Single-stator double-rotor axial flux motor

Abstract

The application relates to a single-stator double-rotor axial flux motor, which comprises a stator assembly, coaxially arranged rotor assemblies arranged on the two sides of the stator assembly, an air gap between the stator assembly and the rotor assemblies, a rotor back plate provided with a rotor core in the rotor back plate, magnetic steel fixedly arranged on the side of the rotor back plate close to the stator assembly, one rotor back plate integrated with a rotating shaft coaxial with the rotor back plate and connected with another rotor back plate through the rotating shaft, a bearing arranged on the rotating shaft, one side of the bearing connected with the rotor back plate, the other side of the bearing connected with the stator assembly, a first gasket arranged between the bearing and the stator assembly, a second gasket arranged between the bearing and the rotor back plate, and the first gasket and the second gasket used for adjusting the size of the air gap.

Description

Technical Field

[0001] This application relates to the field of motor technology, specifically to a single-stator dual-rotor axial flux motor. Background Technology

[0002] Currently, axial flux motors, also known as disc motors, are suitable for drive or servo applications that require thin installation space due to their small axial dimensions, compact structure, high torque power density, and high efficiency. Therefore, axial flux motors are commonly used in electric vehicles, ship drives, wind power generation, mining, and other fields.

[0003] In related technologies, due to factors such as dimensional deviations and assembly tolerances in actual production, the air gap between the stator and rotor is uneven. When the axial flux motor is running, the rotational inertia is easily affected by the uneven air gap. The uneven air gap between the stator and rotor will aggravate the rotor's yaw, resulting in excessive motor vibration. In severe cases, stator rubbing may occur, affecting the safe operation of the motor.

[0004] Therefore, it is necessary to design a new single-stator dual-rotor axial flux motor to overcome the above problems. Summary of the Invention

[0005] This application provides a single-stator dual-rotor axial flux motor, which can solve the technical problem in related technologies where uneven air gap between the stator and rotor easily aggravates rotor sway, and in severe cases, stator rubbing occurs, affecting the safe operation of the motor.

[0006] In a first aspect, embodiments of this application provide a single-stator dual-rotor axial flux motor, comprising: a stator assembly, with rotor assemblies coaxially arranged on both sides of the stator assembly, an air gap between the stator assembly and the rotor assembly, the rotor assembly including a rotor back plate, a rotor core disposed within the rotor back plate, a magnet fixedly disposed on the side of the rotor back plate near the stator assembly, one rotor back plate integrally formed with a rotating shaft coaxial with itself, and connected to the other rotor back plate via the rotating shaft, wherein a bearing is sleeved on the rotating shaft, one side of the bearing is connected to the rotor back plate, the other side of the bearing is connected to the stator assembly, a first shim is disposed between the bearing and the stator assembly, and a second shim is disposed between the bearing and the rotor back plate, the first shim and the second shim being used to adjust the size of the air gap.

[0007] In conjunction with the first aspect, in one embodiment, the stator assembly includes a stator housing and a stator assembly, the stator assembly being installed within the stator housing, the air gap including a first air gap and a second air gap, one rotor assembly having a first air gap with the stator housing, and another rotor assembly having a second air gap with the stator housing, a bearing bushing being embedded within the stator housing, the bearing including a first bearing and a second bearing, the first bearing being provided on one side of the bearing bushing, and the second bearing being provided on the other side of the bearing bushing, a first shim being provided between the first bearing and the bearing bushing and between the second bearing and the bearing bushing, the first shim being used to adjust the size of the first air gap, and a second shim being provided between the second bearing and the rotor back plate, the second shim being used to adjust the size of the second air gap.

[0008] In conjunction with the first aspect, in one embodiment, the stator housing is made of carbon fiber, and the bearing bushing, the first gasket, and the second gasket are all made of stainless steel.

[0009] In conjunction with the first aspect, in one embodiment, the thickness of the first gasket... satisfy: , In the formula The thickness of the magnet. The thickness of the first air gap, This is the distance between the end face of the stator housing and the end face of the bearing bushing. The thickness is that of the first bearing.

[0010] In conjunction with the first aspect, in one embodiment, the thickness of the second gasket... satisfy: , In the formula The thickness of the magnet. The thickness of the first air gap, The thickness of the first bearing. This is the distance between the end face of the rotor back plate and the end face of the magnet. The thickness of the second air gap, The thickness of the stator housing. The thickness of the second bearing. For the thickness of the bearing bushing, The thickness of the first gasket.

[0011] In conjunction with the first aspect, in one embodiment, the magnet includes a plurality of fan-shaped magnet units and a bracket, the plurality of magnet units being mounted on the bracket, and the bracket being bolted to the rotor back plate.

[0012] In conjunction with the first aspect, in one embodiment, the support includes a plurality of main ribs radiating outward from the center, the ends of the main ribs are provided with first bolt holes, the outer periphery of the rotor back plate is provided with a plurality of second bolt holes, and the support is bolted to the rotor back plate by bolts passing through the first bolt holes and the second bolt holes.

[0013] In conjunction with the first aspect, in one embodiment, the rotor core includes a plurality of fan-shaped core units, each core unit having a core protrusion at the middle position of its two inclined sides, each core unit filling a groove in the rotor back plate, and each magnet unit being arranged between two adjacent core protrusions and bonded to the core unit.

[0014] In conjunction with the first aspect, in one embodiment, the end of the shaft is provided with a spline, which engages with a spline hole in another rotor back plate.

[0015] In conjunction with the first aspect, in one embodiment, the shaft is pressed against another rotor back plate by a lock nut.

[0016] The beneficial effects of the technical solutions provided in this application include: By setting a first shim between the bearing and the stator assembly, and a second shim between the bearing and the rotor back plate, the size of the air gap between the stator assembly and the two rotor assemblies is adjusted, ensuring the uniformity and symmetry of the air gap on both sides. This solves the technical problem in related technologies where uneven air gap between the stator and rotor easily aggravates rotor wobble, and in severe cases, stator rubbing occurs, affecting the safe operation of the motor. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 An exploded view of a single-stator dual-rotor axial flux motor provided in an embodiment of this application; Figure 2 A schematic diagram of a single-stator dual-rotor axial flux motor provided in this application embodiment; Figure 3 A cross-sectional view of a single-stator dual-rotor axial flux motor provided in an embodiment of this application; Figure 4 for Figure 3 A magnified view of a section at point A in the middle; Figure 5A schematic diagram illustrating the principle of calculating the thickness of the first gasket and the second gasket, provided for embodiments of this application.

[0019] In the diagram: 1. Stator assembly; 11. Stator housing; 12. Stator assembly; 2. Rotor assembly; 21. Rotor back plate; 22. Rotor core; 221. Core unit; 222. Core rib; 23. Magnet; 231. Magnet unit; 232. Bracket; 3. Shaft; 31. Spline; 4. First gasket; 5. Second gasket; 6. First air gap; 7. Second air gap; 8. Bearing bushing; 9. First bearing; 10. Second bearing. Detailed Implementation

[0020] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present application.

[0021] This application provides a single-stator dual-rotor axial flux motor, which can solve the technical problem that uneven air gap between the stator and rotor can easily aggravate rotor sway, and in severe cases, cause rotor rubbing, affecting the safe operation of the motor.

[0022] See Figure 1-4 As shown in the figure, this application provides a single-stator dual-rotor axial flux motor, which includes: a stator assembly 1, and a rotor assembly 2 coaxially arranged on both sides of the stator assembly 1. An air gap exists between the stator assembly 1 and the rotor assembly 2. The rotor assembly 2 includes a rotor back plate 21, and a rotor core 22 is provided inside the rotor back plate 21. A magnet 23 is fixed on the side of the rotor back plate 21 near the stator assembly 1. One rotor back plate 21 is integrally formed with a rotating shaft 3 coaxial with itself and is connected to the other rotor back plate 21 through the rotating shaft 3. A bearing is sleeved on the rotating shaft 3. One side of the bearing is connected to the rotor back plate 21, and the other side of the bearing is connected to the stator assembly 1. A first shim 4 is provided between the bearing and the stator assembly 1, and a second shim 5 is provided between the bearing and the rotor back plate 21. The first shim 4 and the second shim 5 are used to adjust the size of the air gap.

[0023] In this embodiment, preferably, the single-stator dual-rotor axial flux motor adopts a 10-pole, 12-slot pole-slot mating structure. The rotating shaft 3 is integrally formed with the left rotor back plate 21. Using the left rotor back plate 21 as the assembly reference, the rotor core 22, the magnet 23, the left bearing, the stator assembly 1, and the right bearing are assembled in sequence. Then, the right rotor assembly 2 is symmetrically arranged on one side of the stator assembly 1. The first shim 4 is located at the connection between the left bearing and the stator assembly 1 and the right bearing and the stator assembly 1. The second shim 5 is located at the connection between the right bearing and the right rotor assembly 2. The first shim 4 and the second shim 5 are used to adjust the size of the air gap between the stator assembly 1 and the two rotor assemblies 2. The size of the air gap is changed by adjusting the thickness of the first shim 4 and the second shim 5. The operation is convenient and highly implementable, and the single-stator dual-rotor axial flux motor does not need to be frequently disassembled and reassembled.

[0024] This embodiment solves the technical problem in related technologies that uneven air gaps between the stator and rotor can easily aggravate rotor sway, and in severe cases, cause stator rubbing, affecting the safe operation of the motor. By setting the first shim 4 between the bearing and the stator assembly 1 and the second shim 5 between the bearing and the rotor back plate 21, the size of the air gap between the stator assembly 1 and the two rotor assemblies 2 on both sides can be adjusted to ensure the uniformity and symmetry of the air gap on both sides.

[0025] Further, see Figure 1-4 As shown, in some embodiments, the stator assembly 1 includes a stator housing 11 and a stator assembly 12. The stator assembly 12 is installed inside the stator housing 11. The air gap includes a first air gap 6 and a second air gap 7. One rotor assembly 2 has a first air gap 6 with the stator housing 11, and another rotor assembly 2 has a second air gap 7 with the stator housing 11. A bearing bushing 8 is embedded in the stator housing 11. The bearing includes a first bearing 9 and a second bearing 10. The first bearing 9 is provided on one side of the bearing bushing 8, and the second bearing 10 is provided on the other side. A first shim 4 is provided between the first bearing 9 and the bearing bushing 8, and between the second bearing 10 and the bearing bushing 8. The first shim 4 is used to adjust the size of the first air gap 6. A second shim 5 is provided between the second bearing 10 and the rotor back plate 21. The second shim 5 is used to adjust the size of the second air gap 7.

[0026] In this embodiment, the first shim 4 on the left is used to adjust the size of the first air gap 6, and the first shim 4 on the right is used to adjust the positioning of the stator assembly 1 between the two rotor assemblies 2 and the compensation of the axial position. The first shim 4 on the right will indirectly affect the size of the second air gap 7, and the second shim 5 is used to adjust the size of the second air gap 7.

[0027] Further, see Figure 1 and Figure 4 As shown, in some embodiments, the stator housing 11 is made of carbon fiber, and the bearing bushing 8, the first gasket 4 and the second gasket 5 are all made of stainless steel.

[0028] Further, see Figure 3-5 As shown, in some embodiments, the thickness of the first gasket 4 is... satisfy: , In the formula The thickness of magnet 23, The thickness of the first air gap 6, This is the distance between the end face of the stator housing 11 and the end face of the bearing bushing 8. The thickness of the first bearing 9.

[0029] In this embodiment, the thickness of the first gasket 4 is calculated using the dimensional chain between the first bearing 9 and the stator assembly 1, wherein the thickness of the first gasket 4 is related to the first air gap 6. Exemplarily, the thickness of the magnet 23... Set to 9 cm, the thickness of the first air gap is 6. The distance between the end face of the stator housing 11 and the end face of the bearing bushing 8 is set to 1.3 cm. The thickness of the first bearing 9 is set to 6.1 cm. The thickness was set to 14.97 cm, and the thickness of the first gasket 4 was calculated. The final thickness of the first shim 4 is 1.43 cm, taking axial clearance into account. Set to 1.53 cm.

[0030] Further, see Figure 3-5 As shown, in some embodiments, the thickness of the second gasket 5 is... satisfy: , In the formula The thickness of magnet 23, The thickness of the first air gap 6, The thickness of the first bearing 9, This is the distance between the end face of the rotor back plate 21 and the end face of the magnet 23. The thickness of the second air gap 7 The thickness of the stator housing 11, The thickness of the second bearing 10, The thickness of bearing bushing 8, The thickness of the first gasket 4.

[0031] In this embodiment, the thickness of the second shim 5 is calculated using the dimensional chain between the second bearing 10 and the rotor back plate 21. The thickness of the second shim 5 is related to the thickness of the second air gap 7 and the thickness of the first shim 4. Exemplarily, the thickness of the magnet 23... Set to 9 cm, the thickness of the first air gap is 6. The thickness of the first bearing 9 is set to 1.3 cm. The distance between the end face of the rotor back plate 21 and the end face of the magnet 23 is set to 14.97 cm. The thickness of the second air gap 7 is set to 10 cm. The thickness of the stator housing 11 is set to 1.3 cm. The thickness of the second bearing 10 is set to 52.56 cm. The thickness of bearing bushing 8 is set to 14.97 cm. The thickness of the first gasket 4 is set to 40 cm. The thickness of the second gasket 5 is calculated by setting it to 1.53 cm. The final thickness of the second shim 5 is 1.16 cm, taking axial clearance into account. Set to 1.26 cm.

[0032] Further, see Figure 1 As shown, in some embodiments, the magnet 23 includes a plurality of annular magnet units 231 and a bracket 232, the plurality of magnet units 231 being mounted on the bracket 232, and the bracket 232 being bolted to the rotor back plate 21.

[0033] In this embodiment, the bracket 232 is bolted to the rotor back plate 21, so that the multiple magnet units 231 and the rotor core 22 are axially pressed onto the rotor back plate 21, preventing the magnets 23 and the rotor core 22 from axially separating from the rotor back plate 21 when rotating at high speed, thus forming a stable structure. Exemplarily, ten magnet units 231 are evenly distributed around the circumference of the bracket 232.

[0034] Further, see Figure 1 As shown, in some embodiments, the support 232 includes a plurality of main ribs radiating outward from the center, the ends of the main ribs are provided with first bolt holes, the outer periphery of the rotor back plate 21 is provided with a plurality of second bolt holes, and the support 232 is bolted to the rotor back plate 21 by bolts passing through the first bolt holes and the second bolt holes.

[0035] In this embodiment, multiple main ribs are arranged at equal angular intervals along the axis of the support 232, and a magnetic steel unit 231 accommodating space is formed between two adjacent main ribs. Multiple first bolt holes are evenly distributed on the outer periphery of the support 232. The rotor back plate 21 is configured as a disc, and multiple second bolt holes are evenly distributed on the outer periphery of the rotor back plate 21. Exemplarily, the number of first bolt holes and second bolt holes are both set to ten. The rotor back plate 21 is circumferentially pressed against the rotor core 22 by bolts passing through the first bolt holes and the second bolt holes.

[0036] Further, see Figure 1 As shown, in some embodiments, the rotor core 22 includes a plurality of fan-shaped core units 221. Each core unit 221 has a core protrusion 222 at the middle position of its two inclined sides. Each core unit 221 fills the groove of the rotor back plate 21. Each magnet unit 231 is arranged between two adjacent core protrusions 222 and is bonded to the core unit 221.

[0037] In this embodiment, the rotor back plate 21 is provided with a fan-ring limiting groove to ensure that the iron core unit 221 will not undergo tangential displacement within the fan-ring limiting groove. The thickness of the iron core unit 221 and the thickness of the rotor back plate 21 are reasonably optimized to ensure the supporting strength of the rotor back plate 21 while reducing the eddy current loss of the rotor back plate 21. Adjacent iron core units 221 are spaced apart. The side of the iron core unit 221 near the magnet unit is provided with an iron core protrusion 222 to limit the circumferential movement of the magnet unit 231. At the same time, the two adjacent iron core protrusions 222 form a tangential limiting on the magnet unit 231, forming a stable structure. Exemplarily, ten iron core units 221 are evenly distributed around the circumference of the rotor iron core 22, and ten magnet units 231 are segmentally bonded between two adjacent iron core protrusions 222.

[0038] Further, see Figure 1 As shown, in some embodiments, the end of the rotating shaft 3 is provided with a spline 31, which is bonded to the spline hole of another rotor back plate 21.

[0039] In this embodiment, the axis of the spline 31 coincides with the axis of the spline hole, and one rotor back plate 21 is splined with another rotor back plate 21 through the spline 31, which effectively reduces the radial space occupation while ensuring the same torque transmission capability.

[0040] Further, see Figure 1-3 As shown, in some embodiments, the rotating shaft 3 is pressed against another rotor back plate 21 by a lock nut.

[0041] In this embodiment, the rotor back plate 21 and the rotating shaft 3 are axially locked by the locking nut to ensure the assembly strength of the single stator dual rotor axial flux motor and guarantee the stability of the entire structure.

[0042] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and 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, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0043] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0044] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A single stator double rotor axial flux motor, characterized by, It includes: A stator assembly (1) is provided with a rotor assembly (2) coaxially arranged on both sides of the stator assembly (1), and an air gap is provided between the stator assembly (1) and the rotor assembly (2). The rotor assembly (2) includes a rotor back plate (21), a rotor core (22) is provided inside the rotor back plate (21), and a magnet (23) is fixed on the side of the rotor back plate (21) near the stator assembly (1). One rotor back plate (21) is integrally formed with a rotating shaft (3) coaxial with itself, and is connected to the other rotor back plate (21) through the rotating shaft (3). The rotating shaft (3) is fitted with a bearing. One side of the bearing is connected to the rotor back plate (21), and the other side of the bearing is connected to the stator assembly (1). A first shim (4) is provided between the bearing and the stator assembly (1), and a second shim (5) is provided between the bearing and the rotor back plate (21). The first shim (4) and the second shim (5) are used to adjust the size of the air gap. The stator assembly (1) includes a stator housing (11) and a stator assembly (12), the stator assembly (12) being installed inside the stator housing (11), the air gap including a first air gap (6) and a second air gap (7), one rotor assembly (2) having a first air gap (6) between it and the stator housing (11), and the other rotor assembly (2) having a second air gap (7) between it and the stator housing (11). The stator housing (11) is fitted with a bearing bushing (8). The bearing includes a first bearing (9) and a second bearing (10). The first bearing (9) is provided on one side of the bearing bushing (8), and the second bearing (10) is provided on the other side of the bearing bushing (8). A first shim (4) is provided between the first bearing (9) and the bearing bushing (8) and between the second bearing (10) and the bearing bushing (8). The first shim (4) is used to adjust the size of the first air gap (6). The second shim (5) is provided between the second bearing (10) and the rotor back plate (21), and the second shim (5) is used to adjust the size of the second air gap (7).

2. The single-stator dual-rotor axial flux electric motor of claim 1, wherein, The stator housing (11) is made of carbon fiber, and the bearing bushing (8), the first gasket (4) and the second gasket (5) are all made of stainless steel.

3. The single-stator dual-rotor axial flux motor as described in claim 1, characterized in that, Thickness of the first gasket satisfy: , In the formula The thickness of the magnet. The thickness of the first air gap, This is the distance between the end face of the stator housing and the end face of the bearing bushing. The thickness is that of the first bearing.

4. The single-stator dual-rotor axial flux motor as described in claim 3, characterized in that, The thickness of the second gasket satisfy: , In the formula The thickness of the magnet. The thickness of the first air gap, The thickness of the first bearing. This is the distance between the end face of the rotor back plate and the end face of the magnet. The thickness of the second air gap, The thickness of the stator housing. The thickness of the second bearing. For the thickness of the bearing bushing, The thickness of the first gasket.

5. The single-stator dual-rotor axial flux motor as described in claim 1, characterized in that, The magnet (23) includes multiple annular magnet units (231) and a bracket (232). The multiple magnet units (231) are mounted on the bracket (232), and the bracket (232) is bolted to the rotor back plate (21).

6. The single-stator dual-rotor axial flux motor as described in claim 5, characterized in that, The bracket (232) includes a plurality of main ribs radiating outward from the center. The ends of the main ribs are provided with first bolt holes. The outer periphery of the rotor back plate (21) is provided with a plurality of second bolt holes. The bracket (232) is bolted to the rotor back plate (21) by bolts passing through the first bolt holes and the second bolt holes.

7. The single-stator dual-rotor axial flux motor as described in claim 5, characterized in that, The rotor core (22) includes multiple fan-shaped core units (221). Each core unit (221) has a core protrusion (222) at the middle position of its two inclined sides. Each core unit (221) fills the groove of the rotor back plate (21). Each magnet unit (231) is arranged between two adjacent core protrusions (222) and is bonded to the core unit (221).

8. The single-stator dual-rotor axial flux motor as described in claim 1, characterized in that, The end of the shaft (3) is provided with a spline (31), which is bonded to the spline hole of another rotor back plate (21).

9. The single-stator dual-rotor axial flux motor as described in claim 1, characterized in that, The shaft (3) is pressed against another rotor back plate (21) by a lock nut.

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