Axial magnetic flux hub motor stator assembly, machining method and axial magnetic flux hub motor

Abstract

The invention provides an axial magnetic flux hub motor stator assembly and a processing method thereof, and also provides a hub motor using the stator assembly, which can effectively simplify the processing process flow of the stator assembly and improve the production efficiency. The axial magnetic flux hub motor stator assembly comprises a plurality of stator modules, a PCB and a stator shell, each stator module is provided with a winding, the winding of each stator module is connected with a connection circuit on the PCB, and the connection relation between the windings meets the wiring requirements of motors of different specifications for the windings by changing the connection circuits. A mounting cavity is formed in the middle of the stator shell, the stator module and the PCB are located in the mounting cavity, and the stator module, the PCB and the stator shell are mutually fixed through colloid.

Description

Technical Field

[0001] The present invention relates to the technical field of motor structures, and in particular to an axial flux hub motor stator assembly, a processing method and an axial flux hub motor. Background Art

[0002] With the widespread use of new energy vehicles, in-wheel motors (IWMs) are being widely adopted in electric vehicles. Existing IWMs typically consist of a stator assembly, a rotor assembly, a support shaft, and a wheel rim. The stator and rotor assemblies work together to drive the wheel rim, which in turn drives the tire mounted on the rim.

[0003] The existing hub motor stator assemblies adopt either a stator iron core or a modular approach. The stator iron core has protruding stator teeth, and windings are formed by winding wires on the stator teeth. The modular approach adopts relatively independent stator modules, and windings are formed by winding wires on the stator modules. The stator modules with windings are then formed into a ring and fixed. For the stator assembly obtained by the existing modular approach, the stator modules need to be spliced together one by one, and the windings of each stator module must be connected to each other according to the requirements of motors of different specifications and models during the splicing process (for example, some motors require star connection between stator windings, and some motors require triangle connection between stator windings), which is very time-consuming and labor-intensive. Summary of the Invention

[0004] In response to the problem that the current hub motor stator processing is time-consuming and labor-intensive, the present invention provides an axial flux hub motor stator assembly and a processing method thereof, and also provides a hub motor using the stator assembly, which can effectively simplify the processing process of the stator assembly and improve production efficiency.

[0005] The technical solution is as follows: an axial flux hub motor stator assembly includes multiple stator modules, each of which is provided with a winding, and is characterized in that: it also includes a PCB board and a stator shell; the winding of each stator module is respectively connected to the connection circuit on the PCB board, and the connection relationship between the windings is made to meet the wiring requirements of the windings of motors of different specifications by changing the connection circuit; an installation cavity is provided in the middle of the stator shell, the stator module and the PCB board are located in the installation cavity, and the stator module, the PCB board and the stator shell are fixed to each other by a colloid.

[0006] Furthermore, the stator module includes positioning protrusions and positioning grooves located on opposite sides thereof, and the positioning protrusions and positioning grooves of adjacent stator modules match each other. When the stator modules are enclosed to form an annular structure, the positioning protrusion of one of the stator modules is located in the positioning groove of the adjacent stator module, and the positioning groove of one of the stator modules accommodates the positioning protrusion of the adjacent stator module.

[0007] Furthermore, the middle portion of the stator module is concave for arranging the winding, and an insulating shell is sleeved between the winding and the stator module.

[0008] Furthermore, the stator case includes a base surface, a peripheral portion, and a central mounting portion. When the base surface is in a horizontal direction, the outer periphery of the base surface extends upward to form the peripheral portion, and the center of the base surface extends upward to form the central mounting portion. A mounting hole is provided in the middle of the central mounting portion, and the mounting hole is used to install the support shaft of the axial flux hub motor. The outer side of the central mounting portion, the top of the base surface, and the inner side of the peripheral portion enclose to form the mounting cavity.

[0009] Furthermore, the PCB board is electrically connected to the outside of the axial flux hub motor through a cable, and the cable passes through the avoidance hole located at the central mounting portion and then extends into the cable outlet hole on the support shaft.

[0010] The invention relates to a method for processing a stator assembly of an axial flux hub motor, characterized in that it comprises the following steps: step 1: performing winding processing on an independent stator module, wherein the winding is arranged on the periphery of the stator module and the winding wire end extends out of the stator module;

[0011] Step 2: After assembling multiple stator modules with completed windings to form a ring structure, select a corresponding PCB board according to the specifications of the hub motor, insert the winding wire ends of each stator module into the PCB board to electrically connect the windings to the connection circuit on the PCB board;

[0012] Step 3: After the middle part of the stator housing is connected to the support shaft of the axial flux hub motor, the interconnected stator module and PCB board are placed in the installation cavity in the middle part of the stator housing with the opening facing upward. The cable is passed through the cable outlet hole on the support shaft and the avoidance hole in the middle of the stator housing in sequence, and then electrically connected to the connection circuit on the PCB board;

[0013] Step 4: pre-block the avoidance hole, and then inject glue into the installation cavity of the stator shell to fix the stator module, the PCB board and the stator shell to each other, thereby completing the processing of the stator assembly.

[0014] Furthermore, in step one, the stator module is pressed by silicon steel laminations, and positioning protrusions and positioning grooves are provided on opposite sides of the stator module, and the positioning protrusions and positioning grooves of adjacent stator modules match each other; in step two, the stator modules are spliced together by inserting the positioning protrusion of one of the stator modules into the positioning groove of the adjacent stator module, or accommodating the adjacent positioning protrusion of the positioning groove of one of the stator modules.

[0015] Furthermore, in step 2, the stator modules are assembled and then welded at the joints, and the winding wire ends are inserted into the PCB board and then welded.

[0016] The axial flux hub motor is characterized in that it adopts the above-mentioned axial flux hub motor stator assembly or the axial flux hub motor stator assembly manufactured by the above-mentioned axial flux hub motor stator assembly processing method.

[0017] Furthermore, the axial flux hub motor also includes a rotor assembly, a rim, a bearing and an end cover. The support shaft passes through the axial flux hub motor stator assembly and the rotor assembly and extends from one side or both sides of the axial flux hub motor. The adjacent end faces of the axial flux hub motor stator assembly and the rotor assembly are parallel and have a certain gap; the rotor assembly is fixedly connected to the rim, and the rim at least covers the circumference of the motor and has a tire slot.

[0018] Beneficial effects: 1. The connection of various components in the stator assembly of this solution can be achieved by glue injection. In particular, the stator module and PCB board can be directly placed in the stator shell and then glue is injected into the stator shell to complete the processing, which can greatly simplify the stator assembly processing technology and improve processing efficiency.

[0019] 2. Since the windings can be connected directly to the PCB board to complete the connection between the windings, the installation of the stator assembly is further simplified. At the same time, the PCB board can be replaced to correspond to motors of different specifications without changing the stator assembly structure, which improves the flexibility of motor manufacturing.

[0020] 3. By injecting glue, the various components of the stator assembly are fixed, making the stator a whole, thereby improving the insulation, pressure resistance and thermal conductivity of the motor.

[0021] 4. This solution also uses an axial flux motor instead of the radial flux motor often used in electric vehicles, which improves the motor power density, torque density and efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 Schematic diagram of the stator assembly structure of the axial flux hub motor;

[0023] Figure 2Schematic cross-sectional view of the stator assembly of the axial flux hub motor;

[0024] Figure 3 Schematic diagram of the stator module structure with windings;

[0025] Figure 4 This is a schematic diagram of the PCB structure connected to a stator module;

[0026] Figure 5 Schematic diagram of the structure of the stator housing;

[0027] Figure 6 for Figure 3 Explosion diagram of

[0028] Figure 7 is a cross-sectional schematic diagram of the support shaft;

[0029] Figure 8 It is a cross-sectional schematic diagram of a double-side shaft axial flux hub motor;

[0030] Figure 9 It is a cross-sectional schematic diagram of a single-side shaft axial flux hub motor;

[0031] Figure 10 Schematic diagram of the rotor assembly structure (only one permanent magnet is shown).

[0032] In the accompanying drawings, 1. axial flux hub motor stator assembly; 101. stator module; 1011. positioning protrusion; 1012. positioning groove; 1013. insulating shell; 102. winding; 103. PCB board; 104. stator shell; 1041. base surface; 1042. periphery; 1043. center mounting part; 1044. mounting hole; 1045. avoidance hole; 2. support shaft; 201. cable lead-out hole; 3. rotor assembly; 301. permanent magnet; 302. rotor back iron; 4. rim; 5. bearing; 6. end cover. DETAILED DESCRIPTION

[0033] like Figure 1-Figure 5 The axial flux hub motor stator assembly 1 shown includes multiple stator modules 101, each of which is provided with a winding 102. It also includes a PCB board 103 and a stator housing 104. The winding 102 of each stator module 101 is respectively connected to the connection circuit on the PCB board 103. By changing the connection circuit, the connection relationship between the windings 102 can meet the wiring requirements of the windings of motors of different specifications. An installation cavity is provided in the middle of the stator housing 104. The stator module 101 and the PCB board 103 are located in the installation cavity and are fixed to each other by a colloid.

[0034] Specific, combined Figure 6As shown, the stator module 101 includes positioning protrusions 1011 and positioning grooves 1012 located on opposite sides thereof. The positioning protrusions 1011 and positioning grooves 1012 of adjacent stator modules 101 match each other. When the stator modules 101 are enclosed to form a stator module 101, the stator module 101 is configured as follows. Figure 1 In the annular structure shown, the positioning protrusion 1011 of one stator module 101 is located within the positioning groove 1012 of the adjacent stator module 101. The positioning groove 1012 of one stator module 101 accommodates the positioning protrusion 1011 of the adjacent stator module. This arrangement facilitates positioning and guiding the stator modules 101 when they are spliced together. After the splicing is completed, the cooperation between the protrusion and the groove provides a certain degree of stability to the annular structure. The concave portion in the middle of the stator module 101 is used to accommodate the winding 102. An insulating housing 1013 is provided between the winding 102 and the stator module 101. The use of the insulating housing 1013 can ensure the service life of the stator module 101. Compared with relying solely on the insulating surface of the winding 102 for insulation, once the insulating surface ages and breaks, the conductor contacts the stator module 101, which will damage the motor performance. At the same time, compared with forming an insulating layer on the outer surface of the stator module 101, the insulating layer is more likely to fall off, which also poses a risk.

[0035] Combine Figure 5 As shown, the stator housing 104 specifically includes a base surface 1041, an outer peripheral portion 1042, and a central mounting portion 1043. When the base surface 1041 is in a horizontal direction, the outer periphery of the base surface 1041 extends upward to form the outer peripheral portion 1042, and the center of the base surface 1041 extends upward to form the central mounting portion 1043. A mounting hole 1044 is provided in the center of the central mounting portion 1043. The mounting hole 1044 is used to install the support shaft of the axial flux hub motor. The outer side of the central mounting portion 1043, the top of the base surface 1041, and the inner side of the outer peripheral portion 1042 together form a mounting cavity for accommodating the remaining stator components. It is worth mentioning that a boss can be provided in the mounting cavity to place the stator module 101, thereby raising the stator module 101 so that its top protrudes from the mounting cavity to avoid being covered by the colloid, thereby preventing the presence of colloid in the gap between the stator and rotor and affecting the motor performance. In addition, since the PCB board 103 needs to be electrically connected to the outside of the axial flux hub motor through a cable, the cable can pass through the avoidance hole 1045 located at the central mounting portion 1043 and then extend into the Figure 7 The cable outlet hole 201 on the support shaft 2 is shown to enable the cable to be outlet.

[0036] In order to better reflect the stator assembly structure of this solution simplifies the processing technology, the following is a detailed description of the processing method of the axial flux hub motor stator assembly 1, combined with Figures 1-6As shown, it includes the following steps: Step 1: Winding an independent stator module 101. To ensure winding performance, the independent stator module 101 can be installed on a winding machine for winding. The winding 102 is arranged around the stator module 101, and the winding wire ends extend out of the stator module 101. Specifically, the stator module 101 is pressed from silicon steel laminations. Positioning protrusions 1011 and positioning grooves 1012 are provided on opposite sides of the stator module 101. The positioning protrusions 1011 and positioning grooves 1012 of adjacent stator modules 101 match each other.

[0037] Step 2: After assembling multiple stator modules 101 that have completed winding processing to form a ring structure, select the corresponding PCB board 103 according to the specifications of the hub motor, insert the winding wire end of each stator module 101 into the PCB board 103, and electrically connect the winding 102 to the connection circuit on the PCB board 103. The stator modules 101 are assembled by inserting the positioning protrusion 1011 of one stator module 101 into the positioning groove 1012 of the adjacent stator module 101, or by accommodating the positioning protrusion 1011 of the adjacent stator module 101 in the positioning groove 1012 of one stator module 101. Preferably, to ensure stability and prevent component deformation from affecting the function of the stator assembly, the stator modules 101 are welded at the joints after assembly, and the winding wire ends are inserted into the PCB board 103 and then welded.

[0038] Step 3: After the middle of the stator housing 104 is connected to the support shaft of the axial flux hub motor (for example, by interference fit), the stator module 101 and PCB board 103 connected to each other are placed in the installation cavity in the middle of the stator housing 104 with the opening facing upward. It is worth mentioning that the top of the stator module 101 is located outside the installation cavity to avoid being covered by the colloid. The cables are passed through the following in sequence: Figure 7 The cable outlet hole 201 on the support shaft 2 and the avoidance hole 1045 in the middle of the stator housing 104 are electrically connected to the connection circuit on the PCB board 103.

[0039] Step 4: Pre-block the avoidance hole 1045 to prevent the colloid from leaking, and then inject electronic potting glue into the installation cavity of the stator housing 104 to fix the stator module 101, PCB board 103 and stator housing 104 to form a whole, thereby completing the processing of the stator assembly.

[0040] By adopting the above structure and method, the stator module 101 is easy to assemble, the windings 102 are easy to connect, and the axial flux hub motor stator assembly 1 is formed as a whole by direct glue injection, which is easy to process, greatly simplifies the stator assembly processing technology, and improves processing efficiency.

[0041] On the basis of the above, combined with Figure 8 、 Figure 9The axial flux hub motor shown includes a rotor assembly 3, a rim 4, a bearing 5 and an end cover 6, Figure 10 The rotor assembly 3 is formed by bonding a permanent magnet 301 to a rotor back iron 302. The rotor back iron 302 has evenly distributed guide bosses. A permanent magnet 301 is pasted between two adjacent guide bosses, and the permanent magnets 301 are evenly distributed along the circumferential direction. The support shaft 2 passes through the stator assembly 1 and the rotor assembly 3 of the axial flux hub motor and is connected from one side of the axial flux hub motor (such as Figure 9 as shown) or both sides (as shown Figure 8 The adjacent end faces of the axial flux hub motor stator assembly 1 and rotor assembly 3 are parallel and spaced apart. The rotor assembly 1 can be securely connected to the rim 4 using adhesive. The rim 4 covers at least the circumference of the motor and has a tire slot for mounting a tire. The relatively independent rim 4 allows for replacement of tires as needed. In this solution, the rim 4 extends to one side of the motor, with an end cap 6 located on the other side. The rim 4 and end cap 6 are secured by bolts.

[0042] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by anyone familiar with the art within the technical scope disclosed by the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. An axial flux hub motor stator assembly comprising a plurality of stator modules, each of which is provided with a winding, characterized in that: It also includes a PCB board and a stator shell; the windings of each stator module are respectively connected to the connection circuits on the PCB board. By changing the connection circuits, the connection relationship between the windings meets the wiring requirements of the windings of motors of different specifications. An installation cavity is provided in the middle of the stator shell, and the stator module and the PCB board are located in the installation cavity. The stator module, the PCB board and the stator shell are fixed to each other by a colloid.

2. The axial flux hub motor stator assembly according to claim 1, characterized in that: The stator module includes positioning protrusions and positioning grooves located on opposite sides thereof. The positioning protrusions and positioning grooves of adjacent stator modules match each other. When the stator modules are enclosed to form an annular structure, the positioning protrusion of one stator module is located in the positioning groove of an adjacent stator module, and the positioning groove of one stator module accommodates the positioning protrusion of the adjacent stator module.

3. The axial flux hub motor stator assembly according to claim 1, characterized in that: The middle part of the stator module is concave for arranging the winding, and an insulating shell is sleeved between the winding and the stator module.

4. The axial flux hub motor stator assembly according to claim 1, characterized in that: The stator case includes a base surface, an outer periphery, and a central mounting portion. When the base surface is in a horizontal direction, the outer periphery of the base surface extends upward to form the outer periphery, and the center of the base surface extends upward to form the central mounting portion. A mounting hole is provided in the middle of the central mounting portion, and the mounting hole is used to mount the support shaft of the axial flux hub motor. The outer side of the central mounting portion, the top of the base surface, and the inner side of the outer periphery together form the mounting cavity.

5. The axial flux hub motor stator assembly according to claim 4, characterized in that: The PCB board is electrically connected to the outside of the axial flux hub motor through a cable. The cable passes through the avoidance hole located on the central mounting portion and then extends into the cable outlet hole on the support shaft.

6. A method for processing an axial flux hub motor stator assembly, characterized in that: It includes the following steps: Step 1: Perform winding processing on an independent stator module, wherein the winding is arranged on the periphery of the stator module and the winding wire ends extend out of the stator module; Step 2: After assembling multiple stator modules with completed windings to form a ring structure, select a corresponding PCB board according to the specifications of the hub motor, insert the winding wire ends of each stator module into the PCB board to electrically connect the windings to the connection circuit on the PCB board; Step 3: After the middle part of the stator housing is connected to the support shaft of the axial flux hub motor, the interconnected stator module and PCB board are placed in the installation cavity in the middle part of the stator housing with the opening facing upward. The cable is passed through the cable outlet hole on the support shaft and the avoidance hole in the middle of the stator housing in sequence, and then electrically connected to the connection circuit on the PCB board; Step 4: pre-block the avoidance hole, and then inject glue into the installation cavity of the stator shell to fix the stator module, the PCB board and the stator shell to each other, thereby completing the processing of the stator assembly.

7. The method for machining the stator assembly of an axial flux hub motor according to claim 6, characterized in that: In step one, the stator module is pressed by silicon steel laminations, and positioning protrusions and positioning grooves are provided on opposite sides of the stator module, and the positioning protrusions and positioning grooves of adjacent stator modules match each other; in step two, the stator modules are spliced together by inserting the positioning protrusion of one of the stator modules into the positioning groove of the adjacent stator module, or accommodating the adjacent positioning protrusion of the positioning groove of one of the stator modules.

8. The method for machining the stator assembly of an axial flux hub motor according to claim 6, characterized in that: In step 2, the stator modules are assembled and soldered at the joints, and the winding wire ends are inserted into the PCB board and soldered.

9. Axial flux hub motor, characterized by: The axial flux hub motor stator assembly is manufactured by using the axial flux hub motor stator assembly described in any one of claims 1-5 or the axial flux hub motor stator assembly processing method described in any one of claims 6-8.

10. The axial flux hub motor according to claim 9, characterized in that: The axial flux hub motor also includes a rotor assembly, a rim, a bearing and an end cover. The support shaft passes through the axial flux hub motor stator assembly and the rotor assembly and extends from one side or both sides of the axial flux hub motor. The adjacent end faces of the axial flux hub motor stator assembly and the rotor assembly are parallel and have a certain gap; the rotor assembly is fixedly connected to the rim, and the rim at least covers the circumference of the motor and has a tire slot.

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