Rotor structure of high-torque-density axial flux motor

Abstract

The invention provides a rotor structure of a high-torque-density axial flux motor, and the structure comprises two housings, and the interiors of the two housings are jointly provided with a rotor assembly. The rotor assembly comprises two rotor discs, a limiting column, a connecting ring, main magnetic steel, a guide column, reinforced magnetic steel, a through hole, a limiting disc, a pressing plate, a rotor shaft and an embedding groove; and the rotor shaft is positioned in the two rotor discs. When the rotor structure is disassembled, the two rotor discs and the connecting ring can be separated by disassembling the lower limiting nut, and the limiting disc and the rotor discs can be separated by disassembling the locking nut, so that maintenance personnel can conveniently maintain the rotor structure; compared with the prior art, through the detachable design, on one hand, the overall mass of the rotor structure is reduced, the response speed of the rotor structure is increased, on the other hand, when the rotor structure breaks down, maintenance personnel can quickly decompose and disassemble the rotor structure, and the maintenance difficulty and cost are reduced.

Description

Technical Field

[0001] The present invention relates to a rotor structure, in particular to a rotor structure of a high-torque-density axial flux motor, and belongs to the technical field of axial flux motors. Background Art

[0002] A high-torque-density axial flux motor (HTM) is an axial flux motor that produces high output torque per unit volume or mass. Similar to conventional axial flux motors, HTMs operate based on the principle of electromagnetic induction. Alternating current is passed through the stator windings to generate an alternating magnetic field. This magnetic field exerts electromagnetic forces on the permanent magnets or windings on the rotor, generating torque and driving the rotor. Their unique design allows them to generate greater electromagnetic forces while maintaining the same size and weight, thereby achieving higher torque output. Unlike traditional radial flux motors, the magnetic flux direction is parallel to the motor shaft, and the stator and rotor are typically disc-shaped. This structure provides a more uniform magnetic field distribution, effectively utilizing space, and improving torque density. Permanent magnet materials with high remanence and coercivity, such as neodymium iron boron permanent magnets, are typically used to enhance magnetic field strength and improve the motor's electromagnetic conversion efficiency, thereby generating greater torque.

[0003] The stator winding of an axial flux motor typically uses a multi-phase winding structure, such as a three-phase or multi-phase winding. By rationally designing the number of turns, wire diameter, and winding distribution, the filling factor and electromagnetic utilization of the winding are improved, thereby increasing the motor's output torque. To achieve high torque density, the motor's mechanical structure is compact, using high-strength materials and advanced manufacturing processes to reduce the motor's size and weight while maintaining mechanical strength. Currently, the rotor structure of most axial flux motors on the market adopts an integrated design. This structure, due to the process characteristics of integral molding, gives the rotor a high structural strength. It can effectively resist the dual effects of centrifugal force and electromagnetic force during high-speed operation of the motor, ensuring the stability of the motor operation. However, the limitations of the integrated structure are also very significant. On the one hand, to meet the strength requirements, a large amount of material is often required, resulting in a high overall rotor weight, which not only increases the motor's own rotational inertia but also reduces the response speed. On the other hand, this integrated molding method makes the various rotor components tightly integrated. If problems such as internal permanent magnet demagnetization, winding failure, or local structural damage occur, maintenance personnel will find it difficult to disassemble and replace specific components. Usually, the entire rotor must be removed from the motor, and it may even need to be returned to the factory for processing. This greatly increases the difficulty and cost of maintenance, prolongs downtime for maintenance, and reduces equipment utilization efficiency. Therefore, a rotor structure for a high-torque density axial flux motor is proposed. Summary of the Invention

[0004] In view of this, the present invention provides a rotor structure of a high torque density axial flux motor to solve or alleviate the technical problems existing in the prior art and at least provide a beneficial option.

[0005] The technical solution of the embodiment of the present invention is implemented as follows: the rotor structure of the high torque density axial flux motor includes two housings, and the rotor assembly is commonly disposed inside the two housings; The rotor assembly includes two rotor discs, a limiting column, a connecting ring, a main magnetic steel, a guide column, a reinforcing magnetic steel, a through hole, a limiting disc, a pressure plate, a rotor shaft and an inlay groove; The rotor shaft is located inside the two rotor disks, and grooves are provided on the opposite surfaces of the two rotor disks. The limiting posts are symmetrically fixedly connected to the two sides of the connecting ring. The through holes are provided inside the rotor disks and pass through the grooves. The guide posts are symmetrically fixedly connected to the away surfaces of the two rotor disks. The pressure plates are symmetrically fixedly connected to the outer side walls of the limiting disks. The embedding grooves are symmetrically provided on the outer side walls of the rotor disks. The main magnets are symmetrically bonded to the away surfaces of the two rotor disks, and the reinforcing magnets are embedded inside the embedding grooves.

[0006] Further preferably, the connecting ring is inserted into the inside of the two grooves, the limiting column is inserted into the inside of the through hole, the outer wall of the limiting column is threadedly connected to the limiting nut, and the limiting nut is fitted to the outer wall of the rotor disk.

[0007] Further preferably, the limiting plate is slidably connected to the outer side wall of the guide column, the outer side wall of the guide column is threadedly connected with a locking nut, and the locking nut is fitted to the outer side wall of the limiting plate.

[0008] Further preferably, the pressure plate is attached to the outer side wall of the enhanced magnetic steel, and the enhanced magnetic steel and the main magnetic steel are arranged in an alternating manner.

[0009] Further preferably, the rotor assembly further includes a limiting groove, a connecting seat, a positioning hole, a limiting block, two pressure plates, a positioning column, a stopper, a spring and a fixing ring; The limiting groove is opened on the inner wall of the rotor disk, the connecting seat is fixedly connected to the outer wall of the rotor shaft, the positioning hole is opened inside the connecting seat, the positioning column is symmetrically fixedly connected to the opposite surfaces of the two pressure plates, the spring and the pressure plate are both sleeved on the outside of the rotor shaft, the fixing ring is fixedly connected to the outer wall of the rotor shaft, the stop block is symmetrically fixedly connected to the outer wall of the pressure plate, and the limiting block is symmetrically fixedly connected to the outer wall of the connecting seat.

[0010] Further preferably, the opposing surfaces of the two pressure plates are in contact with the outer side walls of the connecting seat, and the positioning posts are inserted into the interior of the positioning holes.

[0011] Further preferably, the pressure plate is slidably and rotatably connected to the outer side wall of the rotor shaft, one end of the spring abuts against the side of the pressure plate away from the connecting seat, and the other end of the spring abuts against the outer side wall of the fixing ring.

[0012] Further preferably, the limiting block is slidably connected to the inner wall of the limiting groove, and the stopper is attached to the outer wall of the rotor disk.

[0013] Further preferably, the inner side walls of the two casings are both installed with stator cores, the interior of the stator cores is wound with stator windings, and the two casings are fixedly connected by connecting bolts.

[0014] Further preferably, the rotor disk is located between the two stator cores, and the rotor shaft is rotatably connected to the inside of the two casings through two bearings.

[0015] The embodiment of the present invention adopts the above technical solution, which has the following advantages: When the rotor structure is disassembled, the pressure plate is pulled, and the pressure plate drives the positioning column to disengage from the positioning hole. The pressure plate is then rotated, and the pressure plate drives the stop block to correspond to the limit block. At this time, the position limitation of the rotor disk is released, and the rotor disk can be separated from the connecting seat. The limiting nut is then removed to separate the two rotor disks and the connecting ring. The locking nut can be removed to separate the limiting plate from the rotor disk, thereby facilitating maintenance personnel to repair the rotor structure. Compared with the prior art, the rotor structure of the present invention is detachable in design. On the one hand, it reduces the overall mass of the rotor structure and improves the response speed of the rotor structure. On the other hand, when the rotor structure fails, maintenance personnel can quickly disassemble the rotor structure, reducing maintenance difficulty and cost.

[0016] The above summary is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments and features described above, further aspects, embodiments and features of the present invention will be readily apparent by reference to the accompanying drawings and the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0018] Figure 1 A structural diagram of the rotor structure of the high torque density axial flux motor of the present invention; Figure 2 It is a schematic diagram of the structural decomposition of the present invention; Figure 3 This is a structural diagram of the rotor assembly of the present invention; Figure 4 It is a schematic diagram of the exploded structure of the rotor assembly of the present invention; Figure 5 This is a structural diagram of the connecting ring of the present invention; Figure 6 This is a structural diagram of the limit plate of the present invention; Figure 7 This is a structural diagram of the connecting seat of the present invention; Figure 8 It is a structural diagram of the pressure plate of the present invention.

[0019] Figure numerals: 101, rotor assembly; 11, rotor disk; 12, groove; 13, limiting groove; 14, limiting column; 15, connecting ring; 16, main magnet; 17, guide column; 18, reinforcing magnet; 19, through hole; 20, limiting disk; 21, pressure plate; 22, locking nut; 23, limiting nut; 24, rotor shaft; 25, engaging groove; 26, connecting seat; 27, positioning hole; 28, limiting block; 29, pressure plate; 30, positioning column; 31, stop block; 32, spring; 33, fixing ring; 41, housing; 43, stator core; 44, stator winding. DETAILED DESCRIPTION

[0020] Hereinafter, only certain exemplary embodiments are briefly described. As will be appreciated by those skilled in the art, the described embodiments may be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and description are to be considered as illustrative in nature and not restrictive.

[0021] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0022] In the existing technology, the rotor structure of most axial flux motors on the market adopts an integrated design. This structure, due to the process characteristics of integral molding, gives the rotor a high structural strength, and can effectively resist the dual effects of centrifugal force and electromagnetic force during high-speed operation of the motor, ensuring the stability of the motor operation. However, the limitations of the integrated structure are also very significant: on the one hand, in order to meet the strength requirements, a large amount of material is often required, resulting in a high overall weight of the rotor, which not only increases the rotational inertia of the motor itself but also reduces the response speed; on the other hand, this integrated molding method makes the various components of the rotor tightly combined. Once problems such as internal permanent magnet demagnetization, winding failure or local structural damage occur, it is difficult for maintenance personnel to disassemble and replace specific components. Usually, the entire rotor needs to be disassembled from the motor, and may even need to be returned to the factory for processing, which greatly increases the difficulty and cost of maintenance, prolongs downtime for maintenance, and reduces the efficiency of equipment use. To do this, see Figures 1-8 The embodiment of the present invention provides a rotor structure of a high torque density axial flux motor, comprising two housings 41 , wherein a rotor assembly 101 is disposed inside the two housings 41 ; The rotor assembly 101 includes two rotor disks 11, a limiting post 14, a connecting ring 15, a main magnet 16, a guide post 17, a reinforcing magnet 18, a through hole 19, a limiting disk 20, a pressure plate 21, a rotor shaft 24 and an engaging groove 25; The rotor shaft 24 is located inside the two rotor disks 11. Grooves 12 are provided on opposite surfaces of the two rotor disks 11. The limiting posts 14 are symmetrically fixedly connected to both sides of the connecting ring 15. A through hole 19 is provided inside the rotor disk 11 and passes through the groove 12. The connecting ring 15 is inserted into the two grooves 12. The limiting posts 14 are inserted into the through hole 19. The outer wall of the limiting post 14 is threadedly connected to the limiting nut 23. The limiting nut 23 fits the outer wall of the rotor disk 11. The position of the connecting ring 15 can be limited by the groove 12, the position of the limiting post 14 can be limited by the through hole 19, and the position of the limiting post 14 can be limited by the limiting nut 23, thereby ensuring that the two rotor disks 11 can be fixedly connected. When disassembling the rotor disc 11, it is only necessary to remove the lower limit nut 23 to separate the two rotor discs 11 and the connecting ring 15; The guide posts 17 are symmetrically fixedly connected to the away-from-each-other surfaces of the two rotor disks 11. The pressure plates 21 are symmetrically fixedly connected to the outer side walls of the limit plates 20. The limit plates 20 are slidably connected to the outer side walls of the guide posts 17. The outer side walls of the guide posts 17 are threadedly connected with lock nuts 22. The lock nuts 22 fit the outer side walls of the limit plates 20. The limit plates 20 are provided with holes corresponding to the guide posts 17 so that the limit plates 20 can be mounted on the guide posts 17. The position of the limit plates 20 can be limited by the cooperation between the guide posts 17 and the lock nuts 22. The embedding grooves 25 are symmetrically formed on the outer side walls of the rotor disks 11. The main magnets 16 are symmetrically bonded to the separated surfaces of the two rotor disks 11. The reinforcement magnets 18 are embedded in the embedding grooves 25. The pressure plate 21 is attached to the outer side walls of the reinforcement magnets 18. When the position of the limit plate 20 is fixed, the position of the pressure plate 21 is fixed. The pressure plate 21 can limit the position of the reinforcement magnets 18, thereby enhancing the stability of the structure. The enhanced magnetic steels 18 are arranged alternately with the main magnetic steels 16. By arranging the enhanced magnetic steels 18 between adjacent main magnetic steels 16, the interaction of the magnetic fields can be enhanced and the magnetic flux can be increased. Enhanced magnetic field interaction: The motor torque is generated by the interaction between the magnetic field generated by the stator winding 44 and the magnetic field of the rotor magnets. By increasing the number of magnets, the rotor magnetic field strength is enhanced. More magnets interact with the stator magnetic field, thereby generating a greater electromagnetic force. According to the principle that torque equals force multiplied by the moment arm, an increase in electromagnetic force will also increase torque, thereby achieving the purpose of increasing torque. Increase magnetic flux: As the number of magnets increases, the magnetic flux passing through the motor air gap will increase. According to the principles of motor science, the electromagnetic torque is proportional to the product of the magnetic flux and the stator current. When the stator current remains unchanged, the magnetic flux increases and the torque of the motor will also increase.

[0023] In order to solve the problems existing in the prior art, the embodiments of the present invention provide a rotor structure of a high torque density axial flux motor and solve the problems through the above technical solutions: The two rotor disks 11 are connected and fixed by the connecting ring 15, the limiting column 14 and the limiting nut 23, so that a hollow structure is formed inside the rotor, which reduces the weight of the rotor as a whole. Moreover, when the rotor structure needs to be disassembled and maintained, the two rotor disks 11 and the connecting ring 15 can be separated by removing the limiting nut 23, and the limiting disk 20 can be separated from the rotor disk 11 by removing the locking nut 22, thereby facilitating maintenance of the rotor structure by maintenance personnel. Compared with the prior art, the rotor structure of the present invention adopts a detachable design, which, on the one hand, reduces the overall mass of the rotor structure and improves the response speed of the rotor structure; on the other hand, when the rotor structure fails, maintenance personnel can quickly disassemble the rotor structure, reducing maintenance difficulty and cost.

[0024] In one embodiment, the spacing between the enhanced magnetic steel 18 and the main magnetic steel 16 is calculated by the following method: The specific steps of the spacing calculation method include: 1. Determine the basic parameters of the motor Before calculating the magnet spacing, the following motor design parameters must be determined: Rated power and speed: determine the torque requirement of the motor.

[0025] Pole pair number and air gap length: affect magnetic circuit design and magnetic field distribution.

[0026] Rotor disk diameter and thickness: limit the size and layout space of the magnetic steel.

[0027] Permanent magnet material properties: such as remanence, coercive force, etc., affect the magnetic field strength of the magnet.

[0028] 2. Main magnetic steel layout design The main magnet is the main source of the rotor disk magnetic field, and its layout must meet the following requirements: Polarity distribution: The main magnetic steel is usually arranged alternately in N-S poles to form a basic magnetic field polarity distribution.

[0029] Quantity determination: The number of main magnets is determined based on the number of pole pairs and the size of the rotor disk. For example, for a 4-pole motor, 4 main magnets (2 pairs of NS poles) need to be arranged on the rotor disk.

[0030] Preliminary spacing estimation: The spacing between the main magnets must ensure that the magnetic fields of adjacent magnets do not significantly interfere with each other. When making a preliminary estimate, the following principles can be used as a reference: The arc length (or axial length) of the main magnet should be in the ratio of 1 / number of pole pairs to the circumference of the rotor disk.

[0031] The spacing between adjacent main magnets should be greater than 1.5 times the thickness of the magnet to avoid local saturation caused by magnetic field superposition.

[0032] 3. Enhance the role and layout of magnetic steel The enhanced magnet is used to supplement the magnetic field of the main magnet, improve the air gap flux density and torque output. Its layout needs to consider the following factors: Position selection: The enhanced magnets are usually placed between the main magnets, close to the air gap side, to directly enhance the air gap magnetic field.

[0033] Quantity Determination: The number of enhanced magnets depends on the spacing between the main magnets and the magnetic field enhancement requirements. Generally speaking, 1-2 enhanced magnets can be placed in each main magnet spacing.

[0034] Spacing design: The spacing between the reinforced magnetic steel and the main magnetic steel must meet the following conditions: Avoid magnetic field interference: The magnetic field of the booster magnet should work in synergy with the magnetic field of the main magnet, rather than canceling each other out.

[0035] Mechanical strength requirements: To enhance the fixation of the magnetic steel, the mechanical strength of the rotor disk must be considered to avoid structural fragility due to too small a spacing.

[0036] 4. Magnetic Field Simulation and Optimization Since the calculation of the magnetic steel spacing involves complex magnetic field distribution, it needs to be optimized using electromagnetic simulation software (including ANSYS Maxwell and JMAG). The specific steps are as follows: Model building: Build a three-dimensional electromagnetic model based on motor parameters and magnetic steel layout.

[0037] Parametric sweep: Set the distance between the main magnet and the enhanced magnet as a variable, perform a parametric sweep, and observe the changes in magnetic field distribution and torque output.

[0038] Optimization goal: Maximize air gap magnetic flux density: By adjusting the spacing, the air gap magnetic flux density reaches the maximum value.

[0039] Minimize torque fluctuations: Ensure uniform magnetic field distribution and reduce torque pulsation.

[0040] Meet mechanical strength requirements: The stress distribution of the rotor disk must be considered during the simulation process to avoid structural failure due to too small a spacing.

[0041] Result analysis: According to the simulation results, the optimal magnetic steel spacing combination is selected.

[0042] 5. Specific steps for spacing calculation The following are the detailed steps for calculating the magnetic steel spacing. It does not involve formula derivation, but only describes the logical flow: Step 1: Determine the initial spacing of the main magnets Calculate the circumferential distribution angle of the main magnetic steel based on the rotor disk diameter and the number of pole pairs.

[0043] Assuming that the arc length of the main magnet is L1, the circumference of the rotor disk is C, and the number of pole pairs is P, the number of main magnets N=2P.

[0044] The initial spacing S1=(CN×L1) / N (the minimum safety distance between magnets needs to be considered).

[0045] Step 2: Evaluate the insertion position of the reinforcement magnet An enhanced magnetic steel is inserted between the main magnetic steels, and it is assumed that the arc length of the enhanced magnetic steel is L2.

[0046] The insertion position of the enhanced magnet must avoid direct conflict with the magnetic field of the main magnet and is usually selected in an area where the magnetic field of the main magnet is weak.

[0047] The distance S2 between the enhanced magnetic steel and the main magnetic steel is preliminarily determined, and it must satisfy S2>L2 / 2 (to avoid magnetic field superposition).

[0048] Step 3: Magnetic Field Simulation and Spacing Adjustment Create a model in the simulation software and set the preliminary spacing between the main magnet and the enhanced magnet.

[0049] Run the simulation to observe the air gap flux density distribution and torque output.

[0050] If the air gap magnetic flux distribution is uneven or the torque fluctuates greatly, adjust the distance between the main magnet and the enhanced magnet: Increase spacing: reduce magnetic field superposition and reduce the risk of excessive local magnetic density.

[0051] Reduce the spacing: Appropriately reduce the spacing in areas with weak magnetic fields to enhance the magnetic field strength.

[0052] Repeat the simulation until the magnetic field distribution and torque output meet the design requirements.

[0053] Step 4: Mechanical Strength Verification The mechanical stress analysis module is introduced into the simulation to examine the stress distribution of the rotor disk during high-speed rotation.

[0054] If the stress exceeds the allowable value of the material, it is necessary to adjust the magnetic steel spacing or increase the thickness of the rotor disk.

[0055] Ensure the reliability of the magnetic steel fixing structure to avoid the magnetic steel falling off due to centrifugal force.

[0056] Step 5: Thermal Performance Evaluation Consider the effect of the magnet spacing on heat dissipation; too small a spacing may cause local overheating.

[0057] Add a thermal analysis module to the simulation to observe the temperature distribution of the rotor disk.

[0058] If the local temperature is too high, it is necessary to increase the distance between the magnets or add more heat dissipation channels.

[0059] Step 6: Final spacing determination The final spacing between the main magnet and the reinforced magnet is determined based on the comprehensive consideration of magnetic field distribution, torque output, mechanical strength and heat dissipation performance.

[0060] Prototypes were made for experimental verification and fine-tuning was performed based on the experimental results.

[0061] 6. Experimental Verification and Iterative Optimization Prototypes were made and their performance indicators such as torque output, efficiency and temperature rise were tested.

[0062] Compare the experimental data with the simulation results and analyze the reasons for the differences.

[0063] The magnetic steel spacing is adjusted according to the experimental results and iterative optimization is performed until the design requirements are met.

[0064] 7. Experimental Verification and Fault-Tolerant Design High-precision experimental testing platform In order to verify the effectiveness of the magnetic steel spacing design, a high-precision experimental platform needs to be built: Dynamic torque test system: A high-precision torque sensor (such as HBM T40B) is used to measure the motor output torque in real time to verify the accuracy of the simulation results.

[0065] Infrared thermal imager: Monitor the surface temperature distribution of the rotor disk and evaluate whether the heat dissipation design meets the requirements.

[0066] High-speed camera: Capture the deformation of magnetic steel under high-speed rotation to ensure the safety of mechanical structure.

[0067] 8. Fault-Tolerant Design and Reliability Assessment During actual operation, motors may face faults such as magnetic steel demagnetization and local overheating. Therefore, fault-tolerant design is required to improve reliability: Redundant magnetic steel layout: Add backup magnets in key areas and automatically switch to redundant magnets when the main magnets fail.

[0068] Fault diagnosis algorithm: Based on motor current, vibration and other signals, the magnetic steel status is monitored in real time and potential faults are warned.

[0069] Accelerated life test: The long-term reliability of the magnetic steel spacing design is evaluated through extreme operating conditions tests such as high temperature, high humidity, and high vibration.

[0070] Key Considerations Magnetic material properties: Different permanent magnet materials have different remanence and coercive force, so the spacing needs to be adjusted according to the material properties.

[0071] Manufacturing process limitations: The machining and assembly accuracy of the magnetic steel will affect the actual spacing, and tolerances must be reserved in the design.

[0072] Dynamic performance considerations: When the motor runs at high speed, the distance between the magnets may change due to centrifugal force, so dynamic stability must be considered in the design.

[0073] Multi-physics coupling: The coupling effects of magnetic, mechanical, and thermal fields must be fully considered in the simulation to avoid degradation of other performance factors caused by single optimization.

[0074] Calculating the spacing between the main and reinforcement magnets is a key step in the design of axial-field motor rotor disks. This requires coordinated optimization through a multi-step process, including electromagnetic simulation, mechanical strength analysis, and thermal analysis. The design process must balance magnetic field performance, mechanical reliability, and heat dissipation requirements, and experimental verification ensures design effectiveness. Future advances in materials science and simulation technology will enable even more precise optimization of magnet spacing, driving axial-field motors toward even higher torque density and efficiency.

[0075] In one embodiment, a high-strength, non-magnetic material (such as titanium alloy or carbon fiber composite material) is used as the rotor disk matrix to improve mechanical load-bearing capacity. The rotor disk structure is designed through topology optimization, for example, by adding local reinforcement ribs in the magnet mounting area. Dynamic stress analysis is introduced into the simulation to simulate the stress distribution of the motor at maximum speed to ensure that the magnet spacing is within a safe range. Design heat dissipation channels (such as air gaps or thermally conductive fillers) between magnets to improve heat dissipation efficiency through forced air cooling or liquid cooling. Use low-loss permanent magnetic materials (such as samarium cobalt permanent magnets) or apply insulating layers on the surface to reduce eddy current losses. Integrate thermal analysis modules into the simulation to optimize the magnet spacing to balance thermal resistance and magnetic field strength. A modular magnetic steel design is adopted to reduce the processing difficulty through standardized components; 3D printing technology is introduced to manufacture rotor disks to achieve rapid prototyping of complex magnetic steel layouts, and parametric design tools (such as Isight) are used to automatically optimize the magnetic steel spacing and reduce the cost of manual trial and error.

[0076] In one embodiment, the rotor assembly 101 further includes a limiting groove 13, a connecting seat 26, a positioning hole 27, a limiting block 28, two pressure plates 29, a positioning column 30, a stopper 31, a spring 32 and a fixing ring 33; The limiting groove 13 is formed on the inner side wall of the rotor disk 11, the connecting seat 26 is fixedly connected to the outer side wall of the rotor shaft 24, the limiting block 28 is slidably connected to the inner side wall of the limiting groove 13, the stopper 31 is in contact with the outer side wall of the rotor disk 11, and the outer side wall of the connecting seat 26 is in contact with the inner side wall of the rotor disk 11. When the axial flux motor is operating, the rotor disk 11 drives the connecting seat 26 to rotate via the limiting block 28, and the connecting seat 26 drives the rotor shaft 24 to rotate, thereby realizing power transmission; The positioning holes 27 are formed inside the connecting seat 26, and the positioning posts 30 are symmetrically fixedly connected to the opposite surfaces of the two pressure plates 29. The opposite surfaces of the two pressure plates 29 are fitted to the outer wall of the connecting seat 26. The positioning posts 30 are inserted into the positioning holes 27, and the stoppers 31 are symmetrically fixedly connected to the outer wall of the pressure plates 29. The position of the pressure plates 29 can be limited by the cooperation between the positioning holes 27 and the positioning posts 30. When the rotor shaft 24 rotates, the two pressure plates 29 can prevent the rotor disc 11 from falling off from the connecting seat 26, thereby ensuring the stability of the structure. The spring 32 and the pressure plate 29 are both sleeved on the outside of the rotor shaft 24, the fixing ring 33 is fixedly connected to the outer wall of the rotor shaft 24, and the limit block 28 is symmetrically fixedly connected to the outer wall of the connecting seat 26, and the pressure plate 29 slides and rotates to be connected to the outer wall of the rotor shaft 24. One end of the spring 32 abuts the side of the pressure plate 29 away from the connecting seat 26, and the other end of the spring 32 abuts the outer wall of the fixing ring 33. The spring 32 pushes the pressure plate 29, and the position of the pressure plate 29 is fixed, which can limit the position of the rotor disc 11. When it is necessary to separate the rotor disc 11 from the rotor shaft 24, the pressure plate 29 is pulled, and the pressure plate 29 drives the positioning column 30 to disengage from the positioning hole 27, and then the pressure plate 29 is rotated, and the pressure plate 29 drives the stop block 31 to correspond to the limit block 28. At this time, the position limitation of the rotor disc 11 is released, and the rotor disc 11 can be separated from the connecting seat 26.

[0077] In one embodiment, a stator core 43 is installed on the inner side walls of the two housings 41, and a stator winding 44 is wound inside the stator core 43. The two housings 41 are fixedly connected by connecting bolts, and the rotor disk 11 is located between the two stator cores 43. The rotor shaft 24 is rotatably connected to the inside of the two housings 41 through two bearings. When controlling the operation of the axial flux motor, the stator winding 44 is energized. At this time, magnetic fields are generated on both sides of the motor rotor and act on the magnets. The magnetic field interacts with the magnetic field generated by the magnets to generate torque, causing the rotor disk 11 of the axial flux motor to rotate. The rotor disk 11 drives the rotor shaft 24, thereby realizing power output.

[0078] When the present invention is working: the stator winding 44 is energized, and magnetic fields are generated on both sides of the motor rotor and act on the magnetic steel. The magnetic field interacts with the magnetic field generated by the magnetic steel to generate torque, so that the rotor disk 11 of the axial flux motor rotates, and the rotor disk 11 drives the connecting seat 26 to rotate through the limit block 28, and the connecting seat 26 drives the rotor shaft 24 to rotate, thereby realizing power transmission. When the rotor structure is disassembled, the pressure plate 29 is pulled, and the pressure plate 29 drives the positioning column 30 to disengage from the positioning hole 27, and then the pressure plate 29 is rotated, and the pressure plate 29 drives the stop block 31 to correspond to the limit block 28. At this time, the position restriction of the rotor disk 11 is released, and the rotor disk 11 can be separated from the connecting seat 26. Then, the limit nut 23 is removed, and the two rotor disks 11 and the connecting ring 15 can be separated. The lock nut 22 can be removed to separate the limit plate 20 from the rotor disk 11, which makes it convenient for maintenance personnel to repair the rotor structure. Compared with the prior art, the rotor structure of the present invention adopts a detachable design, which, on the one hand, reduces the overall mass of the rotor structure and improves the response speed of the rotor structure; on the other hand, when the rotor structure fails, maintenance personnel can quickly disassemble the rotor structure, reducing maintenance difficulty and cost.

[0079] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various modifications and substitutions within the technical scope disclosed in the present invention, and such modifications and substitutions are intended to be within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be subject to the scope of protection of the claims.

Claims

1. A rotor structure of a high torque density axial flux motor, comprising two housings (41), characterized in that: A rotor assembly (101) is commonly provided inside the two casings (41); The rotor assembly (101) comprises two rotor disks (11), a limiting column (14), a connecting ring (15), a main magnetic steel (16), a guide column (17), a reinforcing magnetic steel (18), a through hole (19), a limiting disk (20), a pressure plate (21), a rotor shaft (24) and an engaging groove (25); The rotor shaft (24) is located inside the two rotor disks (11), and the opposite surfaces of the two rotor disks (11) are provided with grooves (12). The limiting columns (14) are symmetrically fixedly connected to the two sides of the connecting ring (15). The through hole (19) is opened inside the rotor disk (11) and passes through the groove (12). The guide column (17) is symmetrically fixedly connected to the distant surfaces of the two rotor disks (11). The pressure plate (21) is symmetrically fixedly connected to the outer wall of the limiting disk (20). The engaging groove (25) is symmetrically opened on the outer wall of the rotor disk (11). The main magnetic steel (16) is symmetrically bonded to the distant surfaces of the two rotor disks (11), and the reinforcing magnetic steel (18) is engaged inside the engaging groove (25).

2. The rotor structure of the high torque density axial flux motor according to claim 1, characterized in that: The connecting ring (15) is inserted into the inside of the two grooves (12), the limiting column (14) is inserted into the inside of the through hole (19), the outer wall of the limiting column (14) is threadedly connected to the limiting nut (23), and the limiting nut (23) is fitted to the outer wall of the rotor disk (11).

3. The rotor structure of the high torque density axial flux motor according to claim 2, characterized in that: The limiting plate (20) is slidably connected to the outer wall of the guide column (17), and the outer wall of the guide column (17) is threadedly connected to a locking nut (22), and the locking nut (22) is fitted to the outer wall of the limiting plate (20).

4. The rotor structure of the high torque density axial flux motor according to claim 3, characterized in that: The pressing plate (21) is attached to the outer wall of the enhanced magnetic steel (18), and the enhanced magnetic steel (18) and the main magnetic steel (16) are arranged in a staggered manner.

5. The rotor structure of the high torque density axial flux motor according to claim 1, characterized in that: The rotor assembly (101) further includes a limiting groove (13), a connecting seat (26), a positioning hole (27), a limiting block (28), two pressure plates (29), a positioning column (30), a stop block (31), a spring (32) and a fixing ring (33); The limiting groove (13) is provided on the inner wall of the rotor disk (11), the connecting seat (26) is fixedly connected to the outer wall of the rotor shaft (24), the positioning hole (27) is provided inside the connecting seat (26), the positioning column (30) is symmetrically fixedly connected to the opposite surfaces of the two pressure plates (29), the spring (32) and the pressure plate (29) are both sleeved on the outside of the rotor shaft (24), the fixing ring (33) is fixedly connected to the outer wall of the rotor shaft (24), the stopper (31) is symmetrically fixedly connected to the outer wall of the pressure plate (29), and the limiting block (28) is symmetrically fixedly connected to the outer wall of the connecting seat (26).

6. The rotor structure of the high torque density axial flux motor according to claim 5, characterized in that: The opposing surfaces of the two pressure plates (29) are attached to the outer side wall of the connecting seat (26), and the positioning column (30) is inserted into the interior of the positioning hole (27).

7. The rotor structure of the high torque density axial flux motor according to claim 6, characterized in that: The pressure plate (29) is slidably and rotationally connected to the outer wall of the rotor shaft (24), one end of the spring (32) abuts against the side of the pressure plate (29) away from the connecting seat (26), and the other end of the spring (32) abuts against the outer wall of the fixing ring (33).

8. The rotor structure of the high torque density axial flux motor according to claim 7, characterized in that: The limiting block (28) is slidably connected to the inner wall of the limiting groove (13), and the stopper (31) is attached to the outer wall of the rotor disk (11).

9. The rotor structure of the high torque density axial flux motor according to claim 1, characterized in that: The inner side walls of the two housings (41) are both mounted with stator cores (43), the interior of the stator cores (43) is wound with stator windings (44), and the two housings (41) are fixedly connected by connecting bolts.

10. The rotor structure of the high torque density axial flux motor according to claim 9, characterized in that: The rotor disk (11) is located between the two stator cores (43), and the rotor shaft (24) is rotatably connected to the inside of the two casings (41) via two bearings.

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