Modularized mid-motor structure for two-wheeled vehicle and installation method

Abstract

The invention provides a modularized middle motor structure for a two-wheeled vehicle and an installation method, the modularized middle motor structure comprises a left shell, a right shell, a motor module, a transmission module and a middle shaft module, the motor module is integrally installed on the left shell, and the middle shaft module is integrally installed on the right shell; the transmission module is integrally mounted in a space formed by matching the left shell and the right shell; the middle shaft body is rotationally mounted on the right shell, and a mounting site for rotationally mounting the middle shaft body is arranged on the left shell; the transmission shaft and the transmission gear set are matched to enable the output end of the motor shaft to be in transmission connection with the middle shaft body, and the right shell and the machine shell partition plate are each provided with an installation site used for rotationally installing the transmission shaft. Assembly is carried out by taking the mounting site, used for rotationally mounting the middle shaft body, on the left shell, the mounting site, used for rotationally mounting the transmission shaft, on the machine shell partition plate and the mounting site, used for rotationally mounting the transmission shaft, on the right shell as positioning points, the assembly accuracy is improved, and assembly, overhaul and replacement are convenient and fast.

Description

Technical Field

[0001] This invention relates to the field of motor drive system technology, specifically to a modular mid-mounted motor structure and installation method for two-wheeled vehicles. Background Technology

[0002] Currently, mid-drive motors are mostly used in electric power assist systems for two-wheeled vehicles. As market demands increase, mid-drive motors in electric power assist systems for two-wheeled vehicles are developing towards modularity, integration, and lightweight design.

[0003] Chinese patent application CN120462569A discloses a mid-drive motor system and an electric-assisted bicycle, comprising: a torque sensor assembly, an output shaft assembly, a magnetic bracing assembly, a motor, and a controller; the motor gear shaft of the motor is connected to the output shaft assembly in pairs via double gears, and deceleration is performed on the output shaft assembly side; the output shaft assembly includes: a large gear, a one-way needle roller bearing, an output shaft, a third bearing, a ratchet, a pawl, a ratchet ring, and a tensioner; the torque sensor assembly is used to detect the torque of the mid-drive shaft, the magnetic bracing assembly is used to detect the rotational speed of the motor gear shaft, and the controller controls the output torque and rotational speed of the motor based on the detected torque and rotational speed.

[0004] Existing mid-drive motors employ a radial flux structure, where the flux path is distributed radially. This type of motor has the following limitations: 1. Torque density and power density are limited by rotor diameter, requiring increased volume to improve output, which makes it difficult to meet the requirements of lightweight design; 2. The motor drive system is an integral structure, which requires overall assembly, making maintenance and replacement inconvenient. Summary of the Invention

[0005] In view of the deficiencies in the prior art, the purpose of this invention is to provide a modular mid-mounted motor structure and installation method for two-wheeled vehicles.

[0006] According to the present invention, a modular mid-mounted motor structure for a two-wheeled vehicle includes a left housing, a right housing, a motor module, a transmission module, and a central axle module. The motor module is integrated and installed on the left housing, the central axle module is integrated and installed on the right housing, and the transmission module is integrated and installed in the space formed by the left housing and the right housing. The motor module includes a stator core, windings, magnets, a rotor support, a motor shaft, and a housing partition. The housing partition is fixedly connected to the left housing and forms a cavity to accommodate the stator core, windings, magnets, and rotor support. The stator core is fixedly installed on the inner wall of the left housing, and the stator teeth of the stator core are arranged axially. The windings are wound on the stator core. One end of the motor shaft is rotatably installed on the left housing, and the rotor support is fixedly installed on the motor shaft. The magnets are installed on the side wall of the rotor support opposite to the stator core, and the other end of the motor shaft extends out of the housing partition. The central axis module includes a central axis body, which is rotatably mounted on the right housing, and the left housing is provided with mounting points for rotatably mounting the central axis body. The transmission module includes a transmission shaft and a transmission gear set. The transmission shaft and the transmission gear set work together to connect the output end of the motor shaft to the central shaft body. The right housing and the housing partition are both provided with mounting points for rotating the transmission shaft.

[0007] Preferably, a mounting groove is formed on the inner wall of the left housing opposite to the housing partition, and the stator core is fixedly mounted on the inner wall of the left housing by interference fit with the mounting groove through the inner diameter and / or outer diameter.

[0008] Preferably, the transmission gear set includes a first gear and a gear output shaft, the first gear is coaxially fixedly mounted on the transmission shaft, and the first gear meshes with one end of the motor shaft that extends out of the housing partition; The gear output shaft is rotatably mounted on the right housing. The gear output shaft has a stepped surface for mounting bearings. The central shaft body is coaxially assembled with the gear output shaft via bearings. The central shaft body and the gear output shaft are fixedly or rotatably connected. The drive shaft also includes a gear shaft section, and the gear output shaft meshes with the gear shaft section of the drive shaft.

[0009] Preferably, a clutch is provided between the gear output shaft and the central shaft body.

[0010] Preferably, the gear output shaft is rotatably mounted on the right housing via a bearing.

[0011] Preferably, the central axis module further includes a sensor assembly and a positioning bushing. The sensor assembly is disposed on the central axis body, and the positioning bushing is coaxially sleeved on the outside of the sensor assembly, and the positioning bushing is positioned and assembled with the shaft segment of the central axis body.

[0012] Preferably, the mounting point on the left housing allows the central shaft body to be positioned and assembled via bearings; The mounting points on the right housing and housing partition allow the drive shaft to be positioned and assembled via bearings.

[0013] According to the present invention, a modular mid-mounted motor structure and installation method for a two-wheeled vehicle are provided. The installation method includes the following steps: The motor module is integrated and installed into the left housing, and the central shaft module is integrated and installed into the right housing; Install the transmission module onto the right housing or housing partition; Using the mounting points on the left housing for rotating the central shaft body, the mounting points on the housing partition for rotating the drive shaft, and the mounting points on the right housing for rotating the drive shaft as positioning points, the left and right housings are pressed into place and then fixedly connected using fasteners.

[0014] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention integrates the motor module on the left housing and the central shaft module on the right housing through modular design. This allows for separate processing followed by unified assembly. The assembly is performed using the mounting points on the left housing for rotating the central shaft body, the mounting points on the housing partition for rotating the drive shaft, and the mounting points on the right housing for rotating the drive shaft as positioning points. This improves the accuracy of assembly and makes assembly, maintenance, and replacement convenient.

[0015] 2. This invention forms an axial magnetic flux path by winding the windings around the stator teeth arranged axially around the stator core. Combined with a disc rotor, the torque density is greater than that of a radial flux motor of the same volume, which significantly improves the power density and torque density of the motor. This facilitates the miniaturization and lightweight design of the mid-drive motor and helps to reduce the axial volume of the mid-drive motor structure.

[0016] 3. Through the axial magnetic flux layout of this application, the overall structure of the motor is flat, and the space utilization rate inside the motor exceeds 75%, which significantly shortens the axial space of the motor and helps to improve the space utilization rate of the mid-mounted motor structure. Attached Figure Description

[0017] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a schematic diagram illustrating the overall structure of the motor, which is the main feature of this invention. Figure 2 This is an exploded view illustrating the overall structure of the motor, which is the main feature of this invention. Figure 3 This is an assembly diagram that mainly embodies the modular mid-drive motor structure of this invention.

[0018] The figure shows: 1. Right housing; 2. Left housing; 3. Stator core; 4. Winding; 5. Magnet; 6. Rotor support; 61. Rotor yoke; 62. Rotor fixing support; 7. Housing partition; 8. Central shaft body; 9. Motor shaft; 10. Drive shaft; 11. Mounting point; 12. First gear; 13. Gear output shaft; 14. Clutch; 15. Sensor assembly; 16. Positioning bushing. Detailed Implementation

[0019] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0020] like Figures 1 to 3 As shown, a modular mid-mounted motor structure for a two-wheeled vehicle provided by the present invention includes a left housing 2, a right housing 1, a motor module, a transmission module, and a central shaft module. The motor module is integrated and installed on the left housing 2, the central shaft module is integrated and installed on the right housing 1, and the transmission module is integrated and installed in the space formed by the left housing 2 and the right housing 1.

[0021] The motor module includes a stator core 3, windings 4, magnets 5, a rotor support 6, a motor shaft 9, and a housing partition 7. The housing partition 7 is fixedly connected to the left housing 2 and forms a cavity to accommodate the stator core 3, windings 4, magnets 5, and rotor support 6. The stator core 3 is fixedly installed on the inner wall of the left housing 2. The stator teeth of the stator core 3 are arranged axially. The windings 4 are wound on the stator core 3. One end of the motor shaft 9 is rotatably installed on the left housing 2. The rotor support 6 is fixedly installed on the motor shaft 9. The magnets 5 are installed on the side wall of the rotor support 6 opposite to the stator core 3. The other end of the motor shaft 9 extends out of the housing partition 7.

[0022] The central shaft module includes a central shaft body 8, which is rotatably mounted on the right housing 1. The left housing 2 has mounting points 11 for rotatably mounting the central shaft body 8. The transmission module includes a transmission shaft 10 and a transmission gear set. The transmission shaft 10 and the transmission gear set cooperate to drive the output end of the motor shaft 9 to the central shaft body 8. Mounting points 11 for rotatably mounting the transmission shaft 10 are provided on both the right housing 1 and the housing partition 7.

[0023] The technical solution of this application integrates the motor module on the left housing 2 and the central shaft module on the right housing 1 through modular design. This allows for separate processing followed by unified assembly. The mounting points 11 on the left housing 2 for rotating the central shaft body 8, the mounting points 11 on the housing partition 7 for rotating the drive shaft 10, and the mounting points 11 on the right housing 1 for rotating the drive shaft 10 are used as positioning points for assembly, which improves the accuracy of assembly and makes assembly, maintenance, and replacement convenient.

[0024] Specifically, the motor module of this application forms an axial magnetic flux path by winding the winding 4 around the stator teeth arranged axially around the stator core 3. Combined with a disc-type rotor, the torque density is greater than that of a radial flux motor of the same volume, significantly improving the power density and torque density of the motor, facilitating the miniaturization and lightweight design of mid-drive motors. Furthermore, the axial magnetic flux layout of this application results in a flat overall structure for the motor, with an internal space utilization rate exceeding 75%, significantly shortening the axial space of the motor.

[0025] One end of the motor shaft 9 is rotatably mounted on the inner wall of the left housing 2 via a bearing, and the middle section of the motor shaft 9 is rotatably engaged with the housing partition 7 via a bearing. The shaft section of the motor shaft 9 extending out of the housing includes a gear shaft structure, which is formed by hobbing the shaft end and is used for power output.

[0026] The left housing 2 forms a cavity to accommodate the stator core 3, winding 4, magnet 5, and rotor support 6. A housing partition 7 is fixedly installed at the opening of this cavity in the left housing 2. In one feasible embodiment, the connection structure between the housing partition 7 and the left housing 2 can be as follows: the left housing 2 has a mounting position at the opening of the cavity, and the housing partition 7 is fixedly installed at this mounting position using screws, bolts, or other fasteners. The housing partition 7 closes the opening of the cavity in the left housing 2 to form a motor structure.

[0027] More specifically, a mounting groove is formed on the inner wall of the left housing 2 opposite to the housing partition 7. The stator core 3 is fixedly mounted on the inner wall of the left housing 2 by interference fit with the mounting groove through its inner diameter and / or outer diameter. The stator core 3 is embedded and fixed in the inner wall of the left housing 2 by its dimensional design, without the need for other fixing structures and fasteners, which improves the utilization rate of the internal space of the motor and meets the development requirements of motor miniaturization and lightweighting. More specifically, the stator core 3 is made of integral SMC composite material or amorphous alloy powder sintering. The stator teeth of the stator core 3 are located on the side of the stator core 3 close to the rotor support 6, and the end of the stator core 3 away from the rotor support 6 is the mating part between the stator core 3 and the mounting groove. The stator assembly consists of the stator core 3 and the winding 4. After the stator assembly is installed in the left housing 2, it adopts an integral potting process to improve the heat dissipation of the motor.

[0028] Furthermore, multiple magnets 5 are fixedly installed on the sidewalls of the rotor support 6 opposite to the stator core 3 using adhesive, and the multiple stator cores 3 are arranged circumferentially along the rotor support 6. The magnets 5 are fan-shaped, and the outer arc of the magnets 5 coincides with the outer arc of the rotor support 6, which significantly improves the magnetic field strength of the motor rotor.

[0029] The rotor support 6 can be either an integral structure or a split structure. In one feasible embodiment, the integral structure of the rotor support 6 is made entirely of magnetically conductive material. In another feasible embodiment, the split structure of the rotor support 6 includes a rotor yoke 61 and a rotor fixing bracket 62, with the rotor yoke 61 coaxially fixedly mounted on the outer circumference of the rotor fixing bracket 62. The rotor yoke 61 and the stator core 3 are positioned opposite each other and have the same area, and magnets 5 are fixedly mounted on the sidewalls of the rotor yoke 61 opposite to the stator core 3.

[0030] In one feasible implementation, the transmission gear set includes a first gear 12 and a gear output shaft 13. The first gear 12 is coaxially fixedly mounted on the transmission shaft 10, and meshes with one end of the motor shaft 9 extending out of the housing partition 7. The gear output shaft 13 is rotatably mounted on the right housing 1 via bearings. The gear output shaft 13 has a stepped surface inside for mounting the bearings. The central shaft body 8 is coaxially assembled with the gear output shaft 13 via bearings, and the central shaft body 8 is fixedly or rotatably connected to the gear output shaft 13. The transmission shaft 10 also includes a gear shaft section, and the gear output shaft 13 meshes with the gear shaft section of the transmission shaft 10.

[0031] In one feasible embodiment, the gear output shaft 13 is rotatably mounted on the right housing 1 via a bearing, and a clutch 14 is provided between the gear output shaft 13 and the central shaft body 8. The clutch 14 enables a fixed connection or a rotatable connection between the central shaft body 8 and the gear output shaft 13.

[0032] The central axis module also includes a sensor assembly 15 and a positioning bushing 16. The sensor assembly 15 is mounted on the central axis body 8, and the positioning bushing 16 is coaxially sleeved on the outside of the sensor assembly 15, and the positioning bushing 16 is positioned and assembled with the shaft segment of the central axis body 8. It should be noted that the positioning bushing 16 can cooperate with the stepped structure provided on the central axis body 8 to realize the positioning and assembly of the central axis module on the right housing 1.

[0033] The mounting points 11 on the right housing 1 and the housing partition 7 allow the drive shaft 10 to be positioned and assembled via bearings. It should be noted that the assembly of the shaft and bearings in this application can both be achieved by press-fitting.

[0034] According to the present invention, a modular mid-mounted motor structure and installation method for a two-wheeled vehicle are provided. The installation method includes the following steps: The motor module is integrated and installed into the left housing 2, and the central shaft module is integrated and installed into the right housing 1.

[0035] Install the transmission module to the right housing 1 or the housing partition 7.

[0036] Using the mounting points 11 on the left housing 2 for rotating the central shaft body 8, the mounting points 11 on the housing partition 7 for rotating the drive shaft 10, and the mounting points 11 on the right housing 1 for rotating the drive shaft 10 as positioning points, the left housing 2 and the right housing 1 are pressed into place and then fixedly connected by fasteners.

[0037] It should be noted that the motor module, transmission module and central shaft module of the technical solution of this application can be determined during the design. The core of the technical solution of this application lies in the modular design concept and the compact layout of the central motor structure.

[0038] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0039] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A modular mid-mounted motor structure for a two-wheeled vehicle, characterized in that, It includes a left housing (2), a right housing (1), a motor module, a transmission module and a central shaft module. The motor module is integrated on the left housing (2), the central shaft module is integrated on the right housing (1), and the transmission module is integrated in the space formed by the left housing (2) and the right housing (1). The motor module includes a stator core (3), windings (4), magnets (5), a rotor support (6), a motor shaft (9), and a housing partition (7). The housing partition (7) is fixedly connected to the left housing (2) and forms a cavity to accommodate the stator core (3), windings (4), magnets (5), and rotor support (6). The stator core (3) is fixedly installed on the inner wall of the left housing (2). The stator teeth of the stator core (3) are arranged axially. The windings (4) are wound on the stator core (3). One end of the motor shaft (9) is rotatably installed on the left housing (2). The rotor support (6) is fixedly installed on the motor shaft (9). The magnets (5) are installed on the side wall of the rotor support (6) opposite to the stator core (3). The other end of the motor shaft (9) extends out of the housing partition (7). The central axis module includes a central axis body (8), which is rotatably mounted on the right housing (1), and the left housing (2) is provided with a mounting point (11) for rotatably mounting the central axis body (8). The transmission module includes a transmission shaft (10) and a transmission gear set. The transmission shaft (10) and the transmission gear set work together to drive the output end of the motor shaft (9) to the central shaft body (8). The right housing (1) and the housing partition (7) are both provided with mounting points (11) for rotating the transmission shaft (10).

2. The modular mid-mounted motor structure for two-wheeled vehicles as described in claim 1, characterized in that, The left housing (2) has an installation groove on its inner wall opposite to the housing partition (7). The stator core (3) is fixedly installed on the inner wall of the left housing (2) by interference fit with the installation groove through its inner diameter and / or outer diameter.

3. The modular mid-mounted motor structure for two-wheeled vehicles as described in claim 1, characterized in that, The transmission gear set includes a first gear (12) and a gear output shaft (13). The first gear (12) is coaxially fixed on the transmission shaft (10). The first gear (12) meshes with one end of the motor shaft (9) that extends out of the housing partition (7). The gear output shaft (13) is rotatably mounted on the right housing (1). The gear output shaft (13) has a stepped surface for mounting bearings. The central shaft body (8) is coaxially assembled with the gear output shaft (13) through bearings. The central shaft body (8) is fixedly connected or rotatably connected to the gear output shaft (13). The drive shaft (10) also includes a gear shaft section, and the gear output shaft (13) meshes with the gear shaft section of the drive shaft (10).

4. The modular mid-mounted motor structure for a two-wheeled vehicle as described in claim 3, characterized in that, A clutch (14) is provided between the gear output shaft (13) and the central shaft body (8).

5. The modular mid-mounted motor structure for a two-wheeled vehicle as described in claim 3, characterized in that, The gear output shaft (13) is rotatably mounted on the right housing (1) via a bearing.

6. The modular mid-mounted motor structure for a two-wheeled vehicle as described in claim 1, characterized in that, The central axis module also includes a sensor assembly (15) and a positioning bushing (16). The sensor assembly (15) is disposed on the central axis body (8), and the positioning bushing (16) is coaxially sleeved outside the sensor assembly (15), and the positioning bushing (16) is positioned and assembled with the shaft segment of the central axis body (8).

7. The modular mid-mounted motor structure for a two-wheeled vehicle as described in claim 1, characterized in that, The mounting point (11) on the left housing (2) allows the central shaft body (8) to be positioned and assembled via bearings; The mounting points (11) on the right housing (1) and housing partition (7) allow the drive shaft (10) to be positioned and assembled via bearings.

8. A method for installing a modular mid-mounted motor structure for a two-wheeled vehicle, characterized in that, The modular mid-mounted motor structure for a two-wheeled vehicle as described in any one of claims 1 to 7 is installed using the following steps: The motor module is integrated and installed into the left housing (2), and the central shaft module is integrated and installed into the right housing (1). Install the transmission module into the right housing (1) or the housing partition (7); Using the mounting points (11) on the left housing (2) for rotating the central shaft body (8), the mounting points (11) on the housing partition (7) for rotating the transmission shaft (10), and the mounting points (11) on the right housing (1) for rotating the transmission shaft (10) as positioning points, the left housing (2) and the right housing (1) are pressed into place and then fastened together with fasteners.

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