Multilayer axial magnetic flux motor

Abstract

The invention discloses a multilayer axial magnetic flux motor, and relates to the technical field of motors. The stator comprises a stator winding and a stator iron core; the plurality of stators are detachably fixed on the inner side of the shell; the rotor shaft is rotationally connected to the center of the shell; the plurality of rotors are mounted on the rotor shaft; the stators and the rotors are alternately stacked and arranged. The stators and the rotors are stacked in a staggered mode and can be continuously stacked according to requirements, the multi-layer structure of the motor allows the stators to generate a magnetic field so that the rotors of different layers can rotate in the same direction, the types of the stators and the rotors of the multi-layer axial magnetic flux motor can be replaced according to requirements, and the multi-layer axial magnetic flux motor supports an asynchronous motor, a synchronous motor and the asynchronous and synchronous motor mixed stators and rotors. According to the multi-layer axial magnetic flux motor, efficient heat dissipation, flexible power output and energy recovery are achieved through an innovative multi-layer structure and multiple rotor schemes, and the operation efficiency and stability of the motor are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of electric motors, and in particular relates to a multi-layer axial flux motor. Background Art

[0002] A flux motor, especially an axial flux motor, is an electric motor in which the magnetic flux path is arranged along the axial direction. The working principle of the axial flux motor is based on the basic law of electromagnetism, that is, by changing the direction and magnitude of the current passing through the coil (rotor), the magnetic field strength and direction of the coil (rotor) are controlled. Since the magnetic poles of the stator are fixed, when the magnetic field direction and strength of the rotor change, the magnetic field interaction generates the Lorentz force, thereby driving the rotor to rotate.

[0003] Axial flux motors have high torque density, high power-to-weight ratio, compact structure, and are suitable for direct drive systems that require large torque and small volume. They are widely used in new energy vehicles, aerospace, ship propulsion, robotics, wind power generation and other applications that require high torque density and compact space.

[0004] Although axial flux motors have obvious advantages in design and application, they also face some technical and manufacturing challenges. For example, in the existing axial flux motors, the rotor is generally located next to the single-sided magnetic pole of the stator electromagnet. This layout results in the magnetic pole on the other side of the stator electromagnet often not being fully utilized, and there are no axial flux motors on the market that can utilize the magnetic poles on both sides of the electromagnet; in the existing axial flux motor technology, the design of multi-layer stator and rotor structure is not common, and the lack of this structure limits the further improvement of motor performance, especially in terms of torque output and power density; the stator of traditional axial flux motors is usually difficult to replace, which not only increases maintenance costs, but also prolongs downtime.

[0005] At present, it is difficult to manufacture a multi-layer axial flux motor. In view of the problems existing in the prior art, the present invention intends to design a multi-layer axial flux motor with a simple structure and reliable performance to fill the market gap. Summary of the invention

[0006] The purpose of the present invention is to provide a multi-layer axial flux motor to solve the above-mentioned technical problems existing in the prior art.

[0007] To achieve the above object, the present invention provides the following solution: a multi-layer axial flux motor, comprising:

[0008] shell;

[0009] A stator, the stator comprising a stator winding and a stator core; a plurality of the stators are detachably fixed on the inner side of the housing;

[0010] a rotor shaft rotatably connected to the center of the housing;

[0011] The rotor is installed on the rotor shaft; the stator and the rotor are alternately stacked.

[0012] In the multi-layer axial flux motor of the above structure, the stators and rotors are stacked alternately and can be further stacked as required. The multi-layer structure of the motor allows the magnetic field generated by the stator to make the rotors of different layers rotate in the same direction.

[0013] In some optional embodiments of the present invention, the stator is composed of a number of equally divided circles combined into a complete circular ring, such as the stator 1 and stator 2 of two symmetrically arranged semicircles provided in the embodiment of the present invention.

[0014] In some optional embodiments of the present invention, the stator is a complete annular stator, or the stator is composed of a number of equally divided circular stators to form a complete annular ring, or the stator is an integrated U-shaped stator with a notch on one side. It should be understood that the stator can be applied to both synchronous motors and asynchronous motors.

[0015] In some optional embodiments of the present invention, sensors for monitoring the position and speed of the rotor are respectively installed on the stators of each layer, or in some optional embodiments of the present invention, there is an electronic speed regulator, which cooperates with the sensors for monitoring the position and speed of the rotor respectively installed on the stators to jointly control the rotor speed, etc.

[0016] In some optional embodiments of the present invention, each layer of the stators is independently controlled by a control unit. When in operation, part of the stators are powered to increase the driving force on the rotor, and part of the stators are used to convert mechanical energy into electrical energy.

[0017] In some optional embodiments of the present invention, the rotor includes an asynchronous motor rotor and / or a permanent magnet synchronous motor rotor.

[0018] In some optional embodiments of the present invention, when the rotor is an asynchronous motor rotor, it includes an annular rotor core and an internal winding.

[0019] In some optional embodiments of the present invention, when the rotor is a permanent magnet synchronous motor rotor, it includes an annular rotor core and internal permanent magnets.

[0020] In some optional embodiments of the present invention, when the rotor is a hybrid rotor such as an asynchronous motor rotor and a permanent magnet synchronous motor rotor, a magnetic isolation ring can be used to separate two different types of stators and rotors to prevent magnetic field interference.

[0021] The above-mentioned different rotor types of the motor are designed to solve the problems of slow speed-up of asynchronous motors and inability of synchronous motors to be used at high loads for a long time. The motor has the characteristics of fast speed-up and is not afraid of long-term high-load use.

[0022] In some optional embodiments of the present invention, the rotor is axially positioned with respect to the rotor shaft by a fixing ring. The design of the fixing ring and the bearing ensures stable operation of the rotor and reduces friction.

[0023] In some optional embodiments of the present invention, a heat dissipation pipe is connected to the housing, and the heat dissipation pipe extends into the motor for heat dissipation. The heat dissipation pipe includes but is not limited to oil cooling, air cooling, heat pipe radiator, etc.

[0024] In some optional embodiments of the present invention, the housing is a split structure, and when the stator is composed of a number of equally divided circular stators combined into a complete circular ring, a slot is provided on the circumferential side of the housing to facilitate installation of the stator from one side.

[0025] The present invention discloses the following technical effects:

[0026] The multi-layer axial flux motor provided by the present invention can be set with different numbers of stators and rotors according to different uses, and the number of rotor layers and the coil material, number of coils, rotor size and thickness, and different stator materials and sizes, the stator is evenly divided into the number of parts. The rotors and rotors of different layers of the motor are wrapped like an onion structure, and the multi-layer stators and rotors are wrapped with each other. The stators and rotors are staggered but have gaps to facilitate the rotation of the rotor, and the magnetic flux lines on both sides generated by the stator electromagnets are fully utilized. The three rotor schemes of the invention are simple in structure, can improve the replacement and maintenance speed of the motor stator and the heat dissipation efficiency, and meet the various market demands for this type of motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0028] Figure 1 It is a structural schematic diagram of a multi-layer axial flux motor of the present invention;

[0029] Figure 2 An exploded view of the multi-layer axial flux motor of the present invention;

[0030] Figure 3 It is a schematic structural diagram of a rotor in a multi-layer axial flux motor of the present invention;

[0031] Figure 4 This is a schematic structural diagram of a complete annular stator in Embodiment 1 of the present invention;

[0032] Figure 5It is a schematic structural diagram of a stator composed of equally divided circular stators according to the second embodiment of the present invention;

[0033] Figure 6 This is a schematic structural diagram of an integrated U-shaped stator in Embodiment 3 of the present invention;

[0034] Figure 7 It is a schematic diagram of the structure of the housing in some embodiments of the present invention;

[0035] Figure 8 Schematic diagram of the structure of the housing in other embodiments of the present invention.

[0036] In the figure: 1. casing; 11. rotor fixing shaft; 12. casing hinge shaft; 13. stator fixing slot; 14. casing connecting ear; 15. casing fixing part; 16. fixing column; 2. rotor shaft; 3. rotor; 4. stator; 41. complete circular stator; 42. equally divided circular stator; 43. integrated U-shaped stator; 431. stator fixing part; 432. notch; 5. bearing; 6. fixing ring. DETAILED DESCRIPTION

[0037] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0038] In the field of modern industry and transportation, the importance of electric motors as core power sources has become increasingly prominent. However, the market demand for high-performance, easy-to-maintain axial flux motors has not yet been fully met. At present, in axial flux motors, the rotor is generally located on a single side of the stator electromagnet, and the poles on the other side of the stator electromagnet are often not used. There is no axial flux motor that can utilize the poles on both sides of the electromagnet, and there is no axial flux motor with multi-layer stators and rotors. The stator of a traditional axial flux motor is generally difficult to replace. In response to this technical problem, the present invention proposes an innovative multi-layer axial flux motor to improve the replacement and maintenance speed and heat dissipation efficiency of the motor stator, and make up for the lack of such motors in the market.

[0039] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0040] Embodiment 1:

[0041] Reference Figure 1As shown, embodiment 1 of the present invention provides a multi-layer axial flux motor, including a heat dissipation pipe, a housing 1, a stator 4, a rotor 3, a rotor shaft 2 and a sensor arranged in sequence from the outside to the inside, and also includes a fixing ring 6 arranged on the rotor shaft 2 for fixing the rotor 3, and a bearing 5 for connecting the rotor shaft 2 and the housing 1.

[0042] Specifically, the heat dissipation pipe is installed on the housing 1 and can penetrate into the motor along with the slot for installing the stator 4 to dissipate heat for the motor, including but not limited to oil cooling, air cooling, heat pipe radiator and the like.

[0043] The housing 1 has a slot for facilitating installation of the stator 4 on one side, and the housing 1 is of split design and can be opened from the middle, so as to facilitate placement of the rotor 3 and installation of the fixing frame. The fixing frame is used to fix the rotor 3.

[0044] The stator 4 includes a stator winding and a stator core. In this embodiment, the stator 4 is a complete annular stator 41, which is directly installed inside the motor. Figure 4 shown.

[0045] like Figure 7 As shown, in some embodiments of the present invention, the housing 1 is composed of two semicircular shells hingedly connected together. The two semicircular shells are connected by a housing hinge shaft 12, and a housing connecting ear 14 is provided on the opposite side away from the housing hinge shaft 12. Screw holes can be provided on the housing connecting ear 14 to be fastened by bolts, or other clamping structures can be provided. A rotor fixing shaft 11 is provided at the center of the space circle of one of the semicircular shells, and stator fixing grooves 13 are provided on the inner sides of the two semicircular shells for installing the stator 4, and a plurality of housing fixing places 15 are provided on the circumferential side of the semicircular shells. Correspondingly, stator fixing places 431 corresponding to the housing fixing places 15 are provided on the outer circumference of the stator 4 to achieve fixed installation of the stator 4. The housing 1 of this structure is used for installing the following: Figure 4 The full annular stator 41 is shown.

[0046] The rotor 3 may be any one of an asynchronous motor rotor, a permanent magnet synchronous motor rotor, and a hybrid motor rotor.

[0047] In an optional solution, the rotor 3 is an asynchronous motor rotor, which is composed of a circular rotor core and an internal winding, such as a squirrel cage rotor winding, or other asynchronous motor rotor winding types. Multiple rotors 3 are combined on the rotor shaft 2, which is composed of a fixing ring 6 and a fixed spacing. The rotor shaft 2 is the axis, and the stator 4 is composed of a stator winding and a stator core that generate a conversion magnetic field in the corresponding asynchronous motor. The stator 4 is tightly fixed on the housing 1. The stator 4 and the rotor 3 are staggered but have a gap to facilitate the rotation of the rotor 3, and can continue to be superimposed. There is a bearing 5 at the connection between the rotor shaft 2 and the housing 1. In this solution, the sensor can be a sensor of an ordinary asynchronous motor.

[0048] In another optional scheme, the rotor 3 is a permanent magnet synchronous motor rotor, which is composed of a circular rotor core and an internal permanent magnet. Multiple rotors 3 are combined on the rotor shaft 2, and the spacing is fixed by a fixing ring 6. The rotor shaft 2 and the housing 1 are connected with a bearing 5, and the rotor shaft 2 is the axis. The stator 4 is composed of the stator winding and stator core in the corresponding synchronous motor. The stator 4 is tightly fixed on the housing 1. The stator 4 and the rotor 3 are staggered but have a gap to facilitate the rotation of the rotor 3, and can continue to be superimposed. The rotor shaft 2 and the housing 1 are connected with a bearing 5. The sensor is the same as the traditional type of permanent magnet brushless motor. And the sensor is on the stator 4 with different layers, which can realize the effect of generating power for the motor after the stator 4 with some layers is powered on, and the stator 4 with some layers recovers electrical energy, which can be used when braking downhill.

[0049] In another optional scheme, the rotor 3 is a hybrid motor rotor 3, which is composed of a rotor 3 of an asynchronous motor and a rotor 3 of a permanent magnet synchronous motor. Multiple rotors 3 are combined on the rotor shaft 2, and the spacing is fixed by a fixing ring 6. The rotor shaft 2 and the housing 1 are connected with a bearing 5, and the rotor shaft 2 is the axis. The stator 4 is composed of the stator winding and stator core in the corresponding synchronous motor on the wheel disc side of the synchronous motor rotor 3, and the stator 4 is composed of the stator winding and stator core that generate the conversion magnetic field in the corresponding asynchronous motor on the wheel disc side of the asynchronous motor rotor. The stator 4 is tightly fixed on the housing 1, and the stator 4 and the rotor 3 are staggered but have a gap to facilitate the rotation of the rotor 3, and can continue to be superimposed. The rotor shaft 2 and the housing 1 are connected with a bearing 5, and the separation of different types of rotors is isolated from magnetic field interference by a magnetic isolation ring process. The sensor on the stator 4 side of the synchronous motor is the same as the traditional type of permanent magnet brushless motor, and the sensor on the stator 4 side of the asynchronous motor is similar to the sensor of the ordinary asynchronous motor. Such a structure in which the asynchronous motor rotor and the permanent magnet synchronous motor rotor 3 are mixed to form the rotor shaft 2 can solve the shortcomings of the synchronous motor's slow speed increase and the asynchronous motor's inability to operate at high load for a long time and fear of high temperature. The motor of this solution has the characteristics of fast speed increase and is not afraid of long-term high load use.

[0050] In this embodiment, the stator 4 and the rotor 3 are alternately stacked with multiple, such as Figure 1 As shown, from bottom to top, there are the rotor 3 of the first layer, the stator 4 of the second layer, the rotor 3 of the third layer, the stator 4 of the fourth layer, and the rotor 3 of the fifth layer, and the rotors 3 and stators 4 are arranged alternately.

[0051] The rotor shaft 2 is used as an axis to install each rotor 3. Figure 2 As shown, the fixing ring 6 and the bearing 5 are used to fix the rotor 3 on the rotor shaft 2 according to a preset spacing and realize assembly with the housing 1. The fixing ring 6 and the bearing 5 can maintain the precise position and stable rotation of the rotor 3 while reducing friction and wear.

[0052] The sensors are arranged on stators 4 of different layers, so that some layers of stators 4 can be powered to generate power, and some layers of stators 4 can recover electrical energy, especially when braking downhill. Each layer of stators 4 is independently controlled by a control unit. When working, some stators 4 are powered to increase the driving force on the rotor 3, and some stators 4 are used to convert mechanical energy into electrical energy.

[0053] In some embodiments, the sensor can be replaced by an electronic speed regulator with higher precision for controlling the motor speed. The electronic speed regulator adjusts the voltage and current of the motor by receiving a control signal, thereby achieving precise control of the motor speed.

[0054] It should be understood that, in practical applications, the number of stacking layers may be further increased according to the design size and requirements of the motor.

[0055] The multi-layer axial flux motor of the present invention has a shell located at the outermost side, a heat dissipation pipe is arranged on the shell, an electromagnetic stator 4 and a rotor 3 are alternately stacked in the shell, the stator 4 is composed of a stator core and a stator winding, and the magnetic field generated by the stator 4 makes the rotors 3 at different levels rotate in the same direction, the rotor 3 is located on the rotor shaft 2, and the rotor 3 is fixed by a fixing ring 6.

[0056] In the first solution, the rotor 3 is of an asynchronous motor rotor type, and the stator 4 is composed of a stator winding and a stator core that generate a conversion magnetic field in a corresponding asynchronous motor.

[0057] In the first solution, the stator 4 is located on the rotor disc side of the asynchronous motor, and is composed of a stator winding and a stator core that generate a conversion magnetic field in the corresponding asynchronous motor.

[0058] In the second solution, the rotor 3 is a permanent magnet synchronous motor rotor type, and the stator 4 is composed of a stator winding and a stator core in a corresponding synchronous motor.

[0059] In the second solution, the stator 4 is located on the disc side of the synchronous motor rotor 3 and is composed of a stator winding and a stator core in the corresponding synchronous motor.

[0060] In the third solution, the rotor 3 is a hybrid motor rotor 3 type, which is composed of a mixture of an asynchronous motor rotor and a permanent magnet synchronous motor rotor 3 .

[0061] Embodiment 2:

[0062] In the second embodiment, the stator 4 can also be designed as two or more separate structures, such as Figure 5As shown, the second embodiment provides a stator 4 of a symmetrical combination structure, the stator 4 includes a plurality of symmetrically arranged equally divided circular stators 42, and the equally divided circular stators 42 are combined into a stator 4 with a hollow complete circle. It can be understood that, according to actual needs, the stator 4 can be designed into a shape such as N equally divided circles, and combined into a hollow circular stator 4, and the multi-layer stators 4 at the same position are combined and connected into a stator combination, and the connection of the stator combination is a metal fixture with the function of fixing the stator 4 and heat dissipation.

[0063] Embodiment three:

[0064] like Figure 6 As shown, the third embodiment provides another structure of the stator 4 , in which the stator 4 is designed as an integrated U-shaped stator 43 with a notch 432 on one side, and a plurality of stator fixing portions 431 are arranged on the circumference of the integrated U-shaped stator 43 .

[0065] like Figure 8 As shown, Figure 6 The housing 1 is designed as a structure in which two semicircular shells are hinged to cooperate with the integrated U-shaped stator 43, wherein a rotor fixing shaft 11 is arranged at the center of one of the semicircular shells, and a fixing column 16 is arranged between the radial connecting line between the rotor fixing shaft 11 and the inner wall to cooperate with the notch 432 on the integrated U-shaped stator 43.

[0066] The working principle of the embodiment of the present invention is as follows:

[0067] First, the stator 4 is composed of a stator core and a stator winding. When the stator winding is energized, a magnetic field is generated in the stator core to drive the rotor 3 to move. In the asynchronous motor solution (Scheme 1), the rotor 3 is similar to a squirrel cage structure or other internal winding structures of the asynchronous motor rotor. When the rotating magnetic field generated by the stator 4 passes through the rotor 3, a current is induced in the rotor 3. According to the principle of electromagnetic induction, the rotor 3 rotates under the action of a force; in the permanent magnet synchronous motor solution (Scheme 2), the rotor 3 includes a permanent magnet. The rotating magnetic field generated by the stator 4 interacts with the permanent magnets on the rotor 3 to generate a torque to rotate the rotor 3, and the speed of the rotor 3 is synchronized with the magnetic field generated by the stator 4. In the hybrid motor solution (Scheme 3), the characteristics of the asynchronous motor and the permanent magnet synchronous motor are combined, and both the squirrel cage rotor 3 of the asynchronous motor and the permanent magnet of the permanent magnet synchronous motor are utilized to improve the performance of the motor. In this embodiment, the stator 4 and the rotor 3 of the motor are arranged alternately to form a multi-layer structure, and the stator 4 and the rotor 3 of each layer interact with each other to generate torque, so that the entire rotor 3 system rotates. The sensor is used to monitor the operating state of the motor, such as the position and speed of the rotor 3, so as to accurately control the operation of the motor. In some preferred configurations, part of the stator 4 layer can be used to recover electrical energy. For example, when braking downhill, the motor can operate as a generator to convert mechanical energy into electrical energy. The motor generates heat during operation, and the function of the heat dissipation pipe is to conduct this heat away from the inside of the motor to prevent overheating and maintain the efficiency and life of the motor. The design of this motor allows it to maintain efficient and stable performance under different working conditions, whether in situations where rapid acceleration is required or in situations where long-term high-load operation is required. Through the multi-layer structure and different rotor 3 configurations, the motor can adapt to different application requirements and provide a flexible power solution.

[0068] Compared with the prior art, the embodiments of the present invention at least disclose the following beneficial effects:

[0069] The multi-layer axial flux motor of the present invention adopts a multi-layer structure design to improve the efficiency and performance of the motor, and meets different application requirements through the multi-layer structure and different rotor 3 schemes. The design of the heat dissipation system of the present invention helps the motor to operate stably under high load, and the configuration of the sensor increases the control accuracy and energy recovery capability of the motor.

[0070] The details not disclosed in the present invention are conventional technical means well known to those skilled in the art.

[0071] In the description of the present invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, and do not indicate or imply 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 understood as a limitation on the present invention.

[0072] The embodiments described above are only descriptions of the preferred modes of the present invention, and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should all fall within the protection scope determined by the claims of the present invention.

Claims

1. A multi-layer axial flux motor, characterized in that: include: Housing (1); A stator (4), the stator (4) comprising a stator (4) winding and a stator core; a plurality of the stators (4) are detachably fixed on the inner side of the housing (1); A rotor shaft (2) rotatably connected to the center of the housing (1); A rotor (3), wherein a plurality of the rotors (3) are mounted on the rotor shaft (2); and the stators (4) and the rotors (3) are alternately stacked and arranged.

2. The multi-layer axial flux motor according to claim 1, characterized in that: The stator (4) is a complete annular stator (41), or the stator (4) is composed of a plurality of equally divided circular stators (42) combined into a complete annular ring, or the stator (4) is an integrated U-shaped stator (43) with a notch (432) on one side.

3. The multi-layer axial flux motor according to claim 2, characterized in that: Sensors for monitoring the position and speed of the stators (4) are respectively installed on the stators (4) of each layer.

4. The multi-layer axial flux motor according to claim 3, characterized in that: The stators (4) of each layer are independently controlled by a control unit. When working, part of the stators (4) are powered to increase the driving force on the rotor (3), and part of the stators (4) are used to convert mechanical energy into electrical energy.

5. The multi-layer axial flux motor according to claim 1, characterized in that: The rotor (3) comprises an asynchronous motor rotor and / or a permanent magnet synchronous motor rotor.

6. The multi-layer axial flux motor according to claim 5, characterized in that: When the rotor (3) is an asynchronous motor rotor, it comprises a circular rotor core and an internal winding.

7. The multi-layer axial flux motor according to claim 5, characterized in that: When the rotor (3) is a permanent magnet synchronous motor rotor, it comprises an annular rotor core and internal permanent magnets.

8. The multi-layer axial flux motor according to claim 1, characterized in that: The rotor (3) is axially positioned with the rotor shaft (2) via a fixing ring (6).

9. The multi-layer axial flux motor according to claim 1, characterized in that: The housing (1) is connected to a heat dissipation pipe, which extends into the interior of the motor for heat dissipation.

10. The multi-layer axial flux motor according to claim 2, characterized in that: The housing (1) is of a split structure, and when the stator (4) is composed of a plurality of equally divided circular stators (42) combined into a complete circular ring, a slot is provided on the circumferential side of the housing (1) to facilitate installation of the stator (4) from one side.

Images