An oil-cooled axial flux motor

Abstract

The present invention provides an oil-cooled axial flux motor, which belongs to the field of motor technology and solves the technical problems of existing motors such as complex structure, large size, and low heat dissipation efficiency. It includes a stator housing assembly, a main frame assembly is provided inside the stator housing assembly, a cooling pipe assembly and a stator conductive assembly are provided on the main frame assembly, the stator conductive assembly is located on the inner side of the cooling pipe assembly, a connector assembly and a power terminal are provided on the outer side of the stator housing assembly, the connector assembly and the power terminal are both electrically connected to the stator conductive assembly, a motor top plate assembly is provided at the front end of the stator housing assembly, a motor end plate assembly is provided at the rear end of the stator housing assembly, a rotor assembly is provided between the motor end plate assembly and the motor top plate assembly, and the rotor assembly is located on the inner side of the cooling pipe assembly. The present invention adopts an axial flux structure to achieve high torque density and compact design, with a highly integrated structure and axially flattened packaging, achieving a triangular balance of high power, small size, and long life.

Description

Technical Field

[0001] The present invention belongs to the technical field of motors and relates to an axial motor, in particular to an oil-cooled axial flux motor. Background Art

[0002] Cutting-edge fields such as electric vehicles and aviation propulsion place stringent demands on motors to deliver high torque in a compact package. While traditional axial flux motors offer the inherent advantage of high power density, heat accumulation within the windings and stator conductive components creates a performance bottleneck. Heat cannot be dissipated promptly within the confined space, leading to uncontrolled temperature rise and severely limiting sustained output capability and reliability.

[0003] The axial stacking layout blocks the radial heat dissipation path, turning the rotor-stator gap into a high-temperature furnace: the winding heat density exceeds 20W / cm³, the permanent magnets face the risk of demagnetization at temperatures above 150°C, and the insulation material ages rapidly at high temperatures (lifespan decreases exponentially with temperature). Traditional air cooling or shell water cooling solutions are unable to reach the core heat source due to their high thermal resistance.

[0004] Therefore, we propose an oil-cooled axial flux motor, which uses an axial flux structure to achieve high torque density and compact design, precise temperature control of the oil cooling system, highly integrated structure, and axially flat packaging to achieve a triangular balance of high power, small size, and long life. Summary of the Invention

[0005] The purpose of the present invention is to address the above-mentioned problems in the existing technology and propose an oil-cooled axial flux motor. The technical problem to be solved by this invention is: how to realize the axial flux structure of the flux motor with high torque density and compact design, the oil cooling system with precise temperature control and heat dissipation, highly integrated structure, and axial flat packaging to achieve a triangular balance of high power, small size and long life.

[0006] The purpose of the present invention can be achieved through the following technical solutions:

[0007] An oil-cooled axial flux motor includes a stator housing assembly, a main frame assembly is provided inside the stator housing assembly, a cooling pipe assembly and a stator conductive assembly are provided on the main frame assembly, the stator conductive assembly is located on the inner side of the cooling pipe assembly, a connector assembly and a power terminal are provided on the outer side of the stator housing assembly, the connector assembly and the power terminal are both electrically connected to the stator conductive assembly, a motor top plate assembly is provided at the front end of the stator housing assembly, a motor end plate assembly is provided at the rear end of the stator housing assembly, a rotor assembly is provided between the motor end plate assembly and the motor top plate assembly, and the rotor assembly is located on the inner side of the cooling pipe assembly.

[0008] The present invention operates as follows: The connector assembly and power terminals provide a standard interface for external power and control signals to access the motor. They are connected to the stator conductive assembly via internal wiring. Current flows through the stator conductive assembly into its internal windings, generating a rotating magnetic field on the stator side. This rotating magnetic field interacts with the permanent magnets or electromagnetic structures on the rotor assembly, generating electromagnetic torque, causing the rotor assembly to rotate between the motor end plate assembly and the motor top plate assembly. The cooling pipe assembly is connected to an external cooling oil system. Cooling oil enters the cooling pipe assembly to cool the stator conductive assembly, directly absorbing the primary heat generated on the stator side during motor operation. The heated oil leaves the motor, is cooled by an external radiator, and then recirculates back to the cooling pipe assembly, forming a closed-loop cooling system. The stator housing assembly forms the main housing of the motor, providing primary structural support and mechanical protection, and housing internal components. The main frame assembly, located within the stator housing assembly, serves as the internal framework for mounting key components such as the cooling pipe assembly and the stator conductive assembly. The motor end plate assembly and the motor top plate assembly respectively enclose the front and rear ends of the housing, forming a sealed space with the stator housing assembly to protect the internal components and support the bearings.

[0009] The stator housing assembly includes a stator housing body, a plurality of circumferentially evenly distributed assembly protrusions are provided on the outer edge side of the stator housing body, and bidirectional screw holes are provided on the assembly protrusions. Two water-cooling avoidance through holes are provided on the stator housing body, a connector mounting seat and a joint mounting seat are provided on the stator housing body, a connector body is provided on the connector mounting seat, a connector connecting end is plugged into and connected to the connector body, a connector cover is provided on the connector connecting end, and a plurality of evenly distributed amp joints are provided on the joint mounting seat, and the amp joints are plugged into and connected to the amp connecting ends.

[0010] With the above structure, the bidirectional screw holes are used to install the motor end plate assembly and the motor top plate assembly, and the motor end plate assembly and the motor top plate assembly are bidirectionally locked to the shell body to form a vibration-resistant sealed cavity; the water-cooling avoidance through-hole is used for the cooling pipe assembly to pass through the through-hole to access the interior; the connector mounting seat fixes the connector body, and quick plugging and unplugging is achieved through the plug-in connector connection end. When the connector connection end is inserted into the body, the internal reed conducts the circuit; after the connector cover is screwed closed, the sealing ring is triggered to tighten, providing dustproof and waterproof protection, ensuring the reliability of the high-voltage interface and achieving protection; the connector mounting seat integrates multiple ampere connectors, and the ampere connector is used to plug and connect the ampere connection end. When the ampere connection end is inserted, the spring pin is in close contact with the inner wall of the connector, supporting continuous current transmission of hundreds of amperes.

[0011] The motor top plate assembly includes a motor top plate body, which abuts against the front side of the stator housing body. A plurality of circumferentially evenly distributed connecting protrusions are provided on the outer edge side of the motor top plate body. A connecting bolt is provided inside each connecting protrusion. The connecting bolt is screwed into the bidirectional screw hole at the corresponding position. A mounting hole is provided in the middle of the motor top plate body. A sealing ring is provided inside the outward part of the mounting hole. A magnetic bearing is provided inside the inward part of the mounting hole. A plurality of heat dissipation blind holes are provided on the inner end surface of the motor top plate body.

[0012] With the above structure, the motor top plate body serves as the sealing cover plate at the front end of the motor, and is locked with the stator housing body through the bidirectional screw holes of the connecting protrusion and the connecting bolt to form a closed cavity boundary; the sealing ring is pressed against the outside of the mounting hole to prevent the cooling oil / external liquid from penetrating into the magnetic bearing area; the magnetic bearing is embedded in the inner side of the mounting hole, and the shaft of the rotor assembly is suspended contactlessly by electromagnetic force, thereby eliminating mechanical friction loss and supporting ultra-high-speed operation; the array-type heat dissipation blind hole is opened on the inner end surface of the top plate to increase the heat dissipation surface area. When the motor is running, the hot air / oil mist forms turbulence in the heat dissipation blind hole, and the heat is passively dissipated from the hole wall to the top plate metal to the external environment.

[0013] The motor end plate assembly includes a motor end plate body, which abuts against the rear side of the stator housing body. The outer edge side of the motor end plate body is provided with a plurality of circumferentially evenly distributed connecting protrusions 2, and the interior of the connecting protrusions 2 is provided with connecting bolts 2, which are screwed into the bidirectional screw holes at the corresponding positions. The middle part of the motor end plate body is provided with mounting holes 2, the interior of the outward part of the mounting hole 2 is provided with sealing rings 2, the interior of the inward part of the mounting hole 2 is provided with magnetic bearings 2, the inner end surface of the motor end plate body is provided with a plurality of heat dissipation blind holes 2, the inner end surface of the motor end plate body is provided with a plurality of circumferentially evenly distributed mounting protrusions, and the mounting protrusions are provided with mounting screw holes.

[0014] With the above structure, the motor end plate body serves as the sealing cover plate at the rear end of the motor, and is locked with the bidirectional screw hole of the stator housing body through the connecting protrusion 2 and the connecting bolt 2 to form the rear end boundary of the closed cavity; the sealing ring 2 is pressed against the outside of the mounting hole 2 to block the leakage of cooling oil and the invasion of external pollutants; the magnetic bearing 2 is embedded in the inner side of the mounting hole 2, and cooperates with the magnetic bearing 1 to realize the full suspension support of the rotor assembly shaft, eliminate mechanical friction, and support ultra-high-speed operation; the magnetic bearing 2 and the magnetic bearing 1 are electromagnetically connected to form a symmetrical electromagnetic field at both ends of the shaft of the rotor assembly, dynamically adjusting the concentricity of the rotor assembly; the mounting protrusion cooperates with the mounting screw hole to provide a modular mounting platform for fixing the main frame assembly; the inner end face array type heat dissipation blind hole 2 increases the heat dissipation surface area, guides the turbulent heat exchange of oil mist / airflow, and the high-temperature oil mist forms an eddy current in the heat dissipation blind hole 2, which is conducted to the external environment through the end plate metal.

[0015] The structure of the second magnetic bearing is the same as that of the first magnetic bearing. The first magnetic bearing comprises a bearing housing, a plurality of electromagnets evenly distributed around the circumference of the bearing housing are arranged inside the bearing housing, and insulating end plates are arranged at both ends of the bearing housing.

[0016] With the above structure, controllable current is passed through the circumferentially distributed electromagnets to generate a dynamically adjustable magnetic field, which repels the permanent magnets / magnetizers of the rotor assembly, achieving mechanical contact-free suspension of the rotor assembly shaft. The insulating end plates block the axial magnetic leakage of the electromagnets, ensuring that the magnetic field acts concentratedly on the rotor assembly while preventing eddy current losses. The insulating end plates are made of ceramic or engineering plastic to avoid short circuits in the bearing assembly. The bearing housing serves as the mounting base for the electromagnets, and the air gap tolerance between each electromagnet and the rotor assembly is guaranteed through precision machining.

[0017] The main frame assembly includes a mounting frame, and a plurality of circumferentially evenly distributed mounting supports are engaged on the periphery of the mounting frame, and the mounting supports are engaged in the interior of the stator housing body. A plurality of circumferentially evenly distributed storage holes are provided in the interior of the mounting frame, and a mid-position through hole is provided in the middle of the mounting frame. The mounting frame is provided with a plurality of groups of circumferentially evenly distributed water-conducting avoidance holes and a plurality of groups of circumferentially evenly distributed conductive avoidance holes, and each group of water-conducting avoidance holes has two holes, and both the water-conducting avoidance holes and the conductive avoidance holes are connected to the storage holes, and each group of conductive avoidance holes has two holes, and a plurality of mounting blocks are provided at the front side end of the mounting frame, and the number and position of the mounting blocks correspond to the mounting protrusions, and a mounting screw is provided between the mounting block and the mounting protrusion, and the mounting screw is screwed into the mounting screw hole at the corresponding position.

[0018] With the above structure, the mounting frame serves as the internal skeleton of the motor, and is engaged with the stator housing body through the mounting support to absorb thermal deformation stress and carry the stator core, cooling pipe assembly and stator conductive assembly; the center through-hole leaves rotation space for the rotor assembly to ensure air gap uniformity; the placement holes are evenly distributed around the circumference to accurately position the stator core module to achieve boltless snap-on installation; the mounting block is connected to the mounting protrusion through the mounting screw and the mounting screw hole to form an axial preload to resist the torque reaction force of the rotor assembly; water guide avoidance hole: double hole group design guides the cooling pipe assembly to pass through the frame to avoid bending pressure loss; conductive avoidance hole: double hole group layout isolates the phase winding leads to minimize electromagnetic interference.

[0019] The cooling pipe assembly includes two symmetrically arranged cooling pipe modules and a plurality of hollow winding seats evenly distributed around the circumference. The number and position of the hollow winding seats correspond to the storage holes. The cooling pipe module includes a cooling ring pipe. The cooling ring pipes of the two cooling pipe modules are respectively engaged on both sides of the plurality of mounting supports. The inward end faces of the cooling ring pipes are provided with a plurality of circumferentially evenly distributed water connection joints. The upper ends of the cooling pipe modules are provided with water connection joints, which extend out of the water-cooling avoidance through-holes at corresponding positions. The hollow winding seats are engaged inside the storage holes at corresponding positions. The interior is hollow, and two wiring holes and two connecting screw holes are provided at the upper end of the hollow winding seat. The connecting screw holes correspond to the positions of the water guide avoidance holes. The two connecting screw holes are connected to the interior of the hollow winding seat. Water receiving screw tubes are screwed on the connecting screw holes, and the water receiving screw tubes are connected to right-angle joints. The water receiving screw tubes extend from the water guide avoidance holes at the corresponding positions. The directions of the two right-angle joints are opposite, and the two right-angle joints are respectively connected to the water connecting joints at the corresponding positions on the same side. Winding areas are provided on the front and back sides of the hollow winding seat, and the winding areas are respectively connected to the wiring holes on the same side.

[0020] With the above structure, the cooling oil circulation path is: external oil pump → one of the water connection joints → one of the cooling ring pipes → water connection joint → right-angle joint → one of the water connection spiral pipes → hollow cavity of the hollow winding seat → another water connection spiral pipe → right-angle joint → water connection joint → another cooling ring pipe → another water connection joint → external radiator;

[0021] Two symmetrical cooling ring pipes are respectively engaged on both sides of the mounting support to form a parallel cooling circuit, covering the stator area and eliminating heat dissipation dead corners; the winding area is a hollow winding seat with grooves on the front and rear sides to accommodate the stator winding, and the wiring holes guide the wires to pass through and connect to the stator conductive components to realize the electromagnetic function; the water receiving spiral pipe passes through the main frame through the water guide avoidance hole and is connected to the water connection joint of the cooling ring pipe through the right-angle joint; the cooling oil forms turbulence in the inner cavity of the hollow winding seat, directly flushing the winding copper wire; the reversely arranged right-angle joints make the oil flow of the ring pipes on both sides rotate in opposite directions, avoiding unilateral overheating and forming a cooling system; the wiring holes are spatially isolated from the water receiving spiral pipe, and the cooling oil has no contact with the wires, eliminating the risk of leakage.

[0022] The stator conductive component includes a stage B mother ring, a stage A mother ring and a stage C mother ring, and several groups of circumferentially evenly distributed stator winding coils, which are arranged in sequence from back to front. The number of stator winding coils in each group is two. The stator winding coils are all placed inside the winding area at the corresponding position. The stator winding coils are all provided with connecting wires four, which extend from the routing holes and conductive avoidance holes at the corresponding positions. The diameters of the stage A mother ring and the stage C mother ring are equal, the diameter of the stage B mother ring is smaller than the diameter of the stage A mother ring, the outside of the stage B mother ring is provided with several circumferentially evenly distributed connecting wires two, the inside of the stage A mother ring is provided with several circumferentially evenly distributed connecting wires one, the stage Several connecting wires three evenly distributed around the circumference are provided inside the segment C mother ring. The connecting wire four of one of the stator winding coils in each group of stator winding coils is alternately connected to the connecting wire one and the connecting wire three respectively. A busbar connecting wire is connected between the connecting wire four of the other stator winding coil in each group of stator winding coils and the connecting wire two. The stage B mother ring is provided with a stage B power connection terminal, the stage A mother ring is provided with a stage A power connection terminal, and the stage C mother ring is provided with a stage C power connection terminal. The stage B power connection terminal, the stage A power connection terminal and the stage C power connection terminal are respectively connected to the ampere connector wires at the corresponding positions; the stage A mother ring and the stage C mother ring are both connected to the connector body wires.

[0023] Using the above structure, the three main coils are axially layered: the stage A main coil, stage B main coil, and stage C main coil are stacked from back to front to form an axially centralized three-phase neutral point. The stage B main coil has the smallest diameter to fit the internal space. Distributed stator winding coils are grouped and embedded in the winding area. Each group of two coils is connected to different phases, forming a circumferentially evenly distributed three-phase star winding. In each group of stator winding coils, one coil is connected via connecting line 4 to connecting line 1 [Phase A] and connecting line 3 [Phase C]. The other coil is connected via connecting line 4 to the busbar connection and then to connecting line 2 [Phase B].

[0024] The Phase B, Phase A, and Phase C power terminals are each connected to an ampere connector to transmit a hundred-ampere drive current. The Phase A and Phase C busbars are additionally connected to the connector body for transmitting control signals or neutral point monitoring. Asymmetric coil diameter layout: The Phase B busbar with the smallest diameter is placed in the middle layer to balance the three-phase inductance parameters and suppress subharmonics. Short-path connection: The busbar connection directly spans the stator coil and busbar, reducing the winding end length by 30% and reducing copper losses.

[0025] Current path and electromagnetic process: When three-phase power is applied, the current flows from the Ampere connector to the Phase B terminal, the Phase A terminal, and the Phase C terminal, then to the Phase A mother coil, the Phase B mother coil, and the Phase C mother coil, and is distributed to each stator winding coil via connecting wires 1, 2, and 3 and the busbar connection line. The three-phase current generates a phase-difference magnetic field in the circumferentially distributed stator winding coils, synthesizing an axial rotating magnetic flux to drive the rotor assembly.

[0026] The connector body collects the voltages of the stage A and stage C female coils in real time, detects the winding balance state through an algorithm, and triggers fault protection. Extreme space utilization, axial stacking of the female coils saves axial space. Efficient heat dissipation and compatibility: The stator winding coils are directly embedded in the cooling cavity of the winding area to achieve integrated electrical and thermal management.

[0027] The rotor assembly includes a spline shaft 1 and two rotor modules. The two rotor modules are arranged on the spline shaft 1. The rear end of the spline shaft 1 is provided with a fixed end plate. The rear end of the fixed end plate is provided with an internal spline shaft. The internal spline shaft is inserted into the inside of the magnetic bearing 2. The front end of the spline shaft 1 is provided with a connecting shaft. The connecting shaft is inserted into the inside of the magnetic bearing 1. The front end of the connecting shaft is provided with a spline shaft 2. A mounting end plate is provided on the front rotor module. A spline hole 1 is opened inside the mounting end plate. The spline hole 1 cooperates with the spline shaft 1. Several circumferentially evenly distributed assembly screw pairs are provided between the mounting end plate and the two rotor modules and the fixed end plate. The spline shaft 1 and the several circumferentially evenly distributed assembly screw pairs all pass through the center through hole.

[0028] With the above structure, two symmetrical rotor modules are coaxially installed, each embedded with a permanent magnet array to form a double air-gap axial magnetic field, which increases the torque output under the same volume; the spline shaft runs through the two rotor modules and precisely engages through the spline hole one to eliminate the transmission gap; the spline shaft two extends the output end to adapt to the external load; the inner spline shaft is inserted into the magnetic bearing two, and the connecting shaft is inserted into the magnetic bearing one to achieve contactless suspension at both ends of the two rotor modules; the assembly screw pair runs through the fixed end plate, the two rotor modules and the mounting end plate to form a torsion-resistant truss structure to improve the stiffness; the spline fit allows axial thermal expansion of the rotor assembly to avoid thermal stress deformation.

[0029] Three-phase current is passed through the stator winding coil → a rotating magnetic field is generated → the two rotor modules are cut → electromagnetic torque is generated synchronously in the two air gaps → the torque is output through spline shaft one and spline shaft two; the involute tooth profile of spline shaft one meshes with spline hole one; magnetic bearing one and magnetic bearing two monitor the runout of the rotor module in real time → adjust the electromagnetic force → offset the vibration harmonics caused by the uneven magnetic pull of the two rotor components; a gap is reserved on the spline meshing tooth side, and the rotor component slides along the spline shaft when it heats up to avoid jamming.

[0030] The rotor module includes a rotor mounting frame, a second spline hole is opened in the middle position of the rotor mounting frame, and the second spline hole cooperates with the first spline shaft. A plurality of permanent magnet pole pieces evenly distributed around the circumference are provided inside the rotor mounting frame, and adjacent permanent magnet pole pieces are arranged alternately in front and back. An end plate mounting groove is provided in the middle position of the outer end surface of the rotor mounting frame, and the mounting end plate is placed inside the end plate mounting groove of the rotor module on the front side, and the fixed end plate is placed inside the end plate mounting groove of the rotor module on the rear side.

[0031] With the above structure, a high-density permanent magnet magnetic field is generated: alternating permanent magnet pole pieces: the circumferentially evenly distributed permanent magnets are arranged alternately with NS poles to form an axially focused magnetic field, forming a high-intensity axial magnetic field on the surface of the rotor assembly, and improving the utilization rate of magnetic energy; the rotor mounting bracket serves as a magnetic carrier to optimize the direction of the magnetic circuit and reduce magnetic leakage; the second spline hole is precisely engaged with the first spline shaft; the end plate mounting groove, the front / rear end grooves are respectively embedded in the mounting end plate and the fixed end plate, and the rotor assembly is axially locked by interference fit.

[0032] Compared with the existing technology, this oil-cooled axial flux motor has the following advantages:

[0033] The axial flux structure achieves high torque density and compact design. The built-in oil cooling tube assembly directly cools the stator conductive components and windings, breaking through the heat dissipation bottleneck of traditional motors. The motor outputs greater torque within the same volume, supports high-frequency starting and stopping, and transient overloads, meeting the requirements of high-power density scenarios.

[0034] The oil cooling system provides precise temperature control: The cooling oil circulation absorbs heat from core heat-generating components, preventing permanent magnet demagnetization and insulation aging, thereby extending service life. The layered thermal management design isolates the rotor assembly from the stator heat source, and the sealed housing is dust-proof and moisture-proof, ensuring stable operation in harsh operating conditions such as high temperature and dust.

[0035] Highly integrated structure: The stator conductive assembly, cooling pipe assembly, connector assembly and power terminals are modularly arranged, balancing electrical efficiency and ease of maintenance.

[0036] Axially flattened packaging: shortens the magnetic field path, reduces magnetic loss, and significantly reduces axial space occupation, providing solutions for compact space integration in vehicle chassis / aviation powertrain, etc.

[0037] The oil-cooled stator conductive components are wrapped in a design that achieves a new type of heat dissipation. Combined with the inherent advantages of axial magnetic flux, this achieves a perfect balance of high power, small size, and long life. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention.

[0039] Figure 2 It is a schematic diagram of the decomposition structure of the present invention.

[0040] Figure 3 It is a structural schematic diagram of the stator housing assembly in the present invention.

[0041] Figure 4 It is a structural schematic diagram of the motor top plate assembly in the present invention.

[0042] Figure 5 It is a structural schematic diagram of the motor end plate assembly in the present invention.

[0043] Figure 6 It is a structural schematic diagram of the magnetic bearing in the present invention.

[0044] Figure 7 It is a schematic diagram of the exploded structure of some components in the present invention.

[0045] Figure 8 It is a schematic diagram of the exploded structure of the stator winding coil during installation in the present invention.

[0046] Figure 9 It is a structural schematic diagram of the stator conductive component in the present invention.

[0047] Figure 10 It is a schematic diagram of the exploded structure of the rotor assembly in the present invention.

[0048] Figure 11 It is a structural schematic diagram of the rotor module in the present invention.

[0049] In the figure, 1. Motor end plate assembly; 2. Rotor assembly; 3. Stator housing assembly; 4. Cooling pipe assembly; 5. Connector assembly; 6. Motor top plate assembly; 7. Power terminal; 8. Stator conductive assembly; 9. Stator housing body; 10. Bidirectional screw hole; 11. Water cooling avoidance hole; 12. Connector mounting seat; 13. Connector body; 14. Connector connection end; 15. Connector cover; 16. Ampere connection end; 17. Ampere connector; 18. Motor top plate Main body; 19, sealing ring 1; 20, connecting protrusion 1; 21, connecting bolt 1; 22, mounting hole 1; 23, magnetic bearing 1; 24, sealing ring 2; 25, motor end plate main body; 26, connecting protrusion 2; 27, connecting bolt 2; 28, mounting protrusion; 29, magnetic bearing 2; 30, mounting screw hole; 31, bearing housing; 32, insulating end plate; 33, electromagnet; 34, cooling ring; 35, water connection; 36, water connection; 37, stator winding Coil assembly; 38, stage A mother coil; 39, connecting wire one; 40, stage B mother coil; 41, busbar connection; 42, mounting bracket; 43, mounting frame; 44, stage C mother coil; 45, connecting wire three; 46, cooling pipe module; 47, stage C power terminal; 48, mounting block; 49, storage hole; 50, water guide avoidance hole; 51, conductive avoidance hole; 52, connecting wire two; 53, stage B power terminal; 54, stage A power terminal; 55, right angle Connector; 56, water inlet spiral tube; 57, connecting wire four; 58, stator winding coil; 59, winding area; 60, hollow winding seat; 61, wiring hole; 62, connecting screw hole; 63, internal spline shaft; 64, fixed end plate; 65, spline shaft one; 66, connecting shaft; 67, spline shaft two; 68, rotor module; 69, mounting end plate; 70, spline hole one; 71, pole piece; 72, rotor mounting bracket; 73, end plate mounting slot; 74, spline hole two. DETAILED DESCRIPTION

[0050] The following are specific embodiments of the present invention and the accompanying drawings to further describe the technical solutions of the present invention, but the present invention is not limited to these embodiments.

[0051] like Figures 1-11 As shown, the oil-cooled axial flux motor includes a stator housing assembly 3, a main frame assembly is provided inside the stator housing assembly 3, a cooling pipe assembly 4 and a stator conductive assembly 8 are provided on the main frame assembly, the stator conductive assembly 8 is located on the inner side of the cooling pipe assembly 4, a connector assembly 5 and an electrical terminal 7 are provided on the outer side of the stator housing assembly 3, the connector assembly 5 and the electrical terminal 7 are both electrically connected to the stator conductive assembly 8, a motor top plate assembly 6 is provided at the front end of the stator housing assembly 3, a motor end plate assembly 1 is provided at the rear end of the stator housing assembly 3, a rotor assembly 2 is provided between the motor end plate assembly 1 and the motor top plate assembly 6, and the rotor assembly 2 is located on the inner side of the cooling pipe assembly 4.

[0052] The connector assembly 5 and the power terminal 7 provide a standard interface for external power supply and control signals to access the motor, and are connected to the stator conductive assembly 8 through internal circuits. The current flows through the stator conductive assembly 8 into the winding inside it, generating a rotating magnetic field on the stator side. The rotating magnetic field interacts with the permanent magnets or electromagnetic structures on the rotor assembly 2 to generate electromagnetic torque, and the rotor assembly 2 rotates around the motor end plate assembly 1 and the motor top plate assembly 6; the cooling pipe assembly 4 is connected to the external cooling oil system, and the cooling oil enters the cooling pipe assembly 4 to cool the stator conductive assembly 8, directly absorbing the main heat (copper loss and part of the iron loss) generated on the stator side when the motor is running; the heated oil leaves the motor, passes through an external radiator (such as an air-cooled or water-cooled radiator) for cooling, and then circulates back to the cooling pipe assembly 4 to form a closed-loop cooling system; the stator housing assembly 3 constitutes the main housing of the motor, provides main structural support and mechanical protection, and accommodates internal components; the main frame assembly is located in the stator housing assembly 3, and is the internal skeleton for installing key components such as the cooling pipe assembly 4 and the stator conductive assembly 8; the motor end plate assembly 1 and the motor top plate assembly 6 respectively close the front and rear ends of the housing, and together with the stator housing assembly 3 form a closed space to protect the internal components and support the bearings.

[0053] The stator housing assembly 3 includes a stator housing body 9, and a plurality of circumferentially evenly distributed assembly protrusions are provided on the outer edge side of the stator housing body 9, and bidirectional screw holes 10 are provided on the assembly protrusions. The stator housing body 9 is provided with two water-cooling avoidance through holes 11, and a connector mounting seat 12 and a joint mounting seat are provided on the stator housing body 9. The connector mounting seat 12 is provided with a connector body 13, and the connector body 13 is plugged and connected with a connector connection end 14, and the connector connection end 14 is provided with a connector cover 15. The joint mounting seat is provided with a plurality of evenly distributed amp joints 17, and the amp joints 17 are all plugged and connected with amp connection ends 16.

[0054] The bidirectional screw hole 10 is used to install the motor end plate assembly 1 and the motor top plate assembly 6, and the motor end plate assembly 1 and the motor top plate assembly 6 are bidirectionally locked to the stator housing body 9 to form a vibration-proof sealed cavity; the water-cooling avoidance through-hole 11 is used for the cooling pipe assembly 4 to pass through the through-hole to access the interior; the connector mounting seat 12 fixes the connector body 13, and realizes quick plugging and unplugging through the plug-in connector connection end 14. When the connector connection end 14 is inserted into the connector body 13, the internal reed conducts the circuit; after the connector cover 15 is screwed closed, the sealing ring is triggered to tighten, providing dustproof and waterproof protection, ensuring the reliability of the high-voltage interface to achieve IP67 protection; the connector mounting seat integrates multiple ampere connectors 17, and the ampere connector 17 is used to plug and connect the ampere connection end 16. When the ampere connection end 16 is inserted, the spring pin is in close contact with the inner wall of the connector, and the contact area is greater than 50mm² / pin, supporting continuous current transmission of hundreds of amperes.

[0055] The motor top plate assembly 6 includes a motor top plate body 18, which abuts against the front side of the stator housing body 9. The outer edge side of the motor top plate body 18 is provided with a plurality of circumferentially evenly distributed connecting protrusions 20, and the interior of the connecting protrusions 20 is provided with connecting bolts 21. The connecting bolts 21 are screwed into the inside of the bidirectional screw holes 10 at the corresponding positions. A mounting hole 22 is provided in the middle of the motor top plate body 18, and a sealing ring 19 is provided inside the inner outward part of the mounting hole 22, and a magnetic bearing 23 is provided inside the inner inward part of the mounting hole 22. The inner end surface of the motor top plate body 18 is provided with a plurality of heat dissipation blind holes.

[0056] The motor top plate body 18 serves as a sealing cover plate at the front end of the motor, and is locked with the bidirectional screw hole 10 of the stator housing body 9 through the connecting protrusion 20 and the connecting bolt 21 to form a closed cavity boundary; the sealing ring 19 is pressed against the outside of the mounting hole 22 to prevent cooling oil / external liquid from penetrating into the magnetic bearing 23 area; the magnetic bearing 23 is embedded in the inner side of the mounting hole 22, and the shaft of the rotor assembly 2 is non-contactly suspended by electromagnetic force, eliminating mechanical friction loss and supporting ultra-high-speed operation (>20,000 rpm); the array-type heat dissipation blind hole 1 opened on the inner end face of the top plate increases the heat dissipation surface area. When the motor is running, the hot air / oil mist forms turbulence in the heat dissipation blind hole 1, and the heat is passively dissipated from the hole wall to the top plate metal to the external environment.

[0057] The motor end plate assembly 1 includes a motor end plate body 25, which abuts against the rear side of the stator housing body 9. The outer edge side of the motor end plate body 25 is provided with a plurality of circumferentially evenly distributed connecting protrusions 26, and the interior of the connecting protrusions 26 is provided with connecting bolts 27. The connecting bolts 27 are screwed into the bidirectional screw holes 10 at the corresponding positions. A mounting hole 2 is provided in the middle of the motor end plate body 25, and a sealing ring 24 is provided inside the outward part of the inner part of the mounting hole 2, and a magnetic bearing 29 is provided inside the inward part of the inner part of the mounting hole 2. A plurality of heat dissipation blind holes 2 are provided on the inner end surface of the motor end plate body 25, and a plurality of circumferentially evenly distributed mounting protrusions 28 are provided on the inner end surface of the motor end plate body 25, and mounting screw holes 30 are provided on the mounting protrusions 28.

[0058] The motor end plate body 25 serves as the sealing cover plate at the rear end of the motor. It is locked with the bidirectional screw hole 10 of the stator housing body 9 through the connecting protrusion 26 and the connecting bolt 27 to form the rear end boundary of the closed cavity; the sealing ring 24 is pressed against the outside of the mounting hole 2 to block the leakage of cooling oil and the invasion of external pollutants; the magnetic bearing 29 is embedded in the inner side of the mounting hole 2, and cooperates with the magnetic bearing 1 23 to realize the full suspension support of the shaft of the rotor assembly 2, eliminate mechanical friction, and support ultra-high-speed operation; the magnetic bearing 29 and the magnetic bearing 1 23 are electromagnetically connected to form a symmetrical electromagnetic field at both ends of the shaft of the rotor assembly 2, dynamically adjusting the concentricity of the rotor assembly 2; the mounting protrusion 28 cooperates with the mounting screw hole 30 to provide a modular mounting platform for fixing the main frame assembly; the inner end face array type heat dissipation blind hole 2 increases the heat dissipation surface area, guides the oil mist / airflow turbulent heat exchange, and the high-temperature oil mist forms an eddy current in the heat dissipation blind hole 2, which is heat-conducted to the external environment through the end plate metal.

[0059] The structure of magnetic bearing 29 is the same as that of magnetic bearing 1 23 . Magnetic bearing 1 23 includes a bearing housing 31 . A plurality of electromagnets 33 evenly distributed around the circumference are provided inside the bearing housing 31 . Insulating end plates 32 are provided at both ends of the bearing housing 31 .

[0060] Controllable current is fed into the circumferentially distributed electromagnets 33 to generate a dynamically adjustable magnetic field, which repels the permanent magnets / magnetic conductors of the rotor assembly 2, achieving mechanical contact-free suspension of the rotor assembly shaft; the insulating end plates 32 block axial magnetic leakage from the electromagnets 33, ensuring that the magnetic field acts concentratedly on the rotor assembly 2 while preventing eddy current losses; the insulating end plates 32 are made of ceramic or engineering plastics and can withstand high voltages of >2.5kV to prevent short circuits in the bearing assembly; the bearing housing 31 serves as the mounting base for the electromagnets 33, and through precision machining, the air gap tolerance between each electromagnet and the rotor assembly 2 is ensured to be ≤0.05mm.

[0061] The main frame assembly includes a mounting frame 43, and the periphery of the mounting frame 43 is engaged with a number of circumferentially evenly distributed mounting supports 42, which are engaged with the interior of the stator housing body 9. The interior of the mounting frame 43 is provided with a number of circumferentially evenly distributed storage holes 49, and the middle of the mounting frame 43 is provided with a mid-position through hole. The mounting frame 43 is provided with a number of groups of circumferentially evenly distributed water-conducting avoidance holes 50 and a number of groups of circumferentially evenly distributed conductive avoidance holes 51, each group of water-conducting avoidance holes 50 has two, and the water-conducting avoidance holes 50 and the conductive avoidance holes 51 are both connected to the storage holes 49, and each group of conductive avoidance holes 51 has two, and the front side end of the mounting frame 43 is provided with a number of mounting blocks 48, the number and position of the mounting blocks 48 correspond to the mounting protrusions 28, and a mounting screw is provided between the mounting block 48 and the mounting protrusion 28, and the mounting screw is screwed into the mounting screw hole 30 at the corresponding position.

[0062] The mounting frame 43 serves as the internal skeleton of the motor. It engages with the stator housing body 9 through the mounting support 42 to absorb thermal deformation stress and carry the stator core, cooling pipe assembly 4 and stator conductive assembly 8. The mid-position through hole leaves rotation space for the rotor assembly 2 to ensure air gap uniformity (tolerance ±0.1mm). The storage holes 49 are evenly distributed around the circumference to accurately position the stator core module, realizing boltless snap-on installation. The mounting block 48 is connected to the mounting protrusion 28 through the mounting screw and the mounting screw hole 30 to form an axial preload to resist the torque reaction force of the rotor assembly 2. The water guide avoidance hole 50: a double-hole group design guides the cooling pipe assembly 4 to pass through the frame to avoid bending pressure loss (diameter > 1.5 times the pipe diameter); the conductive avoidance hole 51: a double-hole group layout to isolate the phase winding leads and minimize electromagnetic interference (line spacing ≥ 10mm).

[0063] The cooling pipe assembly 4 includes two symmetrically arranged cooling pipe modules 46 and a number of hollow winding seats 60 evenly distributed around the circumference. The number and position of the hollow winding seats 60 correspond to the storage holes 49. The cooling pipe module 46 includes a cooling ring 34. The cooling rings 34 of the two cooling pipe modules 46 are respectively engaged on both sides of the mounting supports 42. The inward end faces of the cooling rings 34 are provided with a number of circumferentially evenly distributed water connection joints 36. The upper ends of the cooling pipe modules 46 are provided with water connection joints 35. The water connection joints 35 extend out of the water-cooling avoidance through-holes 11 at the corresponding positions. The hollow winding seats 60 are engaged inside the storage holes 49 at the corresponding positions. The upper end of the hollow winding seat 60 is provided with two wiring holes 61 and two connecting screw holes 62. The connecting screw holes 62 correspond to the positions of the water guide avoidance holes 50. The two connecting screw holes 62 are connected to the interior of the hollow winding seat 60. The connecting screw holes 62 are screwed with water receiving screw tubes 56, and the water receiving screw tubes 56 are connected to right-angle joints 55. The water receiving screw tubes 56 extend from the water guide avoidance holes 50 at the corresponding positions. The directions of the two right-angle joints 55 are opposite, and the two right-angle joints 55 are respectively connected to the water connecting joints 36 at the corresponding positions on the same side. The front and rear sides of the hollow winding seat 60 are provided with winding areas 59, and the winding areas 59 are respectively connected to the wiring holes 61 on the same side.

[0064] Cooling oil circulation path: external oil pump → one of the water connection joints 35 → one of the cooling ring pipes 34 → water connection joint 36 → right-angle joint 55 → one of the water connection spiral pipes 56 → hollow cavity of the hollow winding seat 60 → another water connection spiral pipe 56 → right-angle joint 55 → water connection joint 36 → another cooling ring pipe 34 → another water connection joint 35 → external radiator;

[0065] Two symmetrical cooling loops 34 are respectively engaged on both sides of the mounting support 42, forming a parallel cooling circuit, covering a 180° area of ​​the stator and eliminating heat dissipation blind spots; the winding area 59 is a groove on the front and rear sides of the hollow winding seat 60 to accommodate the stator winding, and the wiring hole 61 guides the wires through to connect to the stator conductive component 8 to realize the electromagnetic function; the water receiving spiral pipe 56 passes through the mounting frame 43 through the water guide avoidance hole 50 and is connected to the water connection joint 36 of the cooling loop 34 via the right-angle joint 55; the cooling oil forms turbulence in the inner cavity of the hollow winding seat 60, directly flushing the winding copper wire, reducing thermal resistance by 70% → the winding temperature rise is less than 40K; the reversely arranged right-angle joints 55 make the oil flow of the two ring pipes rotate in opposite directions, and the pressure loss difference is less than 5%, avoiding unilateral overheating and forming a cooling system; the wiring hole 61 is spatially isolated from the water receiving spiral pipe 56, and the cooling oil has no contact with the wires, eliminating the risk of leakage.

[0066] The stator conductive component 8 includes a stage B mother ring 40, a stage A mother ring 38 and a stage C mother ring 44 arranged in sequence from back to front, and several groups of circumferentially evenly distributed stator winding coils 58. The number of each group of stator winding coils 58 is two, and the stator winding coils 58 are all placed inside the winding area 59 at the corresponding position. The stator winding coils 58 are each provided with a connecting wire four 57, and the connecting wire four 57 extends from the wiring hole 61 and the conductive avoidance hole 51 at the corresponding position. The diameters of the stage A mother ring 38 and the stage C mother ring 44 are equal, the diameter of the stage B mother ring 40 is smaller than the diameter of the stage A mother ring 38, the outside of the stage B mother ring 40 is provided with a plurality of circumferentially evenly distributed connecting wires 2 52, the inside of the stage A mother ring 38 is provided with a plurality of circumferentially evenly distributed connecting wires 1 39, and the stage C mother ring 4 4 is provided with a plurality of circumferentially evenly distributed connecting wires 3 45. The connecting wire 4 57 of one of the stator winding coils 58 in each group of stator winding coils 58 is alternately connected to the connecting wire 1 39 and the connecting wire 3 45 respectively. A busbar connecting wire 41 is connected between the connecting wire 4 57 of the other stator winding coil 58 in each group of stator winding coils 58 and the connecting wire 2 52. The stage B mother ring 40 is provided with a stage B power connection terminal 53, the stage A mother ring 38 is provided with a stage A power connection terminal 54, and the stage C mother ring 44 is provided with a stage C power connection terminal 47. The stage B power connection terminal 53, the stage A power connection terminal 54 and the stage C power connection terminal 47 are respectively connected to the ampere connector 17 at the corresponding position; the stage A mother ring 38 and the stage C mother ring 44 are both connected to the connector body 13 with wires.

[0067] The three main coils are axially layered: the stage A main coil 38, the stage B main coil 40, and the stage C main coil 44 are stacked from back to front to form an axially centralized three-phase neutral point. The stage B main coil 40 has the smallest diameter to fit within the internal space. Distributed stator winding coils 58 are grouped and embedded in the winding area 59. Each group of two coils is connected to different phases, forming a circumferentially evenly distributed three-phase star winding. In each group of stator winding coils 58, one coil passes through connecting line 4 57 to connecting line 1 39 [Phase A] and connecting line 3 45 [Phase C]. The other coil passes through connecting line 4 57 to busbar connection line 41 and then to connecting line 2 52 [Phase B].

[0068] Phase B power terminal 53, phase A power terminal 54, and phase C power terminal 47 are each connected to the ampere connector 17 to transmit a hundred-ampere drive current. Phase A busbar 38 and phase C busbar 44 are additionally connected to the connector body 13 for transmitting control signals or neutral point monitoring. Asymmetric coil diameter layout: Phase B busbar 40 has the smallest coil diameter placed in the middle layer to balance the three-phase inductance parameters and suppress third harmonics. Short-path connection: The busbar connection 41 directly bridges the stator coil and busbar, reducing the winding end length by 30% and reducing copper losses.

[0069] Current path and electromagnetic process: Three-phase power is applied, and the current flows from the ampere connector 17 → the phase B power terminal 53, the phase A power terminal 54, and the phase C power terminal 47 → the phase A mother ring 38, the phase B mother ring 40, and the phase C mother ring 44 → distributed to each stator winding coil 58 via the connecting line 1 39, the connecting line 2 52, the connecting line 3 45, and the busbar connection line 41. The three-phase current generates a phase difference magnetic field in the circumferentially evenly distributed stator winding coils 58, synthesizing an axial rotating magnetic flux to drive the rotor assembly 2;

[0070] The connector body 13 collects the voltages of the stage A mother coil 38 and the stage C mother coil 44 in real time, detects the winding balance state through an algorithm, and triggers fault protection; extreme space utilization, the mother coils are axially stacked (thickness <15mm), saving 60% axial space compared to traditional radial windings; efficient heat dissipation compatibility: the stator winding coil 58 is directly embedded in the cooling cavity of the winding area 59 to achieve integrated electrical and thermal management.

[0071] The rotor assembly 2 includes a spline shaft 65 and two rotor modules 68. The two rotor modules 68 are arranged on the spline shaft 65. The rear end of the spline shaft 65 is provided with a fixed end plate 64. The rear end of the fixed end plate 64 is provided with an internal spline shaft 63. The internal spline shaft 63 is inserted into the inside of the magnetic bearing 29. The front end of the spline shaft 65 is provided with a connecting shaft 66. The connecting shaft 66 is inserted into the inside of the magnetic bearing 23. The front end of the connecting shaft 66 is provided with a spline shaft 2 67. A mounting end plate 69 is provided on the front rotor module 68. A spline hole 70 is opened inside the mounting end plate 69. The spline hole 70 cooperates with the spline shaft 65. Several circumferentially evenly distributed assembly screw pairs are provided between the mounting end plate 69 and the two rotor modules 68 and the fixed end plate 64. The spline shaft 65 and the several circumferentially evenly distributed assembly screw pairs all pass through the center through hole.

[0072] Two symmetrical rotor modules 68 are coaxially installed, each embedded with a permanent magnet array to form a double air-gap axial magnetic field, which increases the torque output by 80% under the same volume; the spline shaft 1 65 passes through the two rotor modules 68 and precisely engages through the spline hole 1 70 to eliminate the transmission gap; the spline shaft 2 67 extends the output end to adapt to the external load; the inner spline shaft 63 is inserted into the magnetic bearing 2 29, and the connecting shaft 66 is inserted into the magnetic bearing 1 23 to achieve contactless suspension at both ends of the two rotor modules 68; the assembly screw pair passes through the fixed end plate 64, the two rotor modules 68 and the mounting end plate 69 to form a torsion-resistant truss structure to improve stiffness; the spline fit allows the rotor assembly 2 to have an axial thermal expansion of ±0.2mm to avoid thermal stress deformation.

[0073] A three-phase current is applied to the stator winding coil 58, a rotating magnetic field is generated, the two rotor modules 68 are cut, electromagnetic torque is generated synchronously in the two air gaps, and the torque is output through the spline shaft 1 65 and the spline shaft 2 67; the involute tooth profile of the spline shaft 1 65 meshes with the spline hole 1 70, with a contact area greater than 85% and a torque transmission density greater than 200 Nm / kg; the magnetic bearing 1 23 and the magnetic bearing 2 29 monitor the runout of the rotor module 68 in real time, adjust the electromagnetic force, and offset the vibration harmonics caused by the uneven magnetic pull of the two rotor components 2; a 0.1 mm gap is reserved on the spline meshing tooth side, and the rotor component 2 slides along the spline shaft when it heats up to avoid jamming.

[0074] The rotor module 68 includes a rotor mounting frame 72, and a spline hole 2 74 is opened in the middle position of the rotor mounting frame 72, and the spline hole 2 74 cooperates with the spline shaft 1 65. A plurality of permanent magnet pole pieces 71 are evenly distributed around the circumference are provided inside the rotor mounting frame 72, and adjacent permanent magnet pole pieces 71 are alternately arranged in front and back. An end plate mounting groove 73 is provided in the middle position of the outer end surface of the rotor mounting frame 72, and the mounting end plate 69 is placed inside the end plate mounting groove 73 of the rotor module 68 on the front side, and the fixed end plate 64 is placed inside the end plate mounting groove 73 of the rotor module 68 on the rear side.

[0075] High-density permanent magnet magnetic field generation: Alternating permanent magnet pole pieces 71: The circumferentially evenly distributed permanent magnets adopt an alternating arrangement of NS poles to form an axially focused magnetic field, forming a high-intensity axial magnetic field (>1.2T) on the surface of the rotor assembly 2, and the magnetic energy utilization rate is increased by 40%; the rotor mounting bracket 72 serves as a magnetic carrier to optimize the magnetic circuit direction and reduce magnetic leakage (magnetic leakage coefficient <5%); the spline hole 2 74 is precisely engaged with the spline shaft 1 65, with the number of contact teeth ≥12 teeth and the transmitted torque density >300Nm / L; the end plate mounting groove 73, the front / rear end grooves are respectively embedded in the mounting end plate 69 and the fixed end plate 64, and the rotor assembly 2 is axially locked through interference fit (tolerance +0.02 / -0.01mm).

[0076] Working principle of the present invention:

[0077] Installation process: Assemble the housing and frame: elastically snap the mounting frame 43 of the main frame assembly into the inner cavity of the stator housing body 9 through the mounting bracket 42, and align the water-conducting avoidance hole 50 and the conductive avoidance hole 51 with the housing water-cooling avoidance through hole 11;

[0078] Run the mounting screw through the mounting screw holes 30 of the main frame mounting block 48 and the end plate mounting protrusion 28, and apply an axial pre-tightening force (torque ≥ 20 N·m);

[0079] Cooling system integration: Insert the hollow winding seat 60 into the main frame storage hole 49, ensuring that the wiring hole 61 is aligned with the conductive avoidance hole 51; screw the water inlet screw 56 into the hollow winding seat connection screw hole 62 (O-ring sealed), pass it through the water guide avoidance hole 50, and then connect it to the right-angle connector 55; insert the cooling ring pipe 34 on both sides of the mounting bracket 42, and reversely connect the right-angle connector 55 and the ring pipe water connection connector 36 to form a return oil circuit; insert the water inlet connector 35 of the cooling ring pipe 34 into the water cooling avoidance through hole 11 of the shell, and connect it to the external oil circuit quick-plug interface.

[0080] Stator winding and stator conductive assembly assembly: insert the stator winding coil 58 into the winding area 59 of the hollow winding seat, and lead the connecting wire 57 through the wiring hole 61 and the conductive avoidance hole 51;

[0081] Connection by phase: connecting line four 57 of one coil in each group of coils → connecting line one 39 (phase A) + connecting line three 45 (phase C); connecting line four 57 of the other coil → busbar connecting line 41 → connecting line two 52 (phase B); stacking three busbar coils: phase B busbar ring 40 (small ring diameter) → phase A busbar ring 38 → phase C busbar ring 44, phase B power terminal 53, phase A power terminal 54 and phase C power terminal 47 are connected to the ampere connector 17, and phase A busbar ring 38 and phase C busbar ring 44 are additionally connected to the connector body 13.

[0082] Assemble the rotor assembly 2: insert the permanent magnet pole pieces 71 into the rotor mounting bracket 72 in a NS alternating pattern to form a magnetic pole array;

[0083] Align the spline holes 2 74 of the two rotor modules 68 with the spline shaft 1 65 and push them into engagement (tooth side clearance 0.1mm);

[0084] Use an assembly screw pair to penetrate the fixed end plate 64 → the rear rotor end plate mounting slot 73 → the front rotor module 68 → the mounting end plate 69 (embedded in the front rotor end plate mounting slot 73), and lock it into a truss structure.

[0085] The end cover is sealed with the magnetic bearing: the inner spline shaft 63 of the rotor assembly 2 is inserted into the magnetic bearing 29, and the connecting shaft 66 is inserted into the magnetic bearing 1 23; the motor end plate assembly 1 and the motor top plate assembly 6 are locked with the two-way screw hole 10 of the shell by connecting bolt 1 21 and connecting bolt 2 27, and the sealing ring 19 and sealing ring 2 24 press the bearing area; the spline shaft 2 67 extends from the top plate mounting hole 1 22 to connect the external load.

[0086] Workflow (energy conversion closed loop):

[0087] Electromagnetic drive stage: Current input: external power supply via ampere connector 17 → stage B power terminal 53 of stage B female coil 40, stage A power terminal 54 of stage A female coil 38 and stage C power terminal 47 of stage C female coil 44 → stage B female coil 40, stage A female coil 38 and stage C female coil 44 → distributed to stator winding coil 58;

[0088] Magnetic field generation: The three-phase current generates a rotating magnetic field with a phase difference of 120° in the circular coil, and the magnetic flux direction is parallel to the axis of rotation (axial direction);

[0089] Torque output: The rotating magnetic field cuts the permanent magnet pole pieces 71 of the two rotor assemblies 2 → electromagnetic torque is generated synchronously in the double air gaps → the torque is output through the spline shaft 1 65 and the spline shaft 2 67;

[0090] Dynamic suspension control: The displacement sensor monitors the position of the rotor assembly 2 in real time → the controller adjusts the current of the electromagnet 33 of the magnetic bearing 1 23 and the magnetic bearing 2 29 → generates a dynamic repulsive magnetic field → maintains the radial / axial suspension of the rotor assembly 2 (deviation ≤ 5μm), with a rotation speed of 0-50,000rpm without mechanical friction.

[0091] Oil cooling cycle: A [external oil pump] → B (cooling oil 35°C), B → C [water connection joint 35], C → D [cooling loop pipe 34], D → E [water connection joint 36], E → F [right-angle joint 55], F → G [water connection spiral pipe 56], G → H [hollow cavity of hollow winding seat 60], H → I [directly flush winding copper wire], I → J [oil temperature rises to 65°C], J → K [water connection spiral pipe 56 on the other side], K → L [reverse cooling loop pipe 34], L → M [the other water connection joint 35], M → N [external radiator], N → A;

[0092] Heat dissipation efficiency: The turbulent oil flow contacts the winding surface, reducing thermal resistance by 70%; the reverse flow of the double-loop pipes balances the pressure difference (<5%), and the winding temperature rise is <40K.

[0093] Thermal management expansion: Passive heat dissipation: High-temperature oil mist forms eddies in heat dissipation blind holes 1 and 2, which then conduct heat to the environment through the metal end plates (auxiliary heat dissipation efficiency +25%). Thermal deformation compensation: The spline tooth side clearance (0.1mm) allows for axial thermal expansion of rotor assembly 2 of ±0.2mm to prevent sticking.

[0094] Safety monitoring: The connector body 13 collects the voltages of the stage A female ring 38 and the stage C female ring 44 in real time, analyzes the neutral point balance, and triggers overtemperature / overcurrent protection. When a single cooling loop fails, the other loop maintains 60% of its heat dissipation capacity to ensure emergency operation.

[0095] In summary, the axial flux structure achieves high torque density and compact design. The built-in oil cooling pipe assembly 4 directly cools the stator conductive assembly 8 and windings, breaking through the heat dissipation bottleneck of traditional motors. The motor outputs greater torque within the same volume, supports high-frequency starting and stopping, and transient overloads, meeting the requirements of high-power density scenarios.

[0096] The oil cooling system provides precise temperature control: The cooling oil circulates to absorb heat from core heat-generating components, preventing permanent magnet demagnetization and insulation aging, thereby extending service life. A layered thermal management design isolates the rotor assembly 2 from the stator heat source. Combined with the motor end plate assembly 1, stator housing assembly 3, and motor top plate assembly 6, the system is dust- and moisture-proof, ensuring stable operation in harsh operating conditions such as high temperatures and dusty conditions.

[0097] Highly integrated structure: The stator conductive assembly 8 - cooling pipe assembly 4 - connector assembly 5 and power terminal 7 are modularly arranged, taking into account both electrical efficiency and maintenance convenience;

[0098] Axially flattened packaging: shortens the magnetic field path, reduces magnetic loss, and significantly reduces axial space occupation, providing solutions for compact space integration in vehicle chassis / aviation powertrain, etc.

[0099] The "oil-cooled wrapped stator conductive components" design realizes a new type of heat dissipation, combined with the original advantages of axial magnetic flux, to achieve a triangular balance of high power, small size and long life.

[0100] The specific embodiments described herein are merely illustrative of the spirit of the present invention. Persons skilled in the art may make various modifications, additions, or substitutions to the described specific embodiments without departing from the spirit of the present invention or exceeding the scope of the appended claims.

Claims

1. An oil-cooled axial flux motor, comprising a stator housing assembly (3), characterized in that: The stator housing assembly (3) is provided with a main frame assembly inside, and a cooling pipe assembly (4) and a stator conductive assembly (8) are provided on the main frame assembly, and the stator conductive assembly (8) is located on the inner side of the cooling pipe assembly (4); the stator housing assembly (3) is provided with a connector assembly (5) and an electrical terminal (7) on the outer side, and the connector assembly (5) and the electrical terminal (7) are both electrically connected to the stator conductive assembly (8); the front end of the stator housing assembly (3) is provided with a motor top plate assembly (6), and the rear end of the stator housing assembly (3) is provided with a motor end plate assembly (1); a rotor assembly (2) is provided between the motor end plate assembly (1) and the motor top plate assembly (6), and the rotor assembly (2) is located on the inner side of the cooling pipe assembly (4); The main frame assembly includes a mounting frame (43), a plurality of mounting supports (42) evenly distributed around the circumference of the mounting frame (43) are engaged on the periphery of the mounting frame (43), the mounting supports (42) are engaged inside the stator housing body (9), a plurality of placement holes (49) evenly distributed around the circumference of the mounting frame (43) are provided inside the mounting frame (43), a middle through hole is provided in the middle of the mounting frame (43), and a plurality of groups of water-conducting avoidance holes (50) evenly distributed around the circumference of the mounting frame (43) and a plurality of groups of conductive avoidance holes (51) evenly distributed around the circumference of the mounting frame (43) are provided on the mounting frame (43). The number of each group of water-conducting avoidance holes (50) is two, and the water-conducting avoidance holes (50) and the conductive avoidance holes (51) are both connected to the storage holes (49). The number of each group of conductive avoidance holes (51) is two, and a plurality of mounting blocks (48) are provided at the front side end of the mounting frame (43). The number and position of the mounting blocks (48) correspond to the mounting protrusions (28). A mounting screw is provided between the mounting block (48) and the mounting protrusion (28), and the mounting screw is screwed into the inside of the mounting screw hole (30) at the corresponding position. The cooling pipe assembly (4) includes two symmetrically arranged cooling pipe modules (46) and a plurality of circumferentially evenly distributed hollow winding seats (60), the number and position of the hollow winding seats (60) correspond to the storage holes (49), the cooling pipe module (46) includes a cooling ring pipe (34), the cooling ring pipes (34) of the two cooling pipe modules (46) are respectively engaged on both sides of the plurality of mounting supports (42), the inner end faces of the cooling ring pipes (34) are provided with a plurality of circumferentially evenly distributed water connection joints (36), the upper ends of the cooling pipe modules (46) are provided with water connection joints (35), the water connection joints (35) extend out of the water cooling avoidance through holes (11) at the corresponding positions, the hollow winding seats (60) are engaged inside the storage holes (49) at the corresponding positions, and the hollow winding seats (60) are internally provided with water connection joints (35). The upper end of the hollow winding seat (60) is provided with two wiring holes (61) and two connecting screw holes (62), the connecting screw holes (62) correspond to the positions of the water-guiding avoidance holes (50), and the two connecting screw holes (62) are both connected to the interior of the hollow winding seat (60). The connecting screw holes (62) are both screwed with water-receiving screw tubes (56), and the water-receiving screw tubes (56) are both connected with right-angle joints (55), and the water-receiving screw tubes (56) extend from the water-guiding avoidance holes (50) at the corresponding positions. The directions of the two right-angle joints (55) are opposite, and the two right-angle joints (55) are respectively connected to the water-connecting joints (36) at the corresponding positions on the same side. The front and rear sides of the hollow winding seat (60) are both provided with winding areas (59), and the winding areas (59) are respectively connected to the wiring holes (61) on the same side.

2. The oil-cooled axial flux motor according to claim 1, characterized in that: The stator housing assembly (3) comprises a stator housing body (9), a plurality of circumferentially evenly distributed assembly protrusions are provided on the outer edge side of the stator housing body (9), and bidirectional screw holes (10) are provided on the assembly protrusions. Two water-cooling avoidance through holes (11) are provided on the stator housing body (9), a connector mounting seat (12) and a joint mounting seat are provided on the stator housing body (9), a connector body (13) is provided on the connector mounting seat (12), a connector connecting end (14) is plugged and connected to the connector body (13), a connector cover (15) is provided on the connector connecting end (14), and a plurality of evenly distributed ampere joints (17) are provided on the joint mounting seat, and the ampere joints (17) are plugged and connected to the ampere connecting end (16).

3. The oil-cooled axial flux motor according to claim 2, characterized in that: The motor top plate assembly (6) includes a motor top plate body (18), the motor top plate body (18) abuts against the front side of the stator housing body (9), a plurality of circumferentially evenly distributed connecting protrusions (20) are provided on the outer edge side of the motor top plate body (18), a connecting bolt (21) is provided inside each connecting protrusion (20), and the connecting bolt (21) is screwed into the inside of the bidirectional screw hole (10) at the corresponding position, a mounting hole (22) is provided in the middle of the motor top plate body (18), a sealing ring (19) is provided inside the inner outward portion of the mounting hole (22), a magnetic bearing (23) is provided inside the inner inward portion of the mounting hole (22), and a plurality of heat dissipation blind holes are opened on the inner end surface of the motor top plate body (18).

4. The oil-cooled axial flux motor according to claim 3, characterized in that: The motor end plate assembly (1) includes a motor end plate body (25), the motor end plate body (25) abuts against the rear side of the stator housing body (9), the outer edge side of the motor end plate body (25) is provided with a plurality of circumferentially evenly distributed connecting protrusions (26), the interior of each connecting protrusion (26) is provided with a connecting bolt (27), the connecting bolt (27) is screwed into the inside of the bidirectional screw hole (10) at the corresponding position, the middle part of the motor end plate body (25) is provided with a mounting hole (2), the interior of the inner outward portion of the mounting hole (2) is provided with a sealing ring (24), the interior of the inner inward portion of the mounting hole (2) is provided with a magnetic bearing (29), the inner end surface of the motor end plate body (25) is provided with a plurality of heat dissipation blind holes (2), the inner end surface of the motor end plate body (25) is provided with a plurality of circumferentially evenly distributed mounting protrusions (28), and the mounting protrusions (28) are provided with mounting screw holes (30).

5. The oil-cooled axial flux motor according to claim 4, characterized in that: The magnetic bearing 2 (29) has the same structure as the magnetic bearing 1 (23). The magnetic bearing 1 (23) includes a bearing housing (31). A plurality of electromagnets (33) evenly distributed around the circumference are provided inside the bearing housing (31). Insulating end plates (32) are provided at both ends of the bearing housing (31).

6. The oil-cooled axial flux motor according to claim 5, characterized in that: The stator conductive assembly (8) includes a stage B mother ring (40), a stage A mother ring (38) and a stage C mother ring (44) arranged in sequence from back to front, and a plurality of groups of circumferentially evenly distributed stator winding coils (58), each group of stator winding coils (58) has two stator winding coils (58), each of which is placed inside a winding area (59) at a corresponding position, and each of the stator winding coils (58) is provided with a connecting wire four (57), which extends from a wiring hole (61) and a conductive avoidance hole (51) at a corresponding position, the circle diameters of the stage A mother ring (38) and the stage C mother ring (44) are equal, the circle diameter of the stage B mother ring (40) is smaller than the circle diameter of the stage A mother ring (38), the outside of the stage B mother ring (40) is provided with a plurality of circumferentially evenly distributed connecting wires two (52), the inside of the stage A mother ring (38) is provided with a plurality of circumferentially evenly distributed connecting wires one (39), the stage C mother ring (44) A plurality of connecting wires (45) are evenly distributed around the circumference of the inside. The connecting wires (57) of one stator winding coil (58) of each group of stator winding coils (58) are alternately connected to the connecting wires (39) and the connecting wires (45). A busbar connecting wire (41) is connected between the connecting wires (57) of the other stator winding coil (58) of each group of stator winding coils (58) and the connecting wires (52). The stage B mother ring (40) is provided with a stage B power connection terminal (53), the stage A mother ring (38) is provided with a stage A power connection terminal (54), and the stage C mother ring (44) is provided with a stage C power connection terminal (47). The stage B power connection terminal (53), the stage A power connection terminal (54) and the stage C power connection terminal (47) are respectively connected to the ampere connector (17) wires at corresponding positions; the stage A mother ring (38) and the stage C mother ring (44) are both connected to the connector body (13) wires.

7. The oil-cooled axial flux motor according to claim 6, characterized in that: The rotor assembly (2) includes a spline shaft (65) and two rotor modules (68). The two rotor modules (68) are arranged on the spline shaft (65). The rear end of the spline shaft (65) is provided with a fixed end plate (64). The rear end of the fixed end plate (64) is provided with an inner spline shaft (63). The inner spline shaft (63) is inserted into the interior of the magnetic bearing (29). The front end of the spline shaft (65) is provided with a connecting shaft (66). The connecting shaft (66) is inserted into the interior of the magnetic bearing (23). The front end of the connecting shaft (66) is provided with a spline shaft 2 (67), the front rotor module (68) is provided with a mounting end plate (69), the interior of the mounting end plate (69) is provided with a spline hole 1 (70), the spline hole 1 (70) is matched with the spline shaft 1 (65), and a plurality of circumferentially evenly distributed assembly screw pairs are provided between the mounting end plate (69) and the two rotor modules (68) and the fixed end plate (64), and the spline shaft 1 (65) and the plurality of circumferentially evenly distributed assembly screw pairs all pass through the mid-position through hole.

8. The oil-cooled axial flux motor according to claim 7, characterized in that: The rotor module (68) includes a rotor mounting frame (72), a second spline hole (74) is provided in the middle of the rotor mounting frame (72), and the second spline hole (74) is matched with the first spline shaft (65). A plurality of circumferentially evenly distributed permanent magnet pole pieces (71) are provided inside the rotor mounting frame (72), and adjacent permanent magnet pole pieces (71) are alternately arranged in positive and negative directions. An end plate mounting groove (73) is provided in the middle of the outer end surface of the rotor mounting frame (72), and the mounting end plate (69) is placed inside the end plate mounting groove (73) of the rotor module (68) on the front side, and the fixed end plate (64) is placed inside the end plate mounting groove (73) of the rotor module (68) on the rear side.

Images