A low-energy-consumption variable torque motor

Abstract

The present application relates to the technical field of disc type motor, and aims to provide a low energy consumption torque variable motor, which comprises a plurality of disc type motor units arranged along the same line and connected in series on the same output shaft, and the output torque of the output shaft is driven by selecting one or more disc type motor units to drive the output shaft. The present application can reduce energy consumption, meet the demand of large torque output and seamless switching, and the disc type design of the motor unit can reduce the weight and save the cost. The gap between the disc type motor units is also conducive to ventilation and cooling, which is beneficial to maintaining a better temperature condition of the whole machine.

Description

Technical Field

[0001] This invention relates to the field of disc motor technology, and more specifically to a low-energy-consumption variable torque motor. Background Technology

[0002] Disc motors, also known as axial flux motors, are a special type of flat motor. Structurally, the stator and rotor are arranged relatively parallel along the axial direction, with a short axial dimension and a large radial dimension, resembling a disc, resulting in a highly compact and lightweight design. During operation, the disc motor uses the axial magnetic field to generate electromagnetic force to drive the rotor to rotate, achieving a high energy conversion efficiency of over 90%. Compared to traditional motors, it has advantages such as high torque density and fast response speed, outputting greater torque at the same power. Simultaneously, due to its structural characteristics, it operates with low noise and excellent heat dissipation. Currently, disc motors are widely used in new energy vehicle drive systems, aerospace equipment, power tools, and other fields, providing these industries with more efficient and compact power solutions and playing a vital role in the development of modern industry and emerging technologies.

[0003] However, in actual working conditions, due to frequent load changes and different end-user requirements, the required torque varies greatly. A single motor is difficult to meet the needs of different scenarios. Improving the performance of the disc motor by modifying its magnetic materials, magnetic coil wires, etc., is not only costly to develop, but also has a long development cycle.

[0004] This invention utilizes multi-motor linkage to flexibly match loads by starting, stopping, and adjusting the number and speed of the motors. Under light loads, fewer motors operate, saving energy and reducing consumption; under heavy loads, multiple motors work together to output high torque. This solution avoids the waste caused by selecting an oversized motor or the insufficient power caused by selecting an undersized motor, effectively improving system adaptability, reliability, and economy, meeting diverse power needs, and showing broad application prospects in industries, transportation, and other fields. Summary of the Invention

[0005] The purpose of this invention is to provide a low-energy-consumption variable torque motor with flexible and adjustable torque.

[0006] To achieve the above-mentioned objectives, the technical solution adopted by the present invention is: a low-energy-consumption variable torque motor, comprising multiple disc motor units, wherein the multiple disc motor units are arranged along the same straight line and connected in series on the same output shaft, and one or more disc motor units are selected to drive the output shaft to output torque.

[0007] Preferably, the output shaft is composed of multiple segments, each segment of the output shaft corresponding to a disc motor unit, and adjacent segments of the output shaft are connected by a coupling.

[0008] Preferably, the disc motor unit includes a disc-shaped motor housing consisting of a front end cover and a rear end cover, and the output shaft passes through the central hole of the front end cover and the rear end cover, and forms a rotational fit with the front end cover and the rear end cover through a bearing;

[0009] A coil rotor disk is provided inside the motor housing corresponding to the front end cover. The coil rotor disk is sleeved outside the output shaft and fixedly connected to the output shaft. Several excitation coils are wound on the coil rotor disk. A permanent magnet stator disk is fixedly provided inside the motor housing corresponding to the rear end cover. Several magnet tiles are installed on the permanent magnet stator disk, and the permanent magnet stator disk is sleeved outside the output shaft.

[0010] A commutator electrically connected to the excitation coil is provided on the side of the coil rotor disk facing the permanent magnet stator disk. The commutator is in contact with one end of the brush, and the brush terminal passes through the permanent magnet stator disk and extends out of the rear end cover.

[0011] Preferably, it also includes a support frame, which includes a base plate and a plurality of support plates, the number of which is adapted to the disc motor unit; the disc motor unit is connected to the base plate through the support plates.

[0012] Preferably, the number of disc motor units is 3-5.

[0013] Preferably, the coupling is either a sleeve coupling or a flange coupling.

[0014] Preferably, the coupling is a speed-adaptive coupling, which can enable the switching between rigid power connection and magnetic power connection between different sections of the output shaft.

[0015] Preferably, the adaptive coupling includes a housing, and a first connecting shaft and a second connecting shaft passing through both ends of the housing, forming a rotatable fit with the housing, for connecting to various sections of the output shaft; a connecting shaft is provided between the first connecting shaft and the second connecting shaft;

[0016] The first connecting shaft has a cylindrical shaft head on one end facing the connecting shaft. The shaft head has several slots extending along the length of the shaft head on its circumferential surface. A first magnetic disk is provided on the end face of the shaft head.

[0017] A second magnetic disk is provided on the end face of the connecting shaft facing the first connecting shaft, and the end is also provided with a number of claws that are positioned opposite the slots on the head of the first connecting shaft. The claws include a connecting section that mates with the slots and a disengaging section that gradually decreases in size towards the root of the claw. The inner surface of the claws and the surface of the disengaging section are both coated with a rubber layer.

[0018] The second connecting shaft has a groove at one end facing the connecting shaft for the other end of the connecting shaft to be inserted and form a sliding fit along the output shaft axis; the connecting shaft is sealed in the groove by a cover;

[0019] The adaptive coupling also includes an adjustment component for driving the connecting shaft to slide axially along the output shaft between the first connecting shaft and the second connecting shaft.

[0020] Preferably, the adjustment component is an annular adjustment electromagnet disposed on the inner side wall of the housing at one end of the first connecting shaft, and the end of the pawl is embedded with an adjustment permanent magnet. The adjustment electromagnet drives the connecting shaft to move by attracting and repelling the adjustment permanent magnet.

[0021] Preferably, the opposite ends of the first connecting shaft, the second connecting shaft, and the output shaft are all provided with flanges, and the opposite surfaces of the flanges are provided with transmission teeth. The flanges of the first connecting shaft and the output shaft, and the flanges of the second connecting shaft and the output shaft are locked together by flange bolts, and the transmission teeth on the corresponding flanges mesh with each other.

[0022] Preferably, the outer casing has an annular groove on its circumferential surface and is fixed to the base plate by a plate with one end sleeved in the groove.

[0023] The beneficial effects of this invention are mainly reflected in the following: by connecting multiple disc motor units in series on a single output shaft, when the torque demand is low, only one disc motor unit can be energized, while the others remain unenergized, thus achieving energy saving. When high torque output is required, multiple disc motor units can be energized simultaneously. Furthermore, if a single disc motor unit operates continuously for too long, potentially leading to overheating, this invention allows for seamless switching by alternating with another disc motor unit. This invention reduces energy consumption, meets the requirements for high torque output and seamless switching, and the disc-type design of the motor units reduces weight and saves costs. The gaps between the disc motor units also facilitate ventilation and cooling, helping to maintain optimal temperature conditions for the entire machine. Attached Figure Description

[0024] Figure 1 This is a top view of the present invention;

[0025] Figure 2 for Figure 1 The structure shown is viewed from direction AA.

[0026] Figure 3 for Figure 1 The diagram shown is a structural schematic of the unit after the speed adaptive coupling is installed.

[0027] Figure 4 for Figure 3 Enlarged view of section B;

[0028] Figure 5 This is a schematic diagram of the structure of the first connecting shaft;

[0029] Figure 6 This is a schematic diagram of the connecting shaft. Detailed Implementation

[0030] like Figure 1 As shown, this invention is a low-energy-consumption variable torque motor. In its overall structure, it connects multiple disc motors in series, allowing each motor to perform work individually, alternately, or in combination to meet various operating conditions. This invention includes multiple disc motor units 1, typically 3-5 in number. Figure 1 Three are shown. Typically, the motor of this invention also includes a support frame, which comprises a base plate 11 and several support uprights 12, the number of which is adapted to the disc motor unit 1. The disc motor unit 1 is connected to the base plate 11 via the support uprights 12, and there is a large ventilation space between each disc motor unit 1 to facilitate rapid cooling.

[0031] Multiple disc motor units 1 are arranged along the same straight line and connected in series on the same output shaft 2. One or more disc motor units 1 are selectively driven to drive the output shaft 2 to output torque. In other words, when multiple disc motor units 1 are provided, each disc motor unit 1 is arranged as follows: Figure 1 The distribution shown is linear. All power sources are connected to a single output shaft 2, through which torque is output.

[0032] The output shaft 2 can be a single, continuous shaft, connected to the rotor components (coil rotor disk 7) of the disc motor unit 1. However, for improved machining accuracy and flexible assembly, the output shaft 2 is generally composed of multiple segments. Each segment of the output shaft 2 corresponds to one disc motor unit 1, and adjacent segments of the output shaft 2 are connected by a coupling 3. In other words, each disc motor unit 1 has one segment of the output shaft 2, and these segments are connected by couplings 3. There are various types and structures of couplings 3; for example, the coupling 3 can be a sleeve coupling or a flange coupling.

[0033] The specific structure of the disc motor unit 1 of the present invention can be as follows: Figure 2 The structure shown can also utilize various existing disc motor mechanisms. For example... Figure 2 As shown, it includes a disc-shaped motor housing consisting of a front cover 4 and a rear cover 5. The output shaft 2 passes through the central hole of the front cover 4 and the rear cover 5 and is rotatably engaged with the front cover 4 and the rear cover 5 via a bearing 6.

[0034] A coil rotor disk 7 is installed inside the motor housing corresponding to the front end cover 4. The coil rotor disk 7 is sleeved on the output shaft 2 and fixedly connected to the output shaft 2. Several excitation coils are wound on the coil rotor disk 7. A permanent magnet stator disk 8 is fixedly installed inside the motor housing corresponding to the rear end cover 5. Several magnet tiles are installed on the permanent magnet stator disk 8, and the permanent magnet stator disk 8 is sleeved on the output shaft 2.

[0035] The side of the coil rotor disk 7 facing the permanent magnet stator disk 8 is provided with a commutator 9 that is electrically connected to the excitation coil. The commutator 9 is in contact with one end of the brush 10. The terminal of the brush 10 passes through the permanent magnet stator disk 8 and extends out of the rear end cover 5.

[0036] When this disc motor unit 1 is working, it is connected to the power supply through the terminal of the brush 10. With the cooperation of the commutator 9 and the brush 10, the excitation coil on the coil rotor disc 7 is energized, which in turn drives it to rotate relative to the permanent magnet stator disc 8, and finally drives the output shaft 2 fixedly connected to it to rotate.

[0037] Multiple disc motor units 1 are connected in series on a single output shaft 2. When the torque demand is low, only one disc motor unit 1 can be energized, while the others remain unenergized, achieving energy saving. When a high torque output is required, multiple disc motor units 1 can be energized simultaneously. Furthermore, if a disc motor unit 1 operates continuously for an extended period, it may overheat. In this case, another disc motor unit 1 can be controlled to alternate with the first one, achieving seamless switching.

[0038] In the operation of this invention, multiple disc motor units 1 work together, and the output shaft 2 uses the same shaft 2. Therefore, high control precision is required to ensure stable operation of each disc motor unit 1 at the same speed. However, in practical applications, this can increase control difficulty and product cost. If this is not addressed, the slight speed differences between the disc motor units 1, when combined, will cause instability in each section of the output shaft 2. This instability can lead to increased vibration of the output shaft 2 or accelerated bearing wear, especially at high speeds, where this instability becomes more pronounced, while it is less noticeable at low speeds.

[0039] To address the instability of the output shaft 2 that may occur during high-speed rotation or switching / overlapping startup of the disc motor unit 1, this invention further proposes that the coupling 3 be a speed-adaptive coupling 13. This speed-adaptive coupling 13 can switch between rigid and magnetic power connections between the segments of the output shaft 2. In low-speed, high-torque conditions, the segments of the output shaft 2 are connected by rigid power connections. Since the runout of the output shaft 2 is insignificant and controllable, this method ensures stable torque transmission. In high-speed conditions, the segments of the output shaft 2 switch to magnetic power connections. The segments of the output shaft 2 do not directly contact each other rigidly, fully utilizing the high torque transmission efficiency of magnetic power connections at high speeds and isolating eccentric runout between the segments of the output shaft 2, thus ensuring overall operational stability.

[0040] Specifically, combined Figure 3 and 4 As shown, the adaptive coupling 13 includes a housing 14, and a first connecting shaft 15 and a second connecting shaft 16, which are rotatably fitted within both ends of the housing 14 and used for connecting to various sections of the output shaft 2. A connecting shaft 17 is provided between the first connecting shaft 15 and the second connecting shaft 16. The first connecting shaft 15 and the second connecting shaft 16 are directly rigidly connected to the output shaft 2, such as the aforementioned sleeve coupling, flange coupling, etc. When using a flange coupling, in order to further ensure the stability of its transmission and avoid excessive shearing force on the flange bolts, the following connection method can be adopted: the opposite ends of the first connecting shaft 15, the second connecting shaft 16, and the output shaft 2 are all provided with flanges 30, and the opposite surfaces of the flanges 30 are provided with transmission teeth. The flanges 30 of the first connecting shaft 15 and the output shaft 2, and the flanges 30 of the second connecting shaft 16 and the output shaft 2 are locked together by flange bolts, and the transmission teeth on the corresponding flanges 30 mesh with each other.

[0041] The first connecting shaft 15 and the second connecting shaft 16 of the present invention can form a rigid power connection or a magnetic power connection, which is mainly adjusted by the connecting shaft 17 between the two.

[0042] Combination Figure 4 and 5 As shown, a cylindrical shaft head 18 is provided on a section of the first connecting shaft 15 facing the connecting shaft 17. A plurality of slots 19 extending along the length direction of the shaft head 18 are provided on the circumferential surface of the shaft head 18, and a first magnetic disk 20 is provided on the end face of the shaft head 18.

[0043] Combination Figure 4 and 6As shown, a second magnetic disk 21 is provided on the end face of the connecting shaft 17 facing the first connecting shaft 15, and this end is also provided with a plurality of claws 22 whose positions are opposite to the slots 19 on the shaft head 18 of the first connecting shaft 15. The claws 22 include a connecting section 23 that mates with the slots 19, and a root end (i.e., Figure 6 The detachment section 24, which gradually decreases in size (at one end of the main body of the connecting shaft 17).

[0044] The main working principle is that the chuck 22 can move within the slot 19 under the movement of the connecting shaft 17. At low speeds, rigid transmission is achieved through the stable contact between the connecting section 23 and the slot 19. At high speeds, the connecting section 23 of the chuck 22 can extend out of the slot 19, at which point the disengagement section 24 is opposite to the side walls of the slot 19 and does not directly contact it. The power transmission between the first connecting shaft 15 and the connecting shaft 17 is completed through the first magnetic disk 20 and the second magnetic disk 21. To further improve the performance of the speed adaptive coupling 13 of the present invention, the inner surface of the pawl 22 and the surface of the disengagement section 24 are both coated with a rubber layer 25. The rubber layer 25 is made of rubber with a certain hardness. On the one hand, it can provide a certain guidance for the movement of the pawl 22 in the slot 19, and avoid the pawl 22 and the slot 19 from being misaligned after the connecting section 23 is completely extended out of the slot 19. On the other hand, it can also provide a certain reduction and buffering effect on the vibration of each section of the output shaft 2 in the low speed state and during the switching process from low speed to high speed, so as to ensure the smoothness and stability of the switching.

[0045] Regarding the axial movement of the connecting shaft 17, the possible methods are as follows: Figure 4 As shown, the second connecting shaft 16 has a groove 26 at one end facing the connecting shaft 17 for the other end of the connecting shaft 17 to be inserted and form a sliding fit along the output shaft 2 axis. The connecting shaft 17 is encapsulated in the groove 26 by a cover 27. The adaptive coupling 13 also includes an adjustment assembly for driving the connecting shaft 17 to slide along the output shaft 2 axis between the first connecting shaft 15 and the second connecting shaft 16. Generally, the adjustment assembly is an annular adjustment electromagnet 28 disposed on the inner side wall of the housing 14 at the end where the first connecting shaft 15 is located. The end of the pawl 22 is embedded with an adjustment permanent magnet 29. The adjustment electromagnet 28 drives the connecting shaft 17 to move by attracting and repelling the adjustment permanent magnet 29.

[0046] Regarding the overall installation of the speed adaptive coupling 13, in addition to being fitted onto the power connection nodes of each section of the output shaft 2, it can also be further provided with an annular groove 31 on the circumferential surface of the housing 14, and fixed to the base plate 11 by a plate with one end fitted into the groove 31.

Claims

1. A low energy consumption torque variable motor characterized by: The application relates to a disk motor unit (1) which is arranged along the same line and connected in series on the same output shaft (2), and the output torque of the output shaft (2) is driven by selecting one or more disk motor units (1). The output shaft (2) is composed of multiple sections, each section of the output shaft (2) corresponds to one disk motor unit (1), and the adjacent two sections of the output shaft (2) are connected through a shaft coupling (3). The shaft coupling (3) is a rotating speed self-adaptive coupling (13), which can realize the conversion between rigid power connection and magnetic power connection between the sections of the output shaft (2). The self-adaptive coupling (13) comprises a shell (14), a first connecting shaft (15) and a second connecting shaft (16) which are arranged in the two ends of the shell (14) and are in rotating cooperation with the shell (14) and are used for connecting the sections of the output shaft (2); a connection shaft (17) is arranged between the first connecting shaft (15) and the second connecting shaft (16). A cylindrical shaft head (18) is arranged on one section of the first connecting shaft (15) which is close to the connection shaft (17), a plurality of clamping grooves (19) which extend along the length direction of the shaft head (18) are arranged on the circumferential surface of the shaft head (18), and a first magnetic disc (20) is arranged on the end surface of the shaft head (18). A second magnetic disc (21) is arranged on the end surface of one end of the connection shaft (17) which is close to the first connecting shaft (15), a plurality of clamping claws (22) which are opposite to the clamping grooves (19) on the shaft head (18) of the first connecting shaft (15) are arranged on the end surface of the one end of the connection shaft (17), the clamping claw (22) comprises a connection section (23) which is matched with the clamping groove (19) and a separation section (24) which gradually decreases towards the root end of the clamping claw (22), and rubber layers (25) are arranged on the inner surface of the clamping claw (22) and the surface of the separation section (24). An axle groove (26) is arranged on one end of the second connecting shaft (16) which is close to the connection shaft (17) and is used for inserting the other end of the connection shaft (17) and forming a sliding cooperation along the axial direction of the output shaft (2), and the connection shaft (17) is encapsulated in the axle groove (26) through a cover (27). The self-adaptive coupling (13) further comprises an adjusting assembly which is used for driving the connection shaft (17) to slide along the axial direction of the output shaft (2) between the first connecting shaft (15) and the second connecting shaft (16). The adjusting assembly is an annular adjusting electromagnet (28) which is arranged on the inner side wall of the shell (14) on one end of the first connecting shaft (15), an adjusting permanent magnet (29) is embedded on the end of the clamping claw (22), and the adjusting electromagnet (28) drives the connection shaft (17) to move through the attraction and repulsion of the adjusting permanent magnet (29).

2. The low energy consumption variable torque motor of claim 1, wherein: The disk motor unit (1) comprises a disk-shaped motor shell which is composed of a front end cover (4) and a rear end cover (5), the output shaft (2) passes through the central hole of the front end cover (4) and the rear end cover (5) and is in rotating cooperation with the front end cover (4) and the rear end cover (5) through a bearing (6). The front end cover (4) is provided with a coil rotor disc (7) in the corresponding motor shell, the coil rotor disc (7) is sleeved on the output shaft (2) and is fixedly connected with the output shaft (2), a plurality of excitation coils are wound on the coil rotor disc (7); the rear end cover (5) is fixedly provided with a permanent magnet stator disc (8) in the corresponding motor shell, a plurality of magnetic tiles are installed on the permanent magnet stator disc (8), and the permanent magnet stator disc (8) is sleeved on the output shaft (2); The coil rotor disc (7) is provided with a commutator (9) electrically connected with the excitation coil on the side facing the permanent magnet stator disc (8), the commutator (9) is in contact with one end of the brush (10), and the wiring end of the brush (10) penetrates through the permanent magnet stator disc (8) and extends out of the rear end cover (5).

3. The low energy consumption variable torque motor of claim 1, wherein: Further comprising a support frame, the support frame comprises a bottom plate (11) and a plurality of support vertical plates (12), the number of the support vertical plates (12) is matched with the disc type motor unit (1); the disc type motor unit (1) is connected with the bottom plate (11) through the support vertical plates (12).

4. The low energy consumption variable torque motor of claim 1, wherein: The number of the disc type motor unit (1) is 3-5.

5. The low energy consumption variable torque motor of claim 1, wherein: The coupling (3) is one of a sleeve coupling or a flange coupling.

6. The low energy consumption variable torque motor of claim 1, wherein: The opposite ends of the first connecting shaft (15), the second connecting shaft (16) and the output shaft (2) are provided with flanges (30), and the opposite surfaces of the flanges (30) are provided with transmission teeth, the flanges (30) between the first connecting shaft (15) and the output shaft (2) and the flanges (30) between the second connecting shaft (16) and the output shaft (2) are locked through flange bolts, and the transmission teeth on the corresponding flanges (30) are meshed with each other; The outer shell (14) is provided with an annular groove (31) on the circumferential surface, and is fixedly connected with the bottom plate (11) through a supporting plate with one end sleeved in the groove (31).

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