Motor, installation method thereof and electric motorcycle adopting motor

Abstract

The invention discloses a motor, an installation method thereof and an electric motorcycle adopting the motor. The motor comprises a shell, a stator and a rotor. The stator comprises a stator body, a plurality of stator teeth and windings, the stator body is annular, the plurality of stator teeth are distributed around the circumferential direction of the stator body, and each stator tooth is wound with one winding. The stator body and the stator teeth are of a split structure, the stator body is provided with mounting parts, the mounting parts are distributed in the circumferential direction of the stator body, the stator teeth are provided with matching parts matched with the mounting parts, and an assembly gap exists after the mounting parts and the matching parts are mounted; the stator further comprises a plurality of locking structures, each locking structure is located on one mounting part or one matching part, and the locking structures can at least partially fill gaps between the mounting parts and the matching parts after being stressed. The motor is low in machining precision requirement and easy to assemble, and the situation that noise of the electric motorcycle adopting the motor is increased due to the influence of motor machining errors is not prone to occurring.

Description

Technical Field

[0001] This application relates to the field of power and motorcycle technology, specifically to an electric motor and its installation method, and an electric motorcycle using the electric motor. Background Technology

[0002] The electric motorcycle industry is in a phase of rapid development. As a crucial component, the motor directly impacts the core performance of electric motorcycles, such as power and range. Traditional permanent magnet motors suffer from low power density and low winding efficiency due to low winding slot fill factor, leading to poor manufacturing processes. Existing technologies have introduced a structure where the motor stator is segmented and assembled into a circle. While this improves the winding slot fill factor and winding efficiency, it also tends to result in low roundness, leading to uneven air gaps and requiring high machining precision, making assembly difficult. Electric motorcycles using this type of motor are prone to uneven air gaps due to machining errors, resulting in increased operating noise during use. Summary of the Invention

[0003] To address the shortcomings of existing technologies, the present invention aims to provide a motor with low processing precision requirements, simple assembly, and low noise, as well as its installation method and an electric motorcycle using the motor.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: This application provides an electric motor, including a housing, a stator, and a rotor. The stator is at least partially disposed within the housing and includes a stator body, multiple stator teeth, and windings. The stator body is annular, and the multiple stator teeth are circumferentially distributed around the stator body, with a winding wound on each stator tooth. The rotor is coaxially disposed with the stator and can rotate relative to the stator. The stator body and stator teeth are separate structures. The stator body has mounting portions distributed circumferentially around the stator body, and the stator teeth have mating portions that cooperate with the mounting portions. After installation, there is an assembly gap between the mounting portions and the mating portions. The stator also includes multiple locking structures, each located on a mounting portion or a mating portion. The locking structures can deform under pressure to at least partially fill the assembly gap. The locking structures allow for an assembly gap between the stator body and the stator teeth. This gap reduces the requirement for machining precision, minimizes resistance during stator tooth assembly, and allows stator teeth with independently wound windings to be easily inserted into the stator body.

[0005] Furthermore, the locking structure includes a trigger part and a locking part. The trigger part has a receiving space, and the locking part is disposed away from the trigger part and toward the assembly gap, so that the deformation of the locking part can be precisely guided to the assembly gap by the triggering action of the trigger part.

[0006] Furthermore, the locking structure also includes a fastener. When pressure is applied to the fastener, it is interference-fitted with the receiving space, thereby generating pressure from the trigger portion towards the locking portion, causing deformation of the locking portion. Deformation of the locking portion is achieved by applying compressive force through the fastener, making operation simple.

[0007] Furthermore, the space is a through hole, and the fastener is a rivet, resulting in lower manufacturing costs.

[0008] Furthermore, the locking part is a protrusion, and the maximum width of the protrusion cross section is greater than the width of the protrusion root to prevent the stator teeth from loosening in the stator radial direction.

[0009] Furthermore, the cross-section of the protrusion is an inverted trapezoid or an arc shape, which is easy to process and provides a better fixing effect after deformation.

[0010] Furthermore, the mounting part has a receiving groove that can at least partially accommodate the mating part. The presence of the receiving groove allows the mounting part to provide additional support for the stator teeth embedded therein, in addition to mating with the mating part.

[0011] Furthermore, an adhesive is applied between the mating part and the mounting part to further enhance the stability of the connection between the stator body and the stator teeth.

[0012] This application also provides a method for installing a motor, wherein the motor is as described above, and the installation method includes the following steps: Install a winding bracket on the stator teeth; A winding operation is performed on the stator teeth to form a combined component of stator teeth and windings; The stator teeth and winding assembly components are installed into the stator body one by one; Pressure is applied to the locking structure so that the locking structure at least partially fills the assembly gap to form the stator; The stator and rotor are assembled inside the housing.

[0013] This application also provides an electric motorcycle, including a frame, a body panel, and a running gear. The body panel at least partially covers the frame, and the running gear is connected to the frame; wherein the electric motorcycle includes a motor as described above, the motor providing power to the running gear.

[0014] The advantages of this invention are: by designing the stator teeth of the motor separately and the stator body as a single unit, with a clearance fit between the stator teeth and the stator body, the process requirements are low and the assembly efficiency is high. A locking structure is incorporated, utilizing pressure to trigger deformation and fill the assembly gap between the stator teeth and the stator body. This improves the overall consistency and cylindricity of the stator while locking the stator teeth and stator body, preventing uneven air gaps in the motor and reducing vibration and noise. Electric motorcycles using this motor are less prone to increased noise due to motor manufacturing errors. Attached Figure Description

[0015] Figure 1 This is a three-dimensional schematic diagram of the motor provided in the embodiments of this application; Figure 2 This is a cross-sectional view of the motor provided in an embodiment of this application; Figure 3 This is a three-dimensional schematic diagram of the stator provided in the embodiments of this application; Figure 4 This is a cross-sectional view of the stator provided in an embodiment of this application; Figure 5 yes Figure 4 A magnified view of a section at point A in the middle; Figure 6 This is an exploded view of the stator provided in an embodiment of this application; Figure 7 This is a three-dimensional schematic diagram of the stator body provided in the embodiments of this application; Figure 8 This is a cross-sectional view of the stator body provided in an embodiment of this application; Figure 9 yes Figure 8 A magnified view of a section at point B in the middle; Figure 10 This is a three-dimensional schematic diagram of the stator teeth provided in the embodiments of this application; Figure 11 This is a cross-sectional view of another stator provided in an embodiment of this application; Figure 12 This is a cross-sectional view of another stator provided in the embodiments of this application; Figure 13 This is the motor installation method provided in the embodiments of this application; Figure 14 This is a perspective view of the electric motorcycle provided in the embodiments of this application. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0017] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0018] like Figures 1 to 3 As shown, this application embodiment provides a motor 100, including a housing 11, a stator 12, and a rotor 13. The stator 12 is at least partially disposed within the housing 11, and the rotor 13 is coaxially disposed with respect to the stator 12 and can rotate relative to the stator 12. The stator 12 includes a stator body 121, a plurality of stator teeth 122, and windings 123. The stator body 121 is annular, and the plurality of stator teeth 122 are circumferentially distributed around the stator body 121, with a winding 123 wound on each stator tooth 122. The stator body 121 is a single, ring-shaped unit, while the stator teeth 122 are separate structures. This is understandable because: firstly, the integrated stator body 121 avoids the problems of poor cylindricity at the joints, which would otherwise lead to performance degradation and uneven air gap in the motor 100, compared to a scheme where both the stator body 121 and stator teeth 122 are segmented. Secondly, the independence of the segmented stator teeth 122 facilitates separate winding for each tooth, effectively improving the slot fill factor of the motor 100 and reducing resistance and copper losses. Finally, since the winding of the stator teeth 122 is completely unaffected by the stator body 121 and its internal space limitations, the winding difficulty of the winding 123 is reduced, improving the manufacturing efficiency of the motor 100. The specific structure of the motor 100 in this embodiment will be further described below.

[0019] like Figure 3As shown, in this embodiment, the stator body 121 is provided with mounting portions 1211, which are distributed circumferentially around the stator body 121. Typically, the mounting portions 1211 are evenly spaced, with the spacing primarily used to reserve space for the installation of the windings 123. The stator teeth 122 are provided with mating portions 1221 that cooperate with the mounting portions 1211. The mounting portions 1211 and the mating portions 1221 are in a clearance fit, meaning that after installation, there is an assembly gap (not shown). Due to the presence of this assembly gap, compared to a conventional interference fit, not only is the machining accuracy requirement for the mating position lower, but also, when initially aligning the stator teeth 122 with the mating position, no external tooling is needed for guidance, allowing the stator teeth 122 to be easily installed into the stator body 121.

[0020] Specifically, the stator 12 also includes multiple locking structures 124. Each locking structure 124 can be located on a mounting part 1211 or a mating part 1221, so that the stator body 121 and stator teeth 122 can be locked by the deformation of the locking structure 124, thus solving the problem of fastening the connection between the independent stator teeth 122 and the stator body 121. Based on the stator body 121 being an integral ring, the locking structure 124 can make the stator teeth 122 form a pressing part in the radial direction of the stator 12 with the stator body 121 as the reference. By fixing the stator 12 in this way, the concentricity of the inner and outer circles of the stator 12 is high, the air gap of the motor 100 is more uniform, and the performance is more stable.

[0021] Furthermore, the locking action of the locking structure 124 is triggered by applying pressure, which can be applied manually or mechanically automatically. The pressure itself can be mechanical force, or other pressures such as pneumatic or hydraulic pressure. Specifically, when the pressure is mechanical force, a hammer or press can be used to apply impact force to the locking structure 124, causing it to deform. In some embodiments, when the pressure is pneumatic or hydraulic, a tube expander can be used to provide high-pressure gas or liquid. The high-pressure gas or liquid enters the elastic rubber body through the core rod on the tube expander, generating radial pressure. This radial pressure acts on the locking structure 124, causing it to deform and at least partially fill the assembly gap, thereby locking the stator body 121 and the stator teeth 122 together. Compared to mechanical force, pneumatic or hydraulic pressure can be infinitely adjusted as needed, making it suitable for motors 100 with higher precision requirements.

[0022] like Figure 4 and Figure 5As shown, in one implementation, the locking structure 124 includes a trigger portion 1241 and a locking portion 1242. The trigger portion 1241 has a receiving space 1241a, which is used to accommodate components that trigger the deformation of the locking structure 124 or to provide operating space for other external tools. The locking portion 1242 is disposed away from the trigger portion 1241 and toward the assembly gap, and is used to uniformly guide the deformation between the mounting portion 1211 and the mating portion 1221 when the locking structure 124 deforms.

[0023] like Figure 6 As shown, in one implementation, the locking structure 124 also includes a fastener 1243. When pressure is applied to the fastener 1243, the fastener 1243 is in an interference fit with the receiving space 1241a. During the process of pressing the fastener 1243 into the receiving space 1241a, the compressive force generated by the interference fit can force the receiving space 1241a to expand, causing the locking part 1242 to deform, thereby locking the stator body 121 and the stator teeth 122, preventing the stator teeth 122 from radially loosening and axially shifting relative to the stator 12, and improving the strength of the stator 12. In another implementation, the fastener 1243 can be removed after triggering the deformation of the locking part 1242. That is, the fastener 1243 is only used as a tooling for the motor 100. After the stator 12 is assembled, the fastener 1243 can be removed and reused, saving component costs.

[0024] The accommodating space 1241a can be selected from various forms such as through holes and grooves as needed. Specifically, the accommodating space 1241a is a through hole, which penetrates the locking structure 124, making it easier to achieve high consistency in the deformation of the locking part 1242. The through hole itself is easy to process, and both ends can be operated. The fastener 1243 can be any component that can compress the through hole to produce deformation, such as a rivet or a cylindrical pin. More specifically, when the fastener 1243 is a rivet, the length of the rivet can be the same as the depth of the through hole. Assembly can be completed by pressing the rivet completely into the through hole, or a shorter rivet can be used, which can be pressed into the through hole from both ends to complete the assembly, as long as all or part of the through hole is deformed.

[0025] like Figures 7 to 9As shown, in this embodiment, the locking part 1242 can be a protrusion 1242a. In one implementation, the protrusion 1242a is located on the mounting part 1211 and is an integral design with the mounting part 1211; that is, the protrusion 1242a is directly machined onto the stator body 121. Specifically, the maximum width of the cross-section of the protrusion 1242a is greater than the width of the root of the protrusion 1242a. The root of the protrusion 1242a is the transition point between the protrusion 1242a and the mounting part 1211. This arrangement prevents radial loosening of the stator teeth 122. In another implementation, the protrusion 1242a is located on the mating part 1221 and is an integral design with the mating part 1221, that is, it is directly machined on the stator tooth 122. The root of the protrusion 1242a is the connection and transition point between the protrusion 1242a and the mating part 1221. The advantage of this arrangement is that the deformation process of the locking structure 124 is completed on the stator tooth 122. If the protrusion 1242a is damaged during installation, only a single stator tooth 122 can be replaced without re-machining the entire stator 12.

[0026] More specifically, the cross-section of the protrusion 1242a is an inverted trapezoid or an arc shape. When the cross-section of the protrusion 1242a is an inverted trapezoid, that is, the root of the protrusion 1242a is the upper base of the trapezoid, and the gap between the protrusion 1242a and the mating part 1221 is the lower base of the trapezoid, it is easier to find the mounting reference surface. For example Figure 11 As shown, when the cross section of the protrusion 1242a is an arc shape, the accommodating space 1241a can be set at the center of the arc shape. The force on the protrusion 1242a during expansion and deformation is more uniform, the deformation state is easier to control, and the possibility of the stator 12 breaking during the processing or use of the motor 100 is reduced.

[0027] As one implementation, the mounting part 1211 has a receiving groove 1211a, which can at least partially accommodate the mating part 1221. After the mounting part 1211 and the mating part 1221 are installed, the receiving groove 1211a can provide auxiliary support for both sides of the stator teeth 122, preventing the stator teeth 122 from loosening or even breaking when only the locking structure 124 is under force after installation, thus enhancing reliability. Specifically, the cross-sectional shape of the receiving groove 121a is adapted to the cross-sectional shape of the mating part 1221. More specifically, when the locking structure 124 is located on the mounting part 1211, the locking structure 124 is set in the middle of the receiving groove 1211a, and the cross-sectional shape of the mating part 1221 is claw-like. After the stator teeth 122 are installed onto the stator body 121, the claw-like structure of the mating part 1221 clamps the locking structure 124 therein. The outer side of the claw-like structure of the mating part 1221 abuts against the two sides of the receiving groove 1211a. Under this arrangement, the stator teeth 122 are limited by multiple angles, and after installation, the stator 12 is more stable as a whole and less prone to misalignment. Figure 12As shown, when the locking structure 124 is located on the mating part 1221, the locking structure 124 is set in the middle of the mating part 1221. The mating part 1221 has tooth-like structures on both sides. These tooth-like structures can be used to prevent the locking structure 124 from being damaged before the stator teeth 122 are installed. At the same time, the mounting part 1211 is also provided with tooth-like structures. The tooth-like structures on the mounting part 1211 can be locked on both sides of the locking structure 124. In addition, the outer side of the mating part 1221 abuts against the two sides of the receiving groove 1211a. Under this arrangement, the stator teeth 122 can also be limited at multiple angles.

[0028] As one implementation method, an adhesive is applied between the mating part 1221 and the mounting part 1211. Adding adhesive helps prevent loosening caused by insufficient deformation in certain areas of the locking structure 124. Furthermore, compared to fixing only with adhesive, this embodiment eliminates the need to wait for the adhesive to cure before locking the stator teeth 122 to the stator body 121 via the locking structure 124, thus shortening installation time.

[0029] In summary, the stator 12 of the motor 100 provided in this application embodiment is composed of stator teeth 122 and stator body 121 with a clearance fit. The gap is filled by the deformation of the locking structure 124, which can reduce the impact of component processing errors on the assembly process. The locking structure 124 is driven by the trigger part 1241 to deform the locking part 1242 under pressure, so that the stator teeth 122 form a pressing part in the radial direction of the stator 12 with the stator body 121 as the reference. This reduces the problem of uneven air gap of the motor 100 caused by the splicing method of the stator teeth 122, ensures the cylindricity of the inner diameter of the stator 12, reduces the noise and vibration of the motor 100, and improves the output power and operating efficiency of the motor 100.

[0030] This application embodiment also provides an installation method for the motor 100 as described above, which mainly includes the following steps: Step S101: Install a winding bracket on the stator tooth 122 to fix the stator tooth 122; Step S102: A winding operation is performed on the stator teeth 122 to form a combined component of stator teeth 122 and winding 123; Step S103: The combination components of stator teeth 122 and windings 123 are installed into the stator body 121 one by one; Step S104: Apply pressure to the locking structure 124 so that the locking structure 124 at least partially fills the assembly gap to form the stator 12; In step S105, the stator 12 and rotor 13 are assembled in the housing 11 to form the motor 100.

[0031] Based on the motor 100 provided in this embodiment, the winding operations of multiple stator teeth 122 can be performed simultaneously, and they are clearance-fitted with the stator body 121 during assembly, making assembly easy and significantly improving efficiency. The assembled stator 12 can be obtained simply by applying pressure to trigger the deformation of the locking structure 124, thereby completing the overall assembly of the motor 100, simplifying the process.

[0032] As one implementation method, in step S104, the rivet is pressed into one end of the through hole on the locking structure 124. As the through hole expands, the protrusion 1242a deforms, thereby fixing the stator tooth 122 and the stator body 121.

[0033] In one possible implementation, after the stator teeth 122 and winding 123 are formed in step S102, adhesive can be applied between the mating part 1221 and the mounting part 1211. This allows the rivets to be pressed into and removed from both ends of the through-hole on the locking structure 124 after the stator 12 is formed in step S104, meaning only a small portion at both ends of the through-hole undergoes expansion deformation. Under this operation, the final stator 12 does not contain rivets. Furthermore, because adhesive is applied to the assembly gap between the stator teeth 122 and the stator body 121, the cured adhesive can fill the remaining tiny gaps that the locking structure 124 cannot fill after deformation, further strengthening the fastening of the stator teeth 122 and the stator body 121. Since the rivets can be removed and reused, component costs are also saved. Meanwhile, before the adhesive cures, the subsequent installation steps can be carried out directly due to the auxiliary locking effect of the locking structure 124, without having to wait for the adhesive to cure. The adhesive will cure itself after the motor 100 is assembled, which improves the assembly efficiency.

[0034] In summary, the installation method of the motor 100 provided in this application embodiment can independently complete the winding operation of the winding 123 for each stator tooth 122, thereby improving the slot fill factor of the motor 100. When installing the stator tooth 122 into the stator body 121, the assembly gap is set, resulting in minimal assembly resistance. After the stator tooth 122 is installed, pressure is applied to deform the locking structure 124, thereby filling the assembly gap, making the operation simple.

[0035] like Figure 14As shown, this application embodiment also provides an electric motorcycle 200, including a frame 21, a body cover 22, and a running system 23. The frame 21 constitutes the basic framework of the electric motorcycle 200 and serves as the basis for arranging other components; the body cover 22 at least partially covers the frame 21 and is used to protect the electrical components housed therein from dust and water; the running system 23 is connected to the frame 21 and is at least partially disposed below the frame 21 and rotatably connected to the frame 21. The electric motorcycle 200 includes a motor 100 as described above, which provides power to the running system 23.

[0036] It is understood that the electric motorcycle 200 provided in this application embodiment, by adopting the motor 100 as described above, effectively improves the slot fill factor of the motor 100 and avoids the problem of uneven air gap caused by the processing error of the motor 100. Due to its higher operating stability, it helps to improve the output power and operating efficiency.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the above embodiments do not limit the present invention in any way, and all technical solutions obtained by equivalent substitution or equivalent transformation fall within the protection scope of the present invention.

Claims

1. An electric motor, comprising: case; A stator, at least partially disposed within the housing, the stator comprising a stator body, a plurality of stator teeth and windings, the stator body being annular, the plurality of stator teeth being circumferentially distributed around the stator body, and the windings being wound on each stator tooth; A rotor, which is coaxially arranged with the stator and can rotate relative to the stator; Its features are, The stator body and the stator teeth are separate structures. The stator body is provided with a mounting part, which is distributed around the circumference of the stator body. The stator teeth are provided with a mating part that cooperates with the mounting part. After the mounting part and the mating part are installed, there is an assembly gap. The stator also includes a plurality of locking structures, each of which is located on one of the mounting portions or one of the mating portions. The locking structure can deform under pressure to at least partially fill the assembly gap.

2. The motor according to claim 1, characterized in that, The locking structure includes a trigger part and a locking part. The trigger part has a receiving space, and the locking part is disposed away from the trigger part and toward the assembly gap.

3. The motor according to claim 2, characterized in that, The locking structure also includes a fastener, which, when pressure is applied to the fastener, is interference-fitted with the receiving space to generate pressure from the trigger portion toward the locking portion, causing the locking portion to deform.

4. The motor according to claim 3, characterized in that, The accommodating space is a through hole, and the fastener is a rivet.

5. The motor according to claim 2, characterized in that, The locking part is a protrusion, and the maximum width of the protrusion cross-section is greater than the width of the protrusion root.

6. The motor according to claim 5, characterized in that, The cross-section of the protrusion is an inverted trapezoid or an arc shape.

7. The motor according to claim 1, characterized in that, The mounting portion has a receiving groove that can at least partially accommodate the mating portion.

8. The motor according to claim 1, characterized in that, An adhesive is applied between the mating part and the mounting part.

9. A method for installing an electric motor, wherein the electric motor is the motor as described in any one of claims 1 to 8, characterized in that, The installation method includes the following steps: A winding bracket is installed on the stator teeth; A winding operation is performed on the stator teeth to form a combined component of the stator teeth and the winding; The stator teeth and the winding assembly are installed into the stator body one by one; Pressure is applied to the locking structure so that the locking structure at least partially fills the assembly gap to form the stator; The stator and the rotor are assembled within the housing.

10. An electric motorcycle, comprising: Frame; A body panel that at least partially covers the vehicle frame; The walking system is connected to the vehicle frame; Its features are, The electric motorcycle includes a motor as described in any one of claims 1 to 8, the motor providing power to the walking system.

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