Axial flux motor

Abstract

The invention provides an axial magnetic flux motor. A stator structure of the axial magnetic flux motor comprises a stator supporting piece, a plurality of stator iron cores and two pole shoe cover plates. The stator supporting piece is provided with a plurality of accommodating grooves arranged along the circumferential direction, and the accommodating grooves penetrate through the stator supporting piece along the axial direction; the plurality of stator iron cores are correspondingly arranged in the plurality of accommodating grooves, each stator iron core comprises a coil winding and an iron core, the coil winding is provided with an iron core groove penetrating in the axial direction, the iron core is arranged in the iron core groove, the two ends of the iron core extend out of the iron core groove to form two extending ends, and the iron core is of a lamination structure adopting self-bonding silicon steel sheets; the two pole shoe cover plates are correspondingly arranged on the two sides of the stator supporting piece in the axial direction, a containing space for containing the multiple stator iron cores is formed between the two pole shoe cover plates, each pole shoe cover plate is provided with multiple through grooves formed in the circumferential direction, the positions of the multiple through grooves correspond to the positions of the iron cores of the multiple stator iron cores in a one-to-one mode, and the through grooves penetrate through the pole shoe cover plates in the axial direction. And the two extending ends of the iron core correspondingly extend into the corresponding through grooves of the two pole shoe cover plates.

Description

Technical Field

[0001] The present invention relates to the technical field of axial flux motors. Background Art

[0002] Axial flux motors belong to a current emerging type of motor, which have prominent advantages, but also obviously have corresponding disadvantages. For example, the machining processability of axial flux motors is poor, the manufacturing cost is high, and the increase in the motor power density brings an increase in heat generation, which limits the performance of the motor. In particular, for existing axial flux motors adopting the YASA configuration, higher requirements are put forward for the process. The iron cores of such motors are usually die-cast with SMC (Sheet molding compound) materials. The saturation magnetic flux of SMC materials is lower than that of traditional silicon steel materials, thus limiting the performance of the motor to a certain extent. In addition, in application scenarios such as unmanned aerial vehicles and robots, higher requirements are also put forward for the protection level of the electrodes, and existing axial flux motors are difficult to meet the above requirements. Summary of the Invention

[0003] A main object of the present invention is to overcome at least one defect of the above-mentioned prior art, and to provide an axial flux motor with better performance.

[0004] To achieve the above object, the present invention adopts the following technical solutions:

[0005] According to one aspect of the present invention, there is provided an axial flux motor, which includes a rotor structure and a stator structure. The stator structure includes a stator support, a plurality of stator cores, and two pole shoe covers. The stator support has a plurality of receiving grooves arranged circumferentially, and the receiving grooves axially penetrate the stator support. The plurality of stator cores are correspondingly arranged in the plurality of receiving grooves. The stator core includes a coil winding and an iron core. The coil winding has an iron core groove axially penetrating therethrough. The iron core is arranged in the iron core groove, and two extending ends are formed at both ends of the iron core extending out of the iron core groove. The iron core is a laminated structure made of self-bonding silicon steel sheets. The two pole shoe covers are correspondingly arranged on both sides of the stator support in the axial direction. An accommodation space for accommodating the plurality of stator cores is formed between the two pole shoe covers. The pole shoe cover has a plurality of through grooves arranged circumferentially, and the positions of the plurality of through grooves correspond one-to-one to the positions of the iron cores of the plurality of stator cores. The through grooves axially penetrate the pole shoe cover, and the two extending ends of the iron core correspondingly extend into the corresponding through grooves of the two pole shoe covers.

[0006] According to one embodiment of the present invention, the iron core has a main body, which is the part of the iron core located in the iron core slot, and the main body is fixedly connected to the protruding end; wherein: the width of the protruding end is smaller than the width of the main body, so that a limiting step is formed at the corner of the iron core; the width of the through slot is greater than or equal to the width of the protruding end and smaller than the width of the main body; and / or, the thickness of the protruding end is equal to the thickness of the main body.

[0007] According to one embodiment of the present invention, the orthographic projection of the iron core on the reference plane is rectangular, and the reference plane is parallel to the plane formed by the radial direction and the axial direction of the stator support.

[0008] According to one embodiment of the present invention, wherein: a heat-conducting insulating layer is provided on the surface of the iron core; and / or, the voids in the accommodation space not occupied by the stator core are filled with heat-conducting potting glue.

[0009] According to one embodiment of the present invention, the pole shoe cover plate further has a plurality of magnetic circuit isolation grooves, the magnetic circuit isolation grooves penetrate through the pole shoe cover plate along the axial direction, the orthographic projection of the magnetic circuit isolation grooves on the reference plane is arranged around the orthographic projection of the stator core on the reference plane, and the plurality of magnetic circuit isolation grooves include a plurality of radial grooves, a plurality of inner circumferential grooves and a plurality of outer circumferential grooves; each radial groove is located between adjacent through slots and is arranged along the radial direction of the pole shoe cover plate; each inner circumferential groove is located between adjacent radial grooves and is arranged close to the inner peripheral edge of the pole shoe cover plate; each outer circumferential groove is located between adjacent radial grooves and is arranged close to the outer peripheral edge of the pole shoe cover plate; the plurality of magnetic circuit isolation grooves form a plurality of isolation regions on the pole shoe cover plate, the plurality of isolation regions are arranged in a circumferential direction, and each isolation region has one of the through slots.

[0010] According to one embodiment of the present invention, wherein: the distance between one end of the radial groove close to the inner peripheral edge of the pole shoe cover plate and the inner peripheral edge is smaller than the distance between the inner circumferential groove and the inner peripheral edge; and / or, the distance between one end of the radial groove close to the outer peripheral edge of the pole shoe cover plate and the outer peripheral edge is smaller than the distance between the outer circumferential groove and the outer peripheral edge.

[0011] According to one embodiment of the present invention, the rotor structure of the axial flux motor includes two rotor assemblies and bearings, the two rotor assemblies are correspondingly located on both sides of the stator structure in the axial direction, and the rotor assembly includes a rotor support; the rotor support is rotatably connected to the stator structure through the bearing, and a plurality of spokes are provided on the surface of the rotor support away from the stator structure, the plurality of spokes are arranged at intervals in the circumferential direction, and the spokes extend along the radial direction of the rotor support; the plurality of spokes form a centrifugal fan in the axial flux motor.

[0012] According to one embodiment of the present invention, the rotor assembly further includes a rotor back iron and a plurality of permanent magnets; the rotor back iron is disposed on a surface of the rotor support member close to the stator structure; the plurality of permanent magnets are disposed on a surface of the rotor back iron close to the stator structure and are arranged at intervals in the circumferential direction.

[0013] According to one embodiment of the present invention, positioning ribs are provided between adjacent permanent magnets, and the positioning ribs extend in the radial direction of the rotor back iron.

[0014] According to one embodiment of the present invention, wherein: the rotor back iron is adhesively connected to the rotor support member; and / or, the permanent magnet is adhesively connected to the rotor back iron.

[0015] As can be seen from the above technical solutions, the advantages and positive effects of the axial flux motor proposed by the present invention are as follows:

[0016] The stator structure of the axial flux motor proposed by the present invention includes a stator support member, a plurality of stator cores, and two pole shoe covers. The plurality of stator cores are correspondingly disposed in a plurality of receiving grooves of the stator support member. The stator core includes a coil winding and an iron core. The iron core is disposed in an iron core groove of the coil winding. Two protruding ends are formed at both ends of the iron core protruding from the iron core groove. The iron core is a laminated structure made of self-bonding silicon steel sheets. The two pole shoe covers are correspondingly disposed on both sides of the stator support member in the axial direction. An accommodation space for accommodating a plurality of stator cores is formed between the two pole shoe covers. The pole shoe cover has a plurality of through grooves arranged in the circumferential direction. The positions of the plurality of through grooves correspond to the positions of the plurality of iron cores one by one. The through grooves penetrate the pole shoe cover in the axial direction. The two protruding ends of the iron core correspondingly extend into the corresponding through grooves of the two pole shoe covers. Through the above design, the present invention uses a laminated structure of self-bonding silicon steel sheets for the iron core, thereby effectively enhancing the torque performance of the motor. At the same time, the present invention utilizes the cooperation between the protruding ends of the iron core and the through grooves of the pole shoe cover to realize the functional cooperation between the iron core and the permanent magnet located outside the pole shoe cover, and can also realize the positioning of the stator core. Through the above integrated cooperation design of the pole shoe cover and the iron core, the present invention can realize the optimization of the manufacturing process and the improvement of the electromagnetic performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] By considering the following detailed description of the preferred embodiments of the present invention in conjunction with the drawings, various objects, features, and advantages of the present invention will become more apparent. The drawings are only illustrative diagrams of the present invention and are not necessarily drawn to scale. In the drawings, the same reference numerals always represent the same or similar components. Among them:

[0018] Figure 1 is a three-dimensional structural schematic diagram of an axial flux motor shown according to an exemplary embodiment;

[0019] Figure 2 is Figure 1 a schematic plan view of the axial flux motor shown;

[0020] Figure 3 is along Figure 1 the sectional view taken along the straight line A-A in;

[0021] Figure 4 is Figure 1 a schematic exploded perspective view of the axial flux motor shown;

[0022] Figure 5 is Figure 1 a schematic perspective view of the stator structure of the axial flux motor shown;

[0023] Figure 6 is Figure 5 a schematic perspective view of a partial structure of the stator structure shown;

[0024] Figure 7 is Figure 6 a schematic perspective view of the pole shoe cover plate shown;

[0025] Figure 8 is Figure 5 a schematic sectional perspective view of the stator structure during the production and manufacturing process shown;

[0026] Figure 9 is Figure 1 a schematic perspective view of a stator core of the axial flux motor shown;

[0027] Figure 10 is Figure 9 a schematic plan view of the stator core shown;

[0028] Figure 11 is along Figure 10 the sectional view taken along the straight line B-B in;

[0029] Figure 12 is Figure 1 a schematic sectional perspective view of the rotor structure of the axial flux motor shown;

[0030] Figure 13 is Figure 1 a schematic perspective view of the rotor back iron of the axial flux motor shown.

[0031] The description of the reference numerals is as follows:

[0032] 100. Stator structure; 133. Inner circumferential groove;

[0033] 110. Stator support; 134. Outer circumferential groove;

[0034] 120. Stator core; 210. Rotor support

[0035] 121. Coil winding; 211. Spoke

[0036] 1211. Core slot; 220. Rotor back iron

[0037] 122. Iron core; 221. Positioning rib

[0038] 1221. Main body; 230. Permanent magnet

[0039] 1222. Extended end; 250. Bearing

[0040] 1223. Limit step; 310. First potting component

[0041] 130. Pole shoe cover plate; 320. Second potting component

[0042] 131. Through slot; S1. Isolation area

[0043] 132. Radial slot; S2. Glue injection port

[0044] 1321. First end; W1. Width

[0045] 1322. Second end; W2. Width Detailed implementation

[0046] Typical embodiments embodying the features and advantages of the present invention will be described in detail in the following description. It should be understood that the present invention can have various variations in different embodiments, all of which do not depart from the scope of the present invention, and the descriptions and drawings therein are for illustrative purposes in nature and not for limiting the present invention.

[0047] In the following description of different exemplary embodiments of the present invention, reference is made to the accompanying drawings, which form a part of the present invention and in which are shown, by way of example, different exemplary structures, systems, and steps that can implement various aspects of the present invention. It should be understood that other specific solutions of components, structures, exemplary devices, systems, and steps can be used, and structural and functional modifications can be made without departing from the scope of the present invention. Moreover, although terms such as "above", "between", "within", etc. may be used in this specification to describe different exemplary features and elements of the present invention, these terms are used herein only for convenience, for example, according to the directions of the examples described in the accompanying drawings. Nothing in this specification should be construed as requiring a specific three-dimensional direction of the structure to fall within the scope of the present invention.

[0048] Refer to Figure 1, which representatively shows a schematic three-dimensional structure diagram of the axial flux motor proposed by the present invention. In this exemplary embodiment, the axial flux motor proposed by the present invention is described by taking its application to unmanned aerial vehicles or robots as an example. It is easy for those skilled in the art to understand that, in order to apply the relevant designs of the present invention to other application scenarios, various modifications, additions, substitutions, deletions or other changes are made to the following specific embodiments, and these changes are still within the scope of the principle of the axial flux motor proposed by the present invention.

[0049] Refer to Figures 2 to 13 , Figure 2 which representatively shows a schematic plan view of the axial flux motor; Figure 3 which representatively shows a cross-sectional view taken along Figure 1 the straight line A-A in Figure 4 which representatively shows a schematic exploded three-dimensional view of the axial flux motor; Figure 5 which representatively shows a schematic three-dimensional structure diagram of the stator structure 100; Figure 6 which representatively shows a schematic three-dimensional structure diagram of a part of the stator structure 100; Figure 7 which representatively shows a schematic three-dimensional structure diagram of the pole shoe cover plate 130;

[0050] Figure 8 which representatively shows a schematic three-dimensional cross-sectional view of the stator structure 100 during the production and manufacturing process;

[0051] Figure 9 which representatively shows a schematic three-dimensional structure diagram of a stator core 120; Figure 10 which representatively shows a schematic plan view of the stator core 120; Figure 11 which representatively shows a cross-sectional view taken along Figure 10 the straight line B-B in Figure 12 which representatively shows a schematic three-dimensional cross-sectional view of the rotor structure; Figure 13 which representatively shows a schematic three-dimensional structure diagram of the rotor back iron 220. The following will describe in detail the structures, connection methods and functional relationships of the main components of the axial flux motor proposed by the present invention with reference to the above-mentioned drawings.

[0052] As Figures 1 to 11As shown, in an embodiment of the present invention, the axial flux motor proposed by the present invention includes a rotor structure and a stator structure. The stator structure 100 may adopt, for example, a segmented winding structure, and the stator structure 100 includes a stator support 110, a plurality of stator cores 120, and two pole shoe covers 130. Specifically, the stator support 110 has a plurality of receiving grooves arranged circumferentially (for example, evenly spaced along the circumferential direction), and the receiving grooves penetrate the stator support 110 axially. The plurality of stator cores 120 are correspondingly arranged in the plurality of receiving grooves, and the stator core 120 includes a coil winding 121 and a core 122. The coil winding 121 has a core groove 1211 penetrating axially, and the core 122 is arranged in the core groove 1211. For example, the main body 1221 of the core 122 is embedded in the core groove 1211, and the two ends of the core 122 extend out of the core groove 1211 to form two protruding ends 1222, that is, the two protruding ends 1222 are fixedly connected to the two ends of the main body 1221 of the core 122 axially. Among them, the core 122 is a laminated structure made of self-bonding silicon steel sheets, that is, each core 122 is prepared by a lamination process of multiple self-bonding silicon steel sheets. The two pole shoe covers 130 are correspondingly arranged on both sides of the stator support 110 axially, and an accommodating space capable of accommodating a plurality of stator cores 120 is formed between the two pole shoe covers 130. The pole shoe cover 130 has a plurality of through grooves 131 arranged circumferentially, and the positions of the plurality of through grooves 131 correspond to the positions of the plurality of cores 122 one by one. The through grooves 131 penetrate the pole shoe cover 130 axially, and the two protruding ends 1222 of the core 122 correspondingly extend into the corresponding through grooves 131 of the two pole shoe covers 130. That is, the plurality of stator cores 120 are positioned by the two pole shoe covers 130.

[0053] Through the above design, the present invention adopts a laminated structure of self-bonding silicon steel sheets for the core 122, thereby effectively enhancing the torque performance of the motor. At the same time, by using the cooperation between the protruding ends 1222 of the core 122 and the through grooves 131 of the pole shoe cover 130, the present invention can realize the functional cooperation between the core 122 and the permanent magnet 230 located outside the pole shoe cover 130, and can also realize the positioning of the stator core 120. Compared with existing axial flux motors such as YASA configuration products or EMRAX products that require additional installation jigs to achieve the circumferential positioning of the stator core 120, the present invention can directly achieve positioning by using the pole shoe cover 130 without adding additional installation jigs. Through the integrated cooperation design of the above-mentioned pole shoe cover 130 and the core 122, the present invention can optimize the manufacturing process and improve the electromagnetic performance. In addition, compared with existing axial flux motors, the present invention further adopts a non-magnetic yoke motor configuration on the basis of the YASA configuration, and has a high torque volume density. The segmented core 122 winding and the separated pole shoe cover 130 design improve the design flexibility of the motor and can better position and connect the stator electromagnetic part and the housing.

[0054] As Figure 7 , Figures 9 to 11 shown, in an embodiment of the present invention, the iron core 122 has a main body 1221, which is the part of the iron core 122 located in the iron core slot 1211, and the main body 1221 of the iron core 122 is fixedly connected to the protruding end 1222. The width W1 of the protruding end 1222 can be smaller than the width W2 of the main body 1221, so that a limiting step 1223 can be formed at the corner of the iron core 122. On this basis, the width of the through slot 131 of the pole shoe cover plate 130 can be greater than or equal to the width W1 of the protruding end 1222 and smaller than the width W2 of the main body 1221. Through the above design, the present invention can use the limiting step 1223 to realize the limitation of the iron core 122 and the pole shoe cover plate 130, avoid the iron core 122 from slipping out of the through slot 131, and improve the structural stability and reliability of the axial flux motor.

[0055] As Figure 11 shown, based on the design that the width W1 of the protruding end 1222 is smaller than the width W2 of the main body 1221, in an embodiment of the present invention, the ratio of the width W1 of the protruding end 1222 to the width W2 of the main body 1221 can be 0.8 to 0.95, such as 0.8, 0.85, 0.88, 0.9, 0.95, etc. Through the above design, the present invention can avoid the insufficient area of the protruding end 1222 exposed in the through slot 131 due to the too small ratio of the width of the protruding end 1222, and can also avoid the influence on the magnetic circuit, thereby ensuring the normal functional cooperation between the iron core 122 and the permanent magnet 230. At the same time, the present invention can avoid that the ratio of the width of the protruding end 1222 is too large, resulting in a smaller limiting step 1223 and thus a less obvious limiting function. In some embodiments, the ratio of the width W1 of the protruding end 1222 to the width W2 of the main body 1221 can also be less than 0.8, or greater than 0.95, such as 0.79, 0.96, etc., which is not limited to this embodiment.

[0056] As Figure 9 and Figure 11 shown, in an embodiment of the present invention, the thickness of the protruding end 1222 can be equal to the thickness of the main body 1221. Through the above design, the present invention can ensure that the area of the protruding end 1222 exposed in the through slot 131 is larger, and at the same time reduce the complexity of the lamination process of the self-bonding silicon steel sheet.

[0057] As Figure 11 shown, in an embodiment of the present invention, a reference plane is defined, which is parallel to the plane formed by the radial and axial directions of the stator support 110. On the reference plane, the orthographic projection of the iron core 122 can be rectangular. Through the above design, the present invention can further reduce the complexity of the lamination process of the self-bonding silicon steel sheet by using the rectangular iron core 122. It should be noted that in Figures 9 to 11In the illustrated embodiment, when a limiting step 1223 is formed at the corner of the iron core 122 in the radial direction of the stator support 110, the orthographic projection of the iron core 122 is approximately rectangular, which can also be understood as the orthographic projection of the main body of the iron core 122 being rectangular, and the orthographic projection of the protruding end 1222 of the iron core 122 being rectangular.

[0058] In an embodiment of the present invention, the end face of the protruding end 1222 (i.e., the surface on the side of the protruding end 1222 facing away from the main body) is flush with the surface on the side of the corresponding pole shoe cover plate 130 away from the stator support 110.

[0059] As Figure 11 shown, in an embodiment of the present invention, a thermally conductive insulating layer may be provided on the surface of the iron core 122. Through the above design, the present invention can achieve a heat dissipation method of contact heat dissipation on the basis of ensuring insulation performance, effectively solving the heat dissipation problem of the axial flux motor under the high protection design concept.

[0060] Based on the design of providing a thermally conductive insulating layer on the surface of the iron core 122, in an embodiment of the present invention, the thermally conductive insulating layer may be a thermally conductive insulating paper made of boron nitride (BN). In some embodiments, the thermally conductive insulating layer may also adopt other materials of thermally conductive insulating paper or other thermally conductive insulating materials, and is not limited to this embodiment.

[0061] Specifically, the heat generated by the iron core 122 due to the eddy current effect and the heat generated by the coil loss of the coil winding 121 (such as the copper loss of the current-carrying winding) will be transferred to the stator support 110 in a contact heat transfer manner through the thermally conductive insulating layer and the potting adhesive with high thermal conductivity, so as to perform convective heat transfer with the external air, thereby effectively improving the heat dissipation efficiency of the motor and effectively ensuring the heat dissipation capacity of the motor under the characteristics of a high-protection motor.

[0062] As Figure 3 shown, in an embodiment of the present invention, a receiving space for accommodating a plurality of stator cores 120 is formed between the two pole shoe cover plates 130, and the void in the receiving space not occupied by the stator cores 120 is filled with a thermally conductive potting adhesive.

[0063] Among them, Figure 8 Specifically shows a three-dimensional cross-sectional view of the stator structure 100 in the potting process, as Figure 8As shown, the stator core 120 of the stator structure 100 can be fixedly connected to the stator support 110 by potting. For example, after multiple stator cores 120 and the stator support 110 are assembled, a potting tooling can be used to cooperate with the implementation of pouring and filling potting glue. For example, the potting tooling can adopt the first potting component 310 and the second potting component 320 shown in the drawings. These two potting components are respectively arranged on both axial sides of multiple stator cores 120 to achieve axial and radial positioning of the stator core 120 and the stator support 110. Moreover, a plurality of potting ports S2 are formed between the potting components and the stator support 110, and the plurality of potting ports S2 are respectively communicated with a plurality of receiving grooves. Accordingly, by potting through the plurality of potting ports S2, the voids in each receiving groove that are not occupied by the stator core 120 can be filled with thermally conductive potting glue. In addition, the potted combined structure and the stator support cover can be connected using connecting parts such as screws. It should be understood that Figure 8 The process scheme shown is only exemplary and does not limit the present invention from adopting other process schemes to implement the potting of thermally conductive potting glue.

[0064] Furthermore, the materials of the above two potting components can respectively adopt Teflon. After preliminary experimental verification, there is no adhesiveness between the Teflon material and the potting glue, which is suitable as a potting mold in this application scenario.

[0065] As Figures 5 to 7 shown, in an embodiment of the present invention, the pole shoe cover plate 130 can further have a plurality of magnetic circuit isolation grooves. The magnetic circuit isolation grooves axially penetrate the pole shoe cover plate 130, and the orthographic projection of the magnetic circuit isolation grooves on the reference plane is arranged around the orthographic projection of the stator core 120 on the reference plane. The reference plane is parallel to the plane formed by the radial and axial directions of the stator support 110. The plurality of magnetic circuit isolation grooves include a plurality of radial grooves 132, a plurality of inner circumferential grooves 133, and a plurality of outer circumferential grooves 134. Specifically, each radial groove 132 is located between adjacent through grooves 131, and the radial groove 132 is arranged along the radial direction of the pole shoe cover plate 130. Each inner circumferential groove 133 is located between adjacent radial grooves 132, and the inner circumferential groove 133 is arranged closer to the inner peripheral edge of the pole shoe cover plate 130 than the through groove 131. Each outer circumferential groove 134 is located between adjacent radial grooves 132, and the outer circumferential groove 134 is arranged closer to the outer peripheral edge of the pole shoe cover plate 130 than the through groove 131. Accordingly, a plurality of isolation regions S1 are formed on the pole shoe cover plate 130 by the plurality of magnetic circuit isolation grooves. The plurality of isolation regions S1 are arranged in a circumferential direction, and each isolation region S1 has a through groove 131, that is, the plurality of isolation regions S1 respectively correspond to the plurality of stator cores 120. Through the above design, the present invention can effectively optimize the magnetic circuit of the iron core 122, reduce magnetic leakage, and improve the torque of the motor.

[0066] It should be noted that in Figure 7In the illustrated embodiment, the shape of the radial groove 132 may be a straight line, and the straight line corresponding to the straight line extends radially along the pole shoe cover 130. Furthermore, the inner circumferential groove 133 and the outer circumferential groove 134 may be curved, specifically arc-shaped, and the center of the circle corresponding to the arc is suitable to coincide with the center of the pole shoe cover 130. It should be understood that, in some embodiments, the magnetic circuit isolation groove provided on the pole shoe cover 130 may not be limited to the above-mentioned design of distinguishing the radial groove 132, the inner circumferential groove 133 and the outer circumferential groove 134, and according to the different forms of the magnetic circuit isolation groove, it may specifically adopt any possible shape other than a closed shape, such as a broken line (specifically, "凵", The shapes of the through groove 131 and the like are not limited to the straight line and arc shape used in the embodiments shown in the drawings.

[0067] like Figures 5 to 7 As shown, based on the design that the pole shoe cover plate 130 has a radial groove 132, an inner circumferential groove 133 and an outer circumferential groove 134, in one embodiment of the present invention, the radial groove 132 has a first end 1321 and a second end 1322, the first end 1321 is relatively close to the inner circumference of the pole shoe cover plate 130, and the second end 1322 is relatively close to the second end 1322 of the outer circumference of the pole shoe cover plate 130. On this basis, the distance between one end of the radial groove 132 close to the inner circumference of the pole shoe cover plate 130 (for example, the first end 1321) and the inner circumference of the pole shoe cover plate 130 can be less than the distance between the inner circumferential groove 133 and the inner circumference. Through the above design, the present invention can make one end of the radial groove 132 close to the inner circumference of the pole shoe cover plate 130 radially exceed the inner circumferential groove 133, thereby further optimizing the magnetic circuit of the iron core 122.

[0068] like Figures 5 to 7 As shown, in one embodiment of the present invention, the distance between one end (e.g., the second end 1322) of the radial slot 132 close to the outer periphery of the pole shoe cover 130 and the outer periphery of the pole shoe cover 130 may be smaller than the distance between the outer circumferential slot 134 and the outer periphery. Through the above design, the present invention can make one end of the radial slot 132 close to the outer periphery of the pole shoe cover 130 radially exceed the outer circumferential slot 134, thereby further optimizing the magnetic circuit of the core 122.

[0069] like Figure 12 and Figure 13As shown, in an embodiment of the present invention, the rotor structure of the axial flux motor includes two rotor assemblies and a bearing 250 (such as but not limited to a four-point contact bearing), and the two rotor assemblies are correspondingly located on both axial sides of the stator structure 100. Specifically, the rotor assembly includes a rotor support 210. The rotor support 210 is rotatably connected to the stator structure 100 through the bearing 250. A plurality of spokes 211 are provided on the surface of the rotor support 210 away from the stator structure 100. The plurality of spokes 211 are arranged at intervals in the circumferential direction, and the spokes 211 extend radially along the rotor support 210. Accordingly, the plurality of spokes 211 can form a centrifugal fan in the axial flux motor. Through the above design, while the present invention adopts a contact heat dissipation method inside the motor, it can utilize the centrifugal fan formed by the plurality of spokes 211 to disturb the air inside the motor, form an annular flow path inside the motor, thereby improving the overall heat dissipation performance of the motor, and at the same time can avoid the occurrence of local hot spots inside the motor, making the heat generated inside the motor more easily dissipated to the outside, thereby enhancing the reliability of the motor.

[0070] Specifically, the centrifugal fan realizes uniform temperature inside through the way of internal flow disturbance, avoids local overheating of temperature, and can effectively improve the temperature resistance ability of the motor. After realizing uniform temperature inside, the heat can also be conducted to other metal components, further improving the heat dissipation efficiency of the motor.

[0071] As Figure 12 and Figure 13 shown, in an embodiment of the present invention, the rotor assembly further includes a rotor back iron 220 and a plurality of permanent magnets 230. Specifically, the rotor back iron 220 is provided on the surface of the rotor support 210 close to the stator structure 100. The plurality of permanent magnets 230 are provided on the surface of the rotor back iron 220 close to the stator structure 100, and the plurality of permanent magnets 230 are arranged at intervals in the circumferential direction.

[0072] As Figure 13 shown, based on the design that the rotor assembly includes a rotor back iron 220 and a plurality of permanent magnets 230, in an embodiment of the present invention, a plurality of positioning ribs 221 can be provided between adjacent permanent magnets 230. The positioning ribs 221 extend radially along the rotor back iron 220. On this basis, each positioning rib 221 is respectively located between every two adjacent permanent magnets 230 to limit the circumferential distance between adjacent two permanent magnets 230. Through the above design, the present invention can further improve the structural stability and reliability of the motor.

[0073] As Figure 12As shown, based on the design in which the rotor assembly includes a rotor support 210, in an embodiment of the present invention, an annular groove may be provided on a surface of the rotor support 210 close to the stator structure 100, and the rotor back iron 220 and the permanent magnets 230 are both accommodated in the annular groove. On this basis, the rotor back iron 220 is provided at the bottom of the annular groove, and a plurality of permanent magnets 230 are provided on a surface of the rotor back iron 220 facing the notch of the annular groove.

[0074] Based on the design in which the rotor assembly includes a rotor support 210 and a rotor back iron 220, in an embodiment of the present invention, the rotor back iron 220 may be adhesively connected to the rotor support 210.

[0075] Based on the design in which the rotor assembly includes a rotor support 210, a rotor back iron 220, and permanent magnets 230, in an embodiment of the present invention, the permanent magnets 230 are adhesively connected to the rotor back iron 220.

[0076] It should be noted here that the axial flux motors shown in the drawings and described in this specification are only a few examples of many axial flux motors that can employ the principles of the present invention. It should be clearly understood that the principles of the present invention are by no means limited to any details or any components of the axial flux motors shown in the drawings or described in this specification.

[0077] For example, Figure 5 In the shown embodiment, an axial flux motor based on a segmented winding YASA configuration is specifically proposed, which specifically adopts a motor structure with a configuration of 36 slots and 42 poles, that is, the stator structure 100 includes 36 stator cores 120 and 42 permanent magnets 230. It should be understood that according to different design requirements, the axial flux motor proposed by the present invention can also adopt motor structures of other configurations, that is, the number of slots and poles of the motor are not limited to the exemplary designs in the above embodiments and can be designed into other matching types according to various different requirements.

[0078] In summary, the stator structure 100 of the axial flux motor proposed by the present invention includes a stator support 110, a plurality of stator cores 120, and two pole shoe covers 130. The plurality of stator cores 120 are correspondingly arranged in a plurality of receiving grooves of the stator support 110. The stator core 120 includes a coil winding 121 and a core 122. The core 122 is arranged in a core slot 1211 of the coil winding 121. Both ends of the core 122 respectively extend out of the core slot 1211 to form two extending ends 1222. The core 122 is a laminated structure made of self-bonding silicon steel sheets. The two pole shoe covers 130 are correspondingly arranged on both sides of the stator support 110 in the axial direction. An accommodation space for accommodating a plurality of stator cores 122 is formed between the two pole shoe covers 130. The pole shoe cover 130 has a plurality of through slots 131 arranged circumferentially. The positions of the plurality of through slots 131 correspond to the positions of the plurality of cores 122 one by one. The through slots 131 penetrate the pole shoe cover 130 in the axial direction. The two extending ends 1222 of the core 122 correspondingly extend into the corresponding through slots 131 of the two pole shoe covers 130. Through the above structural design, the core 122 of the present invention is a laminated structure made of self-bonding silicon steel sheets, thereby effectively enhancing the torque performance of the motor. At the same time, by using the cooperation between the extending ends 1222 of the core 122 and the through slots 131 of the pole shoe cover 130, the present invention can realize the functional cooperation between the core 122 and the permanent magnet 230 located outside the pole shoe cover 130, and can also realize the positioning of the stator core 120. Through the integrated cooperation design of the pole shoe cover 130 and the core 122, the present invention can realize the optimization of the manufacturing process and the improvement of the electromagnetic performance.

[0079] The exemplary embodiments of the axial flux motor proposed by the present invention have been described in detail above and / or illustrated. However, the embodiments of the present invention are not limited to the specific embodiments described herein. On the contrary, each component and / or step of each embodiment can be used independently and separately from the other components and / or steps described herein. Each component and / or each step of one embodiment can also be combined with the other components and / or steps of other embodiments. When introducing the elements / components / etc. described and / or illustrated herein, the terms "a", "one", and "the above" etc. are used to indicate the existence of one or more elements / components / etc. The terms "comprising", "including", and "having" are used to mean an open inclusion and mean that there can be additional elements / components / etc. in addition to the listed elements / components / etc. Furthermore, the terms "first" and "second" etc. in the claims and the specification are only used as labels and are not numerical limitations on their objects.

[0080] Although the axial flux motor proposed by the present invention has been described according to different specific embodiments, those skilled in the art will recognize that modifications can be made to the implementation of the present invention within the spirit and scope of the claims.

Claims

1. An axial flux motor, characterized in that, It includes a rotor structure and a stator structure, and the stator structure includes: A stator support member having a plurality of receiving grooves arranged circumferentially, and the receiving grooves axially penetrate the stator support member; A plurality of stator cores correspondingly disposed in the plurality of receiving grooves. The stator core includes a coil winding and a core. The coil winding has a core groove axially penetrating it, and the core is disposed in the core groove. Both ends of the core extend out of the core groove to form two protruding ends, and the core is a laminated structure made of self-bonding silicon steel sheets; Two pole shoe cover plates correspondingly disposed on both axial sides of the stator support member. An accommodation space for accommodating the plurality of stator cores is formed between the two pole shoe cover plates. The pole shoe cover plate has a plurality of through grooves arranged circumferentially, and the positions of the plurality of through grooves correspond one by one to the positions of the cores of the plurality of stator cores. The through grooves axially penetrate the pole shoe cover plate, and the two protruding ends of the core correspondingly extend into the corresponding through grooves of the two pole shoe cover plates.

2. The axial flux motor according to claim 1, characterized in that, The core has a main body, and the main body is the part of the core located in the core groove. The main body is fixedly connected to the protruding ends; wherein: The width of the protruding end is smaller than the width of the main body, so that a limiting step is formed at the corner of the core; the width of the through groove is greater than or equal to the width of the protruding end and smaller than the width of the main body; and / or, The thickness of the protruding end is equal to the thickness of the main body.

3. The axial flux motor according to claim 1, wherein The orthographic projection of the core on a reference plane is rectangular, and the reference plane is parallel to the plane formed by the radial direction and the axial direction of the stator support member.

4. The axial flux motor according to claim 1, wherein: A heat-conducting insulating layer is provided on the surface of the core; and / or, The voids in the accommodation space not occupied by the stator core are filled with heat-conducting potting glue.

5. The axial flux motor according to claim 3, wherein The pole shoe cover plate further has a plurality of magnetic path isolation grooves axially penetrating the pole shoe cover plate. The orthographic projection of the magnetic path isolation grooves on the reference plane is arranged around the orthographic projection of the stator core on the reference plane. The plurality of magnetic path isolation grooves include: A plurality of radial grooves, each radial groove being located between adjacent through grooves and arranged in the radial direction of the pole shoe cover plate; A plurality of inner circumferential grooves, each inner circumferential groove being located between adjacent radial grooves and close to the inner peripheral edge of the pole shoe cover plate; and A plurality of outer circumferential grooves, each outer circumferential groove being located between adjacent radial grooves and close to the outer peripheral edge of the pole shoe cover plate; The plurality of magnetic path isolation grooves form a plurality of isolation regions on the pole shoe cover plate. The plurality of isolation regions are arranged circumferentially, and each isolation region has one of the through grooves.

6. The axial flux motor according to claim 5, wherein: The distance between the end of the radial groove close to the inner peripheral edge of the pole shoe cover plate and the inner peripheral edge is smaller than the distance between the inner circumferential groove and the inner peripheral edge; and / or, The distance between the end of the radial groove close to the outer peripheral edge of the pole shoe cover plate and the outer peripheral edge is smaller than the distance between the outer circumferential groove and the outer peripheral edge.

7. The axial flux motor according to claim 1, characterized in that, The rotor structure of the axial flux motor includes two rotor components and bearings. The two rotor components are correspondingly located on both axial sides of the stator structure. The rotor component includes: A rotor support member rotatably connected to the stator structure through the bearing. A plurality of spokes are provided on a surface of the rotor support member away from the stator structure. The plurality of spokes are arranged at intervals in the circumferential direction, and the spokes extend radially along the rotor support member. The plurality of spokes form a centrifugal fan in the axial flux motor.

8. The axial flux motor according to claim 7, characterized in that, The rotor component further includes: A rotor back iron provided on a surface of the rotor support member close to the stator structure; and A plurality of permanent magnets provided on a surface of the rotor back iron close to the stator structure and arranged at intervals in the circumferential direction.

9. The axial flux motor according to claim 8, characterized in that, A positioning rib is provided between adjacent permanent magnets, and the positioning rib extends radially along the rotor back iron.

10. The axial flux motor according to claim 8, wherein: The rotor back iron is adhesively connected to the rotor support member; and / or, The permanent magnet is adhesively connected to the rotor back iron.

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