Stator structure of axial magnetic flux motor

Abstract

An axial magnetic flux motor stator structure comprises a soft magnetic material body and a plurality of strand conductors. The soft magnetic material body is provided with a plurality of magnetic poles and a plurality of slots, and each slot comprises a plurality of layers arranged along an axial direction. A plurality of strand conductors respectively pass through the layers of the slots to form a plurality of windings. After each strand of conductor passes through a lowest layer of the layers, the conductor climbs to pass through a higher layer of the layers until climbing to pass through a highest layer of the layers when crossing to a next magnetic pole position. The strands of conductors comprise a first strand of conductor and a second strand of conductor, and the first strand of conductor and the second strand of conductor remain unchanged at a relative position of the parts, protruding out of the soft magnetic material body, of all the slots when the strands of conductors are wound around the soft magnetic material body.

Description

Technical Field

[0001] This invention relates to a motor structure, particularly the winding structure of the stator of an axial flux motor. Background Technology

[0002] An electric motor is a component used to convert electrical energy into mechanical energy and is widely used in daily life. Current axial motors using distributed winding have conductors arranged circumferentially in the stator slots according to the corresponding magnetic pole positions. To effectively fill the slot space and increase the slot fill factor, the positions of two conductors in adjacent slots must be swapped axially at the protrusion before crossing to the next magnetic pole. This prevents the conductors from being further assembled into a complete winding after bending and shaping, requiring complex forming methods and equipment for the overall winding fabrication. Summary of the Invention

[0003] This invention proposes a stator structure for an axial flux motor, which solves the problems of existing technologies.

[0004] According to some embodiments of the present invention, an axial flux motor stator structure includes multiple magnetic poles, multiple layers, and multiple strands of conductors. The multiple magnetic poles have multiple pole positions. The multiple strands of conductors traverse the layers from one pole position to another to form multiple windings. After each strand of conductor traverses a lowest layer, it ascends and traverses a higher layer each time it reaches the next pole position, until it ascends and traverses a highest layer. The strands of conductors include at least a first strand and a second strand, the relative positions of all portions of the first strand and the second strand remaining constant along the axial direction.

[0005] According to some embodiments of the present invention, each conductor includes a plurality of inner diameter protrusions located in an internal space surrounding the axis of the axial flux motor stator structure, and the two halves of each inner diameter protrusion are positioned relative to each other in the axial direction by a layer difference.

[0006] According to some embodiments of the present invention, each conductor includes a plurality of outer diameter protrusions exposed outside the axial flux motor stator structure, and the two halves of each outer diameter protrusion are positioned relative to each other in the axial direction by a layer difference.

[0007] According to some embodiments of the invention, each conductor includes a plurality of inner diameter protrusions located in an internal space surrounding the axis of the axial flux motor stator structure, and half of each inner diameter protrusion of the second conductor is located axially above the half of the inner diameter protrusion immediately adjacent to that of the first conductor.

[0008] According to some embodiments of the present invention, each of the conductors includes a plurality of outer diameter protrusions exposed outside the axial flux motor stator structure, and half of each of the outer diameter protrusions of the second conductor is located axially above the half of the outer diameter protrusion immediately adjacent to that of the first conductor.

[0009] According to some embodiments of the present invention, each of the conductors includes a plurality of inner diameter protrusions located in an internal space surrounding the axis of the axial flux motor stator structure, and each of the inner diameter protrusions of the second conductor is positioned at least partially above the corresponding inner diameter protrusion of the first conductor in the axial direction.

[0010] According to some embodiments of the present invention, each of the conductors includes a plurality of outer diameter protrusions exposed outside the axial flux motor stator structure, and each of the outer diameter protrusions of the second conductor is positioned at least partially above the corresponding outer diameter protrusion of the first conductor in the axial direction.

[0011] According to some embodiments of the present invention, each strand of the conductor is formed by bending a continuous linear conductor or by assembling or welding multiple linear conductors.

[0012] According to some embodiments of the present invention, each strand of the conductor is wound around the stator structure of the axial flux motor in a spiral or star-shaped arrangement.

[0013] According to some embodiments of the present invention, the stator structure of the axial flux motor further includes a soft magnetic material body having some magnetic poles and a plurality of slots, each of the slots including the layers arranged along an axial direction.

[0014] According to some embodiments of the present invention, each conductor includes a plurality of inner diameter protrusions, a plurality of receiving portions and a plurality of outer diameter protrusions, the receiving portions being located within the slots, the inner diameter protrusions being located in an internal space surrounding the axis of the axial flux motor stator structure, and the outer diameter protrusions being exposed outside the axial flux motor stator structure.

[0015] According to some embodiments of the present invention, the conductors pass through the slots of the soft magnetic material body and partially protrude from the soft magnetic material body toward an internal space surrounding the axis of the soft magnetic material body and an outer diameter sidewall of the soft magnetic material body.

[0016] According to some embodiments of the present invention, each conductor includes a plurality of inner diameter protrusions located in the interior space of the soft magnetic material body, and the two halves of each inner diameter protrusion have a layer difference from each other in the axial direction.

[0017] According to some embodiments of the present invention, each conductor includes a plurality of outer diameter protrusions exposed outside the outer diameter sidewall of the soft magnetic material body, and the two halves of each outer diameter protrusion have a layer difference from each other in the axial direction.

[0018] According to some embodiments of the present invention, each conductor includes a plurality of inner diameter protrusions, a plurality of receiving portions and a plurality of outer diameter protrusions, the receiving portions being located within the slots, the inner diameter protrusions being located within the internal space of the soft magnetic material body, and the outer diameter protrusions being exposed outside the outer diameter sidewall of the soft magnetic material body.

[0019] In summary, the axial flux motor stator structure of this invention uses a spiral or star-shaped arrangement of each conductor in a circumferentially ascending structure. Each time a conductor reaches the next magnetic pole position, it ascends one layer within the slot, continuously ascending along the magnetic poles until the top layer of the slot is reached. This conductor structure ensures that the relative vertical positions of different conductors remain constant during winding, preventing vertical overlap. This allows the conductors to be easily assembled into a complete winding after forming, and solves the shortcomings of previous designs. After each conductor reaches the top layer of the slot, a connecting section allows current to be connected in series to the next conductor, continuing the same structure to ascend layer by layer to the top layer.

[0020] The above description will be given in detail below with reference to the embodiments, and a further explanation of the technical solution of the present invention will be provided. Attached Figure Description

[0021] To make the above and other objects, features, advantages and embodiments of the present invention more apparent and understandable, the accompanying drawings are described below:

[0022] Figure 1 A perspective view of the stator structure of an axial flux motor according to an embodiment of the present invention is shown;

[0023] Figure 2 Show Figure 1 A three-dimensional view of the soft magnetic material body in the stator structure of an axial flux motor;

[0024] Figure 3 A perspective view of a conductor according to an embodiment of the present invention is shown;

[0025] Figure 4 Show Figure 3 A side view of a conductor;

[0026] Figure 5 Show Figure 4 A top view of a conductor; and

[0027] Figure 6 A diagram showing the configuration of two conductors according to an embodiment of the present invention; and

[0028] Figure 7 This illustrates a winding of the same phase according to an embodiment of the present invention; and

[0029] Figure 8 A perspective view of the stator structure of a coreless axial flux motor is shown.

[0030] Explanation of icon numbers

[0031] 100: Stator structure of axial flux motor

[0032] 100a: Coreless stator structure

[0033] 110: Soft magnetic material body

[0034] 110a: Slot

[0035] 110b: Interior space

[0036] 110c: Outer diameter sidewall

[0037] 110t: Silicon steel sheet

[0038] L1, L2, L3, Ln: Layers

[0039] 120: Conductor

[0040] 120W: Winding

[0041] 120cl: Connecting segment

[0042] 121: Conductor

[0043] 121b: Bottom

[0044] 121t: Top

[0045] 121o: Outer diameter protrusion

[0046] 121o1: Half

[0047] 121o2: Half

[0048] 121i: Inner diameter protrusion

[0049] 121i1: Half

[0050] 121i2: Half

[0051] 121r: Containment Department

[0052] 122: Conductor

[0053] 122b: Bottom

[0054] 122t: Top

[0055] 122o: Outer diameter protrusion

[0056] 122o1: Half

[0057] 122o2: Half

[0058] 122i: Inner diameter protrusion

[0059] 122i1: Half

[0060] 122i2: Half

[0061] 123: Conductor

[0062] 123b: Bottom

[0063] 123t: Top

[0064] 125: Conductor

[0065] 125b: Bottom

[0066] 125t: Top

[0067] 127: Conductor

[0068] 127b: Bottom

[0069] 127t: Top

[0070] AD: Axial Detailed Implementation

[0071] To make the description of the present invention more detailed and complete, reference can be made to the accompanying drawings and the various embodiments described below, in which the same numbers represent the same or similar elements. Furthermore, well-known elements and steps are not described in the embodiments to avoid unnecessarily limiting the invention. In the context of the embodiments and the scope of the claims, unless specifically defined herein, "a" and "the" may refer to one or more.

[0072] Please refer to Figure 1 , Figure 2The stator structure 100 of the axial flux motor includes a soft magnetic material body 110 and multiple strands of conductors 120. The soft magnetic material body 110 has multiple magnetic poles and multiple slots 110a. In some embodiments of the present invention, the soft magnetic material body 110 includes 24 slots 110a through which multiple conductors 120 pass to form multiple windings, i.e., multiple distributed windings. Taking a three-phase flux motor as an example, 24 slots 110a divided by 3 (phase) yields 8 magnetic poles. In other words, the area of ​​three slots forms one magnetic pole. In some embodiments of the present invention, the soft magnetic material body 110 is composed of multiple silicon steel sheets 110t stacked along the axial direction AD or along the radial direction. In some embodiments of the present invention, the soft magnetic material body 110 is composed of soft magnetic composite (SMC). In some embodiments of the present invention, each slot 110a includes multiple layers (L1, L2, L3 to Ln) arranged along the axial direction AD, and a single conductor occupies only a single layer when passing through the slot.

[0073] Please refer to Figure 3 , Figure 4 , Figure 5 Conductors 121 are used to pass through slots 110a of the soft magnetic material body 110 to form windings. In some embodiments of the invention, each conductor 121 includes a plurality of inner diameter protrusions 121i, a plurality of receiving portions 121r, and a plurality of outer diameter protrusions 121o. Each receiving portion 121r is located within a corresponding slot of the soft magnetic material body 110 and connects between the corresponding inner diameter protrusion 121i and outer diameter protrusion 121o. The soft magnetic material body 110 is generally a hollow columnar structure. The inner diameter protrusions 121i are located in the internal space 110b of the soft magnetic material body 110, and the outer diameter protrusions 121o are exposed outside the outer diameter sidewall 110c of the soft magnetic material body 110 (see reference). Figure 5 The internal space 110b is located between the soft magnetic material body 110 and an axis, i.e., the soft magnetic material body 110 surrounds the axis to form the internal space 110b. In some embodiments of the invention, each conductor 121 includes a plurality of inner diameter protrusions 121i located in the internal space 110b of the soft magnetic material body 110 surrounding the axis (see reference). Figure 5 Furthermore, the two halves (121i1, 121i2) of each inner diameter protrusion 121i have a layer difference along the axial direction AD (see reference). Figure 3 Half 121i2 is one layer higher than half 121i1). In some embodiments of the invention, each conductor 121 includes a plurality of outer diameter protrusions 121o exposed outside the outer diameter sidewall 110c of the soft magnetic material body 110 (see reference). Figure 5Each outer diameter protrusion 121o has two halves (121o1, 121o2) with a layer difference along the axial direction AD (see reference). Figure 3 Half 121o2 is one layer higher than half 121o1. In some embodiments of the invention, each conductor 121 passes through the lowest layer of these layers (see reference). Figure 4 For example, after the bottom 121b is located at level L1, it ascends and traverses a higher level (e.g., L2) each time it reaches the next magnetic pole position, until it ascends and traverses the highest level among these levels (see reference). Figure 4 For example, the top 121t is located in the Ln layer. In some embodiments of the invention, each conductor 121 is formed by bending a continuous linear conductor. In other embodiments of the invention, each conductor 121 comprises multiple linear conductors assembled or welded together.

[0074] Please refer to Figure 6 This diagram shows Figure 1Two conductors (121 / 122) of a plurality of conductors pass through adjacent slots of a soft magnetic material body 110. For clarity of the positional relationship of the two conductors (121, 122), the soft magnetic material body 110 is omitted from the diagram. After each conductor (121, 122) passes through a lowest level of the slot (e.g., bottom ends 121b, 122b are located at the lowest level), it ascends through a higher level of the slots each time it reaches the next magnetic pole position, until it ascends through a highest level of the slots (e.g., top ends 121t, 122t are located at the highest level). In some embodiments of the invention, each inner diameter protrusion 122i of conductor 122 is at least partially located above the corresponding inner diameter protrusion 121i of conductor 121 in the axial direction AD (e.g., half 122i2 of conductor 122 is located above half 122i1 of conductor 121). In some embodiments of the invention, each outer diameter protrusion 122o of conductor 122 is at least partially located above the corresponding outer diameter protrusion 121o of conductor 121 in the axial direction AD (e.g., half 122o2 of conductor 122 is located above half 122o1 of conductor 121). In some embodiments of the invention, half 122i2 of each inner diameter protrusion 122i of conductor 122 is located above the immediately adjacent half 121i1 of inner diameter protrusion 121i of conductor 121 in the axial direction AD. In some embodiments of the invention, half 122o2 of each outer diameter protrusion 122o of conductor 122 is located above the immediately adjacent half 121o1 of outer diameter protrusion 121o of conductor 121 in the axial direction AD. In some embodiments of the present invention, when the two conductors (121, 122) are wound around the soft magnetic material body 110, the relative positions of the portions of all slots 110a protruding from the soft magnetic material body 110 along the axial direction AD remain unchanged throughout the entire winding process; that is, the relative positions of the upper and lower layers remain unchanged. For example, the relative positions of the outer diameter protrusions of the two conductors remain unchanged, and / or the relative positions of the inner diameter protrusions of the two conductors remain unchanged. In some embodiments of the present invention, when the two conductors (121, 122) are wound around the soft magnetic material body 110, they are arranged in a spiral or star shape.

[0075] Please refer to Figure 7The winding 120w comprises multiple conductors (121, 123, 125, 127) connected together. The bottom end 121b of conductor 121 passes through a lowest layer (e.g., L1) in the corresponding slot, and then, upon reaching the next magnetic pole position, ascends through a higher layer in that slot until the top end 121t ascends through the highest layer in that slot. Similarly, the bottom end 123b of conductor 123 passes through a lowest layer (e.g., L1) in the corresponding slot, and then, upon reaching the next magnetic pole position, ascends through a higher layer in that slot until the top end 123t ascends through the highest layer in that slot. Two conductors (121, 123) are connected in series by a connecting section 120cl. Next, after the bottom end 125b of conductor 125 passes through the lowest layer (e.g., L1) in the corresponding slot, it rises and passes through a higher layer in the slot each time it reaches the next magnetic pole position, until the top end 125t of conductor 125 rises and passes through the highest layer in the slot. The two conductors (123, 125) are connected in series by a connecting section 120cl. Next, after the bottom end 127b of conductor 127 passes through the lowest layer (e.g., L1) in the corresponding slot, it rises and passes through a higher layer in the slot each time it reaches the next magnetic pole position, until the top end 127t of conductor 127 rises and passes through the highest layer in the slot. The two conductors (125, 127) are connected in series by a connecting section 120cl. Multiple conductors (121, 123, 125, 127) are connected in series via connecting section 120cl to form a winding 120w. Taking a three-phase flux motor as an example, the windings of the other two phases (e.g., the windings of the U phase and the V phase) are also formed in a similar manner to fill the remaining slots 110a of the soft magnetic material body 110, which will not be elaborated here.

[0076] Please refer to Figure 8 The attached figure shows a coreless stator structure 100a of an axial flux motor with multiple conductors 120. This coreless stator structure 100a does not have a soft magnetic material body (e.g., Figure 1 , Figure 2 The soft magnetic material body 110 in the middle can achieve a simple structure. Although no soft magnetic material body is set, the coreless stator structure 100a still has multiple magnetic poles, and has multiple magnetic pole positions and layers, and the conductor 120 has a similar structure to the coreless stator structure 100a. Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 The conductors shown (121, 122, 123, 125, 127) have similar characteristics. Each conductor 120 moves from one magnetic pole position to the next after passing through the lowest layer, while simultaneously ascending to a higher layer, until it reaches the highest layer. The relative positions of the various parts of the conductor remain constant in the axial direction.

[0077] The axial flux motor stator structure of this invention uses a spiral or star-shaped arrangement of each conductor in a circumferentially ascending structure. Each time a conductor reaches the next magnetic pole position, it ascends one layer within the slot, continuing this process along the magnetic poles until the top layer of the slot is reached. This conductor structure ensures that the relative vertical positions of different conductors remain constant during winding, preventing vertical overlap. This allows the conductors to be easily assembled into a complete winding after forming, and solves various deficiencies that occurred in previous designs. After each conductor reaches the top layer of the slot, a connecting section allows current to be connected in series to the next conductor, and the same structure is used to continue ascending layer by layer to the top layer.

[0078] Although the present invention has been disclosed above by way of embodiments, it is not intended to limit the present invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the scope of the appended claims.

Claims

1. A stator structure for an axial flux motor, comprising: Multiple magnetic poles have multiple magnetic pole positions; Multiple layers; and Multiple conductors, each passing through multiple layers, move from one magnetic pole position to another to form multiple windings. Each of the conductors, after traversing the lowest layer of the plurality of layers, ascends and traverses a higher layer each time it reaches the next magnetic pole position, until it ascends and traverses the highest layer of the plurality of layers. The plurality of conductors includes at least a first conductor and a second conductor, and the relative positions of all portions of the first conductor and the second conductor remain unchanged along the axial direction.

2. The axial flux motor stator structure according to claim 1, wherein each of the conductors includes a plurality of inner diameter protrusions located in an internal space, the internal space surrounding the axis of the axial flux motor stator structure, and the positions of two halves of each inner diameter protrusion in the axial direction differ from each other by a layer.

3. The axial flux motor stator structure according to claim 1, wherein each conductor includes a plurality of outer diameter protrusions exposed outside the axial flux motor stator structure, and the positions of the two halves of each outer diameter protrusion in the axial direction have a layer difference from each other.

4. The axial flux motor stator structure according to claim 1, wherein each of the conductors includes a plurality of inner diameter protrusions located in an internal space surrounding the axis of the axial flux motor stator structure, and half of each of the inner diameter protrusions of the second conductor is located above half of the inner diameter protrusion immediately adjacent to that of the first conductor in the axial direction.

5. The axial flux motor stator structure according to claim 1, wherein each of the conductors includes a plurality of outer diameter protrusions exposed outside the axial flux motor stator structure, and half of each of the outer diameter protrusions of the second conductor is located above half of the outer diameter protrusion immediately adjacent to that of the first conductor in the axial direction.

6. The axial flux motor stator structure according to claim 1, wherein each of the conductors includes a plurality of inner diameter protrusions located in an internal space surrounding the axis of the axial flux motor stator structure, and the position of each of the inner diameter protrusions of the second conductor in the axial direction is at least partially located above the corresponding inner diameter protrusion of the first conductor.

7. The axial flux motor stator structure according to claim 1, wherein each of the conductors includes a plurality of outer diameter protrusions exposed outside the axial flux motor stator structure, and the position of each of the outer diameter protrusions of the second conductor in the axial direction is at least partially above the corresponding outer diameter protrusion of the first conductor.

8. The axial flux motor stator structure according to claim 1, wherein each strand of the conductor is formed by bending a continuous linear conductor, or by assembling or welding multiple linear conductors.

9. The axial flux motor stator structure according to claim 1, wherein each strand of the conductor is wound around the axial flux motor stator structure in a helical or star-shaped arrangement.

10. The axial flux motor stator structure according to claim 1 further comprises a soft magnetic material body, the soft magnetic material body having a plurality of magnetic poles and a plurality of slots, each of the slots comprising the plurality of layers arranged axially.

11. The axial flux motor stator structure according to claim 10, wherein each conductor includes a plurality of inner diameter protrusions, a plurality of receiving portions and a plurality of outer diameter protrusions, the plurality of receiving portions being located within the plurality of slots, the plurality of inner diameter protrusions being located in an internal space surrounding the axis of the axial flux motor stator structure, and the plurality of outer diameter protrusions being exposed outside the axial flux motor stator structure.

12. The axial flux motor stator structure according to claim 10, wherein the plurality of conductor strands pass through the plurality of slots of the soft magnetic material body and partially protrude from the soft magnetic material body toward the inner space surrounding the axis of the soft magnetic material body and the outer diameter sidewall of the soft magnetic material body.

13. The axial flux motor stator structure according to claim 12, wherein each of the conductors includes a plurality of inner diameter protrusions located in the internal space of the soft magnetic material body, and the positions of two halves of each inner diameter protrusion in the axial direction are different from each other by a layer.

14. The axial flux motor stator structure according to claim 12, wherein each of the conductors includes a plurality of outer diameter protrusions exposed outside the outer diameter sidewall of the soft magnetic material body, and the positions of the two halves of each outer diameter protrusion in the axial direction are different from each other by a layer.

15. The axial flux motor stator structure according to claim 12, wherein each conductor includes a plurality of inner diameter protrusions, a plurality of receiving portions and a plurality of outer diameter protrusions, the plurality of receiving portions being located within the plurality of slots, the plurality of inner diameter protrusions being located within the internal space of the soft magnetic material body, and the plurality of outer diameter protrusions being exposed outside the outer diameter sidewall of the soft magnetic material body.

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