force, thereby reducing the impact force received by the first bend.

[0172] Example 5: This example is basically the same as Example 1, except that, as shown in Figures 20-21, the end cap 40 includes an insert ring 423b and a shielding ring 423a; the insert ring 423b and the shielding ring 423a partially overlap; the insert ring 423b, the shielding ring 423a, and the inner wall of the rim 10 are tightly fitted; the matching relationship between the shielding ring 423a, the insert ring 423b, and the inner wall of the rim 10 is as follows:

[0173] An insertion cavity is formed between the outer wall of the shielding ring 423a and the inner wall of the rim 10, and the insert ring 423b is inserted into the insertion cavity; the insert ring and the inner wall of the rim 10 are welded together; a plurality of magnetic steel sheets 80 are provided on the inner wall of the shielding ring 423a;

[0174] Alternatively, the matching relationship between the shielding ring 423a, the insert ring 423b and the inner wall of the rim 10 is: the outer wall of the shielding ring 423a is tightly fitted with the inner wall of the rim 10; the outer side of the insert ring 423b is tightly fitted with the inner side of the shielding ring 423a, and the inner wall of the insert ring 423b is provided with several magnetic steel sheets 80.

[0175] The above embodiments are only preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, any equivalent changes made based on the structure, shape, and principle of the present invention should be included in the scope of protection of the present invention.

Claims

1. A hub motor, characterized in that: A rim (10) is used to carry a tire; the rim is annular, and the circumference of the rim is inwardly recessed to form an inner groove (101); An end cap (40) includes a disc-shaped end cap body (42), a circular ring portion (423), and a flange portion (424); the end cap body extends from a first side of the rim and extends from a second side of the rim; the circular ring portion (423) is located in the middle of the rim; and the flange portion (424) is located on the first side of the rim. End cover 2 (90) is arranged on the first side of the rim; end cover 2 is mounted on flange portion 1 (424) of end cover 1; end cover 1 and end cover 2 cooperate to form an inner cavity of the hub; A plurality of magnetic steel sheets (80) are arranged on the inner wall of the annular portion (423) of the first end cover (40); the rim (10), the first end cover (40), the second end cover (90) and the magnetic steel sheets (80) cooperate to form a rotor assembly; A fixed shaft (20) passes through the end cover 1 and the end cover 2; bearings are respectively provided in the middle of the end cover 1 and the end cover 2; both ends of the fixed shaft are passed through the bearings; A stator assembly is mounted on the fixed shaft (20).

2. The hub motor according to claim 1, characterized in that: Bead seats (102a) are provided on both sides of the inner groove (101); Both sides of the bead seat (102a) extend upward to form a rim (103a), and the rim (103a) is provided with an outer rim portion (1031a) or an inner rim portion (1032a); The side wall (113) of the inner groove is inclined toward the middle of the rim; the included angle b between the side wall (113) of the inner groove and the bottom wall (111) of the inner groove is greater than or equal to 80 degrees, and the included angle b is less than 90 degrees.

3. The hub motor according to claim 2, characterized in that: The rim comprises a metal sheet, The two sides of the metal plate in the width direction are folded upward to form a first bending portion (104a). The metal plate between the two first bent portions (104a) forms the bottom wall (111) of the inner groove, and the two first bent portions form the side walls (101) of the inner groove; the bending angle of the first bent portion (104) is greater than 90 degrees; The upper side of the first bending portion (104a) is folded outward to form a second bending portion (105a); The outer side of the second bending portion (105a) is further folded upward to form a third bending portion (106a); The outer end of the third bent portion (106a) is further bent outward or inward to form the wheel rim (103a); The metal plate is bent into a circular ring along the length direction and welded end to end to form the wheel rim (10); The thickness of the rim is 1.5 mm to 2 mm.

4. The hub motor according to claim 2, characterized in that: A transition section 1 (1001) is provided between the bottom wall of the inner groove (101) and the side wall of the inner groove (101); the thickness of the transition section 1 (1001) is less than the thickness of the bottom wall (111); the thickness of the transition section 1 (1001) is less than the thickness of the side wall; the transition section 1 (1001) is located at the bend between the side wall and the bottom wall; when the first bend portion is folded outward, it is first folded downward to form a transition section 2 (1002), and then folded outward to form the second bend portion (106a); the transition section 2 (1002) extends downward and outward; the second bend portion (106a) extends outward and upward.

5. The hub motor according to claim 1, characterized in that: An inner disc seat (41) is provided in the middle of the end cover body (42); The inner disc seat includes a base (411) in the shape of a disk; The outer edge of the base (411) is folded outward horizontally to form a brake ring (412); The middle portion of the base (411) is folded outward to form a stepped inner ring portion 1 (414) and an inner ring portion 2 (415); The middle part of the end cover body (42) is horizontally folded outward to form a second brake ring (426). (426) is mounted on the outside of brake ring 1 (412) and welded into one piece.

6. The hub motor according to claim 5, characterized in that: The outer end portion of the end cover body (42) extends horizontally toward the direction of the second end cover (90) to form a circular ring portion (423); The annular portion (423) passes through the rim (10) and fits against the inner wall of the inner groove (101) of the rim; the front end of the annular portion (423) is folded outward to form a flange portion (424); the inner wall of the annular portion (423) is adhered with the magnetic steel sheet (80); The end cover body (42) and the bent portion (103) of the annular portion (423) are welded to the inner wall of the rim as a whole, and / or the outer edge of the flange portion (424) is welded to the inner wall of the rim (10) as a whole; The edge of the second end cover (90) is provided with a second flange portion (901); the second flange portion (901) and the first flange portion (424) are detachably connected as a whole through a plurality of bolt connection components (902), so that the first end cover (40) and the second end cover (90) are tightly fitted.

7. The hub motor according to claim 6, characterized in that: The edge of the end cover body (42) is expanded outward to form a retaining ring portion (491), which is larger than the inner diameter of the inner groove (101) of the rim; the retaining ring portion (491) and the annular portion (423) are transitioned through an arc segment (492), and the arc segment (492) fits the corner (110) of the inner groove (101) of the rim.

8. The hub motor according to claim 7, characterized in that: The end cover body (42) is provided with one or more annular reinforcing ribs (422); the base (411) of the inner disc seat (41) is provided with a plurality of radially arranged strip reinforcing ribs (413); the length of the brake ring 1 (412) is greater than the length of the brake ring 2 (426); the brake ring 2 (426) and the bending portion 2 (430) of the end cover body (42) are welded to the annular surface of the brake ring 1 (412).

9. The hub motor according to claim 1, characterized in that: A plurality of "Π"-shaped connecting strips (50) are provided in the inner groove (101) of the rim (10), and the three bending portions (501) on both sides of the connecting strips (50) are welded to the corresponding rim wall surfaces.

10. The in-wheel motor according to any one of claims 1 to 9, characterized in that: The end cap (40) includes an insert ring (423b) and a shielding ring (423a); the insert ring (423b) and the shielding ring (423a) are partially overlapped; The insert ring (423b), the shielding ring (423a) and the inner wall of the rim (10) are tightly fitted together; the matching relationship between the shielding ring (423a), the insert ring (423b) and the inner wall of the rim (10) is: An insertion cavity is formed between the outer wall of the shielding ring (423a) and the inner wall of the rim (10), and the insertion ring (423b) is inserted into the insertion cavity; the insertion ring and the inner wall of the rim (10) are welded together; and a plurality of magnetic steel sheets are provided on the inner wall of the shielding ring (423a); Alternatively, the matching relationship between the shielding ring (423a), the insert ring (423b) and the inner wall of the rim (10) is as follows: the outer wall of the shielding ring (423a) is tightly fitted with the inner wall of the rim (10); the outer side of the insert ring (423b) is tightly fitted with the inner side of the shielding ring (423a), and the inner wall of the insert ring (423b) is provided with a plurality of magnetic steel sheets.

Images