Axial flux dual-motor system and vehicle

Abstract

The invention discloses an axial magnetic flux dual-motor system and a vehicle. The axial magnetic flux dual-motor system comprises a shell assembly which is provided with a controller mounting cavity, a motor mounting cavity and a speed reducer mounting cavity; the controller is positioned in the controller mounting cavity; the two axial magnetic flux motors are arranged in the motor mounting cavity side by side in the axial direction of the axial magnetic flux motors and are electrically connected with the controller; and the two planet rows are located in the speed reducer mounting cavity and symmetrically distributed on the outer sides of the two axial magnetic flux motors, and the two planet rows are in transmission connection with rotor assemblies of the two axial magnetic flux motors correspondingly. According to the whole axial magnetic flux dual-motor system, the axial size of an electric drive body is greatly reduced by adopting a dual-axial magnetic flux motor design and a single planet row transmission design, the electric drive integration design function is improved, and compared with the prior art, the axial magnetic flux dual-motor system is smaller in size, lighter in weight and lower in cost.

Description

Technical Field

[0001] The present application belongs to the technical field of axial flux dual motor systems, and in particular, relates to an axial flux dual motor system and a vehicle. Background Art

[0002] In the existing distributed drive system, the left and right motors use radial permanent magnet synchronous motors, plus a double planetary gear arrangement structure. However, when the radial motor ensures a large output torque, it is inevitable to increase the axial stack length of the stator to improve the torque density, which leads to an increase in the size of the distributed dual electric drive and cannot achieve the optimal design of lightweight and integrated electric drive. Therefore, how to achieve the smallest axial size and lightest weight of the distributed drive while ensuring that the electric drive has a high torque density is a technical problem that needs to be solved urgently. Summary of the invention

[0003] The present application aims to solve at least one of the technical problems existing in the prior art. To this end, the present application proposes an axial flux dual motor system and a vehicle with a compact structure and a small axial size.

[0004] In a first aspect of the present application, an axial flux dual motor system is provided, comprising:

[0005] The housing assembly is provided with a controller installation cavity, a motor installation cavity and a reducer installation cavity;

[0006] A controller, located in the controller installation cavity;

[0007] Two axial flux motors are arranged side by side in the motor installation cavity along the axial direction of the axial flux motor, and are both electrically connected to the controller;

[0008] Two planetary gears are located in the reducer installation cavity and are symmetrically distributed on the outsides of the two axial flux motors. The two planetary gears are respectively connected to the rotor assemblies of the two axial flux motors.

[0009] In some embodiments, the housing assembly includes a motor housing, a controller housing and two reduction gearboxes, the two reduction gearboxes are respectively connected to the openings at both ends of the motor housing and are close to the rotor assembly; the reduction gearboxes and the motor housing together form the motor mounting cavity, the inner cavity of the controller housing forms the controller mounting cavity, and the inner cavity of the reduction gearbox forms the reducer mounting cavity.

[0010] In some embodiments, both of the axial flux motors are of a single-stator dual-rotor structure, including a rotor shaft and a first rotor assembly, a stator assembly, and a second rotor assembly arranged in sequence along the axial direction of the rotor shaft, the rotor shaft being fixedly connected to the output part of the first rotor assembly, and the rotor shaft being transmission-connected to the output part of the second rotor assembly.

[0011] In some embodiments, both the first rotor assembly and the second rotor assembly include a turntable, a rotor core, rotor magnets, and a rotor skeleton arranged in sequence; the turntable is connected to the rotor skeleton to axially limit the rotor core and the rotor magnets.

[0012] In some embodiments, the rotor shaft includes a first shaft section, a spline shaft, and a third shaft section connected in sequence; the rotor shaft and the turntable of the first rotor assembly are of an integral structure; the rotor shaft is key-connected to the turntable of the second rotor assembly through the spline shaft; a first rotor bearing and a second rotor bearing are press-fitted on the first shaft section.

[0013] In some embodiments, the two axial flux motors are arranged side by side along the axis with the second rotor assemblies approaching each other.

[0014] The axial flux dual-motor system further includes two resolvers. The stators of the two resolvers are respectively connected to the motor housing, and the rotors of the two resolvers are respectively connected to the turntables of the two second rotor assemblies.

[0015] In some embodiments, the first shaft section is provided with an internal spline; the sun gear of the planetary gear set is provided with an input shaft, and the input shaft is in transmission connection with the internal spline of the first shaft section.

[0016] An oil seal is provided between the reduction gearbox and the turntable of the first rotor assembly.

[0017] In some embodiments, the rotor magnets include a plurality of magnet units distributed in a circumferential array; each magnet unit includes a plurality of magnet sheets stacked in sequence along the radial direction, and adjacent magnet sheets are adhesively fixed; the magnet sheets are flat plates or arc-shaped plates.

[0018] In some embodiments, a recess is provided on the side of the magnet unit, and the recesses of two adjacent magnet units form a receiving groove, and the rotor skeleton is embedded in the receiving groove and abuts against the bottom wall of the recess.

[0019] In some embodiments, the turntable has an inner cavity, and the inner wall of the turntable is provided with a plurality of first limiting ribs spaced apart along the circumferential direction. The inner cavity of the turntable is divided into a plurality of first limiting grooves by the first limiting ribs.

[0020] The rotor core includes a plurality of soft magnetic sheets distributed in a circumferential array; the plurality of soft magnetic sheets are respectively arranged in a plurality of the first limiting grooves in a one-to-one correspondence; the soft magnetic sheets are adhesively fixed to the turntable.

[0021] The soft magnetic sheet is provided with a second limiting rib, and the second limiting rib is distributed in a staggered manner with the first limiting rib; adjacent two soft magnetic sheets form a second limiting groove through the second limiting rib; a plurality of the magnetic steel units are correspondingly arranged in a plurality of the second limiting grooves.

[0022] In some embodiments, the stator assembly includes a stator housing having a stator installation cavity, a stator winding, a stator core, and a stator bushing located in the stator installation cavity; the stator winding is wound around the stator core;

[0023] The stator housing is provided with an oil inlet hole, an oil outlet hole, and a copper bus bar outlet communicating with the stator installation cavity; the three-phase copper bus bars of the stator winding extend out through the copper bus bar outlet.

[0024] In some embodiments, the stator core includes a plurality of soft magnetic blocks distributed in a circumferential array;

[0025] The stator winding includes a plurality of coil windings spaced circumferentially and evenly distributed, and connection lines for connecting the coil windings; a plurality of the coil windings are correspondingly wound around a plurality of the soft magnetic blocks;

[0026] A plurality of blocking members are arranged at intervals in the circumferential direction in the stator housing, and the blocking members are located between the coil windings and the stator housing, so that the blocking members, the coil windings, and the stator housing enclose to form a cooling oil passage;

[0027] Both the coil windings and the connection lines are flat wires; the connection lines penetrate through the blocking members.

[0028] In some embodiments, the stator housing is annular; the stator housing includes two housing sub-components, and the two housing sub-components are sealed by a first sealing member;

[0029] The stator assembly further includes two stator bushings, and the two stator bushings are press-fitted into the annular holes of the two housing sub-components respectively, and the two stator bushings are sealed by a second sealing member;

[0030] A sealing insert is arranged in the stator housing, and the sealing insert is coated on the three-phase copper bus bars, embedded in the copper bus bar outlet and located outside the first sealing member.

[0031] In some embodiments, the stator housing is made of a non-magnetic material; the tensile strength of the stator housing is above 1500 MPa, and the stiffness is above 20000 N / mm.

[0032] In some embodiments, the axial flux dual motor system further includes two oil pumps and two oil coolers. The oil pump and the oil cooler on the same side are respectively installed on the speed reducer and the motor housing on the same side;

[0033] A plurality of oil channels are provided in the box walls of the motor housing and the two controller housings. The oil pump, the oil cooler, the stator installation cavity and the reducer installation cavity are sequentially connected through the oil channels to form an electric drive lubrication and cooling circuit.

[0034] In some embodiments, a first bearing is provided between the planetary gear set and the speed reducer; a communicating oil guiding cavity and an oil guiding hole are provided on the planetary gear shaft of the planetary gear set; the planetary gears of the planetary gear set are installed on the planetary gear shaft through a second bearing, and the second bearing corresponds to the position of the oil guiding hole;

[0035] An oil collecting tray is provided on the speed reducer, and the oil collecting tray is connected to the planet carrier of the planetary gear set; the oil collecting tray is provided with oil nozzles having the same number as the planetary gear shafts, and the oil nozzles extend into the corresponding oil guiding cavities, to communicate the oil guiding cavity and the oil collecting cavity of the oil collecting tray;

[0036] The installation space of the first bearing and the oil collecting cavity of the oil collecting tray are respectively communicated with the corresponding oil channels.

[0037] In some embodiments, the speed reducer includes a speed reducer housing and an end cover connected thereto, and the speed reducer housing is connected to the motor housing;

[0038] The planet carrier is provided with an output shaft, and the first bearing is provided between the output shaft and the end cover;

[0039] The oil collecting tray is annular and sleeved on one end of the planet carrier away from the output shaft.

[0040] In some embodiments, a third bearing and a fourth bearing are provided between the sun gear and the planet carrier of the planetary gear set;

[0041] One end of the planet carrier away from the output shaft is provided with an axially protruding flange, the oil collecting tray is sleeved outside the flange, and the fourth bearing is embedded inside the flange.

[0042] In some embodiments, a storage cavity communicating with the reducer installation cavity is provided at the bottom of the speed reducer, and an oil filter and a magnet are provided in the box wall of the speed reducer. Both the oil filter and the magnet are provided in the oil channel communicating with the storage cavity.

[0043] In some embodiments, the oil cooler is an oil-water heat exchanger; a water cooling chamber for heat exchange with the controller is provided in the controller housing, and a plurality of water channels are provided in the box wall of the motor housing and / or the controller housing, and the oil-water heat exchanger is connected to the water cooling chamber through the water channels.

[0044] In a second aspect of the present application, a vehicle is provided, comprising the above-mentioned axial flux dual-motor system.

[0045] According to one or more embodiments of the present application, an axial flux dual-motor system is provided, including a housing assembly, provided with a controller mounting cavity, a motor mounting cavity and a reducer mounting cavity; a controller is located in the controller mounting cavity; two axial flux motors are arranged side by side in the motor mounting cavity along the axial direction of the axial flux motor, and are both electrically connected to the controller; two planetary gears are located in the reducer mounting cavity and are symmetrically distributed on the outsides of the two axial flux motors, and the two planetary gears are respectively connected to the rotor assemblies of the two axial flux motors in a transmission manner.

[0046] According to the axial flux dual motor system provided by one or more embodiments of the present application, the axial size of the stator and rotor of the axial flux motor is very advantageous. Under the same power, the axial size, volume and weight are reduced by 1 / 3. The entire axial flux dual motor system, by adopting a dual axial flux motor design and a single planetary gear transmission design, greatly compresses the axial size of the electric drive body and improves the integrated design function of the electric drive. Compared with the prior art, it is smaller in size, lighter in weight and lower in cost. It not only solves the problem that the electric drive structure cannot meet the space layout of the whole vehicle due to its large size, but also improves the overall torque density of the electric drive, further improves the comprehensive efficiency of the electric drive, and solves the problems of the existing technology that only uses dual radial permanent magnet motors, resulting in large electric drive size, low torque density and power density. At the same time, it greatly solves the problem of limited space layout of the electric drive in the whole vehicle, and fully realizes the lightweight design goal of new energy vehicles. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following is a brief introduction to the drawings required for use in the description of the embodiments. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0048] Figure 1 A schematic structural diagram of an axial flux dual motor system in one or more embodiments of the present application is shown.

[0049] Figure 2 Shows Figure 1 Full cutaway view of the axial flux dual motor system.

[0050] Figure 3 Shows Figure 1 Schematic diagram of the assembly structure of the planetary gear set and the reduction gearbox in the axial flux double-motor system of

[0051] Figure 4 Shows Figure 1 Schematic diagram of the structure of the oil sump in the axial flux double-motor system of Figure 1 .

[0052] Figure 5 Shows Figure 1 Schematic diagram of the structure of the oil sump in the axial flux double-motor system of Figure 2 .

[0053] Figure 6 Shows Figure 1 Full section of the oil sump in the axial flux double-motor system of Figure 1 .

[0054] Figure 7 Shows Figure 1 Full section of the oil sump in the axial flux double-motor system of Figure 2 .

[0055] Figure 8 Shows Figure 1 Schematic diagram of the structure of the oil circuit in the axial flux double-motor system of Figure 1 .

[0056] Figure 9 Shows Figure 1 Schematic diagram of the structure of the oil circuit in the axial flux double-motor system of Figure 2 .

[0057] Figure 10 Shows Figure 1 Schematic diagram of the structure of the oil circuit in the axial flux double-motor system of Figure 3 .

[0058] Figure 11 Shows Figure 1 Schematic diagram of the structure of the oil circuit in the axial flux double-motor system of Figure 4 .

[0059] Figure 12 Shows Figure 1 Schematic diagram of the structure of the oil circuit in the axial flux double-motor system of Figure 5 .

[0060] Figure 13 Shows Figure 1 Schematic block diagram of the structure of the cooling and lubrication circuit in the axial flux double-motor system of

[0061] Figure 14 Shows Figure 1Schematic diagram of the stator assembly of the axial flux dual-motor system. To facilitate the display of the internal structure of the stator bushing, the first rotor bearing and the second rotor bearing are hidden.

[0062] Figure 15 Shows Figure 14 Exploded view of the stator assembly of

[0063] Figure 16 Shows Figure 14 Full sectional view of the stator assembly of

[0064] Figure 17 Shows Figure 14 Schematic diagram of the structure of the housing sub-component of the stator assembly of

[0065] Figure 18 Shows Figure 14 Schematic diagram of the assembly structure of the stator winding and the stator core of the stator assembly of

[0066] Figure 19 Shows Figure 14 Schematic diagram of the structure of the flow path of the cooling oil fluid of the stator assembly of

[0067] Figure 20 Shows Figure 19 Schematic diagram of the structure of the cooling oil duct of the stator assembly of

[0068] Figure 21 Shows Figure 14 Schematic diagram of the connection structure of the winding coils, connecting wires and blocking parts in the stator winding of

[0069] Figure 22 Shows Figure 14 Schematic diagram of the structure of the sealing insert of the stator assembly of

[0070] Figure 23 Shows Figure 14 Schematic diagram of the structure of the stator bushing of the stator assembly of

[0071] Figure 24A Shows Figure 1 Schematic diagram of the structure of the first rotor assembly of the axial flux dual-motor system of

[0072] Figure 24B Shows Figure 1 Schematic diagram of the structure of the second rotor assembly of the axial flux dual-motor system of

[0073] Figure 25 Shows Figure 24B Exploded view of the second rotor assembly of the axial flux motor of

[0074] Figure 26 Shows Figure 24BSchematic structural diagram of the turntable of the second rotor assembly.

[0075] Figure 27 Shows Figure 24B Schematic structural diagram of the assembly of the turntable of the second rotor assembly and the rotor iron core.

[0076] Figure 28 Shows Figure 24B Schematic structural diagram of the assembly of the turntable of the second rotor assembly, the rotor iron core and the rotor magnet.

[0077] Figure 29 Shows Figure 24B Schematic structural diagram of the rotor skeleton of the second rotor assembly.

[0078] Figure 30 Shows Figure 24B Schematic structural diagram of the magnet unit of the second rotor assembly.

[0079] Figure 31A Shows the schematic structural diagram of the magnet unit of the rotor assembly in some other embodiments of the present application.

[0080] Figure 31B Shows the schematic structural diagram of the magnet unit of the rotor assembly in still some other embodiments of the present application.

[0081] Figure 32 Shows the comparison chart of the eddy current losses of different rotor assemblies.

[0082] Figure 33 Shows the comparison chart of the eddy current losses of the magnet units of different rotor assemblies.

[0083] Description of the reference numerals in the drawings: 1000 - Axial flux dual - motor system; 100 - Axial flux motor; 200 - Housing assembly, 201 - Water channel; 210 - Motor housing, 210a - Motor mounting cavity, 211 - Mounting plate, 212 - Fourth oil channel, 213 - Fifth oil channel, 214 - Sixth oil channel; 220 - Reducer, 220a - Reducer mounting cavity; 221 - Reducer housing, 2211 - Second oil channel; 222 - End cover, 2221 - First oil channel, 2222 - Third oil channel, 2223 - Opening, 2224 - Plug, 2225 - Oil filter, 2226 - Magnet; 230 - Controller housing, 230a - Controller mounting cavity, 230b - Water - cooling cavity, 231 - Main body, 232 - Cover plate. 300 - Controller; 400 - Reducer; 410 - Planetary gear set, 411 - Sun gear, 4111 - Input shaft, 4112 - Support stop; 412 - Planet carrier, 4121 - Output shaft, 4122 - Flange; 413 - Planet gear; 414 - Planet gear shaft, 414a - Oil - guiding cavity, 414b - Oil - guiding hole; 415 - Ring gear; 420 - First bearing; 430 - Second bearing; 440 - Third bearing; 450 - Oil sump, 450a - Oil - collecting cavity, 451 - Oil outlet nozzle, 452 - Oil baffle, 453 - Avoidance area, 454 - Mounting hole. 500 - Oil pump; 600 - Oil cooler; 700 - Resolver; 801 - First oil seal; 802 - Second oil seal.

[0084] 100 - Axial flux motor: 110 - Stator assembly; 111 - Stator housing, 111a - Stator mounting cavity, 111b - Oil inlet hole, 111c - Oil outlet hole, 111d - Copper - bus outlet, 111e - Cooling oil channel, 111f - Ring hole, 111g - First sealing groove, 111h - Clamping groove, 111i - Core fixing groove, 1111 - Housing sub - part, 1112 - Support block, 1113 - Inner ring part, 1114 - Outer ring part; 112 - Stator winding, 1121 - Coil winding, 1122 - Connecting wire, 11221 - Main body section, 11222 - Joint section, 1123 - Blocking piece, 1124 - Three - phase copper bus; 113 - Stator core, 1131 - Soft magnetic block; 114 - Stator bushing, 1141 - Stopper step, 1142 - Shaft hole, 1143 - Ring plate, 1144 - Bushing bolt; 115a - First rotor bearing; 115b - Second rotor bearing; 116 - Sealing insert, 1161 - Insert main body, 1162 - Sealing sleeve; 117 - First seal; 118 - Second seal; 119 - Pressure plate.

[0085] 120a - First rotor assembly; 120b - Second rotor assembly; 121 - Rotor shaft, 1211 - First shaft section, 1212 - Spline shaft, 1213 - Third shaft section, 1214 - Spline groove, 1215 - Hole shoulder; 122a - First turntable; 122b - Second turntable, 1221 - Internal spline, 1222 - First mounting portion, 1223 - Second mounting portion, 1224 - First limiting rib, 1225 - First limiting groove, 1226 - Limiting protrusion, 1227 - Lug, 12271 - Threaded through - hole, 1228 - Axial cavity wall, 1229 - Circumferential cavity wall; 123 - Rotor magnet, 1231 - Magnet unit, 12311 - Magnet sheet, 12312 - Recess, 12313 - Accommodating groove, 12314 - Groove; 124 - Rotor iron core, 1241 - Soft magnetic sheet, 12411 - Second limiting rib, 1242 - Second limiting groove; 125 - Rotor skeleton, 1251 - Fixed ring, 1252 - Retaining arm, 1253 - Connecting portion; 126 - Rotor bolt; 130 - Pressure ring. Detailed implementation manners

[0086] In order to enable those skilled in the art in the technical field to which the present application belongs to more clearly understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present application.

[0087] In addition, the present application may repeat reference numerals and / or reference letters in different examples. This repetition is for the purpose of simplification and clarity, and does not in itself indicate the relationship between the various embodiments and / or arrangements discussed. In addition, the present application provides examples of various specific processes and materials, but those of ordinary skill in the art may be aware of the application of other processes and / or the use of other materials.

[0088] The specific technical solutions of the present application will be described in detail below with reference to the accompanying drawings that are not necessarily drawn to scale. Among them, similar or identical reference numerals may be used to designate the same or similar parts in different figures. The use of similar or identical reference numerals in different figures does not mean that all the figures including the similar or identical reference numerals constitute a single or the same embodiment. The accompanying drawings generally illustrate the various embodiments discussed in the present application by way of example and not by way of limitation.

[0089] Please refer to Figure 1 and Figure 2In the first aspect of the present application, an axial flux dual-motor system 1000 is provided, comprising a housing assembly 200, a controller 300 and at least one motor. The controller 300 is electrically connected to the motor, and on the one hand, provides three-phase current to the stator assembly of the motor, and on the other hand, communicates data with the vehicle controller 300 to control the working condition of the motor and feedback the working parameters of the motor.

[0090] The controller 300 is connected to the housing assembly 200. The controller 300 may be an independent part connected to the housing assembly 200. The controller 300 may also be installed inside the housing assembly 200. The motor is installed in the housing assembly 200, and the housing assembly 200 serves as the motor housing of the motor.

[0091] In order to meet the cooling requirements of the stator assembly 110 in the motor, in some embodiments, the axial flux dual motor system 1000 also includes an oil pump 500 and an oil cooler 600. The oil pump 500 and the oil cooler 600 are respectively installed at different positions of the housing assembly 200, and the oil pump 500, the oil cooler 600 and the stator housing 111 are respectively connected. The oil pump pumps the oil into the oil cooler 600, and the oil cooler 600 is used to cool the oil. The oil cooler 600 can cool the oil by air cooling or water cooling, which is not limited in this application. The oil inlet of the oil cooler 600 is connected to the oil pump 500, and the oil outlet of the oil cooler 600 is connected to the oil inlet hole 111b of the stator assembly 110.

[0092] In some embodiments, the axial flux dual motor system 1000 further includes a reducer 400, which is connected to the motor for reducing the power output by the motor and outputting it to the outside. The reducer 400 can be an independent reducer 400 connected to the housing assembly 200. The reducer 400 can also be installed inside the housing assembly 200. The reducer 400 can adopt a planetary gear 410, a gear reduction mechanism, etc., which is not limited in this application.

[0093] The motor can be a radial motor or an axial flux motor, which is not limited in this application. In some embodiments, the motor is an axial flux motor. The axial flux dual motor system 1000 can be a single motor system or a dual motor system. Figure 2 In some embodiments, the axial flux dual motor system 1000 adopts a dual motor system, and both motors are axial flux motors 100. The two axial flux motors 100 are arranged side by side along the axial direction. Then the axial flux dual motor system 1000 includes two reducers 400, which are respectively connected to the two axial flux motors 100 for transmission, and are used to output the power output by the two axial flux motors 100 after deceleration.

[0094] See also Figure 1 and Figure 2, shows a schematic diagram and a full cross-sectional view of the structure of the axial flux dual motor system 1000 in some embodiments, wherein the axial flux dual motor system 1000 is configured with two axial flux motors 100 and two single planetary gear reducers. The housing assembly 200 is provided with a controller installation cavity 230a, a motor installation cavity 210a and a reducer installation cavity 220a. The controller 300 is located in the controller installation cavity 230a, and the two axial flux motors 100 are arranged side by side in the motor installation cavity 210a along the axial direction of the axial flux motor 100. The two planetary gears 410 are located in the reducer installation cavity 220a and are symmetrically distributed on the outside of the two axial flux motors 100, so that the axial flux dual motor system 1000 is generally symmetrical in structure. The two planetary gears 410 are respectively connected to the rotor assemblies of the two axial flux motors 100 in a transmission manner, and are used to output the power output by the two axial flux motors 100 to the outside after deceleration and torque increase.

[0095] In some embodiments, the housing assembly 200 includes a motor housing 210, a controller housing 230 and two reduction boxes 220, and the two reduction boxes 220 are respectively connected to the openings at both ends of the motor housing 210 and are close to the rotor assembly. The reduction box 220 and the motor housing 210 are enclosed to form a motor installation cavity 210a, the inner cavity of the controller housing 230 forms a controller installation cavity 230a, and the inner cavity of the reduction box 220 forms a reducer installation cavity 220a. Along the axial direction of the axial flux motor 100, the motor housing 210 and the two reduction boxes 220 share the same box wall, which can significantly reduce the axial size of the axial flux dual motor system 1000.

[0096] The reducer box 220 is provided with an oil storage chamber (not shown in the figure) inside, which is communicated with the reducer installation chamber 220a, and the oil dripped by the components installed in the reducer installation chamber 220a is gathered in the oil storage chamber. The oil storage chamber can be formed by the bottom part of the reducer installation chamber 220a, or it can be an oil pan additionally arranged at the bottom of the reducer installation chamber 220a, and this application does not limit it.

[0097] In some embodiments, the motor housing 210 and the main body 231 of the controller housing 230 are an integrated structure, that is, one of the chambers of the motor housing 210 is used as the motor installation chamber 210a, and the other chamber is used as the controller installation chamber 230a. The cover plate 232 of the controller housing 230 is connected to the motor housing 210 to seal the controller installation chamber 230a. The integration of the motor housing 210 and the controller housing 230 can significantly reduce the size of the axial flux dual motor system 1000 in the direction perpendicular to the axial direction.

[0098] To further reduce the axial size of the axial flux dual motor system 1000 and improve the power density of the axial flux dual motor system 1000, please refer to Figure 2In some embodiments, a spline groove 1214 is provided in the rotor shaft 121 of the axial flux motor 100, and an input shaft 4111 is provided in the sun gear 411 of the planetary row 410, and the input shaft 4111 is key-connected with the spline groove 1214. The torque output by the rotor shaft 121 is transmitted to the planetary row 410 through the sun gear 411. In some embodiments, the first shaft section 1211 of the rotor shaft 121 is hollow inside, and a spline groove 1214 is provided on the inner wall thereof.

[0099] Since the spline fitting of the input shaft 4111 and the rotor shaft 121 is not visible, the input shaft 4111 and the rotor shaft 121 can only be assembled blindly. To avoid interference between the two during assembly, please refer to Figure 2 In some embodiments, a shoulder is provided on the inner wall of the rotor shaft 121, and a support stopper 4112 is provided on the input shaft 4111. When the input shaft 4111 moves axially until the support stopper 4112 abuts against the shoulder and is axially limited, the spline groove 1214 of the rotor shaft 121 is stably engaged with the external spline of the input shaft 4111, and the end of the input shaft 4111 will not interfere with the cavity wall of the rotor shaft 121. In addition, the support stopper 4112 is slidably matched with the inner wall of the rotor shaft 121, and can also play a role in guiding and ensuring the coaxiality of the sun gear 411 and the rotor shaft 121.

[0100] Taking the axial flux dual motor system 1000 configured with two axial flux motors 100 with an overall outer diameter of 310 mm as an example, the outer envelope size of the axial flux dual motor system 1000 is 380*420*290 mm, of which the axial size is 420 mm and the height is 290 mm. The smaller axial size allows the axial flux dual motor system 1000 to be directly installed between the two wheels along the Y direction (the width direction of the vehicle), and the torque output by the two planetary gears 410 drives the two wheels respectively.

[0101] In the planetary gear 410, the sun gear 411 and the input shaft 4111 may be an integrated structure, and the sun gear 411 and the input shaft 4111 may also be connected by a key, bolt, etc., which is not limited in the present application. In some embodiments, the input shaft 4111 and the sun gear 411 are integrally formed to form a gear shaft, and the gear shaft is a hollow shaft to reduce the weight of the gear shaft, and the hollow shaft can also allow lubricating oil to enter, thereby lubricating the meshing portion between the spline groove 1214 of the rotor shaft 121 and the external spline of the input shaft 4111, and the matching portion between the support stop 4112 of the input shaft 4111 and the inner wall of the rotor shaft 121.

[0102] To prevent oil leakage, several oil seals are provided at the connection between the planetary gear 410 and the reduction gearbox 220. Figure 2 and Figure 3, in some embodiments, the sun gear 411 of the planetary gear set 410 is provided with an input shaft 4111, the carrier 412 of the planetary gear set 410 is provided with an output shaft 4121, and a first bearing 420 is provided between the output shaft 4121 and the reduction gearbox 220. That is to say, the planetary gear set 410 adopts a structural form with the sun gear 411 as the input and the carrier 412 as the output. Correspondingly, a first oil seal 801 is provided between the input shaft 4111 and the reduction gearbox 220. A second oil seal 802 is provided between the output shaft 4121 and the reduction gearbox 220, and the second oil seal 802 is located outside the first bearing 420. To prevent lubricating oil from entering the motor mounting cavity 210a, a first oil seal 801 is provided between the reduction gearbox 220 and the turntable of the rotor assembly it is close to. In some embodiments, the reduction gearbox 220 includes a connected reduction gearbox housing 221 and an end cover 222. The first oil seal 801 is installed between the reduction gearbox housing 221 and the input shaft 4111, and the second oil seal 802 is installed between the end cover 222 and the output shaft 4121.

[0103] Please refer to Figure 2 , in some embodiments, two axial flux motors 100 are arranged side by side along the axial direction with the second rotor assemblies 120b approaching each other. The stators of the two resolvers 700 are respectively connected to the motor housing 210, and the rotors of the two resolvers 700 are respectively connected to the two second turntables 122b. Specifically, an installation plate 211 may be provided inside the motor housing 210, and the stators of the two resolvers 700 are symmetrically installed on both sides of the installation plate 211 by bolts. Second installation parts 1223 are provided on the second turntables 122b of the two axial flux motors 100, and the rotors of the resolvers 700 are sleeved on the second installation parts 1223 in an interference fit manner. First installation parts 1222 are provided on the first turntables 122a of the two axial flux motors 100. The first installation parts 1222 are annular protrusions, the reduction gearbox 220 is sleeved on the first installation parts 1222, and the first oil seal 801 is installed between the reduction gearbox 220 and the first installation parts 1222.

[0104] Please refer to Figure 2 , in some embodiments, the reduction gearbox 220 includes a connected reduction gearbox housing 221 and an end cover 222. The reduction gearbox housing 221 is connected to the motor housing 210, and the oil seal is installed between the reduction gearbox housing 221 and the first installation parts 1222. The carrier 412 of the planetary gear set 410 is provided with an output shaft 4121, and a first bearing 420 is provided between the output shaft 4121 and the end cover 222. To prevent lubricating oil from leaking, a second oil seal 802 is provided between the output shaft 4121 and the end cover 222.

[0105] In the related art, the reduction gearbox part of the distributed dual-motor axial-flux dual-motor system mostly adopts the passive lubrication and cooling method of gear oil agitation, resulting in large oil agitation losses and low efficiency. However, compared with the parallel-axis gear reduction mechanism, the planetary gear set 410 structure is more compact, and the ring gear 415 is not easily agitated with oil. Therefore, the oil agitation lubrication method cannot well meet the lubrication requirements of the planetary gear set 410. For this reason, in the axial-flux dual-motor system 1000 provided in this application, by setting an oil collecting tray 450, active oil injection lubrication is carried out on the planetary gear set 410.

[0106] Please refer to Figure 2 and Figure 3 , in some embodiments, an oil collecting tray 450 is provided on the planet carrier 412. The oil collecting tray 450 is annular, and the oil collecting tray 450 is sleeved on one end of the planet carrier 412 away from the output shaft 4121 and rotates together with the planet carrier 412. The oil collecting tray 450 is provided with oil nozzles 451 having the same number as the planet gear shafts 414 of the planetary gear set 410. Lubricating oil liquid is input into the oil collecting tray 450, and the lubricating oil liquid can flow out through each oil nozzle 451 and flow to each planetary gear 413 and the corresponding bearing.

[0107] Please refer to Figure 4 and Figure 5 , which shows a schematic structural diagram of the oil collecting tray 450 in some embodiments. A plurality of oil baffle plates 452 are provided in the oil collecting tray 450. The number of the oil baffle plates 452 is the same as the number of the oil nozzles 451, and the root positions of each oil baffle plate 452 are respectively close to the corresponding oil nozzles 451. By setting the oil baffle plates 452, the oil liquid can converge at the roots of the oil baffle plates 452 in the rotating oil collecting tray 450 so that the oil liquid can enter the oil nozzles 451.

[0108] Please refer to Figure 6 , in some embodiments, the oil baffle plates 452 are inclined radially with respect to the oil collecting tray 450. Along the rotation direction of the oil collecting tray 450, the roots of the oil baffle plates 452 are located in front of the corresponding oil nozzles 451, and the free ends of the oil baffle plates 452 are located behind the corresponding oil nozzles 451. When the oil collecting tray 450 rotates along the Figure 6 direction shown by the arrow in Figure 6 , the oil liquid will rotate relative to the oil collecting tray 450 due to inertia. It can be understood that when the oil collecting tray 450 and the oil liquid both rotate along the

[0109] Please refer to Figure 7, in some embodiments, the oil sump 450 is mounted on the planet carrier 412 by screws. To facilitate the installation of the screws, a plurality of avoidance areas 453 are provided on the side plate of the oil sump 450 on the side away from the oil outlet nozzle 451, and a plurality of mounting holes 454 are provided on the side plate of the oil sump 450 where the oil outlet nozzle 451 is located. Each avoidance area 453 corresponds to each mounting hole 454 one by one. During installation, a sleeve can be set in the avoidance area 453, and the screw can be installed through the internal space of the sleeve to prevent the screw from accidentally falling into the oil collecting cavity 450a.

[0110] The lubricating oil can be input into the oil sump 450 through an externally provided oil pipe, or the lubricating oil can be transported by opening an oil passage in the box wall of the housing assembly 200. Further, the cooling oil of the stator assembly 110 of the axial flux motor 100 can be mixed with the lubricating oil of the planetary gear set 410, that is, the oil first enters the stator assembly 110 to cool the stator assembly 110, and then is transported to the oil sump 450 through the oil passage 220c opened in the box wall of the housing assembly 200. After the oil lubricates the planetary gear set 410, it finally falls into the reducer installation cavity 220a. The oil pump 500 is communicated with the reducer installation cavity 220a, and pumps the oil falling into the reducer installation cavity 220a to the stator assembly 110.

[0111] The planet wheel shaft 414 of the planetary gear set 410 is provided with a communicating oil guiding cavity 414a and an oil guiding hole 414b; the planet gear 413 of the planetary gear set 410 is mounted on the planet wheel shaft 414 through a second bearing 430, and the second bearing 430 corresponds to the position of the oil guiding hole 414b. The oil sump 450 is connected to the planet carrier 412 of the planetary gear set 410; the oil sump 450 is provided with oil outlet nozzles 451 having the same number as the planet wheel shafts 414, and the oil outlet nozzles 451 extend into the corresponding oil guiding cavities 414a to communicate the oil guiding cavities 414a and the oil collecting cavity 450a of the oil sump 450.

[0112] Please refer to Figures 8 to 12 , the oil passage opened in the box wall of the housing assembly 200 includes a first oil passage 2221 and a second oil passage 2211. The oil pump 500 is communicated with the oil storage cavity through the first oil passage 2221, and the oil collecting cavity 450a of the oil sump 450 is communicated with the second oil passage 2211. Please refer to Figures 8 to 12 , the oil passage opened in the box wall of the housing assembly 200 further includes a third oil passage 2222, a fourth oil passage 212, a fifth oil passage 213 and a sixth oil passage 214. The third oil passage 2222 is communicated with the installation space of the first bearing 420; the oil cooler 600 is communicated with the oil pump 500 through the fourth oil passage 212. The oil cooler 600 is communicated with the oil inlet hole 111b of the stator housing 111 through the fifth oil passage 213, and the oil outlet hole 111c of the stator housing 111 is communicated with both the second oil passage 2211 and the third oil passage 2222 through the sixth oil passage 214.

[0113] In some embodiments, the housing assembly 200 includes a motor housing 210, a speed reducer 220, and a controller housing 230. The speed reducer 220 includes a connected speed reducer housing 221 and an end cover 222. The speed reducer 220 is connected to the end opening of the motor housing 210 and is close to the first rotor assembly 120a. A first oil passage 2221 and a third oil passage 2222 are both provided in the end cover 222, a second oil passage 2211 is provided in the speed reducer housing 221, a fourth oil passage 212 and a sixth oil passage 214 are both provided in both the motor housing 210 and the speed reducer housing 221, and a fifth oil passage 213 is provided in the motor housing 210.

[0114] Please refer to Figure 8 , an oil storage cavity is provided at the bottom of the speed reducer 220. An oil filter 2225 and a magnet 2226 are provided in the wall of the speed reducer 220, and both the oil filter 2225 and the magnet 2226 are provided in the first oil passage 2221. The first oil passage 2221 has two openings 2223 communicating with the outside, and plugs 2224 are provided in both of the two openings 2223. The oil filter 2225 and the magnet 2226 are respectively close to the two openings 2223. After the axial flux dual-motor system 1000 operates for a period of time, it is necessary to clean or replace the oil filter 2225 and the magnet 2226. The corresponding opening 2223 can be opened through the plug 2224, and then the oil filter 2225 or the magnet 2226 in the opening 2223 can be removed for cleaning or replacement.

[0115] Please refer to Figure 1 , in some embodiments, the housing assembly 200 is further provided with a water cooling cavity 230b. A plurality of water channels 201 are provided in the wall of the housing assembly 200. The oil cooler 600 is communicated with the water cooling cavity 230b through the water channels 201. The controller 300 is located in the controller installation cavity 230a and exchanges heat with the water cooling cavity 230b. Specifically, the water cooling cavity 230b is provided on the controller housing 230, and can be a cavity provided inside the controller housing 230, or can be a groove provided inside the controller housing 230 sealed by a cover plate to form the water cooling cavity 230b. The inlets and outlets of the water channels 201 are provided on the motor housing 210, and the water channels 201 are mainly provided in the wall of the motor housing 210.

[0116] In some embodiments, the axial flux motor 100 includes a stator assembly 110 and a first rotor assembly 120a and a second rotor assembly 120b located on both sides of the stator assembly 110. The first rotor assembly 120a is connected to the stator assembly 110 through a first rotor bearing 115a, and the second rotor assembly 120b is connected to the stator assembly 110 through a second rotor bearing 115b. The stator assembly 110 is provided with a shaft hole 1142 for the rotor shaft 121 to pass through. The rotor shaft 121 of the axial flux motor 100 penetrates through the stator assembly 110. The rotor shaft 121 is fixedly connected to the output part of the first rotor assembly 120a and is drivingly connected to the output part of the second rotor assembly 120b. Both the first rotor bearing 115a and the second rotor bearing 115b are sleeved on the rotor shaft 121.

[0117] For ease of understanding, the side where the first rotor assembly 120a is located is denoted as the first side, which can also be referred to as the first end; the side where the second rotor assembly 120b is located is denoted as the second side, which can also be referred to as the second end. The extending direction of the rotor shaft 121 of the axial flux motor 100 is denoted as the axial direction, the circumferential direction of the disc structure of the axial flux motor 100 is denoted as the circumferential direction, and the direction of the connection line between the center and the circumference of the stator assembly 110 and the rotor assembly of the axial flux motor 100 is denoted as the radial direction. The first side, the first end, the second side, the second end, the axial direction, the circumferential direction, and the radial direction described below can all refer to the above interpretations.

[0118] Please refer to Figure 14 、 Figure 15 and Figure 16 In some embodiments, the stator assembly 110 of the axial flux motor 100 includes a stator housing 111 having a stator mounting cavity 111a, as well as a stator winding 112 and a stator core 113 located in the stator mounting cavity 111a. The stator winding 112 is wound around the stator core 113. The stator housing 111 is provided with an oil inlet hole 111b, an oil outlet hole 111c, and a copper busbar outlet 111d communicating with the stator mounting cavity 111a. The three-phase copper busbars 1124 of the stator winding 112 extend out through the copper busbar outlet 111d. Cooling oil is circulated into the stator mounting cavity 111a through the oil inlet hole 111b and the oil outlet hole 111c, and the stator winding 112 and the stator core 113 are immersed in the circulating oil for heat dissipation.

[0119] Both the stator winding 112 and the stator core 113 can adopt an integral structure. For example, the stator core 113 is annular, and the stator winding 112 is wound around the annular stator core 113. In some embodiments, both the stator winding 112 and the stator core 113 are split structures. Please refer to Figure 18, the stator core 113 includes a plurality of soft magnetic blocks 1131 distributed in a circumferential array, and the plurality of soft magnetic blocks 1131 are evenly and spaced apart in the circumferential direction. It can be understood that the material of the stator core 113 is not limited to soft magnetic materials. Please refer to Figure 18 and Figure 19 , the stator winding 112 includes a plurality of coil windings 1121 that are circumferentially spaced and evenly distributed, and connection lines 1122 for connecting the coil windings 1121. The plurality of coil windings 1121 are respectively wound around the plurality of soft magnetic blocks 1131.

[0120] Please refer to Figure 18 and Figure 19 , a plurality of blocking members 1123 are provided in the stator housing 111. The blocking members 1123 are located between the coil windings 1121 and the stator housing 111. The blocking members 1123 are circumferentially spaced between the coil windings 1121 and the stator housing 111, so that the blocking members 1123, the coil windings 1121 and the stator housing 111 enclose a cooling oil passage 111e. The oil fluid flows into the cooling oil passage 111e from the oil inlet hole 111b, soaks the stator core 113 and the stator winding 112 in the stator installation cavity 111a, and flows out from the oil outlet hole 111c after heat exchange with the stator core 113 and the stator winding 112. To avoid interfering with the magnetic field, the blocking members 1123 are made of non-magnetic materials, such as non-metals such as plastics, carbon fibers, rubbers, ceramics, or non-magnetic metals.

[0121] The stator housing 111 is annular, and its annular hole 111f is used for the rotor shaft 121 to pass through and for installing the rotor bearing. The two housing components 1111 are fixedly connected by bolts on the outer ring portion 1114 of the stator housing 111. To ensure the structural strength of the outer ring portion 1114, the wall thickness of the outer ring portion 1114 is 15 mm to 25 mm. There are intervals between the coil windings 1121 and both the outer ring portion 1114 and the inner ring portion 1113 of the stator housing 111. The circumferential intervals between adjacent coil windings 1121 are communicated through the intervals between the coil windings 1121 and the inner ring portion 1113. Please refer to Figure 4 , in some embodiments, a plurality of support blocks 1112 are provided on the inner ring portion 1113 of the stator housing 111. The shape of the end face of the support block 1112 matches the shape of the end of the coil winding 1121. The support block 1112 abuts against the end of the corresponding coil winding 1121 to radially limit the coil winding 1121.

[0122] In some embodiments, the number of support blocks 1112 is less than the number of coil windings 1121, such that the circumferential intervals between adjacent coil windings 1121 communicate through regions where no support blocks 1112 are provided between the coil windings 1121 and the inner ring portion 1113. As an implementation, a support block 1112 can be provided for every other coil winding 1121. By providing the support blocks 1112, on the one hand, the coil windings 1121 can be supported radially, and on the other hand, the formation of a circulating flow of oil along the interval between the coil windings 1121 and the inner ring portion 1113 can be blocked, forcing the oil to enter the circumferential intervals between adjacent coil windings 1121.

[0123] In some embodiments, the interval between the coil windings 1121 and the outer ring portion 1114 of the stator housing 111 is greater than the interval between the coil windings 1121 and the inner ring portion 1113 of the stator housing 111. Then, the oil will mainly flow within the interval between the coil windings 1121 and the outer ring portion 1114 and it is difficult to actively enter the circumferential intervals between adjacent coil windings 1121 and the interval between the coil windings 1121 and the inner ring portion 1113. By disposing the blocking member 1123 within the interval between the coil windings 1121 and the outer ring portion 1114 and having the blocking member 1123 distributed in a staggered manner with respect to the circumferential intervals between adjacent coil windings 1121, the oil is forced to flow towards the circumferential intervals between adjacent coil windings 1121 and the interval between the coil windings 1121 and the inner ring portion 1113, thereby forming Figure 20 the S-shaped circulating cooling circuit shown, which has a larger heat dissipation area and better cooling effect. When 10 L / min of cooling oil is passed through the stator housing, the average temperature inside the stator can be maintained at about 85°C and the maximum temperature is less than 150°C.

[0124] In addition to blocking the flow of oil along the annular gap between the coil windings 1121 and the stator housing 111, the blocking member 1123 can also assist in fixing the connection wires 1122. Please refer to Figure 21 , in some embodiments, the connection wires 1122 penetrate through the blocking member 1123, and the connection wires 1122 are fixed by the blocking member 1123. Please refer to Figure 21 , in some embodiments, both the coil windings 1121 and the connection wires 1122 are flat wires. To facilitate the connection of the connection wires 1122 to the blocking member 1123 and the coil windings 1121, in some embodiments, the connection wires 1122 include a main body section 11221 and a joint section 11222. The main body section 11221 is straight or arc-shaped and penetrates through the blocking member 1123. The joint section 11222 is welded to the coil windings 1121, and the joint section 11222 is generally in a bent structure.

[0125] To facilitate the installation of the three-phase copper busbar 1124 and accommodate its thermal expansion and contraction, the size of the copper busbar outlet 111d must be larger than that of the three-phase copper busbar 1124. As a result, there will be a slight gap between the copper busbar outlet 111d and the three-phase copper busbar 1124, forming a leakage point. Since the gap is too small, it is difficult to seal it with conventional seals, and only glue can be used for sealing. However, the oil has a certain pressure, and the temperature of the oil is relatively high, so the durability of the sealant is difficult to adapt to the environment at the installation location of the three-phase copper busbar 1124.

[0126] To solve the above problems, please refer to Figure 15 and Figure 19 , in some embodiments, a sealing insert 116 is provided in the stator housing 111. The sealing insert 116 is wrapped around the three-phase copper busbar 1124 and embedded in the copper busbar outlet 111d. The sealing insert 116 is made of an elastic material (such as rubber, silicone, etc.) and can be elastically deformed under pressure. Therefore, it can seal the slight gap between the stator housing 111 and the three-phase copper busbar 1124, making the sealing reliability of the stator assembly 110 higher.

[0127] To facilitate the installation of the stator core 113 and the stator winding 112, the stator housing 111 adopts a split structure. Please refer to Figure 15 and Figure 16 , in some embodiments, the stator housing 111 includes two housing components 1111. The two housing components 1111 surround to form a stator installation cavity 111a. The oil inlet hole 111b, the oil outlet hole 111c, and the copper busbar outlet 111d can be respectively arranged on different housing components 1111, or can be formed by the two housing components 1111 surrounding each other. The structures of the two housing components 1111 can be the same, which is equivalent to splitting the housing component 1111 in half; the structures of the two housing components 1111 can also be different. For example, one is an annular groove body and the other is an annular cover plate. More structural forms of the housing component 1111 are not enumerated here.

[0128] Please refer to Figure 16 , the two housing components 1111 are sealed by a first seal 117, and the first seal 117 realizes the outer ring seal of the stator housing 111. The sealing insert 116 is located outside the first seal 117. The first seal is formed by the first seal 117 at the copper busbar outlet 111d, and the second seal is formed by the sealing insert 116 at the copper busbar outlet 111d. With this unique sealing design, when the stator cooling system applies a high air pressure of 2.5 bar internally, the leakage pressure drop is still less than the industry requirement standard of 135 Pa / min, and the reliability is higher.

[0129] The copper busbar outlet 111d can be an integral opening, and the U, V, and W phase copper busbars 1124 are all located in the copper busbar outlet 111d; the copper busbar outlet 111d can also be three openings, and the U, V, and W phase copper busbars 1124 are respectively located in the three openings. Please refer to Figure 17 , the copper busbar outlet 111d is provided on one of the housing sub-parts 1111. The copper busbar outlet 111d includes three openings. A first sealing groove 111g for assembling the first seal 117 is provided on the other housing sub-part 1111. The sealing insert 116 is clamped and fixed by the two housing sub-parts 1111. It can be understood that the sealing insert 116 is made of an elastic material, such as rubber, silica gel, etc., and can be of the same material as the first seal 117.

[0130] Please refer to Figure 22 , which shows a schematic structural diagram of the sealing insert 116 in some embodiments. The sealing insert 116 includes a connected insert body 1161 and three sealing sleeves 1162. The U, V, and W phase copper busbars 1124 are respectively in interference fit with the three sealing sleeves 1162. The insert body 1161 is respectively connected to the two housing sub-parts 1111, and a fixing method such as bonding or bolt connection can be adopted. The two housing sub-parts 1111 are both provided with three clamping grooves 111h, and the three sealing sleeves 1162 are respectively located in the three clamping grooves 111h and are clamped and fixed by the two housing sub-parts 1111.

[0131] Please refer to Figure 15 , considering that the sealing insert 116 is made of soft rubber material, if directly connected to the bolt, the connection part is prone to cracking. Therefore, in some embodiments, a pressing plate 119 is provided on the outer side of the sealing insert 116. The pressing plate 119 is made of a metal material or a non-metal plate with higher strength, such as resin. The insert body 1161 is clamped between the pressing plate 119 and the stator housing 111. The bolt passes through the insert body 1161 and is screwed to the pressing plate 119 and the two housing sub-parts 1111 respectively, so as to clamp and fix the insert body 1161.

[0132] In some embodiments, the stator housing 111 is made of a non-magnetic material that does not impede the magnetic circuit. The non-magnetic material can specifically be a non-magnetic non-metallic material, such as carbon fiber, phenolic resin, Teflon, etc.; or a non-magnetic metallic material, such as stainless steel, aluminum alloy, titanium alloy, etc. The stator housing 111 mainly serves to protect the internal stator core 113 and stator winding 112. It is required that the tensile strength of the stator housing 111 is above 1500 MPa and the stiffness is above 20000 N / mm. Moreover, when the stator assembly 110 is applied to an axial flux motor, to make the air gap between the stator and the rotor smaller, the wall thickness at the thinnest part of the stator housing 111 should not exceed 1 mm. In some embodiments, the material of the stator housing 111 is carbon fiber, and the wall thickness at the thinnest part (at the iron core fixing groove 111i) of the stator housing 111 made of carbon fiber material is only 0.5 mm to 0.7 mm. The high-strength carbon fiber material makes the stator housing 111 have extremely high stiffness and strength, capable of withstanding a torque of more than 600 N·m and a squeezing force of more than 10000 N without being damaged.

[0133] Please refer to Figure 15 and Figure 16 , in some embodiments, based on the fact that the stator housing 111 is a non-metallic material, to strengthen the structure of the stator housing 111, the stator assembly 110 further includes more than one stator bushing 114, and all the stator bushings 114 are metal bushings. The stator housing 111 is annular, the stator bushings 114 are embedded in the annular hole 111f of the stator housing 111, and the inner cavity of the stator bushing 114 forms the shaft hole 1142 of the stator assembly 110. A stop step 1141 is provided on the inner cavity wall of the stator bushing 114, and one end of the rotor bearing is axially limited by the stop step 1141 of the stator bushing 114, as Figure 16 shown.

[0134] In some embodiments, the two stator bushings 114 are in interference fit with two housing sub-parts 1111 respectively, so that there is no leakage between the stator bushing 114 and the corresponding housing sub-part 1111. The two stator bushings 114 are sealed by a second seal 118. A sealing groove can be provided on any one of the two stator bushings 114, or sealing grooves are provided on the opposite end faces of the two stator bushings 114. The second seal 118 is embedded in the sealing groove and is deformed by clamping the two stator bushings 114.

[0135] The clamping force between the two stator bushings 114 can be provided by the bolts connecting the two housing sub-parts 1111. Considering that the bolts connecting the two housing sub-parts 1111 are distributed on the outer periphery of the stator housing 111, and the two stator bushings 114 are both located in the annular hole 111f of the stator housing 111, the received binding force is limited. For this reason, please refer to Figure 23, in some embodiments, two stator bushings 114 are fixedly connected by bushing bolts 1144. Annular plates 1143 can be arranged in both of the two stator bushings 114 for connecting the bushing bolts 1144. After the two stator bushings 114 are locked by the bushing bolts 1144, they jointly clamp the second seal 118 to achieve the inner ring seal of the stator housing 111.

[0136] It can be understood that, in some embodiments, the stator housing 111 is made of a non-magnetic metal material with a certain strength. Then, the stator housing 111 is integrally annular, and the inner ring hole of the stator housing 111 forms a shaft hole. A stop step is arranged on the hole wall of the inner ring hole of the metal stator housing 111 to axially limit the bearing. The inner rings of the two housing components 1111 of the metal stator housing 111 are sealed by the second seal 118 to achieve the inner ring seal of the stator housing 111.

[0137] To limit the tangential movement of the stator core 113, please refer to Figure 17 , in some embodiments, the stator housing 111 is provided with a plurality of core fixing grooves 111i communicating with the stator mounting cavity 111a. The ends of the stator core 113 are embedded in the core fixing grooves 111i and abut against the stator housing 111, and the stator housing 111 realizes axial, tangential and radial limits on the stator core 113. It can be understood that the axial dimension of the stator core 113 is greater than that of the stator winding 112, so that at least one end of the stator core 113 is exposed relative to the stator winding 112, and the exposed part of the stator core 113 extends into the core fixing grooves 111i. The area between the core fixing grooves 111i abuts against the stator winding 112, that is, the groove walls of the core fixing grooves 111i are in contact with the coil winding 1121, and the stator housing 111 and the stator core 113 jointly realize axial, tangential and radial limits on the stator winding 112.

[0138] In some embodiments, the core fixing grooves 111i are formed by the concave areas in the stator housing 111. The core fixing grooves 111i are at least located on the axial inner wall of the stator housing 111 on the side close to the rotor of the axial flux motor. It can not only limit the stator core 113, but also reduce the thickness of the barrier between the rotor magnet and the stator core 113 in the axial flux motor, and reduce the influence of the stator housing 111 on the magnetic circuit.

[0139] The number, shape and distribution mode of the core fixing grooves 111i are the same as those of the soft magnetic blocks 1131. The core fixing grooves 111i and the soft magnetic blocks 1131 can adopt an interference fit or a clearance fit. To further fix the soft magnetic blocks 1131, glue can be applied in the core fixing grooves 111i, and each soft magnetic block 1131 is adhesively fixed to the stator housing 111 by using the glue.

[0140] In some embodiments, the rotor shaft 121 and the output portion of the first rotor assembly 120a are an integrated structure; the rotor shaft 121 is keyed to the output portion of the second rotor assembly 120b. It is understandable that the rotor shaft 121 itself can also directly serve as the output portion of the first rotor assembly 120a. The rotor shaft 121 at least includes a first shaft segment 1211 and a spline shaft 1212 connected, the first rotor bearing 115a and the second rotor bearing 115b are both mounted on the first shaft segment 1211, and the spline shaft 1212 is keyed to the output portion of the second rotor assembly 120b.

[0141] See also Figure 2 In some embodiments, the rotor shaft 121 includes a first shaft segment 1211, a spline shaft 1212 and a third shaft segment 1213 which are connected in sequence. The first rotor bearing 115a and the second rotor bearing 115b are both interference fit with the first shaft segment 1211. The spline shaft 1212 is key-connected to the output portion of the second rotor assembly 120b. The third shaft segment 1213 is used to install a pressure ring 130 to limit the axial displacement of the spline shaft 1212 and the second rotor assembly 120b.

[0142] See also Figure 24A and Figure 24B , respectively showing the structural schematic diagrams of the first rotor assembly 120a and the second rotor assembly 120b, Figure 25 The exploded view of the second rotor assembly 120b is shown. Figure 25 The description is exemplarily made based on the exploded view of the second rotor assembly 120 b , and unless otherwise specified, the description of the exploded view of the second rotor assembly 120 b is also applicable to the first rotor assembly 120 a .

[0143] See also Figure 25 , Figure 24A and Figure 24B In some embodiments, the first rotor assembly 120a and the second rotor assembly 120b each include a turntable, a rotor core 124, a rotor magnet 123 and a rotor frame 125 which are arranged in sequence; the turntable is connected to the rotor frame 125 to limit the axial position of the rotor core 124 and the rotor magnet 123. The rotor core 124 and the rotor magnet 123 are both distributed in a circumferential array. For ease of understanding, the turntable of the first rotor assembly 120a is recorded as the first turntable 122a, and the turntable of the second rotor assembly 120b is recorded as the second turntable 122b, then the rotor shaft 121 and the first turntable 122a are an integrated structure, and the spline shaft 1212 of the rotor shaft 121 is key-connected with the inner spline 1221 of the second turntable 122b. Unless the first turntable 122a and the second turntable 122b are specifically mentioned, the description of “turntable” below is applicable to both the first turntable 122a and the second turntable 122b.

[0144] The rotor core 124 and the rotor magnet 123 can be of an integral structure or a split structure respectively, and the present application does not limit this. Please refer to Figure 28 , in some embodiments, the rotor magnet 123 includes a plurality of magnet units 1231 distributed in a circumferential array. There is a certain circumferential gap between two adjacent magnet units 1231, and a plurality of the gaps are equal. The magnet unit 1231 can be in the shape of a rectangle, a circle, a polygon, a sector, etc., and the present application does not limit this. Please refer to Figure 28 and Figure 30 , in some embodiments, the magnet unit 1231 is in the shape of a sector, so that the width of the gap between two adjacent magnet units 1231 remains unchanged along the radial direction. The gap between two adjacent magnet units 1231 can be used for air flow to pass through, so that the rotor assembly is naturally cooled.

[0145] In some embodiments, a groove 12314 is provided in the magnet unit 1231, and the groove 12314 penetrates the magnet unit 1231 along the thickness direction (i.e., the axial direction) of the magnet unit 1231. The shape of the groove 12314 can be a straight groove 12314 (as shown in Figure 30 ), an arc groove 12314 (as shown in Figure 31A ), an S-shaped groove 12314 or a vortex groove 12314 (as shown in Figure 31B ), and the present application does not limit this.

[0146] In some embodiments, the magnet unit 1231 adopts a stepped segmented design. Please refer to Figure 30 and Figure 31A , the magnet unit 1231 includes a plurality of magnet sheets 12311 stacked in sequence along the radial direction. The adjacent magnet sheets 12311 are adhesively fixed. The magnet sheet 12311 is a flat plate or an arc plate. When the magnet sheet 12311 is a flat plate, the groove 12314 of the magnet unit 1231 can be regarded as a straight groove 12314, and the magnet block can be cut into a plurality of magnet sheets 12311 by wire cutting, with high precision. Then the magnet sheets 12311 are bonded with glue, and the thickness of the glue is very thin, generally 20 - 30 um. When the magnet sheet 12311 is an arc plate, the groove 12314 of the magnet unit 1231 can be regarded as an arc groove 12314, and the radius of curvature of the arc plate can be further set to be the same as the radius of the rotor circumference where the arc plate is located.

[0147] Please refer to Figure 28 and Figure 30, in some embodiments, a recess 12312 is provided on the side of the magnet unit 1231. The recesses 12312 of two adjacent magnet units 1231 form a receiving groove 12313. The opening of the receiving groove 12313 faces the side where the rotor skeleton 125 is located. The rotor skeleton 125 is inserted into the receiving groove 12313 and abuts against the bottom wall of the recess 12312. By providing the recess 12312, the rotor skeleton 125 can be installed, and at the same time, it is avoided that the rotor skeleton 125 covers the main part of the magnet unit 1231 and affects the magnetic circuit. The rotor skeleton 125 can abut against the circumferential groove wall of the receiving groove 12313, so that the rotor skeleton 125 can not only axially limit the rotor magnet 123, but also tangentially limit the rotor magnet 123 (tangent to the circumferential direction), overcome the centrifugal force of the rotor magnet 123 rotating at high speed, and inhibit the tangential movement of the rotor magnet 123.

[0148] In some embodiments, the thickness of the rotor skeleton 125 is not greater than the depth of the receiving groove, and the rotor skeleton 125 will not protrude after being inserted into the receiving groove. That is to say, the rotor skeleton 125 will not increase the axial dimension of the rotor assembly. In some embodiments, the rotor skeleton 125 is a carbon fiber skeleton. The carbon fiber skeleton has high structural strength and light weight, and can further reinforce the magnet. Please refer to Figure 29 , which shows a schematic structural diagram of the rotor skeleton 125. The rotor skeleton 125 includes a fixing ring 1251 located at the center and a plurality of retaining arms 1252 connected to the fixing ring 1251 in the circumferential direction. The number of the retaining arms 1252 is the same as the number of the magnet units 1231. A connecting portion 1253 is provided at the outer end of the retaining arm 1252 for installing the rotor bolt 126. The rotor skeleton 125 is connected to the turntable by a plurality of rotor bolts 126.

[0149] The turntable not only serves as the output part of the rotor assembly, but also is used to install the rotor core 124, the rotor magnet 123 and the rotor skeleton 125, and plays a limiting role on the above components. Please refer to Figure 26 , as an implementation scheme, the turntable is a disc-shaped groove structure with an inner cavity. The rotor core 124, the rotor magnet 123 and the rotor skeleton 125 are all located in the inner cavity of the turntable. A plurality of lugs 1227 with threaded through holes 12271 are provided on the outer periphery of the turntable. The rotor skeleton 125 is connected to the lugs 1227 of the turntable by a plurality of rotor bolts 126. The length of the stud section of the rotor bolt 126 extending into the threaded through hole 12271 is less than the axial length of the threaded through hole 12271, so that the remaining part in the threaded through hole 12271 can be screwed with the bolt on the rotor tool during the overall assembly of the motor, realizing the multi-purpose use of the threaded through hole 12271. As another implementation scheme, the turntable can also be a hollowed-out skeleton structure (refer to the structure of the rotor skeleton 125), and a plurality of mounting posts with threaded holes are provided thereon for connecting the rotor skeleton 125. More implementation schemes of the turntable are not enumerated here.

[0150] In some embodiments, the turntable has an inner cavity, and a limiting structure for tangentially limiting the rotor core 124 is provided in the inner cavity of the turntable. The specific form of the limiting structure is designed according to the structure of the rotor core 124. For example, in some embodiments, the rotor core 124 is annular, and the limiting structure can be a concave-convex structure that cooperates with the rotor core 124 in a concave-convex manner. In other embodiments, please refer to Figure 25 and Figure 27 , the rotor core 124 includes a plurality of soft magnetic sheets 1241 distributed in a circumferential array, and a plurality of first limiting ribs 1224 are provided on the axial cavity wall 1228 of the turntable at intervals in the circumferential direction. The inner cavity of the turntable is divided into a plurality of first limiting grooves 1225 by the first limiting ribs 1224, and a plurality of soft magnetic sheets 1241 are correspondingly arranged in the plurality of first limiting grooves 1225. The rotor core 124 is tangentially limited by the first limiting ribs 1224 to inhibit the tangential movement of the rotor core 124. It can be understood that the material of the rotor core 124 is not limited to soft magnetic materials. In some embodiments, the soft magnetic sheets 1241 are adhesively fixed to the turntable to prevent the soft magnetic sheets 1241 from being adsorbed by the rotor magnet 123 during the assembly process of the rotor assembly, and the adhesive fixation can also limit the soft magnetic sheets 1241. In some embodiments, the thickness of the rotor core 124 is 2 mm to 6 mm.

[0151] Please refer to Figure 25 and Figure 28 , in some embodiments, the rotor magnet 123 includes a plurality of magnet units 1231 distributed in a circumferential array. Second limiting ribs 12411 are provided on the soft magnetic sheets 1241. The second limiting ribs 12411 are distributed in a staggered manner with the first limiting ribs 1224. The second limiting ribs 12411 extend radially. The second limiting ribs 12411 can be located in the middle or at the edge of the soft magnetic sheets 1241, which is not limited in this application. Adjacent two soft magnetic sheets 1241 form a second limiting groove 1242 through the second limiting ribs 12411, and a plurality of magnet units 1231 are correspondingly arranged in the plurality of second limiting grooves 1242. Since the rotor core 124 and the rotor skeleton 125 are distributed on opposite sides of the rotor magnet 123, both sides of the rotor magnet 123 are tangentially limited and axially limited by the second limiting ribs 12411 and the rotor skeleton 125 respectively. Further, in some embodiments, the inner circumferential surface of the rotor magnet 123 abuts against the fixing ring 1251 of the rotor skeleton 125, and the outer circumferential surface abuts against the circumferential cavity wall 1229 of the turntable, and the radial limitation of the rotor magnet 123 is realized jointly by the turntable and the rotor skeleton 125.

[0152] Through the above structure, each component of the rotor assembly forms a complete assembly and rotates together. Moreover, the first limiting rib 1224 of the turntable tangentially limits the rotor core 124, and the second limiting rib 12411 of the rotor core 124 and the rotor skeleton 125 jointly tangentially limit the rotor magnet 123. As a result, the axial thickness of the tangential limiting structure can be reduced, making the tangential limiting structure stronger and more conducive to the production and processing of parts.

[0153] The turntable can further serve as the installation base for other accessories of the axial flux motor. In some embodiments, the turntable is provided with at least one outwardly protruding raised portion, and the raised portion is annular, which can be used for limiting the bearing, installing the resolver, installing the oil seal, installing the snap ring, etc. As an implementation scheme, both the first turntable 122a and the second turntable 122b are provided with two outwardly protruding portions. The two outwardly protruding portions of the first turntable 122a are respectively: the first installation portion 1222 provided on the first end face of the first turntable 122a for installing the oil seal; the limiting protrusion 1226 provided on the second end face of the first turntable 122a for axially limiting the first side of the first rotor bearing 115a. The two outwardly protruding portions of the second turntable 122b are respectively: the second installation portion 1223 provided on the second end face of the second turntable 122b for installing the rotor of the resolver (resolver for short); the limiting protrusion 1226 provided on the first end face of the second turntable 122b for axially limiting the second side of the second rotor bearing 115b.

[0154] In some embodiments, the axial flux dual-motor system 1000 further includes two oil temperature detection components, namely: the first oil temperature detection component, installed on the oil pump 500 or the housing assembly 200 for detecting the oil temperature of the oil storage cavity; and the second oil temperature detection component, provided at the oil outlet hole 111c of the stator assembly 110 for detecting the outlet oil temperature of the stator assembly 110. The resolver 700, the first oil temperature detection component, and the second oil temperature detection component are all electrically connected to the controller. As an implementation scheme, the first oil temperature detection component is integrated in the PCB circuit board of the electric oil pump for monitoring the oil temperature T0 of the oil storage cavity, and the second oil temperature detection component is arranged at the oil outlet hole 111c of the stator assembly 110 for monitoring the oil temperature T1 after the stator is cooled.

[0155] According to different working conditions of the axial flux dual-motor system 1000, the controller 300 estimates the motor power according to the thermal model, estimates the heat generated by the stator assembly 110, and then combines the oil temperature T0 at the oil outlet of the oil pump 500 to further estimate the outlet oil temperature T2 of the stator. According to the difference between the oil temperature T1 monitored by the sensor and the estimated oil temperature T2 after the stator is cooled, it is closed-loop input to the controller 300. According to the established electric drive thermal model, the rotation speed of the oil pump 500 is changed in real time to adjust the lubricating oil flow rate entering the stator assembly 110 and the inner cavity of the speed reducer 220, so as to realize the system cooling and lubrication function.

[0156] In addition, in some embodiments, an oil level surface with a certain height H may be set in the reducer installation cavity 220a of the speed reducer 220, and the height of the oil suction port of the oil pump 500 is set to be higher than the lowest point of the oil storage cavity of the speed reducer 220, that is, the height difference between the height of the oil suction port of the oil pump 500 and the lowest point of the oil storage cavity of the speed reducer 220 is H. When the temperature of the stator assembly 110 is relatively low and lubricating oil is not required for cooling, to reduce the power loss of the oil pump 500, when the oil suction port of the oil pump 500 is lower than the lowest oil level surface in the cavity of the speed reducer 220 (at this time, the oil suction of the oil pump is not smooth or no oil can be sucked), the oil pump 500 is controlled to stop. At this time, several gears and bearings in the speed reducer 220 drive the lubricating oil in its cavity to splash and lubricate through the planetary gear 413 and the planet carrier 412 to ensure the normal operation of the planetary gear set 410.

[0157] According to the axial flux motor 100 provided by one or more of the above embodiments, it has the following beneficial effects:

[0158] (1) The axial flux motor 100 provided in the present application has a simple and compact structure, with a unique sealing, cooling system, and electromagnetic scheme structure design and material selection application. Under the same volume (for example: the overall outer diameter of the axial flux motor is 310 mm, the thickness is 130 mm; the outer diameter of the rotor assembly is 280 mm, the thickness is 44 mm; the outer diameter of the stator assembly is 310 mm, the thickness is 45 mm), compared with other types of axial flux motors, the performance and efficiency are higher. The peak torque of the motor is 650 N·m, the peak power is 250 KW, the maximum speed is 12,000 rpm, the maximum efficiency is 97.5%, and the effective air gap is less than 2 mm (the physical air gap is 1.3 mm, and the effective air gap is 1.8 mm). Compared with the traditional radial flux motor, under the same volume, the weight is 30% lower, and the performance is at least 30% higher.

[0159] (2) For the axial flux motor 100 provided in the present application, the stator assembly adopts oil immersion cooling, and the stator winding 112 and the stator core 113 are immersed in the circulating oil for heat dissipation. When 10 L / min of cooling oil is passed inside the stator housing, the average temperature inside the stator can be maintained at about 85°C, and the maximum temperature is less than 150°C.

[0160] (3) For the axial flux motor 100 provided in the present application, the rotor assembly adopts a carbon fiber skeleton to fix the rotor magnet 123, restricting the tangential movement of the rotor magnet 123 under the action of high-speed rotation centrifugal force and the axial movement under the action of magnetic suction force.

[0161] (4) For the axial flux motor 100 provided in this application, since the back plate (axial cavity wall 1228) of the turntable of the rotor assembly is a single piece of metal plate and is not composed of stacked silicon steel sheets, large eddy current losses are likely to occur when the main magnetic circuit passes through. By installing the rotor iron core 124 made of soft magnetic material on the turntable, the soft magnetic sheet 1241 serves as a partition between the rotor magnet 123 and the turntable. With such a structural design, the eddy current losses of the magnet are further reduced. Under the operating conditions of peak speed and peak power, installing the rotor iron core 124 made of soft magnetic material (SMC) on the turntable 122 can effectively reduce the eddy current losses by 85% compared with the scheme without soft magnetic material (i.e., the interval = 0), as Figure 32 shown.

[0162] (5) For the axial flux motor 100 provided in this application, the rotor assembly can effectively reduce the eddy current losses by setting grooves 12314 in the rotor magnet 123. Compared with a solid magnet block of the same size, the eddy current losses are reduced by more than 95%. Please refer to Figure 33 . Under the operating conditions of peak speed and peak power, when the radial segmentation is 20 (i.e., the magnet unit 1231 is divided into 20 magnet sheets 12311 as a whole), the eddy current losses of the rotor magnet 123 are 2 kW. Compared with the rotor magnet 123 without grooves 12314 and with a radial segmentation of 0 (i.e., the magnet unit 1231 is a solid magnet block), the eddy current losses are reduced by more than 90%.

[0163] The axial flux dual - motor system 1000 provided according to one or more of the above - mentioned embodiments has the following beneficial effects:

[0164] (a) For the axial flux dual - motor system 1000 provided in this application, two axial flux motors are used as the electric drive output. Combining the characteristics of small axial size and large output torque of the axial flux motor, and then combining with the design of a single planetary gear train transmission mechanism with simple structure and low manufacturing cost, it greatly improves the convenience of electric drive vehicle layout and realizes the trend requirements of new energy vehicles such as high power density and lightweight of the electric drive.

[0165] (b) For the axial flux dual - motor system 1000 provided in this application, by using the immersion cooling design scheme, the temperature of the stator coil under high - power and high - torque operating conditions can be greatly reduced, and the electric drive efficiency can be improved.

[0166] (c) For the axial flux dual - motor system 1000 provided in this application, by using the co - oil cavity design of the motor and the reduction gearbox and adopting the automatic lubrication and cooling scheme, the overall lubricating oil volume of the electric drive can be accurately controlled, which can further improve the comprehensive efficiency of the electric drive, reduce the overall weight of the electric drive, and realize the lightweight design of the electric drive.

[0167] (d) The axial flux dual-motor system 1000 provided by this application uses an integrated design solution that integrates a dual-axial flux motor with a single-stage planetary gear set, greatly reducing the total number of components in the electric drive, making the power transmission simpler and more efficient. The overall axial dimension is reduced by 30% compared to the existing dual-motor distributed drive technology, and the vehicle adaptability is higher, further increasing the driving range of new energy vehicles.

[0168] In the second aspect of the embodiments of this application, a vehicle is provided. The vehicle includes the axial flux dual-motor system according to any one of the embodiments in the first aspect above. The vehicle can be a pure electric vehicle or a hybrid vehicle, and this application does not make any restrictions.

[0169] In this application, unless otherwise clearly specified and limited, the first feature being "on" or "under" the second feature may include direct contact between the first and second features, or may include the first and second features not being in direct contact but being in contact through additional features therebetween. Moreover, the first feature being "above", "over" and "on top of" the second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the first feature has a higher horizontal height than the second feature. The first feature being "under", "below" and "beneath" the second feature includes the first feature being directly below and obliquely below the second feature, or simply indicating that the first feature has a lower horizontal height than the second feature.

[0170] In the description of this application, it should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise" is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing this application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to this application.

[0171] It should be noted that all directional indications in the embodiments of this application are only used to explain the relative positional relationship and movement conditions between components in a specific posture. If this specific posture changes, the directional indications will also change accordingly.

[0172] In this application, unless otherwise clearly defined and limited, terms such as "connection" and "fixation" shall be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two components or the interaction relationship between two components, unless otherwise clearly limited. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0173] In addition, in this application, descriptions such as "first" and "second" are only for descriptive purposes and should not be construed as indicating or implying their relative importance or implicitly indicating the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more features. In the description of this application, "a plurality" means two or more, unless otherwise clearly and specifically defined.

[0174] In the description of this specification, the descriptions with reference to terms such as "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of this application. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, those skilled in the art can combine and combine the different embodiments or examples described in this specification.

[0175] In addition, the technical solutions between various embodiments can be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0176] Although the embodiments of this application have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and purposes of this application, and the scope of this application is defined by the claims and their equivalents.

Claims

1. An axial flux dual motor system, characterized in that: include: The housing assembly is provided with a controller installation cavity, a motor installation cavity and a reducer installation cavity; A controller, located in the controller installation cavity; Two axial flux motors are arranged side by side in the motor installation cavity along the axial direction of the axial flux motor, and are both electrically connected to the controller; Two planetary gears are located in the reducer installation cavity and are symmetrically distributed on the outsides of the two axial flux motors. The two planetary gears are respectively connected to the rotor assemblies of the two axial flux motors.

2. The axial flux dual motor system according to claim 1, characterized in that: The housing assembly includes a motor housing, a controller housing and two reduction gearboxes, the two reduction gearboxes are respectively connected to the openings at both ends of the motor housing and are close to the rotor assembly; the reduction gearbox and the motor housing together form the motor mounting cavity, the inner cavity of the controller housing forms the controller mounting cavity, and the inner cavity of the reduction gearbox forms the reducer mounting cavity.

3. The axial flux dual motor system according to claim 2, characterized in that: Both of the axial flux motors are of a single-stator dual-rotor structure, including a rotor shaft and a first rotor assembly, a stator assembly and a second rotor assembly arranged in sequence along the axial direction of the rotor shaft. The rotor shaft is fixedly connected to the output part of the first rotor assembly, and the rotor shaft is transmission-connected to the output part of the second rotor assembly.

4. The axial flux dual motor system according to claim 3, characterized in that: The first rotor assembly and the second rotor assembly both include a turntable, a rotor core, a rotor magnet and a rotor frame which are arranged in sequence; the turntable is connected to the rotor frame to axially limit the rotor core and the rotor magnet.

5. The axial flux dual motor system according to claim 4, characterized in that: The rotor shaft comprises a first shaft section, a spline shaft and a third shaft section which are connected in sequence; the rotor shaft and the turntable of the first rotor assembly are an integrated structure; the rotor shaft is key-connected to the turntable of the second rotor assembly via the spline shaft; the first shaft section is interference-fitted with a first rotor bearing and a second rotor bearing.

6. The axial flux dual motor system according to claim 5, characterized in that: The two axial flux motors are arranged side by side along the axial direction with the second rotor assemblies close to each other; The axial flux dual-motor system also includes two resolvers, the stators of the two resolvers are respectively connected to the motor housing, and the rotors of the two resolvers are respectively connected to the turntables of the two second rotor assemblies.

7. The axial flux dual motor system according to claim 6, characterized in that: The first shaft section is provided with an internal spline; the sun gear of the planetary gear is provided with an input shaft, and the input shaft is drivingly connected with the internal spline of the first shaft section; An oil seal is provided between the reduction box and the rotating disk of the first rotor assembly.

8. The axial flux dual motor system according to claim 4, characterized in that: The rotor magnetic steel comprises a plurality of magnetic steel units distributed in a circumferential array; the magnetic steel unit comprises a plurality of magnetic steel sheets stacked in sequence along the radial direction, and adjacent magnetic steel sheets are glued and fixed; the magnetic steel sheets are flat plates or arc-shaped plates.

9. The axial flux dual motor system according to claim 8, characterized in that: A recess is provided on the side of the magnetic steel unit, and the recesses of two adjacent magnetic steel units form a receiving groove. The rotor frame is embedded in the receiving groove and pressed against the bottom wall of the recess.

10. The axial flux dual motor system according to claim 8, characterized in that: The turntable has an inner cavity, and the inner wall of the turntable is provided with a plurality of first limiting ribs spaced apart along the circumferential direction, and the inner cavity of the turntable is divided into a plurality of first limiting grooves by the first limiting ribs; The rotor core comprises a plurality of soft magnetic sheets distributed in a circumferential array; the plurality of soft magnetic sheets are arranged in a plurality of first limiting grooves in a one-to-one correspondence; the soft magnetic sheets are glued and fixed to the turntable; The soft magnetic sheet is provided with a second limiting rib, which is staggered with the first limiting rib; two adjacent soft magnetic sheets form a second limiting groove through the second limiting rib; and a plurality of the magnetic steel units are arranged in a one-to-one correspondence in a plurality of the second limiting grooves.

11. The axial flux dual motor system according to any one of claims 3 to 10, characterized in that: The stator assembly comprises a stator housing having a stator mounting cavity, and a stator winding, a stator core and a stator bushing located in the stator mounting cavity; the stator winding is wound on the stator core; The stator housing is provided with an oil inlet hole, an oil outlet hole and a copper bar outlet which are communicated with the stator installation cavity; the three-phase copper bars of the stator winding extend out through the copper bar outlet.

12. The axial flux dual motor system according to claim 11, characterized in that: The stator core includes a plurality of soft magnetic blocks distributed in a circumferential array; The stator winding comprises a plurality of coil windings spaced and evenly distributed along the circumferential direction and connecting wires for connecting the coil windings; the plurality of coil windings are wound one by one on the plurality of soft magnetic blocks; The stator housing is provided with a plurality of blocking members spaced apart along the circumferential direction, and the blocking members are located between the coil winding and the stator housing, so that the blocking members, the coil winding and the stator housing are surrounded to form a cooling oil channel; The coil winding and the connecting wire are both flat wires; the connecting wire runs through the blocking member.

13. The axial flux dual motor system according to claim 11, characterized in that: The stator housing is annular; the stator housing includes two housing parts, and the two housing parts are sealed by a first sealing member; The stator assembly further comprises two stator bushings, which are respectively interference-fitted in the annular holes of the two housing components, and the two stator bushings are sealed by a second sealing member; A sealing insert is provided in the stator housing, and the sealing insert is coated on the three-phase copper bar, embedded in the copper bar outlet and located on the outside of the first sealing member.

14. The axial flux dual motor system according to claim 11, characterized in that: The stator shell is made of non-magnetic material; the tensile strength of the stator shell is above 1500MPa and the rigidity is above 20000N / mm.

15. The axial flux dual motor system according to claim 11, characterized in that: It also includes two oil pumps and two oil coolers, wherein the oil pump and the oil cooler located on the same side are respectively installed on the reduction box and the motor housing on the same side; A plurality of oil passages are provided in the walls of the motor housing and the two controller housings, and the oil pump, the oil cooler, the stator mounting cavity and the reducer mounting cavity are sequentially connected through the oil passages to form an electric drive lubrication cooling circuit.

16. The axial flux dual motor system according to claim 15, characterized in that: A first bearing is provided between the planetary gear train and the reduction box; the planetary gear shaft of the planetary gear train is provided with a communicating oil guide cavity and an oil guide hole; the planetary gear of the planetary gear train is mounted on the planetary gear shaft through a second bearing, and the second bearing corresponds to the position of the oil guide hole; The reducer is provided with an oil collecting pan, which is connected to the planet carrier of the planetary gear; the oil collecting pan is provided with oil outlet nozzles having the same number as the planetary gear shafts, and the oil outlet nozzles extend into the corresponding oil guide chambers to connect the oil guide chambers and the oil collecting chambers of the oil collecting pan; The installation space of the first bearing and the oil collecting cavity of the oil collecting pan are respectively communicated with the corresponding oil passages.

17. The axial flux dual motor system according to claim 16, characterized in that: The reduction box comprises a reduction box body and an end cover connected thereto, and the reduction box body is connected to the motor housing; The planet carrier is provided with an output shaft, and the first bearing is provided between the output shaft and the end cover; The oil collecting pan is annular and sleeved on an end of the planet carrier away from the output shaft.

18. The axial flux dual motor system according to claim 17, characterized in that: A third bearing and a fourth bearing are provided between the sun gear of the planetary row and the planet carrier; An end of the planet carrier away from the output shaft is provided with a convex edge protruding along the axial direction, the oil collecting pan is sleeved on the outer side of the convex edge, and the fourth bearing is embedded in the inner side of the convex edge.

19. The axial flux dual motor system according to claim 16, characterized in that: An oil storage cavity connected to the reducer mounting cavity is provided at the bottom of the reduction box, an oil filter and a magnet are provided in the wall of the reduction box, and the oil filter and the magnet are both provided in the oil passage connected to the oil storage cavity.

20. The axial flux dual motor system according to claim 15, characterized in that: The oil cooler is an oil-water heat exchanger; a water cooling chamber for heat exchange with the controller is provided in the controller housing, and a plurality of water channels are provided in the box wall of the motor housing and / or the controller housing, and the oil-water heat exchanger is connected to the water cooling chamber through the water channels.

21. A vehicle, characterized in that: An axial flux dual motor system comprising any one of claims 1-20.

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