Hub motor

Abstract

The invention belongs to the technical field of electric vehicle accessories, and particularly relates to a hub motor which comprises a rim. The motor comprises a first end cover, a second cover, a plurality of magnetic steel sheets, a fixing shaft and a stator assembly. The rim, the end cover I, the end cover II and the magnetic steel sheet are matched to form a rotor assembly; a circular ring part of an end cover I penetrates through a rim and is attached to the inner wall of an inner groove of the rim; the flange part I of the circular ring part is detachably connected with the flange part II of the end cover II through a bolt connecting component; by means of the design, the first end cover and the second end cover are directly matched in a sealed mode, independent metal rings in an existing design are reduced, and the sealing effect is remarkably improved; the width of the first flange part and the width of the second flange part can be set automatically, more glue sealing areas are provided, and the sealing effect is higher.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of electric vehicle accessories, and particularly relates to a wheel hub motor. BACKGROUND

[0002] The application is a divisional application of CN2023800100079, a wheel hub motor.

[0003] Patents with application numbers CN201920996599.7 and CN202020876366.6 both disclose a waterproof wheel hub motor, which comprises a wheel rim, a metal ring is welded to the inner wall of the wheel rim, the inner wall of the metal ring is bonded with a magnetic steel sheet through glue, the magnetic steel sheet, the metal ring and the wheel rim form an outer rotor structure; a stator winding is installed on a fixed shaft; an inner threaded hole is arranged on each side of the metal ring, and two end covers are fixed through bolts; The disadvantages are as follows: 1. Although the end cover and the metal ring are fixed through bolts and sealed through glue, in order to save costs, the thickness of the metal ring will not exceed 6 mm, therefore, the contact area between the metal ring and the end cover is limited, and the effect of the glue is poor; both ends of the metal ring need to be sealed with the end cover, and after long-term use, the aging of the glue will cause the waterproofing to fail, water will enter the motor, causing the stator winding to leak, and affecting the safety and service life of the motor; 2. Only the wheel rim is punched and welded by an iron plate, and the punching process is suitable for thin metal parts; when the wheel hub motor brakes, the brake seat will be subjected to a large circumferential shear force, and the brake seat must have a certain thickness. At the same time, in order to save costs, the thickness of the motor end cover outside the brake seat is thin, resulting in uneven thickness of the motor end cover; the uneven thickness of the motor end cover cannot be punched by a thin iron plate, and the motor end cover must be made of cast aluminum, which is high in cost; 3. Under the demand of reducing the number of parts and costs of the wheel hub, the thickness of the wheel rim and the end cover is also becoming thinner, and manufacturers can reduce the thickness of the wheel rim and the end cover to 1.7 mm; correspondingly, the thinner the thickness of the wheel rim, the greater the risk of impact deformation; the end cover is too thin, resulting in insufficient support strength; 4. When the electric vehicle accelerates or climbs, the stator winding outputs a large current continuously, causing the temperature inside the wheel hub to be high, resulting in an increase in internal air pressure; the gas will be discharged from the gap between the end cover and the metal ring and the gap between the fixed shaft and the end cover, and after the internal temperature cools down, the air in the external environment will be sucked into the wheel hub. At this time, the humid air or water flow in the external environment will enter the inside of the wheel rim; 5. The magnet is directly glued to the inner wall of the metal ring, which is then welded to the rim. The magnet's mounting base is the inner wall of the metal ring, while the mounting base for the fixed shaft is the mounting seat on the end cap. Upon final assembly, there is a slight deviation between the central axis of the inner wall of the metal ring (axis 1) and the central axis of the mounting seat (axis 2), resulting in uneven force distribution on both sides of the rim. Although this difference is extremely minor, prolonged operation will still lead to wear on the fixed shaft, increasing the likelihood of misalignment between the end cap and the metal ring, and potentially causing leaks. 6. A wire-passing hole is provided on the fixed shaft. The lead wire of the stator winding extends out of the hub through the wire-passing hole and connects to the controller wire of the electric vehicle. The sealing effect of the lead wire and the wire-passing hole is generally poor, and moisture in the environment can easily enter the interior of the hub through the wire-passing hole. Summary of the Invention

[0004] The purpose of this invention is to provide a hub motor that is simple in structure, has high strength, low cost, and good waterproof performance.

[0005] The objective of this invention is achieved as follows: A hub motor, including A rim for supporting a tire; the rim is annular in shape, with an inwardly recessed groove on its circumference; End cap one includes a disc-shaped end cap body, an annular portion, and a flange portion one; the end cap body extends into the rim from a first side and extends out from a second side of the rim; the annular portion is located in the middle of the rim; the flange portion one is located on the first side of the rim; End cap two is disposed on the first side of the rim; end cap two is mounted on the flange portion one of end cap one; end cap one and end cap two cooperate to form the inner cavity of the hub; Several magnetic steel sheets are disposed on the inner wall of the annular portion of the first end cover; the magnetic steel sheets are connected to the inner wall of the annular portion by adhesive bonding; the rim, the first end cover, the second end cover, and the magnetic steel sheets cooperate to form a rotor assembly; A fixed shaft passes through end cap one and end cap two; bearings are respectively provided in the middle of end cap one and end cap two; both ends of the fixed shaft pass through the bearings. A stator assembly, which is mounted on the fixed shaft.

[0006] Tire bead seats are provided on both sides of the inner groove; The two sides of the bead seat extend upward to form a rim, and the rim is provided with an outwardly turned edge or an inwardly turned edge; The sidewall of the inner groove is inclined toward the middle of the rim; the included angle b between the sidewall and the bottom wall of the inner groove is ≥80 degrees and <90 degrees.

[0007] Preferably, the rim comprises a metal plate, The metal plate is folded upwards at both sides in the width direction to form first bending parts, the metal plate between the two first bending parts forms a bottom wall of the inner groove, and the two first bending parts form side walls of the inner groove; the bending angle of the first bending part is greater than 90 degrees; The upper side of the first bending part is folded outwards to form a second bending part; The outer side of the second bending part is folded upwards to form a third bending part; The outer end of the third bending part is bent outwards or inwards to form the rim; The metal plate is curved into a circular ring along the length direction and is welded at the head and tail to form the rim; The thickness of the rim is 1.5mm-2mm.

[0008] Preferably, a transition section one is arranged between the bottom wall of the inner groove and the side wall of the inner groove, the thickness of the transition section one is less than the thickness of the bottom wall, and the thickness of the transition section one is less than the thickness of the side wall; the transition section one is located at the bending part between the side wall and the bottom wall.

[0009] Preferably, when the first bending part is folded outwards, it is first folded downwards to form a transition section two, and then folded outwards to form the second bending part; The transition section two extends downwards and outwards, and the second bending part extends outwards and upwards.

[0010] The end cover one comprises an end cover body, which is disc-shaped; the outer end part of the end cover body extends horizontally in the direction of the end cover two to form a circular ring part; The circular ring part passes through the rim and adheres to the inner wall of the inner groove of the rim; the front end of the circular ring part is folded outwards to form a flange part one; the inner wall of the circular ring part is adhered with the magnetic steel sheet; The bending part one of the end cover body and the circular ring part is welded with the inner wall of the rim to be integrated, and / or the outer edge of the flange part one is welded with the inner wall of the rim to be integrated; The edge of the end cover two is provided with a flange part two; the flange part two and the flange part one are detachably connected as a whole through a plurality of bolt connecting members, so that the end cover one and the end cover two are tightly matched. Preferably, the edge of the end cover body is expanded outwards to form a blocking ring part, which is larger than the inner hole diameter of the inner groove of the rim; the blocking ring part and the circular ring part are connected through a circular arc section, which is matched with the corner of the inner groove of the rim.

[0011] Preferably, the middle part of the end cover body is provided with an inner disc seat; The inner disc seat comprises a base, which is disc-shaped; The outer edge of the base is outwardly horizontally folded to form a brake ring one; The middle part of the base is outwardly folded to form a stepped inner ring part one and an inner ring part two; The middle part of the end cover body is outwardly horizontally folded to form a brake ring two, which is sleeved on the outside of the brake ring one and welded as a whole.

[0012] Preferably, the end cover body and the inner disc seat are thin iron pieces; the thickness of the end cover body and the inner disc seat is 1.5mm-3mm.

[0013] Preferably, one or more annular reinforcing ribs are arranged on the end cover body; a plurality of strip reinforcing ribs arranged in a radial manner are arranged on the base of the inner disc seat.

[0014] Preferably, the length of the brake ring one is greater than the length of the brake ring two; the brake ring two and the bent part two of the end cover body are welded with the ring surface of the brake ring one.

[0015] Preferably, a plurality of "Π" shaped connecting strips are arranged in the inner groove of the rim, and the bent part three on both sides of the connecting strip is welded with the corresponding rim wall surface.

[0016] Preferably, a bearing is arranged in the middle part of the end cover one and the end cover two; the fixed shaft is arranged in the bearing; the fixed shaft is obliquely provided with a threading hole, and the lead-out wire of the wheel hub motor extends out of the threading hole; the threading hole includes an inclined section, the inner wall of the inclined section is provided with a step part, and the outer side of the step part is provided with an internal thread part; the lead-out wire includes a plurality of wire cores; A threading hole is arranged on the fixed shaft of the wheel hub, and the lead-out wire of the wheel hub motor extends out of the threading hole; The lead-out wire includes a plurality of wire cores and an outer skin sleeve; the outer skin sleeve is wrapped outside the plurality of wire cores; the outer wall of the outer skin sleeve is sealingly matched with the threading hole; a gap channel is formed between the wire cores, and one end of the gap channel is communicated to the inner cavity of the wheel hub motor; The outer end of the lead-out wire extends upward to the inside of the motor vehicle shell; An exhaust joint is arranged on the outer end of the lead-out wire, and a separation chamber is arranged in the exhaust joint; a first joint, a second joint and a third joint are arranged on the circumferential side of the separation chamber; The outer skin sleeve and the wire core are inserted into the first joint, and the outer skin sleeve and the first joint are sealed; The wire core passes through the separation chamber and extends out of the second joint; the wire core and the second joint are sealed; The gap channel between the wire cores is communicated to the separation chamber.

[0017] Preferably, a gas-permeable and liquid-impermeable valve member is arranged on the third joint, and the separation chamber is communicated with the external environment through the gas-permeable and liquid-impermeable valve member.

[0018] Preferably, the exhaust joint comprises a shunt joint and a sheath; the sheath is wrapped outside the shunt joint; The shunt joint is internally provided with the separation chamber, and the first end, the second end and the third end of the shunt joint are arranged on the peripheral side of the separation chamber; the sheath sleeve and the core are inserted into the first end, and the sheath sleeve and the first end are sealed; the core extends out of the second end, and the third end is provided with an exhaust hole.

[0019] Preferably, the outer end of the lead wire extends to the inside of the controller of the electric vehicle; after the core extends out of the second joint, the core is connected with the circuit board of the controller.

[0020] Preferably, the second end is provided with a rubber sleeve body one, a plurality of through holes are pre-formed on the rubber sleeve body one, and the through holes correspond to the cores one by one; the cores pass through the corresponding through holes.

[0021] Preferably, the outer side of the rubber sleeve body one is provided with a clamping ring; and the sheath wraps the rubber sleeve body one.

[0022] Preferably, the outer wall of the sheath sleeve and the threading hole are sealed by glue.

[0023] Preferably, the threading hole comprises an inclined section, the inner wall of the inclined section is provided with a stepped portion, and the outer side of the stepped portion is provided with an internal thread portion; A rubber sleeve body two is in the shape of a ring; the rubber sleeve body two is sleeved on the outer side of the sheath sleeve and abuts against the stepped portion; A copper sleeve is sleeved on the outer side of the sheath sleeve and abuts against the rubber sleeve body two; the copper sleeve tightens the sheath sleeve; A nut sleeve is sleeved on the outer side of the sheath sleeve and abuts against the copper sleeve; the nut sleeve is screwed into the internal thread portion and presses the rubber sleeve body two.

[0024] Preferably, the threading hole is obliquely arranged on the fixed shaft; the outer side of the sheath sleeve is sleeved with a protection spring; one end of the protection spring is embedded in the inclined section of the threading hole and fixed, and the other end of the protection spring extends to the outer side of the threading hole.

[0025] The end cover one comprises an insertion ring and a shielding ring; the insertion ring and the shielding ring are partially overlapped; the insertion ring, the shielding ring and the inner wall of the rim are closely attached; the cooperation relationship among the shielding ring, the insertion ring and the inner wall of the rim is: An insertion cavity is formed between the outer side wall of the shielding ring and the inner wall of the rim, and the insertion ring is inserted into the insertion cavity; the insertion ring and the inner wall of the rim are welded into one body; the inner side wall of the shielding ring is provided with a plurality of magnetic steel sheets; Or, the cooperation relationship between the shielding ring, the inserted ring and the inner wall of the rim is that the outer side wall of the shielding ring is tightly fitted with the inner wall of the rim; the outer side of the inserted ring is tightly fitted with the inner side of the shielding ring, and the inner side wall of the inserted ring is provided with a plurality of magnetic steel sheets.

[0026] An electric vehicle comprises the hub motor.

[0027] Compared with the prior art, the present application has the following prominent and beneficial technical effects: The circular ring part of the end cover one penetrates the rim and is attached to the inner wall of the inner groove of the rim; the flange part one of the circular ring part and the flange part two of the end cover two are detachably connected through the bolt connection member; the design makes the end cover one and the end cover two directly sealed and matched, reduces the independent metal ring in the existing design, and significantly improves the sealing effect; the width of the flange part one and the flange part two can also be self-set, so that the area for glue sealing is larger and the sealing effect is higher.

[0028] The end cover one is combined with the end cover main body and the inner disc seat, the brake ring one of the inner disc seat and the brake ring two of the end cover main body are nested and welded; the brake ring one and the brake ring two superimpose to form a brake seat, the thickness of the brake seat can meet the strength requirement, the end cover main body and the inner disc seat can be made of 1.5mm-2mm thick iron plate punched, and the cost is significantly reduced.

[0029] The edge of the end cover main body is outwardly expanded to form a blocking ring part, the blocking ring part is larger than the inner hole diameter of the inner groove of the rim; the blocking ring part and the circular ring part are transitioned through a circular arc segment, and the circular arc segment is attached to the corner of the inner groove of the rim. The blocking ring part and the flange part one can be matched to clamp the rim, so that the cooperation between the end cover one and the rim is more compact, even if the welding is uneven or partially falls off, there will be no problem, and the service life is prolonged.

[0030] One or more annular reinforcing ribs are arranged on the end cover main body; a plurality of radially arranged strip-shaped reinforcing ribs are arranged on the base of the inner disc seat. The stress of the hub includes radial impact force, axial impact force and circumferential shear force, the radial impact force is loaded and dispersed by the rim, the axial impact force is mainly loaded and dispersed by the end cover main body, the annular reinforcing rib design makes the load effect better, the circumferential shear force is mainly loaded and dispersed by the inner disc seat, and the strip-shaped reinforcing rib design makes the load effect better and the strength better.

[0031] The length of the brake ring one is greater than the length of the brake ring two; the brake ring two and the bending part two of the end cover main body are welded with the annular surface of the brake ring one; when subjected to axial impact force, the design makes the load effect more concentrated on the end cover main body, and the stability is better.

[0032] The several "Π" shaped connecting strips arranged in the inner groove of the rim, the bending parts three on the two sides of the connecting strips are welded with the corresponding rim wall surface; for the rim with thinner thickness, the design of the connecting strips can prevent the rim from opening outward, and ensure the strength of the rim.

[0033] The outer end of the lead-out wire of the application extends upward to the inside of the electric vehicle shell, for example, is directly connected to the inside of the controller, these parts are at a relatively high position, generally will not contact water; a branch joint is installed at the outer end of the lead-out wire, a separation chamber is arranged in the branch joint; the gas and oil liquid in the hub can pass through the gap channel between the wire cores, conduct to the separation chamber, and then be released to the external environment through the separation chamber.

[0034] The protective spring of the application can effectively prevent the outer skin sleeve from being scratched by the fixing shaft, and protect the inner wire core. BRIEF DESCRIPTION OF DRAWINGS

[0035] Figure 1 is a schematic diagram of a wheel hub motor.

[0036] Figure 2 is an exploded view of the wheel hub (the stator assembly is not shown).

[0037] Figure 3 is a cross-sectional view of the wheel hub (the stator assembly is not shown).

[0038] Figure 4 is a schematic diagram of the cooperation of the rim and the end cover.

[0039] Figure 5 is a schematic diagram of the end cover one.

[0040] Figure 6 is a partial cross-sectional view of the end cover one.

[0041] Figure 7 is a schematic diagram of the outer end of the lead-out wire.

[0042] Figure 8 is a cross-sectional view of the outer end of the lead-out wire.

[0043] Figure 9 is an exploded view of the outer end of the lead-out wire.

[0044] Figure 10 is one of the schematic diagrams of the cooperation of the fixing shaft and the lead-out wire.

[0045] Figure 11 is the second schematic diagram of the cooperation of the fixing shaft and the lead-out wire.

[0046] Figure 12 is a schematic diagram of the rim and the end cover one.

[0047] Figure 13 is Figure 12is an enlarged view of A in FIG.

[0048] Figure 14 is one of the installation schematic diagrams of the magnetic steel sheet.

[0049] Figure 15 is another installation schematic diagram of the magnetic steel sheet.

[0050] Figure 16 is a schematic diagram of the rim of Example 2.

[0051] Figure 17 is a schematic diagram of the rim of Example 3.

[0052] Figure 18 is a schematic diagram of the structure of the rim of Example 4.

[0053] Figure 19 is a schematic diagram of the stress state of the rim of Example 4.

[0054] Figure 20 is one of the schematic diagrams of the cooperation of the rim, end cover one and end cover two of Example 5.

[0055] Figure 21 is another schematic diagram of the cooperation of the rim, end cover one and end cover two of Example 5.

[0056] Meaning indicated by the reference signs in the drawings: 10 - rim; 20 - fixed shaft; 30 - lead wire; 40 - end cover one; 50 - connecting strip; 61 - oil seal one; 62 - oil seal two; 71 - bearing one; 72 - bearing two; 80 - magnetic steel sheet; 90 - end cover two; 21 - threading hole; 22 - oblique section; 221 - step portion; 222 - internal thread portion; 301 - wire core; 302 - protective spring; 303 - through hole; 304 - rubber sleeve body two; 305 - copper sleeve; 306 - nut sleeve; 307 - outer skin sleeve; 308 - air pipe; 309 - valve member; 41 - inner disc seat; 42 - end cover body; 411 - base; 412 - brake ring one; 414 - inner ring portion one; 413 - strip-shaped reinforcing rib; 415 - inner ring portion one; 421 - end cover annular surface; 422 - annular reinforcing rib; 423 - circular ring portion; 424 - flange portion one; 425 - inner screw portion one; 426 - brake ring two; 427 - positioning step; 428 - recessed portion; 429 - abutting annular surface; 430 - bent portion two; 431 - welded portion three; 432 - end cover abutting portion; 441 - brake ring three; 442 - base two; 443 - embedded block; 444 - mounting hole; 445 - clamping groove; 446 - limiting step; 46 - valve member two; 491 - ring segment; 492 - circular segment; 493 - bolt segment; 494 - positioning flange; 495 - nut; 496 - inner screw segment II; 501 - welding segment I; 901 - flange segment II; 902 - bolt connecting member; 101 - inner groove; 102 - welding segment II; 103 - bending segment I; 110 - corner; 111 - bottom wall of inner groove; 113 - side wall of inner groove; a - inner inclination angle; 3000 - exhaust joint; 3000A - first joint; 3000B - second joint; 3000C - third joint; 3011 - envelope; 3011A - first end of envelope; 3011B - second end of envelope; 3011C - middle hole segment of envelope; 3012 - shunt joint; 3012A - first end; 3012B - second end; 3012C - third end; 3012D - separation chamber; 3012C1 - exhaust hole; 3013 - gas-permeable and liquid-impermeable valve member; 3013A - hollow hole; 3013B - polymer film layer; 3014 - clamping ring; 3015 - rubber sleeve I; 3015A - through hole. DETAILED DESCRIPTION

[0057] The application will be further described below in conjunction with specific embodiments: Embodiment one, as Figures 1-15 A wheel hub motor, comprising a rim 10, an end cover one 40, an end cover two 90, a plurality of magnetic steel sheets 80, a fixed shaft 20 and a stator assembly, the stator assembly is connected with the core of the lead wire, the stator assembly is prior art, which will not be expanded in this application; The rim 10 is used for bearing tires; the rim is annular, and an inner groove 101 is formed by inwardly recessing a circumferential side of the rim; The end cover one 40 comprises a disc-shaped end cover body 42, a ring segment 423 and a flange segment one 424; the end cover body extends into the first side of the rim and extends out of the second side of the rim; the ring segment 423 is located in the middle of the rim; the flange segment one 424 is located in the first side of the rim; The end cover two 90 is arranged on the first side of the rim; the end cover two is mounted on the flange segment one 424 of the end cover one; the end cover one and the end cover two cooperate to form an inner cavity of the wheel hub; therefore, the end cover one and the end cover two are directly cooperated without passing through the rim; the parts cooperated by the end cover two and the end cover one are both flat surfaces (i.e., the flange segment one and the flange segment two are both flat surfaces), and the sealing effect of the glue is better; Several magnets 80 are disposed on the inner wall of the annular portion 423 of the first end cover 40; the magnets 80 are connected to the inner wall of the annular portion 423 by adhesive bonding; the rim 10, the first end cover 40, the second end cover 90 and the magnets 80 cooperate to form a rotor assembly; after the stator assembly inside the hub is energized, the magnets of the rotor assembly are subjected to the magnetic field and generate driving force.

[0058] A fixed shaft 20 passes through the first end cover and the second end cover; bearings are respectively provided in the middle of the first end cover and the second end cover; both ends of the fixed shaft pass through the bearings. A stator assembly, which is mounted on the fixed shaft 20.

[0059] Preferably, the outer periphery of the flange portion 424 is fitted to the inner wall of the shoulder of the rim; a certain distance is provided between the flange portion 424 and the side wall of the inner groove of the rim; this distance is used for the flange portion 424 to form a threaded sleeve portion 425, which is a structure on the flange portion 424 that protrudes into the rim. The outer wall of the flange portion 1, the outer wall of the annular portion 423, the side wall of the inner groove of the rim, and the inner wall of the shoulder of the rim cooperate with each other to form a transition cavity 104. Although the wheel hub manufacturer will provide an annular weld portion 2 102 between the outer edge of the flange portion 1 and the inner wall of the shoulder of the rim, the weld portion 2 102 is at risk of partial detachment due to the impact-prone working environment of the rim during operation. In addition, due to the issue of processing precision, the weld portion 2 102 is also at risk of incomplete welding, that is, liquid from the external environment may enter the transition cavity 104. Therefore, it is necessary to pre-weld the transition cavity 104. Electrophoretic coating is also performed inside 04; therefore, a through groove needs to be provided at the flange, which connects the transition cavity and the external environment of the hub; during electrophoresis, the electrophoretic solution enters the transition cavity 104 through the through groove. After electrophoresis is completed, the rim only needs to be lifted; the lifting position is generally chosen to be the vent 114, as the rest of the rim is relatively smooth and not easy to lift stably; since the through groove and the vent on the rim are respectively located on different sides of the rim; the vent and the through groove are arranged diagonally opposite to each other on the vertical rolling plane of the hub, the projected positions of the vent and the through groove are 180 degrees apart. When the rim is lifted through the vent, the through groove is exactly at the bottom of the corresponding transition cavity 104, and the electrophoretic solution can be smoothly discharged; after drying, a rubber stopper is installed at the opening of the through groove; the rubber stopper seals the through groove and prevents liquid from entering the transition cavity.

[0060] Preferably, the inner wall of the circular ring part 423 is provided with an auxiliary ring, the auxiliary ring comprises a ring body 804 and a plurality of partition strips 802 arranged on the ring body; the length of the partition strip is about half the length of the magnetic steel sheet, and the auxiliary ring is designed so that the magnetic steel sheet 80 can be more firmly pasted on the inner wall of the circular ring part 423, and the glue can fully enter between each magnetic steel sheet; the magnetic steel sheet is a flat sheet, and the inner wall of the circular ring part 423 is arc-shaped, so that there is a certain gap between the magnetic steel sheet and the inner wall of the circular ring part 423, and when the glue is injected, the partition strip can slightly hinder the flow rate of the glue, so that the glue can better enter the gap between the magnetic steel sheet and the inside of the circular ring part. The magnetic steel sheet 80 is embedded between two adjacent partition strips; the width of the partition strip is 2-3 mm; and the auxiliary ring is adhered to the inner wall of the circular ring part.

[0061] The end cover one 40 comprises an end cover body 42, which is disc-shaped; the outer end of the end cover body 42 extends horizontally in the direction of the end cover two 90 to form a circular ring part 423; The circular ring part 423 passes through the rim 10 and adheres to the inner wall of the inner groove 101 of the rim; the front end of the circular ring part 423 is outwardly folded to form a flange part one 424; and the inner wall of the circular ring part 423 is pasted with the magnetic steel sheet 80; The bending part one 103 of the end cover body 42 and the circular ring part 423 is welded to be integrated with the inner wall of the rim, and / or the outer edge of the flange part one 424 is welded to be integrated with the inner wall of the rim 10; and the bending part one 103 forms a welding point; The edge of the end cover two 90 is provided with a flange part two 901; the flange part two 901 and the flange part one 424 are detachably connected to be integrated through a plurality of bolt connecting members 902, so that the end cover one 40 and the end cover two 90 are tightly matched, and the sealing effect is significantly improved; the width of the flange part one and the flange part two can also be self-set, so that the area for glue sealing is larger, and the sealing effect is higher. Compared with the traditional hub, the embodiment can further reduce the risk of magnetic leakage and improve the anti-interference ability to the outside.

[0062] Preferably, the middle part of the end cover body 42 is provided with an inner disc seat 41; The inner disc seat comprises a base 411, which is disc-shaped; The outer edge of the base 411 is outwardly and horizontally folded to form a brake ring one 412; The middle part of the base 411 is outwardly folded to form a stepped inner ring part one 414 and an inner ring part two 415; The middle part of the end cover body 42 is outwardly and horizontally folded to form a brake ring two 426, which is sleeved on the outside of the brake ring one 412 and welded to be integrated.

[0063] Preferably, the end cover body 42 and the inner disc seat 41 are thin iron pieces; the thickness of the end cover body 42 and the inner disc seat 41 is 1.5mm-3mm. The brake ring one and the brake ring two superimpose to form a brake seat, and the thickness of the brake seat can meet the strength requirement. When the end cover body 42 and the inner disc seat 41 are both selected as 2mm thick iron plate and stamped, the thickness of the brake seat can reach 4mm, thereby meeting the strength requirement; this design fully utilizes the assembly of the two stamped parts, and the cost reduction effect is remarkable. The casting process is time-consuming and laborious, the stamping process is simple and reliable, and the cost difference between the two is huge.

[0064] Preferably, the end cover body 42 is provided with one or more annular reinforcing ribs 422; the base 411 of the inner disc seat 41 is provided with a plurality of strip-shaped reinforcing ribs 413 arranged in a radial manner. The annular reinforcing ribs 422 and the strip-shaped reinforcing ribs 413 not only increase the strength under this structure, but also are more effective for specific loads.

[0065] The applicant analyzes the stress condition of the hub, which can be divided into radial impact force, axial impact force and circumferential shear force.

[0066] The radial impact force is generally caused by hitting a stone or a step during driving, and the radial impact force is caused by the rim load and dispersed; therefore, the radial impact force has little effect on the two motor end covers.

[0067] The axial impact force is generally caused by the lateral impact of the electric vehicle, and the impact is mainly borne by the main body of the electric vehicle, and has little effect on the hub; the main body of the end cover bears the load and disperses it, and the design of the annular reinforcing rib makes the load effect better.

[0068] The circumferential shear force is the main stress of the hub, and the brake drum will exert a circumferential shear force on the brake seat every time the brake is applied; the inner disc seat is a directly stressed component, and the design of the strip-shaped reinforcing rib makes the load effect better and the strength better.

[0069] Preferably, the length of the brake ring one 412 is greater than the length of the brake ring two 426; the brake ring two 426 and the bent part two 430 of the end cover body 42 are welded with the annular surface of the brake ring one 412, and the position of the bent part two 430 forms a welding point. When subjected to axial impact force, this design makes the load effect more concentrated on the end cover body, and the stability is better. The middle part of the brake ring one 412 and the brake ring two 426 are also welded into one body by spot welding technology, and the welding point is located at the welding part three 431.

[0070] Preferably, several "Π" shaped connecting strips 50 are arranged in the inner groove 101 of the rim 10, and the bending part three 501 on both sides of the connecting strip 50 is welded with the corresponding rim wall surface. When the thickness of the rim is relatively thin, for example, the thickness of the rim is 1.7mm, the design of the connecting strip can prevent the rim from opening outward and ensure the strength of the rim. The bending part three 501 forms a welding point.

[0071] Preferably, the middle part of the end cover one 40 and the end cover two 90 is provided with a bearing; the fixed shaft 20 is arranged in the bearing; the fixed shaft is obliquely provided with a threading hole 21, and the lead-out wire 30 of the hub motor extends out of the threading hole 21; the threading hole 21 includes an inclined section 22, the inner wall of the inclined section is provided with a step part 221, and the outer side of the step part is provided with an internal thread part 222; the lead-out wire 30 includes several wire cores 301; The fixed shaft 20 of the hub is provided with a threading hole 21, and the lead-out wire 30 of the hub motor extends out of the threading hole 21; the lead-out wire 30 includes several wire cores 301 and an outer skin sleeve 307; the outer skin sleeve 307 covers the outside of the several wire cores 301; the outer wall of the outer skin sleeve 307 is sealingly matched with the threading hole 21; the wire core 301 generally has six, three thick wires corresponding to the U, V, W three wires of the stator winding, and three thin wires corresponding to the Hall sensor; At present, some models directly install the controller of the electric vehicle on the stator assembly in the hub, and the power line of the core wire is connected with the battery, and the signal line of the core wire is bidirectionally connected with the external central control device; The outer end of the lead-out wire 30 extends upward to the inside of the motor vehicle shell; direct exposure to the environment is avoided, and the protection effect is improved; An exhaust joint 3000 is installed at the outer end of the lead-out wire 30, the exhaust joint 3000 is provided with a separation chamber 3012D, and a first joint 3000A, a second joint 3000B and a third joint 3000C are arranged on the periphery of the separation chamber 3012D; The outer skin sleeve and the wire core are inserted into the first joint 3000A, and the outer skin sleeve and the first joint 3000A are sealed; The wire core 301 passes through the separation chamber 3012D and extends out of the second joint 3000B; the wire core 301 and the second joint 3000B are sealed; The gap channel between the wire cores 301 is communicated to the separation chamber 3012D.

[0072] The third joint 3012C is provided with a gas-permeable and liquid-impermeable valve member 3013, and the separation chamber 3012D communicates with the external environment through the gas-permeable and liquid-impermeable valve member 3013.

[0073] Preferably, the exhaust joint 3000 comprises a shunt joint 3012 and a sleeve 3011; the sleeve 3011 is wrapped outside the shunt joint 3012; the first joint 3000A and the first end 3011A of the sleeve form a double seal with the outer skin sleeve 307.

[0074] The shunt joint 3012 is internally provided with the separation chamber 3012D, and the first end 3012A, the second end 3012B and the third end 3012C are arranged on the peripheral side of the separation chamber 3012D; the shunt joint 3012 can also be arranged in a three-way shape or a spherical shape; when the shunt joint 3012 is spherical, the first end 3012A, the second end 3012B and the third end 3012C are three hole positions distributed on the spherical surface; The end of the outer skin sleeve is inserted into the first end 3012A and sealed; The wire core 301 is inserted into the first end 3012A, passes through the separation chamber 3012D, and then extends out of the second end 3012B; the wire core 301 and the second end 3012B are sealed; the wire core 301 is circular, and a gap channel is formed between multiple wire cores 301; one end of the gap channel is connected to the inner cavity of the hub motor, and the other end of the gap channel is connected to the separation chamber 3012D; air and oil cannot pass through the second end 3012B again, ensuring the stability of the controller.

[0075] The threading hole 21 is arranged on the fixed shaft; since the amount of oil (generally silicon oil, which is not conductive) inside the hub is generally small, the fixed shaft is not submerged; when the hub rotates, the oil will splash into the gap channel between the wire cores; instead of blocking the gap channel between the wire cores, the present application selects the gap channel as an exhaust channel; air and a small amount of oil in the hub will be discharged upward along the gap channel and then processed through the shunt joint 3012.

[0076] The air-permeable and liquid-impermeable valve member 3013 can be purchased from the market; its core function is to guide the gas to the external environment through a layer of high molecular film 3013, but prevent liquid from passing through, which can completely prevent oil leakage and prevent water vapor from entering.

[0077] The outer end of the lead-out wire 30 extends to the inside of the controller of the electric vehicle; after the wire core 301 extends out of the second end 3012B, it is connected to the circuit board of the controller.

[0078] The second end 3012B is provided with a rubber sleeve body 3015, and a plurality of through holes 3015A are pre-formed on the rubber sleeve body 3015, which correspond to the wire cores 301 one by one; the wire cores 301 pass through the corresponding through holes 3015A.

[0079] The rubber sleeve 3015 is provided with a clamping ring 3014 on the outside. The clamping ring 3014 can contract the rubber sleeve 3015, so that the rubber sleeve 3015 can seal the gap channel between the wire cores 301.

[0080] The shunt joint 3012 is wrapped with a sleeve 3011 on the outside; the sleeve 3011 wraps the rubber sleeve 3015 at the same time, achieving the effect of complete sealing.

[0081] The wire hole 21 comprises an inclined segment 22, the inner wall of the inclined segment is provided with a stepped portion 221, and the outer side of the stepped portion is provided with an internal thread portion 222. A rubber sleeve 304 is annular; the rubber sleeve 304 is sleeved on the outside of the outer skin sleeve 307 and abuts against the stepped portion 221. A copper sleeve 305 is sleeved on the outside of the outer skin sleeve 307 and abuts against the rubber sleeve 304; the copper sleeve tightens the outer skin sleeve 307. A nut sleeve 306 is sleeved on the outside of the outer skin sleeve 307 and abuts against the copper sleeve 305; the nut sleeve 306 is screwed into the internal thread portion 222 and presses the rubber sleeve 304.

[0082] When the nut sleeve is screwed into the internal thread portion, the rubber sleeve 304 is pressed, the front segment of the rubber sleeve 304 abuts against the stepped portion 221, the rubber sleeve 304 is deformed by external force and presses the outer skin sleeve 307, the design is to seal the outer skin sleeve and the wire hole 21; the outer skin sleeve 307 is fixed by the copper sleeve, the stability and sealing of the lead-out wire are ensured, and water cannot enter. The nut sleeve and the rubber sleeve 304 further fix the lead-out wire on the outside of the hub and improve the sealing performance.

[0083] The wire hole 21 is obliquely arranged on the fixed shaft; the outer side of the outer skin sleeve 307 is sleeved with a protective spring 302; one end of the protective spring is embedded in the inclined segment 22 of the wire hole 21 and is fixed, and the other end of the protective spring extends to the outside of the wire hole 21. The wire hole 21 has a burr that can cut the outer skin sleeve, and the protective spring 302 can isolate the burr of the wire hole; the protective spring 302 is directly clamped into the wire hole and can be pulled out with greater force. The iron in the application refers to steel. In the application, the rubber parts that are in direct contact with oil are generally made of fluorine-containing rubber. Ordinary rubber will swell, crack, lose elasticity and even disintegrate after long-term contact with oil.

[0084] Embodiment 2 is basically the same as Embodiment 1, and the difference is that the shape of the inner groove 101 of the rim is improved.

[0085] The included angle b between the side wall 113 of the inner groove and the bottom wall 111 of the inner groove is less than 90 degrees, and the angle b can be set to 80-90 degrees (not including 90 degrees), and the embodiment is 85 degrees.

[0086] Therefore, the side wall 113 of the inner groove is inclined inwardly in the middle of the rim. This design makes the rim tend to be squeezed inward when the rim is subjected to a radial impact force. Because of the presence of the tire, the rim is hindered when it is squeezed inward, so that the ability to resist the radial impact force is stronger.

[0087] Preferably, a plurality of connecting strips 50 are arranged in the inner groove 101, and the bent portions 501 on both sides of the connecting strips 50 are welded to the corresponding rim wall. In combination with the design of the connecting strips 50, the stability of the rim can be double-protected, that is, it is not easy to deform inwardly or outwardly. The connecting strips 50 are also iron stamping parts, and the bent portions at both ends have a certain elasticity and toughness; although the side wall 113 of the inner groove is inclined inwardly, the inclination angle is generally small, so when the connecting strips 50 are installed in the inner groove, the two sides of the connecting strips 50 can be directly squeezed by external force to deform and enter. Then the bent portions 501 on both sides of the connecting strips 50 are welded to the rim side wall to form a welded portion. For a rim with a thickness of 1.7 mm, for example, the design of the connecting strips can prevent the rim from opening outwardly and ensure the strength of the rim. The bent portions 501 form the welding points. Preferably, the connecting strips 50 are in the shape of Π.

[0088] In this embodiment, the end cover 40 is installed with a drum brake ring 424.

[0089] The side wall 113 of the inner groove is inclined to the middle of the rim; the included angle b between the side wall 113 of the inner groove and the bottom wall 111 of the inner groove is greater than 80 degrees and less than 90 degrees, not including 90 degrees. The inwardly inclined structure in this application refers to the side wall 113 of the inner groove being inclined inwardly.

[0090] The hub will produce a radial impact force when it hits a stone or a step during driving, and the radial impact force is borne and dispersed by the rim; the design of the included angle b makes the rim tend to be squeezed inward when the rim is subjected to a radial impact force. Because of the presence of the tire, the rim is hindered when it is squeezed inward, so that the ability to resist the radial impact force is stronger.

[0091] Preferably, the rim comprises a metal plate, the two sides of the metal plate in the width direction are folded upward to form first bent portions 104a, and the metal plate between the left and right first bent portions 104a forms the bottom wall 111 of the inner groove, and the two first bent portions form the side wall 101 of the inner groove; the bending angle of the first bent portion 104a is greater than 90 degrees; The upper side of the first bent portion 104a is folded outward to form a second bent portion 105a; The outer side of the second bend 105a is then folded upward to form the third bend 106a; The outer end of the third bending portion 106a is bent outward or inward to form the rim 103a; The metal sheet is bent into a ring shape along its length and welded end to end to form the rim 10; The thickness of the wheel rim is 1.5mm to 2mm; the thickness can be 1.6mm, 1.7mm, 1.8mm, or 1.9mm. The thinner the wheel rim, the lower the production cost, but the weaker the impact resistance.

[0092] Preferably, the included angle b is 81 degrees, 82 degrees, 83 degrees, 84 degrees, 85 degrees, 86 degrees, 87 degrees, 88 degrees, or 89 degrees.

[0093] Example 3 is basically the same as Example 1, except that, as follows: Figure 17 As shown, the partial structure of this embodiment can be slightly modified to form another embodiment that is basically the same as the first embodiment. The difference is that the edge of the end cap body 42 extends outward to form a retaining ring portion 491, which is larger than the inner diameter of the inner groove 101 of the rim. The retaining ring portion 491 and the ring portion 423 are connected by an arc segment 492, which fits the corner 110 of the inner groove 101 of the rim. The retaining ring portion and the flange portion can cooperate to clamp the rim, making the fit between the end cap and the rim tighter. Even if the welding is uneven or partially detached, there will be no problem, thus extending the service life. The retaining ring portion is formed after the end cap is installed into the rim. A spinning device is inserted into the interior of the end cap to spin the edge of the end cap body 42, causing the edge of the end cap body 42 to extend outward by a certain distance, thereby forming the retaining ring portion 491.

[0094] An outwardly extending bolt portion 493 is formed on the flange portion 424.

[0095] Example 4 is basically the same as Example 1, except that a bead seat 102a is provided on both sides of the inner groove 101 of the rim; the two sides of the bead seat 102a extend upward to form a rim 103a, the rim 103a is provided with an outwardly flanged portion 1031; the rim 103a is provided with an inwardly flanged portion 1032; a transition section 1001 is provided between the bottom wall and the side wall of the inner groove 101, the thickness of the transition section 1001 is less than the thickness of the bottom wall 111, and the thickness of the transition section 1001 is less than the thickness of the side wall; the transition section 1001 is located at the bend between the side wall and the bottom wall. This design makes it easier to shape the first bend during processing.

[0096] Preferably, when the first bend folds outward, it first folds downward to form transition section two 1002, and then folds outward to form the second bend 106a; the transition section two 1002 extends downward and outward; the second bend 106a extends outward and upward. This design allows the rim to release a certain amount of impact force at transition section two when it receives impact force, and then extend the impact force to transition section two; in fact, as Figure 5 As mentioned above, when an impact force is received, the first corner A, the second corner B, the third corner C, and the fourth corner D successively bear a certain amount of impact force, thereby reducing the impact force received by the first bending part.

[0097] Example 5 is basically the same as Example 1, except that, as follows: Figures 20-21 The end cap 40 includes an insertion ring 423b and a shielding ring 423a; the insertion ring 423b and the shielding ring 423a are partially overlapped; the insertion ring 423b, the shielding ring 423a, and the inner wall of the rim 10 are tightly fitted together; the fitting relationship between the shielding ring 423a, the insertion ring 423b, and the inner wall of the rim 10 is as follows: An insertion cavity is formed between the outer wall of the shielding ring 423a and the inner wall of the rim 10, and the insertion ring 423b is inserted into the insertion cavity; the insertion ring and the inner wall of the rim 10 are welded together; a plurality of magnetic steel sheets 80 are provided on the inner wall of the shielding ring 423a. Alternatively, the fit between the shielding ring 423a, the insertion ring 423b, and the inner wall of the rim 10 is as follows: the outer wall of the shielding ring 423a fits tightly against the inner wall of the rim 10; the outer side of the insertion ring 423b fits tightly against the inner side of the shielding ring 423a, and the inner wall of the insertion ring 423b is provided with several magnetic steel pieces 80.

[0098] The above embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A hub motor, characterized in that, A rim (10) is used to support a tire; the rim is annular and has an inwardly recessed groove (101) on its circumference. End cap 1 (40) includes a disc-shaped end cap body (42), an annular portion (423) and a flange portion 1 (424); the end cap body extends into the rim from a first side and extends out from a second side of the rim; the annular portion (423) is located in the middle of the rim; the flange portion 1 (424) is located on the first side of the rim; End cap 2 (90) is disposed on the first side of the rim; the end cap 2 is mounted on the flange portion 1 (424) of the end cap 1; the end cap 1 and the end cap 2 cooperate to form the inner cavity of the hub; Several magnetic steel plates (80) are disposed on the inner wall of the annular portion (423) of the first end cover (40); the rim (10), the first end cover (40), the second end cover (90) and the magnetic steel plates (80) cooperate to form a rotor assembly; A fixed shaft (20) passes through the first end cover and the second end cover; bearings are respectively provided in the middle of the first end cover and the second end cover; the two ends of the fixed shaft pass through the bearings; A stator assembly, which is mounted on the fixed shaft (20); The edge of the end cap body (42) extends outward to form a retaining ring (491), which is larger than the inner diameter of the inner groove (101) of the rim. The retaining ring (491) and the ring (423) are connected by an arc segment (492), which fits the corner (110) of the inner groove (101) of the rim.

2. The hub motor according to claim 1, characterized in that, The inner groove (101) is provided with bead seats (102a) on both sides. The two sides of the bead seat (102a) extend upward to form a rim (103a), and the rim (103a) is provided with an outwardly turned edge (1031a) or an inwardly turned edge (1032a). The sidewall (113) of the inner groove is inclined toward the middle of the rim; the included angle b between the sidewall (113) of the inner groove and the bottom wall (111) of the inner groove is ≥80 degrees and the included angle b<90 degrees.

3. A hub motor according to claim 2, characterized in that, The rim comprises a metal sheet. The metal sheet is folded upward on both sides in the width direction to form a first bend (104a), and the metal sheet between the two first bends (104a) forms the bottom wall (111) of the inner groove (101), and the two first bends form the side wall (113) of the inner groove (101); the bending angle of the first bend (104) is greater than 90 degrees. The upper side of the first bend (104a) is folded outward to form a second bend (105a). The outer side of the second bend (105a) is then folded upward to form a third bend (106a). The outer end of the third bend (106a) is then bent outward or inward to form the rim (103a). The metal sheet is bent into a ring shape along its length and welded at both ends to form the rim (10). The thickness of the wheel rim is 1.5mm to 2mm.

4. A hub motor according to claim 2, characterized in that, A transition section one (1001) is provided between the bottom wall of the inner groove (101) and the side wall of the inner groove (101). The thickness of the transition section one (1001) is less than the thickness of the bottom wall (111) and the thickness of the transition section one (1001) is less than the thickness of the side wall. The transition section one (1001) is located at the bend between the side wall and the bottom wall. When the first bend folds outward, it first folds downward to form a transition section two (1002) and then folds outward to form a second bend (105a). The transition section two (1002) extends downward and outward. The second bend (105a) extends outward and upward.

5. A hub motor according to claim 1, characterized in that, An inner plate seat (41) is provided in the middle of the end cap body (42). The inner disc seat includes The base (411) is disc-shaped; The outer edge of the base (411) is folded outward horizontally to form a brake ring (412); The middle part of the base (411) is folded outward to form a stepped inner ring part one (414) and an inner ring part two (415). The middle part of the end cap body (42) is folded outward horizontally to form a second brake ring (426). The second brake ring (426) is fitted onto the outside of the first brake ring (412) and welded together.

6. A hub motor according to claim 5, characterized in that, The outer end of the end cap body (42) extends horizontally toward the end cap two (90) to form an annular portion (423). The annular portion (423) passes through the rim (10) and fits the inner wall of the inner groove (101) of the rim; the front end of the annular portion (423) is folded outward to form a flange portion (424); the magnetic steel sheet (80) is pasted on the inner wall of the annular portion (423). The bent portion (103) of the end cap body (42) and the annular portion (423) is welded to the inner wall of the rim, and / or the outer edge of the flange portion (424) is welded to the inner wall of the rim (10). The edge of the second end cap (90) is provided with a second flange (901); the second flange (901) and the first flange (424) are detachably connected as one unit by a number of bolted connecting members (902), so that the first end cap (40) and the second end cap (90) are tightly fitted together.

7. A hub motor according to claim 5, characterized in that: The end cap body (42) is provided with one or more annular reinforcing ribs (422); the base (411) of the inner disc seat (41) is provided with several radially arranged strip reinforcing ribs (413); the length of brake ring one (412) is greater than the length of brake ring two (426); brake ring two (426) and the bent part two (430) of the end cap body (42) are welded to the annular surface of brake ring one (412).

8. A hub motor according to claim 1, characterized in that: The inner groove (101) of the rim (10) is provided with several "Π"-shaped connecting strips (50), and the bent portions (501) on both sides of the connecting strips (50) are welded to the corresponding rim wall.

9. A hub motor according to any one of claims 1-8, characterized in that: The end cap (40) includes an insertion ring (423b) and a shielding ring (423a); the insertion ring (423b) and the shielding ring (423a) are partially overlapped; The insertion ring (423b), the shielding ring (423a), and the inner wall of the rim (10) fit together tightly; the fit relationship between the shielding ring (423a), the insertion ring (423b), and the inner wall of the rim (10) is as follows: An insertion cavity is formed between the outer wall of the shielding ring (423a) and the inner wall of the rim (10), and the insertion ring (423b) is inserted into the insertion cavity; the insertion ring and the inner wall of the rim (10) are welded together; a number of magnetic steel sheets are provided on the inner wall of the shielding ring (423a); Alternatively, the fit between the shielding ring (423a), the insertion ring (423b), and the inner wall of the rim (10) is as follows: the outer wall of the shielding ring (423a) fits tightly against the inner wall of the rim (10); the outer side of the insertion ring (423b) fits tightly against the inner side of the shielding ring (423a), and the inner wall of the insertion ring (423b) is provided with several magnetic steel plates.

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