Two-wheel electric vehicle hub motor structure with third-generation hub bearing unit integrated rim

Abstract

The invention discloses a two-wheel electric vehicle hub motor structure with a third-generation hub bearing unit integrated rim. Comprising a rotor shell, a third-generation hub bearing unit, a stator shell and a main shaft, the stator shell is sleeved with the rotor shell, the rotor shell is sleeved with a hub of the two-wheeled electric vehicle, an electromagnetic driving structure and a sealing structure are arranged between the rotor shell and the stator shell, and the rotor shell and the stator shell are connected to the main shaft in a sleeving mode through a third-generation hub bearing unit. The hub motor is used for being arranged in a narrow space of a small-size rim, and the performance limit is improved; and meanwhile, the endurance, the performance, the safety and the service life of the vehicle can be improved, the light weight and the structural simplicity of the product are guaranteed, the use amount of copper wires can be remarkably reduced while the performance is improved, and the production cost of the motor is reduced.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of two-wheeled electric vehicle parts manufacturing, and relates to a hub motor of a two-wheeled electric vehicle, in particular to a two-wheeled electric vehicle hub motor structure integrated with a rim by a third generation hub bearing unit. BACKGROUND

[0002] Two-wheeled electric vehicles are generally divided into three types of electric bicycles, electric mopeds and electric motorcycles. At present, manufacturers on the market generally use multi-strand concentrated winding motors, but such products have certain technical bottlenecks or defects. The main disadvantages are: the concentrated winding motor for two-wheeled electric vehicles generally has low efficiency, which is not conducive to improving the mileage of the vehicle. The motor structure is usually closed at both ends, and the circuit and related accessories are wrapped inside the entire motor, which cannot be fully cooled. When the motor temperature rises too fast, the running performance will be reduced. Even if a motor with more heat, high power and high torque is used, the running performance cannot be improved. SUMMARY

[0003] In view of the problems existing in the above background technology, the present application designs a two-wheeled electric vehicle hub motor structure integrated with a rim by a third generation hub bearing unit, which is a new structure of high-power hub motor. It should have the characteristics of high efficiency, light weight, high stability, etc., and need to have more excellent heat dissipation performance to break through the performance limit of the motor used in the current industry, while bringing better safety, durability, controllability and improving user experience.

[0004] The stator part and the rotor part in the present application are connected using a third generation hub bearing unit, and the rotor shell is designed according to the rim specification and can install a vacuum tire, which belongs to the technical field of two-wheeled electric vehicle parts manufacturing.

[0005] In the field of motor design, the larger the motor size, the easier it is to improve power and torque in structural design. However, the current two-wheeled electric vehicles generally use 12-inch rims, and the internal space is small. How to break through the performance bottleneck in limited space by clever design has become a difficult problem. The present application breaks through the traditional barriers and innovates in design.

[0006] To achieve the above purpose, the present application adopts the following technical solutions:

[0007] It comprises a main shaft;

[0008] It comprises a stator shell which is sleeved outside the main shaft;

[0009] It comprises a rotor shell which is sleeved outside the stator shell, and the rotor shell is used to sleeve the hub of the two-wheeled electric vehicle;

[0010] The third generation hub bearing unit is used for connecting the rotor shell and the stator shell to the main shaft.

[0011] The electromagnetic driving structure and the sealing structure are arranged between the rotor shell and the stator shell.

[0012] The third generation hub bearing unit comprises an outer ring part and an inner ring part which are freely rotatably connected to each other, the outer ring part is freely rotatably connected to the outside of the inner ring part, and the inner ring part is coaxially fixedly connected to the main shaft.

[0013] The outer ring part is coaxially connected to the rotor shell.

[0014] The inner ring part is coaxially connected to the stator shell and directly or indirectly connected to the outside of the main shaft.

[0015] The rotor shell is asymmetrically arranged outside the stator shell, the rotor shell comprises a ring part and a disc part, the ring part is arranged outside the periphery of the stator shell with a gap between the ring part and the stator shell, the disc part is arranged outside the front end surface of the stator shell with a gap between the disc part and the stator shell, the inner ring of the disc part is fixedly connected to the outer ring part of the third generation hub bearing unit, and the outer ring of the disc part is fixedly connected to one side end surface of the ring part.

[0016] The outer ring of the upper sealing plate is fixedly and sealingly connected to the other side end surface of the ring part, and the inner ring of the upper sealing plate is sealingly connected between the sealing ring and the rear end surface of the stator shell.

[0017] The traditional design has five main parts, two bearings are arranged in the left and right parts of the rotor part, and the left and right parts of the rotor part are embedded into the bearing mounting surface of the main shaft from both sides. The number of parts is large, the bending of the main shaft caused by load and impact will reduce the coaxiality precision. The present application has only a few main parts less than five, the coaxiality of each part is high, the load and impact resistance is high, and the service life is long.

[0018] The front end surface of the stator shell is fixedly connected with a heat sink, the stator shell and the heat sink are provided with a stator groove for assembling the electromagnetic driving structure, and the front side of the heat sink is sealingly connected with the disc part of the rotor shell through a sealing ring.

[0019] The electromagnetic driving structure comprises a rotor steel yoke, a permanent magnet and a continuous wave copper wire group, the continuous wave copper wire group is embedded and installed in the stator groove, the rotor steel yoke is fixedly installed on the inner periphery of the ring part of the rotor shell, the permanent magnet is fixed on the inner periphery of the rotor steel yoke, and there is a gap between the permanent magnet and the continuous wave copper wire group.

[0020] The outer circumferential surface of the stator shell and the fins is circumferentially spaced apart to form a plurality of stator slots, and the stator teeth are formed between adjacent stator slots, each stator slot is substantially axially opened along the main shaft and is obliquely parallel through, and the continuous wave copper wire group is embedded in the stator slot from outside to inside.

[0021] The three-phase line box, the sensor line, the three-phase line and the bus bar are included, one end of the three-phase line and the sensor line is arranged in the three-phase line box and is connected with the continuous wave copper wire group and the sensor through the bus bar respectively, the sensor is installed on the fin, and the other end of the three-phase line and the sensor line passes through the upper sealing plate from the three-phase line box, and is electrically connected with the external controller through the electrical connector.

[0022] The rotor component and the stator component in the application are connected by using a third generation hub bearing unit of a passenger car, the bearing unit is miniaturized and designed to be light in weight in a narrow space, and the gap between the stator component and the rotor component exists and is sealed by a sliding friction sealing ring, thereby meeting the requirements of waterproof and dustproof.

[0023] The circumferential outer edge portion of the stator shell is internally provided with an internal water channel in the form of an arc occupying a 270-degree central angle, and the two ends of the internal water channel are respectively provided with a water inlet and a water outlet, and the water inlet (101) and the water outlet are respectively used for the entry and outflow of the cooling liquid.

[0024] The copper wire in each turn in the stator slot of the stator shell is not parallel to the axial direction, but is inclined to the tangential direction by an angle of 4.75-5.3 degrees on the basis of being originally parallel to the axial direction.

[0025] The continuous wave copper wire group is divided into a plurality of copper wire windings, each copper wire winding is continuously wound in an S-shaped path with two stator slots as a period, that is, each copper wire winding is continuously wound in an S-shaped path on a plurality of stator slots with an interval of two stator slots, the adjacent copper wire windings are wound in a staggered manner with an interval of k stator slots in a preset clockwise direction along the circumferential direction of the stator shell, k is usually equal to 1, and the preset clockwise direction is one of clockwise and counterclockwise directions, and each stator slot is substantially axially opened along the main shaft of the motor and is obliquely parallel through, so that the copper wire of the copper wire winding wound in the stator slot is also inclined to the main shaft of the motor.

[0026] Each stator slot of the stator shell is not completely axially opened along the main shaft, but is inclined to the tangential direction by an angle of 4.75-5.3 degrees on the basis of being originally parallel to the axial direction, so that the copper wire of the copper wire winding wound in the stator slot is arranged to be inclined to the tangential direction by an angle of 4.75-5.3 degrees on the basis of being originally parallel to the axial direction.

[0027] The continuous wave winding copper wire group includes four copper wire windings with different lengths, and the four copper wire windings are used for winding in the continuous stator slots covering 1 / 4, 2 / 4, 3 / 4 and 4 / 4 of the entire circumference of the stator shell respectively.

[0028] Or / and the continuous wave winding copper wire group includes four copper wire windings with different starting points, and the starting points of the four copper wire windings are respectively from the stator slots on the middle of the upper side, the middle of the left side, the middle of the lower side and the middle of the right side of the stator shell.

[0029] Or / and the continuous wave winding copper wire group includes four copper wire windings with different ending points, and the ending points of the four copper wire windings are respectively wound into the stator slots on the middle of the upper side, the middle of the left side, the middle of the lower side and the middle of the right side of the stator shell.

[0030] The present application forms simple and effective winding and wiring through the special design of different groups, wiring and connection in the continuous wave winding copper wire group, the entire amount of copper is significantly reduced, and the performance and efficiency of motor control can be significantly improved.

[0031] The continuous wave winding copper wire group includes seven copper wire windings with different lengths and distribution positions, each copper wire winding includes three copper wire windings, and a total of 21 copper wire windings.

[0032] The first copper wire winding includes three copper wire windings covering 1 / 4 of the complete circumference of the stator shell, wherein each two adjacent copper wire windings are arranged by staggered winding with one stator slot interval in the preset clockwise direction, the starting points of the three copper wire windings are respectively from the three stator slots close to the middle of the upper side of the stator shell, and the ending points are respectively wound into the three stator slots on the middle of the left side of the stator shell.

[0033] The second copper wire winding includes three copper wire windings covering 2 / 4 of the complete circumference of the stator shell, wherein each two adjacent copper wire windings are arranged by staggered winding with one stator slot interval in the preset clockwise direction, the starting points of the three copper wire windings are respectively from the three stator slots on the middle of the upper side of the stator shell, and the ending points are respectively wound into the three stator slots close to the middle of the lower side of the stator shell.

[0034] The third copper wire winding includes three copper wire windings covering 3 / 4 of the complete circumference of the stator shell, wherein each two adjacent copper wire windings are arranged by staggered winding with one stator slot interval in the preset clockwise direction, the starting points of the three copper wire windings are respectively from the three stator slots close to the middle of the upper side of the stator shell, and the ending points are respectively wound into the three stator slots on the middle of the right side of the stator shell.

[0035] The fourth copper wire winding includes three copper wire windings each covering the complete circumferential 4 / 4 stator slot of the stator shell, wherein each two adjacent copper wire windings are arranged in a staggered manner along the circumferential direction by one stator slot in the preset clockwise direction, and the starting first end of the three copper wire windings is respectively wound from the three stator slots in the middle of the upper side of the stator shell, and the terminal end is respectively wound to the three stator slots close to the middle of the upper side of the stator shell.

[0036] The fifth copper wire winding includes three copper wire windings each covering the complete circumferential 3 / 4 stator slot of the stator shell, wherein each two adjacent copper wire windings are arranged in a staggered manner along the circumferential direction by one stator slot in the preset clockwise direction, and the starting first end of the three copper wire windings is respectively wound from the three stator slots close to the middle of the left side of the stator shell, and the terminal end is respectively wound to the three stator slots in the middle of the upper side of the stator shell.

[0037] The sixth copper wire winding includes three copper wire windings each covering the complete circumferential 2 / 4 stator slot of the stator shell, wherein each two adjacent copper wire windings are arranged in a staggered manner along the circumferential direction by one stator slot in the preset clockwise direction, and the starting first end of the three copper wire windings is respectively wound from the three stator slots in the middle of the lower side of the stator shell, and the terminal end is respectively wound to the three stator slots close to the middle of the upper side of the stator shell.

[0038] The seventh copper wire winding includes three copper wire windings each covering the complete circumferential 1 / 4 stator slot of the stator shell, wherein each two adjacent copper wire windings are arranged in a staggered manner along the circumferential direction by one stator slot in the preset clockwise direction, and the starting first end of the three copper wire windings is respectively wound from the three stator slots close to the middle of the right side of the stator shell, and the terminal end is respectively wound to the three stator slots in the middle of the upper side of the stator shell.

[0039] Among the 21 copper wire windings of the seven different lengths and different distribution positions:

[0040] On the left side of the stator shell: the terminal end of the three copper wire windings of the first copper wire winding is respectively connected to the starting first end of the three copper wire windings of the fifth copper wire winding;

[0041] On the lower side of the stator shell: the terminal end of the three copper wire windings of the second copper wire winding is respectively connected to the starting first end of the three copper wire windings of the sixth copper wire winding;

[0042] On the right side of the stator shell: the terminal end of the three copper wire windings of the third copper wire winding is respectively connected to the starting first end of the three copper wire windings of the seventh copper wire winding;

[0043] On the upper side of the stator shell:

[0044] The first end of the starting point of the first copper wire winding and the first end of the starting point of the last copper wire winding of the third copper wire winding are correspondingly connected, the first end of the starting point of the first copper wire winding and the first end of the starting point of the last copper wire winding of the sixth copper wire winding are correspondingly connected, and the first end of the starting point of the middle one of the second copper wire winding and the fourth copper wire winding and the last end of the terminal of the middle one of the fifth copper wire winding and the seventh copper wire winding are connected together;

[0045] The first end of the starting point of the middle one of the first copper wire winding, the first end of the starting point of the middle one of the third copper wire winding, the last end of the terminal of the middle one of the fourth copper wire winding and the last end of the terminal of the middle one of the sixth copper wire winding are connected together to form the second phase of the three-phase wire; the first end of the starting point of the first copper wire winding of the second copper wire winding and the fourth copper wire winding and the last end of the terminal of the first copper wire winding of the fifth copper wire winding and the seventh copper wire winding are connected together to form the third phase of the three-phase wire; and the first end of the starting point of the last copper wire winding of the second copper wire winding and the fourth copper wire winding and the last end of the terminal of the last copper wire winding of the fifth copper wire winding and the seventh copper wire winding are connected together to form the first phase of the three-phase wire.

[0046] The core advantage of the present application is that the coaxiality of each component is extremely high, the structure is more compact, the load resistance and impact resistance are good, the service life is long, the abnormal vibration of the motor caused by the high-speed running of the motor at 120 km / h is eliminated, and the safety, stability and comfort of the vehicle running are improved.

[0047] The core advantage of the present application is that the core advantage of the present application is that the motor is slow to heat up and fast to cool down, and the fatal defect that the heat source stator component is wrapped inside the rotor component and cannot be effectively cooled in the traditional design is solved.

[0048] The core advantage of the present application is that the circuit structure adopts continuous wave winding technology, and the wave winding copper wire is bent and formed at a certain angle, instead of being parallel to the axial line, so that the special designed continuous wave winding copper wire group makes the cogging torque smaller, reduces the vibration and noise, reduces the high-order harmonic, and further reduces the iron loss, so that the motor efficiency is improved to 90%. The coil length and area are increased, the heat dissipation space is larger, and the efficiency is higher.

[0049] The two-wheeled electric vehicle wheel hub motor designed by the application after the above design is not simply summarized and optimized by various processes, materials and design ideas, and is not simply upgraded and modified. Instead, the original design structure framework is broken out, the characteristics and advantages of the third generation wheel hub bearing unit are ingeniously used under the condition of the narrow space of the 12-inch rim, the overall design structure and essential characteristics of the motor are changed, the solution to the core difficulty of heat dissipation is found, and the electromagnetic scheme is rearranged, so that more excellent motor performance (see Table 1 for parameter comparison) and less copper resource consumption are obtained by using new technology and new materials, and a new path for the sustainable development of the 12-inch rim two-wheeled electric vehicle motor is opened up.

[0050] The size of the wheel hub of the two-wheeled electric vehicle in the application is less than 13 inches, usually 12 inches.

[0051] The beneficial effects and performances of the application are:

[0052] The newly developed wheel hub motor of the application can be arranged in the narrow space of the two-wheeled electric vehicle using a 12-inch rim tire, and can exceed the performance limit of the industry benchmark motor; at the same time, the vehicle's endurance, performance, safety and service life are improved, and the overall technical level of the two-wheeled electric vehicle market is improved.

[0053] At the same time, the solution of the application also realizes the light weight and simple structure of the product, and significantly reduces the use amount of copper wire while improving the performance, thereby reducing the production cost of the motor.

[0054] The application effectively solves the heat dissipation of the motor. The core heating area is a continuous wave winding copper wire group. The heat in this area is rapidly conducted to the stator shell by the special epoxy resin of the application. The surface exposed to the outside and the water channel inside the stator shell provide heat dissipation function to help the motor control the operating temperature.

[0055] The application first applies the continuous wave winding copper wire technology to the 12-inch wheel hub motor, and the embedded wire direction is arranged from outside to inside at an inclined angle, which is different from the traditional inside-out technology. Under the premise of using the same quality of copper wire, the continuous wave winding copper wire group of the application provides stronger motor torque output, higher motor operating speed and higher motor operating efficiency than the concentrated winding group.

[0056] The third generation wheel hub bearing unit used in the application is specially customized and adapted to the application. The axial load that can be borne by the bearing unit is extremely large, which is at the level of a passenger car. When the vehicle is turning at high speed, it can provide higher stability and safety, and the service life can reach the lifetime maintenance-free of the vehicle.

[0057] The sealing ring used in the application is much larger in size than the sealing ring of the traditional concentrated winding motor. The material selection and structure design are the first attempt in the development of 12-inch hub motor. The accumulated technical experience and test data help the industry to vigorously explore this technology and break the technical and price monopoly of foreign enterprises. BRIEF DESCRIPTION OF DRAWINGS

[0058] Figure 1 is a structural schematic diagram of a traditional multi-strand concentrated winding motor.

[0059] Figure 2 is a structural schematic diagram of the application.

[0060] Figure 3 is a perspective view of the rotor of the application installed with a rotor steel yoke, permanent magnets and a rotor shell.

[0061] Figure 4 is a perspective sectional view of the water channel design structure of the stator water cooling scheme of the application.

[0062] Figure 5 is a planar sectional view of the water channel design of the stator water cooling scheme of the application.

[0063] Figure 6 is a schematic diagram of the stator shell core and the angle inclination design of No. 1 copper wire of the application.

[0064] Figure 7 is a schematic diagram of the stator of the application removing the continuous wave winding copper wire group.

[0065] Figure 8 is a schematic diagram of the concentrated winding motor stator.

[0066] Figure 9 is a schematic diagram of the outer stator and inner rotor structure of the continuous wave winding copper wire group motor.

[0067] Figure 10 is a schematic diagram of the vehicle support and motor installation structure of the two-wheeled electric vehicle.

[0068] Figure 11 is a schematic diagram of the four specifications of winding copper wire used in the application.

[0069] Figure 12 is a schematic diagram of the insertion position and installation state of No. 1 wire of the application.

[0070] Figure 13 is a schematic diagram of the copper wire insertion and stacking wiring of the application.

[0071] Figure 14 is a schematic diagram of the circuit wire group assembly wiring of the application.

[0072] Figure 15It is the circuit axial schematic view of the stator of the present application.

[0073] Figure 16 It is the circuit axial schematic view of the stator of the present application.

[0074] Figure 17 It is the schematic view of the copper wire No. 1-21 of the present application.

[0075] Figure 18 It is the position structure view of the copper wire No. 1-21 of the present application on the stator shell.

[0076] Figure 19 It is the partial enlarged view of Figure 21

[0077] Figure 20 It is the wiring diagram of the partial circuit line group of the present application.

[0078] Figure 21 It is the joint point view of the wiring diagram of the circuit line group of the present application.

[0079] Figure 22 It is the schematic view of the three-phase electric connection structure of the busbar of the present application.

[0080] In the figure: rotor shell (1), heat sink (2), sealing ring (3), third generation hub bearing unit (4), rotor steel yoke (5), permanent magnet (6), upper sealing plate (7), sealing ring (8), continuous wave winding copper wire group (9), stator shell (10), main shaft (11), three-phase line box (12), sensor line (13), three-phase line (14), busbar (15), sensor (16), connecting assembly (17), stator core (18);

[0081] Internal water channel (101), water inlet (102), water outlet (103). DETAILED DESCRIPTION

[0082] The technical scheme of the present application will be further specifically explained in combination with the drawings, but it is not the limitation to the protection scope of the present application.

[0083] More specifically, as shown in Figure 2 The motor structure includes stator, rotor, third generation hub bearing unit 4, main shaft 11, three-phase line box 12, three-phase line 14, sensor 16, sensor line 13, sealing ring 3, sealing ring 8, upper sealing plate 7. The stator contains stator core 18, stator shell 10, continuous wave winding copper wire group 9, connecting assembly 17, busbar 15, epoxy resin protective layer, heat sink 2. The rotor contains rotor shell 1, rotor steel yoke 5, permanent magnet 6.

[0084] ​The rotor shell 1 of one of the rotor components is sleeved on the outer periphery of the stator shell 10 of one of the stator components, the rotor shell 1 is sleeved on the tire of the two-wheeled electric vehicle, the electromagnetic driving structure and the sealing structure are arranged between the rotor shell 1 and the stator shell 10, and the rotor shell 1 and the stator shell 10 are both sleeved and connected to the main shaft 11 through the third generation hub bearing unit 4, and the rotor shell 1 and the stator shell 10 are respectively installed on the rotating outer ring part and the stationary inner ring part of the third generation hub bearing unit 4.

[0085] During the working process, the main shaft 11 remains non-rotating, the busbar 15 receives electric energy through the three-phase wire 14, the continuous wave winding copper wire group 9 is electrified to the electromagnetic stator core 18, so that the stator core generates an alternating magnetic field, the alternating magnetic field interacts with the permanent magnet 6 to generate kinetic energy, drives the rotor shell 10 provided with the rotor steel yoke 5 and the permanent magnet 6 to rotate around the stator and the main shaft 11, and the high-efficiency and stable operation of the motor is realized.

[0086] In the application, the main shaft 11 is connected to the vehicle support at both ends, and the main shaft 11 is generally non-rotating.

[0087] The rotor shell 1 and the outer ring part of the third generation hub bearing unit 4 are coaxially fixedly sleeved and connected, so that the rotor shell 1 and the outer ring part of the third generation hub bearing unit 4 rotate together; the stator shell 10 and the inner ring part of the third generation hub bearing unit 4 are coaxially fixedly sleeved and connected, so that the stator shell 10 and the inner ring part of the third generation hub bearing unit 4 are fixed and stationary; the inner ring part of the third generation hub bearing unit 4 is coaxially fixedly sleeved on the main shaft 11.

[0088] The rotor shell 1 is asymmetrically arranged on the outer side of the stator shell 10; the rotor shell 1 is one of the rotor components, and the rotor shell 1 comprises an annular column-shaped ring part and an annular disc part; the ring part is arranged with a gap between the outer periphery of the stator shell 10 and the stator shell 10; the disc part is arranged with a gap between the outer side of the front end face of the stator shell 10 and the stator shell 10; the inner ring center hole of the disc part is fixedly sleeved on the rotating outer ring part of the third generation hub bearing unit 4; the outer ring of the disc part and one side end face of the ring part are fixedly connected into one body; the disc part is designed with an induction wheel structure, which cooperates with the sensor 16 installed on the heat sink 2 to generate an electric signal; the disc part is arranged with a gap between the rear end face of the disc part and the stator shell 10; the inner ring center hole of the disc part is fixedly sleeved on the rotating outer ring part of the third generation hub bearing unit 4; and the outer ring of the disc part and one side end face of the ring part are fixedly connected into one body.

[0089] The outer side of the rear end face of the stator shell 10 is provided with an annular sealing ring 8, the outer ring of the sealing ring 8 and the other side end face of the ring part are fixedly and sealingly connected with the rear end face of the stator, and the inner ring of the sealing ring 8 is sealingly connected between the right side lip and the upper sealing plate 7 and the rear end face of the stator shell 10.

[0090] The traditional design has five main components, two bearings are respectively installed in the left and right parts of the rotor component, and the left and right parts of the rotor component are embedded into the bearing mounting surface of the main shaft from both sides. The number of internal components of the motor is large, and the bending of the main shaft under load and impact will reduce the coaxiality precision. The present application only has four main structural components, i.e. the stator, the rotor, the third generation hub bearing unit 4 and the main shaft 11, has fewer main components, and the coaxiality of each component is extremely high, resistant to load and impact, and has long service life.

[0091] Generally, the motor design of the electric vehicle hub for small size hub is limited by the problems of poor sealing effect and short service life of large size sealing ring, and the continuous wave copper wire winding motor is usually designed as an outer stator and inner rotor structure, so as to design a small sealing structure to adapt to the performance and structure of the small size sealing ring.

[0092] The two-wheeled electric vehicle hub motor design scheme of the present application adopts an outer rotor and inner stator permanent magnet synchronous motor design, which has the advantages of high efficiency, high power density, fast motor response, high reliability, energy saving and the like. In order to adapt to the structure of the motor, a large size sealing ring is developed, and the structure design and material selection are optimized to improve the problems of poor sealing effect and short service life.

[0093] As an optimization, the present application breaks out of the traditional design idea of two-wheeled electric vehicle hub motor, and no longer uses the existing structure design of main shaft penetrating the stator component and being fixed, rotor component installing single row bearing, and left and right parts wrapping the stator component. The present application ingeniously utilizes the structural characteristics of the third generation hub bearing unit, respectively arranges and installs the rotor component in the rotating outer ring part of the third generation hub bearing unit 4 bearing, arranges and installs the stator component in the static inner ring part of the third generation hub bearing unit 4 bearing, and penetrates the main shaft 11 through the center of the static inner ring part of the third generation hub bearing unit 4 bearing and is fixed Figure 2 . This is the first time such design appears in a 12-inch or smaller rim motor.

[0094] The front end face of the stator shell 10 is fixedly connected with the heat dissipation fin 2, and the front end face of the stator shell 10 and the heat dissipation fin 2 is provided with a mounting table for assembling the sensor 16 at a low position; the front side of the heat dissipation fin 2 is sealingly connected through the friction sealing surface of the disc part of the rotor shell 1 and the sealing ring 3. In this way, the front end face of the stator shell 10 is connected through the components heat dissipation fin 2, rotor shell 1 and sealing ring 3 to form a friction sealing structure, which can achieve the purposes of dustproof and waterproof.

[0095] The electromagnetic driving structure comprises a rotor yoke 5, permanent magnets 6, a busbar 15, a connecting assembly 17 and a continuous wave copper wire group 9. The continuous wave copper wire group 9 is embedded in the stator core slot and the copper wire is insulated from the surface of the stator core slot by insulation paper. The end of each copper wire of the continuous wave copper wire group 9 is overlapped with the connecting assembly 17 to form a three-phase circuit. The three-phase circuit is partially connected to the busbar 15, and the busbar 15 receives power through a three-phase line 14. The rotor yoke 5 is fixedly installed on the inner circumferential surface of the ring part of the rotor shell 1, and the permanent magnets 6 are fixed on the inner circumferential surface of the rotor yoke 5. There is a gap between the permanent magnets 6 and the continuous wave copper wire group 9.

[0096] In the embodiment, the heat sink 2 cooperates with one side of the stator shell 10 to replace the stator shell 10 as a part of the stator shell 10. The stator core is installed on the outer periphery of the stator shell 10 and the heat sink 2 as a whole. The stator slot is opened for installing the continuous wave copper wire group 9.

[0097] The outer circumferential surface of the stator shell 10 and the heat sink 2 is spaced apart in the circumferential direction to form a plurality of stator slots. The stator teeth are formed between adjacent stator slots. Each stator slot is substantially axially opened along the main shaft 11 and is inclined to be parallel to the both ends. The outer side of the stator slot is also penetrated, and the continuous wave copper wire group 9 is embedded in the stator slot from the outside to the inside.

[0098] The stator core 18 is fixedly installed on the outer circumferential surface of the stator shell 10. The outer circumferential surface of the stator core 18 is spaced apart in the circumferential direction to form a plurality of stator core slots for embedding the copper wire. The stator core teeth are formed between adjacent stator core slots. Each stator core slot is substantially axially opened along the main shaft 11 and is inclined to be parallel to the both ends. The continuous wave copper wire group 9 is embedded in the stator core slot from the outside to the inside.

[0099] According to the operating condition of the motor, the wire group is embedded from the outside to the inside. A double-component epoxy resin with a thermal conductivity of 1.2 is customized and developed to wrap and fix the wire group. After the continuous wave copper wire group 9 is wound in the stator slot, it is effectively fixed. In this way, the wire group is in full contact with the epoxy resin, and the heat is quickly absorbed by the epoxy resin and conducted to the aluminum alloy shell of the stator shell 10. The heat is finally transmitted to the external environment by using the water cooling scheme. Moreover, the wire group is wrapped inside the epoxy resin, and the wire group is fixed firmly and will not fall off and scratch to cause short circuit under high-speed rotation. There is no need to worry about water leakage and dust ingress, which ensures the safety of the motor operation and withstands 30g impact, far exceeding the operating condition of the two-wheeled electric vehicle.

[0100] The electrical components include a three-phase terminal box 12, a sensor 16, a sensor wire 13, three-phase wires 14 and a busbar 15, the busbar 15 is arranged in the three-phase terminal box 12, and one end of the continuous wave copper wire group 9 and the three-phase wires 14 is connected, the three-phase wires 14 and the sensor wire 13 are arranged in the three-phase terminal box 12 and connected with the continuous wave copper wire group 9 and the sensor through the busbar 15, and the other end of the three-phase wires 14 and the sensor wire 13 is connected with the external controller through the upper sealing plate 7.

[0101] More specifically, as shown in Figure 7 , the ends of the copper wires of the continuous wave copper wire group 9 are connected by using a connecting assembly 17, and part of the lines are connected with three copper connectors in the busbar 15 which are not in contact with each other, so as to form a three-phase circuit. The other ends of the three copper connectors are connected with the three-phase wires 14 which are not in contact with each other. The three-phase wires 14 are led out from the three-phase terminal box 12 to the rear end surface of the motor and connected with the inverter. The sensor 16 is arranged on the heat sink 2 and connected with the sensor wire 13, the sensor wire 13 is led out from the sealing hole of the heat sink 2 to the rear end surface of the motor, and the end of the sensor wire 13 is connected with an electrical connector which is connected with the controller.

[0102] The circumferential outer edge part of the stator shell 10 is provided with an internal water channel 101 which occupies an arc of 270 degrees, the internal water channel 101 is arranged from one side of the electrical components to the other side of the electrical components through the circumferential outer edge of the stator shell 10, and the two ends of the internal water channel 101 are respectively provided with a water inlet 102 and a water outlet 103, the water inlet 102 and the water outlet 103 are respectively used for the entering and flowing out of the cooling liquid.

[0103] As a preferred embodiment, the rotor shell 1 and the stator shell 10 of the present application are made of ZL101a aluminum alloy material, which is light in weight, strong in plasticity, low in cost and excellent in heat dissipation performance. According to the heat dissipation requirement, the present application designs a water cooling scheme on the stator shell 10 to help the motor to control the temperature change more effectively.

[0104] The water cooling scheme: the internal water channel 101 is arranged in the stator as a cooling water channel, the cooling liquid enters through the water inlet 102 and flows out through the water outlet 103, so as to take away the heat (see Figure 4 and Figure 5 ). The above scheme is realized by arranging the compact and ingenious improved structure of the present application.

[0105] The most difficult problem of motor heat dissipation is the biggest obstacle to improve the performance of the motor. In the present application, the hub bearing unit is in the middle position, the stator part and the rotor part are respectively installed on the axial front and back of the hub bearing unit (i.e. bearing), the rotor part does not need to completely wrap the stator part, and the area of the stator part exposed to the air is designed with heat dissipation fins and special water cooling channels. The combined structure design makes the motor temperature rise slowly and the cooling speed up, and completely solves the fatal defect that the heat source stator part is wrapped inside the rotor part in the traditional design and cannot be effectively cooled.

[0106] The continuous wave winding copper wire group 9 adopts the structure design of wave winding copper wire and inclined non-axial parallel, and has innovative design characteristics.

[0107] As shown in Figure 6 , the copper wire of each turn of the continuous wave winding copper wire group 9 in the stator core slot of the stator shell 10 is not parallel to the axial direction, that is, each stator core slot of the outer peripheral surface of the stator shell 10 is not completely opened along the axial direction of the main shaft 11, but is inclined to the tangential direction by an angle of 4.75°-5.3° on the basis of the original parallel to the axial direction, so that the copper wire in the stator core slot in the continuous wave winding copper wire group 9 is also arranged obliquely, as shown in Figure 6 .

[0108] The present application specially inclines the wire group in the axial direction by a special angle, and the inclination angle of the wire group is designed to be 4.95°+0.35° / -0.2°, which is combined with the structure characteristics of the continuous wave winding copper wire, as shown in Figure 6 The advantages are as follows: 1) the cogging torque is small, and the vibration and noise are reduced; 2) the high-order harmonics are reduced, and the iron loss is reduced, so that the motor efficiency is improved to 90%; 3) the coil length and area are increased, so that the heat dissipation space is larger and the efficiency is higher.

[0109] As shown in Figure 12 , the continuous wave winding copper wire group 9 is divided into a plurality of copper wire windings with different lengths and different distribution positions, and each copper wire winding is continuously wound in an S-shaped path on a plurality of stator slots every two stator slots. That is, in each stator slot wound by each copper wire winding, two adjacent stator slots wound are separated by two vacant stator slots, thereby forming continuous wave winding with three stator slots as a period. The continuous wave winding copper wire group 9 is connected to the external inverter controller after passing through the three-phase wire 14 and the busbar 15.

[0110] As shown in Figure 12 , each copper wire winding is a copper wire with two ends, and the two ends of the copper wire are not connected in a closed loop. The subsequent connection design connects the two ends of the copper wire of each copper wire winding.

[0111] As shown in Figure 13As shown, adjacent copper wire windings are usually staggered by one stator slot at a fixed clockwise direction along the circumference of the stator housing. The fixed clockwise direction is either clockwise or counterclockwise.

[0112] Multiple copper wire windings exist within the same stator slot, with each winding's copper wires stacked and embedded from the inside out within that slot. This staggered winding and stacking arrangement ensures that each stator slot contains the same number of copper wire windings. The final result is as follows: Figure 14-15 As shown, a multi-layered continuous wave is wound around the copper wire.

[0113] like Figure 16 As shown, the stator slots are opened through both ends and the outer side in the axial direction. Each stator slot is basically opened along the axial direction of the motor main shaft and is inclined parallel to both ends, so that the copper wires of the copper wire windings wound in the stator slots are also arranged inclined to the motor main shaft.

[0114] like Figure 11 As shown, the continuous wave winding copper wire group 9 includes four copper wire windings of different lengths. The four copper wire windings of different lengths are respectively used to wind in a number of consecutive stator slots that cover and occupy the entire circumference of the stator housing 10, approximately 1 / 4, 2 / 4, 3 / 4, and 4 / 4 of the total number of stator slots.

[0115] Alternatively, the continuous wave winding copper wire group 9 includes four copper wire windings with different starting points. The starting points of the four copper wire windings are respectively wound from the stator slots at the middle position on the upper side, the middle position on the left side, the middle position on the lower side, and the middle position on the right side of the stator housing 10.

[0116] Alternatively, the continuous wave winding copper wire group 9 includes four copper wire windings with different endpoints. The endpoints of the four copper wire windings with different endpoints are respectively wound to the stator slots at the middle of the upper side, the middle of the left side, the middle of the lower side, and the middle of the right side of the stator housing 10.

[0117] Each of the above copper wire windings is also wound in a continuous wave with a periodic S-shaped winding path, with three stator slots as the period.

[0118] like Figure 17 As shown, the continuous wave winding copper wire group 9 includes seven different copper wire windings of different lengths and different distribution positions. Each copper wire winding group contains three copper wire windings, for a total of 21 copper wire windings.

[0119] like Figure 18 As shown in (a), the first type of copper wire winding includes three copper wire windings, each covering a full circumferential 1 / 4 of the stator slot of the stator housing 10, namely wires 1-3, as follows: Figure 13Wherein each two adjacent copper wire windings are arranged in a fixed anticlockwise direction with one stator slot interval, that is, the starting point and the ending point are arranged in a fixed clockwise direction with one stator slot interval. The starting ends of the three copper wire windings are respectively wound from the three stator slots near the upper middle of the stator shell 10, and after winding through the stator shell 10 in a fixed anticlockwise direction, the ending ends are respectively wound to the three stator slots in the middle of the left side of the stator shell 10.

[0120] As shown in Figure 18 (b), the second copper wire winding includes three copper wire windings covering 2 / 4 stator slots of the stator shell 10, which are respectively No. 4-6 wires, wherein each two adjacent copper wire windings are arranged in a fixed anticlockwise direction with one stator slot interval, that is, the starting point and the ending point are arranged in a fixed clockwise direction with one stator slot interval; and the first copper wire winding No. 4 wire is also arranged in a fixed anticlockwise direction with one stator slot interval compared with the last copper wire winding No. 3 wire in the previous copper wire winding. The starting ends of the three copper wire windings are respectively wound from the three stator slots in the middle of the upper side of the stator shell 10, and after winding through the stator shell 10 in a fixed anticlockwise direction, the ending ends are respectively wound to the three stator slots near the lower middle of the stator shell 10.

[0121] As shown in Figure 18 (c), the third copper wire winding includes three copper wire windings covering 3 / 4 stator slots of the stator shell 10, which are respectively No. 7-9 wires, wherein each two adjacent copper wire windings are arranged in a fixed anticlockwise direction with one stator slot interval, that is, the starting point and the ending point are arranged in a fixed clockwise direction with one stator slot interval; and the first copper wire winding No. 7 wire is also arranged in a fixed anticlockwise direction with one stator slot interval compared with the last copper wire winding No. 6 wire in the previous copper wire winding. The starting ends of the three copper wire windings are respectively wound from the three stator slots near the upper middle of the stator shell 10, and after winding through the stator shell 10 in a fixed anticlockwise direction, the ending ends are respectively wound to the three stator slots in the middle of the right side of the stator shell 10.

[0122] As shown in Figure 18(d) as shown, the fourth copper wire winding contains three copper wire windings each covering 4 / 4 stator slots in the complete circumferential direction of the stator shell 10, which are No. 10-12 wires, wherein each two adjacent copper wire windings are arranged in a staggered manner with a fixed counterclockwise interval of one stator slot in the circumferential direction, that is, the starting point and the ending point are arranged with a fixed clockwise interval of one stator slot; and the first copper wire winding No. 10 wire is also arranged in a staggered manner with a fixed counterclockwise interval of one stator slot in the circumferential direction compared with the last copper wire winding No. 9 wire in the previous copper wire winding. The starting points of the three copper wire windings correspond to the same three stator slots as the starting points of the three copper wire windings of the second copper wire winding, which start from the three stator slots in the middle of the upper side of the stator shell 10, and after being wound in a fixed counterclockwise direction through 4 / 4 stator slots in the complete circumferential direction of the stator shell 10, the ending points are wound to the three stator slots close to the middle of the upper side of the stator shell 10.

[0123] As Figure 18 (e) as shown, the fifth copper wire winding contains three copper wire windings each covering 3 / 4 stator slots in the complete circumferential direction of the stator shell 10, which are No. 13-15 wires, wherein each two adjacent copper wire windings are arranged in a staggered manner with a fixed counterclockwise interval of one stator slot in the circumferential direction, that is, the starting point and the ending point are arranged with a fixed clockwise interval of one stator slot; and the first copper wire winding No. 13 wire is also arranged in a staggered manner with a fixed counterclockwise interval of one stator slot in the circumferential direction compared with the last copper wire winding No. 12 wire in the previous copper wire winding. The starting points of the three copper wire windings are respectively wound from the three stator slots close to the middle of the left side of the stator shell 10, and after being wound in a fixed counterclockwise direction through 3 / 4 stator slots in the complete circumferential direction of the stator shell 10, the ending points of the three copper wire windings and the starting points of the three copper wire windings of the second copper wire winding and the fourth copper wire winding correspond to the same three stator slots, which are respectively wound to the three stator slots in the middle of the upper side of the stator shell 10.

[0124] As Figure 18(f) As shown in Fig. 6, the sixth copper wire winding includes three copper wire windings, 16-18, each of which covers 2 / 4 of the complete circumferential direction of the stator shell 10, and each of which is arranged to be wound in a fixed counterclockwise direction with one stator slot offset between every two adjacent copper wire windings, i.e., the start point and the end point are arranged to be separated by one stator slot in a fixed clockwise direction. In addition, the first copper wire winding 16 is also arranged to be wound in a fixed counterclockwise direction with one stator slot offset in the circumferential direction compared to the last copper wire winding 15 of the previous copper wire winding. The start points of the three copper wire windings are arranged to be wound from the three stator slots in the middle of the lower side of the stator shell 10. After being wound in a fixed counterclockwise direction through 2 / 4 of the complete circumferential direction of the stator shell 10, the end points of the three copper wire windings are arranged to be wound into the three stator slots in the middle of the upper side of the stator shell 10, which are the same as the end points of the three copper wire windings of the fourth copper wire winding.

[0125] As shown in Fig. 4, Figure 18 (g) As shown in Fig. 7, the seventh copper wire winding includes three copper wire windings, 19-21, each of which covers 1 / 4 of the complete circumferential direction of the stator shell 10, and each of which is arranged to be wound in a fixed counterclockwise direction with one stator slot offset between every two adjacent copper wire windings, i.e., the start point and the end point are arranged to be separated by one stator slot in a fixed clockwise direction. In addition, the first copper wire winding 19 is also arranged to be wound in a fixed counterclockwise direction with one stator slot offset in the circumferential direction compared to the last copper wire winding 18 of the previous copper wire winding. The start points of the three copper wire windings are arranged to be wound from the three stator slots in the middle of the right side of the stator shell 10. After being wound in a fixed counterclockwise direction through 1 / 4 of the complete circumferential direction of the stator shell 10, the end points of the three copper wire windings are arranged to be wound into the three stator slots in the middle of the upper side of the stator shell 10, which are the same as the start points of the three copper wire windings of the second copper wire winding and the fourth copper wire winding, and the end points of the three copper wire windings of the fifth copper wire winding.

[0126] In the copper wire windings 1-21, each two adjacent copper wire windings are arranged to be wound in a fixed counterclockwise direction with one stator slot offset in the circumferential direction.

[0127] As shown in Fig. 4, Figure 21-19 In the 21 copper wire windings of the seven different lengths and distribution positions, as shown in Fig. 4,

[0128] As shown in Fig. 4, Figure 19 (b) and Figure 20As shown in Fig. 1 (a) and Fig. 1 (b), the end terminals of the three copper wire windings of the first kind of copper wire winding are respectively connected to the start terminals of the three copper wire windings of the fifth kind of copper wire winding, i.e. the end terminal 1E of the No. 1 wire and the start terminal 13S of the No. 13 wire can be tightly electrically connected through the metal hoop connecting assembly, the end terminal 2E of the No. 2 wire and the start terminal 14S of the No. 14 wire can be tightly electrically connected through the metal hoop connecting assembly, and the end terminal 3E of the No. 3 wire and the start terminal 15S of the No. 15 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0129] As shown in Fig. 1 (a) and Fig. 1 (b), Figure 19 (c) and Figure 20 As shown in Fig. 1 (a) and Fig. 1 (b), the end terminals of the three copper wire windings of the second kind of copper wire winding are respectively connected to the start terminals of the three copper wire windings of the sixth kind of copper wire winding, i.e. the end terminal 4E of the No. 4 wire and the start terminal 16S of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, the end terminal 5E of the No. 5 wire and the start terminal 17S of the No. 17 wire can be tightly electrically connected through the metal hoop connecting assembly, and the end terminal 6E of the No. 6 wire and the start terminal 18S of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0130] As shown in Fig. 1 (a) and Fig. 1 (b), Figure 19 (d) and Figure 20 As shown in Fig. 1 (a) and Fig. 1 (b), the end terminals of the three copper wire windings of the third kind of copper wire winding are respectively connected to the start terminals of the three copper wire windings of the seventh kind of copper wire winding, i.e. the end terminal 7E of the No. 7 wire and the start terminal 19S of the No. 19 wire can be tightly electrically connected through the metal hoop connecting assembly, the end terminal 8E of the No. 8 wire and the start terminal 20S of the No. 20 wire can be tightly electrically connected through the metal hoop connecting assembly, and the end terminal 9E of the No. 9 wire and the start terminal 21S of the No. 21 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0131] The connecting assembly 7 is a conductive component that does not contact each other. The connecting assembly 7 helps the end of each copper wire winding to be efficiently electrically connected.

[0132] As shown in Fig. 1 (a) and Fig. 1 (b), Figure 19 (a) and Figure 20 As shown in Fig. 1 (a) and Fig. 1 (b), on the upper side of the stator shell 10:

[0133] The start terminals of the first and last copper wire windings of the first kind of copper wire winding are respectively connected to the start terminals of the first and last copper wire windings of the third kind of copper wire winding, i.e. the start terminal 1S of the No. 1 wire and the start terminal 7S of the No. 7 wire can be tightly electrically connected through the metal hoop connecting assembly, and the start terminal 3S of the No. 3 wire and the start terminal 9S of the No. 9 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0134] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0135] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0136] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0137] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0138] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0139] As Figure 15 and Figure 22As shown, a busbar 15 is installed on the upper side of the stator housing 10. The three phases of the three-phase line 14 are connected to the three phases of the busbar 15 through the electrical wires on the stator housing 10, and finally the busbar 15 leads out to the inverter via a three-phase cable.

[0140] In specific implementation, such as Figure 11 As shown, this invention uses four types of winding copper wires, and twenty-one wires are made according to different lengths at the beginning and end. Each copper wire is arranged in sequence with a code.

[0141] like Figure 12 , Figure 13 , Figure 14 As shown, twenty-one copper wires are sequentially embedded into the stator core by a specialized production line from the outside in, and the copper wires are insulated from the core using insulating paper.

[0142] like Figure 16 , Figure 15 In this system, copper wires are soldered together using connectors to form a specially designed three-phase circuit. The three-phase circuit is ultimately connected to a three-phase cable via a busbar, and then from there to the inverter. The system operates by the controller receiving and outputting signals to the inverter, which then adjusts the current and voltage of the circuit to influence the output of the electromagnetic system and control its operation.

[0143] This invention features a special axial tilt design for the continuous wave wound copper wire, with the tilt angle set at 4.95° (+0.35° / -0.2°). Combined with the structural characteristics of the continuous wave wound copper wire itself, this design offers the following advantages: 1) Reduced cogging torque, resulting in lower vibration and noise; 2) Reduced high-order harmonics, thereby lowering iron losses and improving motor efficiency; 3) Increased coil length and area, providing more space for heat dissipation, improving heat dissipation, and increasing efficiency.

[0144] The embodiments of the present invention are as follows:

[0145] Example 1 (Solution of the present invention):

[0146] like Figure 1 As shown, traditional multi-strand concentrated winding motors are internally enclosed, making heat dissipation difficult and severely impacting motor performance. The dual-bearing rotation method also reduces coaxiality accuracy, thus affecting the smoothness of motor operation.

[0147] In this invention, the rotor housing 1, as the main rotor component, adopts an external structure. Figure 2 The rotor has 28 pairs of permanent magnets mounted on its surface. The outer casing is designed with a tire mounting surface based on the 3.5MT-12 wheel rim specifications, and is designed for tubeless tires.

[0148] like Figure 2As shown, the outer contour of the rotor shell 1 of the present application matches the 12-inch tire and can be directly installed with the tire. The rotating system uses a third-generation hub bearing unit 4 to connect the stator shell 10 and the rotor shell 1, which is easier to control the assembly precision and structural stability, and can enhance the smoothness of the motor operation. The permanent magnet 6 and the continuous wave copper wire group 9 form a permanent magnet synchronous circuit system, which has the advantages of high efficiency, high power density, high reliability, fast response, energy saving, etc. It greatly improves the control, endurance and safety of the two-wheeled electric vehicle.

[0149] The continuous wave copper wire group 9 is wrapped and cured by pouring epoxy resin, which has the characteristics of waterproof, dustproof, corrosion-resistant, impact-resistant, and fast heat dissipation.

[0150] The upper sealing plate 7 is designed as an open design, and air can enter from the right side to contact the inner cavity of the stator shell 10, the third-generation hub bearing unit 4, and the rotor shell 1, facilitating overall heat dissipation of the motor.

[0151] The above water cooling scheme is set, and a water cooling pipeline is arranged in the inner cavity of the stator shell 10, and the inlet and outlet pipes are connected to the water tank from the opening of the upper sealing plate 7.

[0152] The traditional centralized winding motor design generates more heat, and it is difficult to further improve the performance of the motor under the premise of difficult motor heat dissipation. In the present application, the stator shell 10 is used as the main stator component in the form of built-in structure (see Figure 2 ), abandoning the multi-strand centralized winding structure of the original technical bottleneck, the new stator winding uses continuous wave copper wire, a total of 21 copper wires are embedded in the stator core 18 of the stator from the outside to the inside layer by layer, and then the three-phase circuit is connected according to the specific wiring scheme.

[0153] As a preferred embodiment, the present application is limited by the Φ330mm space of the 12-inch rim, and uses a diameter of 1.87mm round enameled copper wire with a larger current passing amount, uses a continuous wave winding process, designs 21 inclined wire groups, and inserts them into the stator core 18 from the outside to the inside layer by layer according to the specific distribution points described above. Then, according to the wiring position, each wire group is connected to form a three-phase circuit.

[0154] As shown in Figure 3 , the permanent magnets 6 are fixed to the inner circumferential surface of the rotor yoke 5 respectively, and the air gap between the plurality of magnet blocks and the continuous wave copper wire group 9 of the stator shell 10 is designed to be in the range of 0.8mm-1mm. As a preferred embodiment, the magnet blocks are made of neodymium iron boron magnets. In the specific implementation, the circuit design of the continuous wave copper wire group 9 of the stator component is matched and simulated, the size of the single magnet is 56mm×12mm×2.3mm, a total of 28 pairs, 56 magnets, all surface-mounted on the inside of the rotor component. Combined with the shape range of the stator component, the rotor component is adaptively designed.

[0155] The minimum diameter of the outer wall of the rotor shell 1 is Φ299.2 mm. On the basis of the minimum diameter profile of the outer wall, the tire mounting surface structure is designed according to the standard size of a 12-inch rim, and the final overall outer contour diameter is determined as Φ330 mm.

[0156] In a specific implementation, the sensor 16 uses an eddy current sensor, and the sensor line 13 connected with the thermistor is guided to the controller. The three-phase circuit is led out by the busbar 15 (see Figure 2 ), connected to the three-phase line 14, which is connected to the inverter, which is finally connected to the power supply to form a circuit system. The above components form an input and output system of electrical signals and electrical energy.

[0157] Through testing, the hub bearing unit in the application is designed to be small under the condition of a load of 400 kg, and fully considers the working conditions of load and impact, meets the rated dynamic load Cr: 61.8 KN, the rated static load Cor: 54.7 KN, the axial play 0-0.03 mm, is a passenger car level, and the service life can reach more than 150,000 kilometers. The cooperation structure of the stator part and the rotor part is processed by one clamping to ensure that the coaxiality is less than 0.05 mm. The coaxiality cooperation precision of the hub bearing unit, the stator part and the rotor part after installation is extremely high, so that abnormal vibration of the motor caused by load or impact when the motor runs at a speed of 120 kilometers per hour is eliminated, and the safety, stability and comfort of vehicle driving are improved.

[0158] Example 2 (the scheme of the application):

[0159] The difference between example 1 and example 2 is only that the applied voltage is different, and the rated voltage applied is set to 72 V. Example 1 is 100 V. The motor structure and parameters of example 1 and example 2 are consistent, and the voltage is different because the voltage provided by the inverter is different, and the performance exhibited is different.

[0160] Comparative example 1:

[0161] As shown in Figure 1 , comparative example 1 is a traditional concentrated winding motor, the stator shell is in the center of the motor, and the rotor shell completely wraps the stator shell. As shown in Figure 8 , the copper wire group in the stator shell is wound in the stator core slot one by one, and then the stator core is embedded on the stator shell. Due to the limitation of the concentrated winding structure, the copper wire cannot be arranged at an inclined angle. The electromagnetic performance after the above design is shown in the benchmark motor performance index in the parameter comparison table, and the performance is similar to that of the application.

[0162] Comparative example 2:

[0163] As shown in Figure 9As shown, the comparative example 2 is a traditional continuous wave winding motor. Limited by the technical difficulty of the large sealing ring, the copper wire group is arranged on the outer periphery of the rotor after being embedded in the stator core. In this way, the size of the sealing ring is reduced to meet the working condition requirements. Figure 10 As shown, the two-wheel electric vehicle requires a main shaft to connect the two supports, but the rotor of the comparative example 2 motor is in the center of the motor, and it is impossible to arrange a stationary main shaft, so such a structure is not suitable for the structural requirements of the two-wheel electric vehicle motor.

[0164] Table 1: Comparison of performance parameters of the conventional existing benchmark motor

[0165]

[0166] As shown in the above table, under the same 72V voltage platform, the speed, peak torque, peak power, and motor efficiency of the present application are stronger than the industry benchmark motor, with a speed increase of about 0.8%, a peak torque increase of about 10%, a peak power increase of about 56%, a motor efficiency increase of 5%, and a weight reduction of 17%. The performance of the vehicle, such as endurance, acceleration, and climbing, is greatly improved.

[0167] In addition, the current industry leader has put forward new demands for high-performance vehicles, which require a voltage platform of 96V, a speed of ≥1500rpm, a peak torque of ≥450N.m, a peak power of ≥33kw, and a motor efficiency of ≥92%. The voltage platform of the present application can reach 100V, meeting the voltage platform requirements, and the motor performance indicators also meet the requirements.

[0168] In summary, after several rounds of electromagnetic tests, the outer diameter of the stator part of the embodiments 1 and 2 of the present application is designed to be 274mm in diameter. The total copper wire usage is about 1kg, which is only 40% of the copper wire usage of the benchmark motor, saving a large amount of copper resources. The motor efficiency is increased from 85% (benchmark motor) to 92% (new structure motor).

[0169] The above specific embodiments are used to explain and illustrate the present application, rather than limit the present application. Any modifications and changes made to the present application within the spirit and protection scope of the claims are included in the protection scope of the present application.

[0170] The above is only a preferred embodiment of the present application, so any equivalent changes or modifications made to the structure, features and principles described in the scope of the present application are included in the scope of the present application. The above is only a preferred embodiment of the present application, so any equivalent changes or modifications made to the structure, features and principles described in the scope of the present application are included in the scope of the present application.

Claims

1. A two-wheeled electric vehicle wheel hub motor structure integrated with a rim by a third generation wheel hub bearing unit, comprising: a main shaft (11) ; a stator housing (10) sleeved on the main shaft (11) ; a rotor housing (1) sleeved on the stator housing (10) ; a third generation wheel hub bearing unit (4), the rotor housing (1) and the stator housing (10) are both connected to the main shaft (11) through the third generation wheel hub bearing unit (4) ; and an electromagnetic drive structure and a sealing structure arranged between the rotor housing (1) and the stator housing (10). 2.The two-wheeled electric vehicle wheel hub motor structure integrated with a rim by a third generation wheel hub bearing unit according to claim 1, wherein: the third generation wheel hub bearing unit (4) comprises an outer ring part and an inner ring part which are freely rotatably connected to each other; the outer ring part is coaxially sleeved and connected to the rotor housing (1) ; and the inner ring part is coaxially sleeved and connected to the stator housing (10) and directly or indirectly sleeved on the main shaft (11). 3.The two-wheeled electric vehicle wheel hub motor structure integrated with a rim by a third generation wheel hub bearing unit according to claim 1, wherein: the rotor housing (1) is asymmetrically arranged on the outside of the stator housing (10) ; the rotor housing (1) comprises a ring part and a disc part, the ring part is arranged with a gap between the stator housing (10) at the outer periphery of the stator housing (10), the disc part is arranged with a gap between the stator housing (10) at the outer side of the front end face of the stator housing (10), the inner ring of the disc part is fixedly sleeved on the outer ring part of the third generation wheel hub bearing unit (4), and the outer ring of the disc part is fixedly connected to one side end face of the ring part. 4.The two-wheeled electric vehicle wheel hub motor structure integrated with a rim by a third generation wheel hub bearing unit according to claim 3, wherein: an upper sealing plate (7) is arranged on the outside of the rear end face of the stator housing (10), the outer ring of the upper sealing plate (7) is fixedly and sealingly connected to the other side end face of the ring part, and the inner ring of the upper sealing plate (7) is sealingly connected between the rear end face of the stator housing (10) through a sealing ring (8). 5.The two-wheeled electric vehicle wheel hub motor structure integrated with a rim by a third generation wheel hub bearing unit according to claim 1, wherein: a heat sink (2) is fixedly connected to the front end face of the stator housing (10), the stator housing (10) and the heat sink (2) are provided with stator grooves on the outer peripheral surfaces thereof for assembling the electromagnetic drive structure, and the front side of the heat sink (2) is sealingly connected to the disc part of the rotor housing (1) through a sealing ring (3). 6.The two-wheeled electric vehicle wheel hub motor structure integrated with a rim by a third generation wheel hub bearing unit according to claim 5, wherein: the electromagnetic drive structure comprises a rotor steel yoke (5), a permanent magnet (6) and a continuous wave copper wire group (9), the continuous wave copper wire group (9) is embedded and installed in the stator groove, the rotor steel yoke (5) is fixedly installed on the inner periphery of the ring part of the rotor housing (1), the permanent magnet (6) is fixedly installed on the inner periphery of the rotor steel yoke (5), and there is a gap between the permanent magnet (6) and the continuous wave copper wire group (9). ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 7. The two-wheeled electric vehicle hub motor structure integrated with the third generation of hub bearing unit and rim according to claim 5, characterized in that: the outer circumferential surface of the stator housing (10) and the fin (2) is circumferentially spaced apart to form a plurality of stator slots, and the stator teeth are formed between adjacent stator slots, each stator slot is substantially axially opened along the main shaft (11) and is inclined parallel through, and the continuous wave winding copper wire group (9) is embedded in the stator slot from outside to inside.

8. The two-wheeled electric vehicle hub motor structure integrated with the third generation of hub bearing unit and rim according to claim 1, characterized in that: It includes three-phase line box (12), sensor line (13), three-phase line (14) and busbar (15), one end of three-phase line (14) and sensor line (13) is placed in three-phase line box (12) through busbar (15) and is connected with continuous wave winding copper wire group (9) and sensor respectively, sensor (16) is installed on fin (2), the other end of three-phase line (14) and sensor line (13) passes through upper sealing plate (7) after passing through three-phase line box (12) and is electrically connected with external controller through electrical connector.

9. The two-wheeled electric vehicle hub motor structure integrated with the third generation of hub bearing unit and rim according to claim 1, characterized in that: the circumferential outer edge part of the stator housing (10) is internally provided with an arc-shaped internal water channel (101) occupying 270 degrees of the center angle, and the two ends of the internal water channel (101) are respectively provided with water inlet (102) and water outlet (102), and the water inlet (101) and the water outlet (102) are respectively used for the entering and flowing out of the cooling liquid.

10. The two-wheeled electric vehicle hub motor structure integrated with the third generation of hub bearing unit and rim according to claim 1, characterized in that: the copper wire in each turn in the stator slot of the stator housing (10) is not parallel to the axial direction, but is inclined to the tangential direction by an angle of 4.75°-5.3° on the basis of the original parallel to the axial direction.

11. The two-wheeled electric vehicle hub motor structure integrated with the third generation of hub bearing unit and rim according to claim 1, characterized in that: the continuous wave winding copper wire group (9) is divided into a plurality of copper wire windings, each copper wire winding is continuously wound in an S-shaped path with two stator slots as a period; adjacent copper wire windings are wound in a staggered manner with a preset hourglass direction along the circumferential direction of the stator housing (10) and are spaced apart by k stator slots; and the copper wire of the copper wire winding wound in the stator slot is inclined to the main shaft of the motor.

12. The motor electromagnetic drive structure using continuous wave winding copper wire and multi-layer stacking according to claim 11, characterized in that: the continuous wave winding copper wire group (9) includes four kinds of copper wire windings with different lengths, and the four kinds of copper wire windings are respectively used for winding in the continuous stator slots covering 1 / 4, 2 / 4, 3 / 4 and 4 / 4 of the entire circumferential direction of the stator housing (10). Or / and the continuous wave winding copper wire group (9) includes four different starting points of copper wire winding, and the starting points of the four different starting points of copper wire winding are respectively wound from the middle of the upper side, the middle of the left side, the middle of the lower side and the middle of the right side of the stator shell (10) The stator slot starts winding; Or / and the continuous wave winding copper wire group (9) includes four different ending points of copper wire winding, and the ending points of the four different ending points of copper wire winding are respectively wound to the middle of the upper side, the middle of the left side, the middle of the lower side and the middle of the right side of the stator shell (10) The stator slot ends.

13. The electromagnetic drive structure of the motor using continuous wave winding copper wire and multi-layer stacking according to claim 11, wherein: The continuous wave winding copper wire group (9) includes seven different lengths and distribution positions of copper wire winding, each copper wire winding includes three copper wire windings, and a total of 21 copper wire windings; The first copper wire winding includes three copper wire windings covering the complete circumferential 1 / 4 stator slot of the stator shell (10), and the starting points of the three copper wire windings are respectively wound from the three stator slots close to the upper side of the stator shell (10) The end of the terminal is wound to the three stator slots of the left side of the stator shell (10); The second copper wire winding includes three copper wire windings covering the complete circumferential 2 / 4 stator slot of the stator shell (10), and the starting points of the three copper wire windings are respectively wound from the three stator slots of the upper side of the stator shell (10) The end of the terminal is wound to the three stator slots close to the middle of the lower side of the stator shell (10); The third copper wire winding includes three copper wire windings covering the complete circumferential 3 / 4 stator slot of the stator shell (10), and the starting points of the three copper wire windings are respectively wound from the three stator slots close to the upper side of the stator shell (10) The end of the terminal is wound to the three stator slots of the right side of the stator shell (10); The fourth copper wire winding includes three copper wire windings covering the complete circumferential 4 / 4 stator slot of the stator shell (10), and the starting points of the three copper wire windings are respectively wound from the three stator slots of the upper side of the stator shell (10) The end of the terminal is wound to the three stator slots close to the upper side of the stator shell (10); The fifth copper wire winding includes three copper wire windings covering the complete circumferential 3 / 4 stator slot of the stator shell (10), and the starting points of the three copper wire windings are respectively wound from the three stator slots close to the left side of the stator shell (10) The end of the terminal is wound to the three stator slots of the upper side of the stator shell (10); The sixth copper wire winding includes three copper wire windings covering the complete circumferential 2 / 4 stator slot of the stator shell (10), and the starting points of the three copper wire windings are respectively wound from the three stator slots of the lower side of the stator shell (10) The end of the terminal is wound to the three stator slots close to the upper side of the stator shell (10); The seventh copper wire winding includes three copper wire windings covering a complete circumferential 1 / 4 stator slot of the stator shell (10), and the starting first ends of the three copper wire windings are wound from the three stator slots near the right middle of the stator shell (10), and the ending last ends are wound to the three stator slots on the upper middle of the stator shell (10).

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