An axial flux motor

Abstract

The application relates to the technical field of electric machines, in particular to an axial flux motor. The axial flux motor comprises an output shaft, a stator and an adjusting mechanism, the stator comprises a plurality of iron cores, an installation channel is formed in the middle of each iron core, and the installation channel is filled with cooling liquid. The adjusting mechanism comprises a plurality of adjusting components, and each adjusting component comprises a heat equalizing ring. The heat equalizing ring is used for contacting the iron core to enhance the heat dissipation effect of the iron core. A silk screen is arranged in the heat equalizing ring, and the heat equalizing ring is filled with working liquid. The overall density of the heat equalizing ring is smaller than the density of the cooling liquid. When the output shaft is vertically arranged, the heat equalizing ring increases the contact area between the heat equalizing ring and the upper part of the iron core through floating, so as to compensate the influence of gravity on the capillary effect and realize uniform heat dissipation of the upper part and the lower part of the iron core. The axial flux motor is provided to solve the problems of low heat dissipation efficiency and uneven heat dissipation of the existing axial flux motor.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and more specifically to an axial flux motor. Background Technology

[0002] An axial flux motor is a rotary motor in which the magnetic field direction is parallel to the axis of the motor shaft. Unlike traditional radial flux motors, where the magnetic field passes through the air gap radially, the stator and rotor discs of an axial flux motor are arranged axially, and the magnetic lines of force pass through the thin, disc-shaped air gap axially. This unique magnetic circuit topology makes it flat in shape, with significant advantages such as short axial length and compact structure.

[0003] These motors are primarily used in applications requiring high power density, high torque density, and limited axial installation space. Thanks to their flat structure and excellent flux utilization, axial flux motors demonstrate significant application potential in electric vehicle drives, hybrid power systems, wind power direct-drive generation, aerospace, and high-performance industrial servo systems. Their design is particularly well-suited for advanced configurations such as in-wheel motor drives and integrated drive units, contributing to improved efficiency and power density of the entire drive system.

[0004] For example, the invention patent application CN120281125A discloses an axial flux motor in which the heat generated by the iron core is transferred to the stator support through a thermally conductive insulating layer and a potting compound with high thermal conductivity via contact heat exchange, thereby achieving convective heat exchange with the external air. However, in this method, heat must pass through multiple interfaces and materials sequentially, with each layer introducing significant thermal resistance, resulting in low overall heat transfer efficiency and difficulty in quickly dissipating the large amount of heat generated under high power density. The potting compound not only has limited thermal conductivity, but its coverage also increases the heat capacity of the stator and may hinder internal airflow, causing heat to easily accumulate in the iron core and winding areas. This heat storage effect will lead to an increase in the internal temperature of the motor, making it difficult to achieve uniform heat dissipation, and posing a risk of localized overheating in critical components such as the windings, thus affecting insulation life and magnetic material performance. Summary of the Invention

[0005] This invention provides an axial flux motor to solve the problems of low heat dissipation efficiency and uneven heat dissipation in existing axial flux motors.

[0006] The present invention provides an axial flux motor with the following technical solution: An axial flux motor includes a housing, an output shaft, a stator, an adjusting mechanism, and two rotors. The output shaft is rotatably disposed within the housing. The rotors and the output shaft are fixedly connected, and the two rotors are spaced apart along the axial direction of the output shaft.

[0007] The stator is positioned between two rotors and comprises multiple iron cores circumferentially distributed along the output shaft. Each iron core has a mounting channel in its center, containing coolant. A baffle is installed within the mounting channel, dividing it into inlet and outlet channels circumferentially distributed along the output shaft. The baffle comprises multiple radially distributed dividing plates along the output shaft, with adjacent dividing plates forming a connecting channel that connects the inlet and outlet channels.

[0008] The regulating mechanism includes multiple regulating components, each disposed within a communicating channel. Each regulating component includes a heat-spreading ring, the axial direction of which is radially aligned with the output shaft. The heat-spreading ring can rotate about its own axis and move axially along the output shaft. The heat-spreading ring is used to contact the iron core to achieve a cooling effect on the iron core. A wire mesh is installed inside the heat-spreading ring, and its interior is filled with a working fluid, which circulates within the heat-spreading ring under capillary action. The overall density of the heat-spreading ring is less than the density of the coolant.

[0009] When the output shaft is set vertically, the heat dissipation ring increases its contact area with the upper part of the iron core by floating upwards, so as to compensate for the effect of gravity on capillary action.

[0010] Furthermore, the iron core comprises multiple iron plates, which are distributed sequentially along the radial direction of the output shaft.

[0011] Furthermore, along the direction that gradually moves away from the output shaft, the length of multiple iron plates along the tangential direction of the output shaft gradually increases, and the diameter of multiple heat dissipation rings gradually increases to adapt to the shape of the iron plates.

[0012] Furthermore, each iron sheet includes a first plate, a second plate, and an intermediate plate. The first and second plates are distributed sequentially along the axial direction of the output shaft, and the intermediate plate connects the first and second plates. When the output shaft is vertically positioned, the first plate is located above the second plate. Each iron core has two coils, both wound around the entire iron core composed of multiple stacked iron sheets. The two coils are located between the first plate and the intermediate plate, and between the second plate and the intermediate plate, respectively.

[0013] Furthermore, the adjustment mechanism also includes a rotating rod, which is arranged radially along the output shaft. Each rotating rod is located in a mounting channel and is situated in the center of the intermediate plate. Multiple heat-spreading rings in each mounting channel are rotatably mounted on a rotating rod.

[0014] Furthermore, each adjustment component also includes a soft washer, which is coaxially arranged with the heat-spreading ring and located inside the heat-spreading ring. The soft washer is used to abut against the rotating rod and is capable of deformation.

[0015] Furthermore, each rotor includes multiple magnetic blocks, which are sequentially distributed along the circumference of the output shaft. Within the same rotor, adjacent magnetic blocks have opposite magnetic properties. The magnetic blocks of the two rotors are staggered, such that any magnetic block in one rotor corresponds circumferentially to the position between two adjacent magnetic blocks in the other rotor.

[0016] Furthermore, the outer casing is equipped with an inlet pipe, an outlet pipe, and a water pump. The inlet pipe is connected to multiple inlet channels, and the outlet pipe is connected to multiple outlet channels. The water pump is used to pump coolant into the inlet channels.

[0017] Furthermore, an axial flux motor also includes a drive mechanism, which includes a three-phase power supply connected to the stator to supply power to the stator to drive the rotor to rotate. The stator can drive the rotor to rotate after being energized.

[0018] Furthermore, the drive mechanism also includes two end caps, which are disposed within the housing, with each end cap located on the side of one rotor away from the other rotor.

[0019] The beneficial effects of this invention are as follows: In an axial flux motor, the cooling ring of this invention contacts the iron core through an adjustment mechanism, thereby enhancing the heat dissipation effect on the iron core. When the output shaft is in the vertical direction, the working fluid inside the cooling ring is affected by gravity, resulting in a greater capillary effect at the lower part of the cooling ring than at the upper part. Since the overall density of the cooling ring is less than that of the coolant, the cooling ring floats upwards under buoyancy, causing the contact area between the cooling ring and the upper part of the iron core to be greater than the contact area between the cooling ring and the lower part of the iron core. This makes the heat dissipation effect of the cooling ring on the upper and lower parts of the iron core more consistent.

[0020] Furthermore, after the vapor chamber ring floats to the top, the coolant flows over its lower part, generating a rotational torque that causes the vapor chamber ring to rotate. This rotation continuously renews the contact area between the vapor chamber ring and the upper and lower parts of the core, further ensuring the uniformity of heat dissipation. Simultaneously, under the action of centrifugal force, the overall capillary action strength within the vapor chamber ring is enhanced, further improving heat dissipation efficiency. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of an axial flux motor provided in an embodiment of the present invention;

[0023] Figure 2 A cross-sectional view of an axial flux motor provided in an embodiment of the present invention;

[0024] Figure 3 for Figure 2 Enlarged view of point C in the middle;

[0025] Figure 4 A schematic diagram of the core structure of an axial flux motor provided in an embodiment of the present invention;

[0026] Figure 5 A cross-sectional view of the core of an axial flux motor provided in an embodiment of the present invention;

[0027] Figure 6 for Figure 5 Enlarged view of point D in the middle;

[0028] Figure 7 for Figure 5 Sectional view along the middle AA direction;

[0029] Figure 8 for Figure 5 Sectional view along the BB direction;

[0030] Figure 9 An exploded view of the core of an axial flux motor provided in an embodiment of the present invention;

[0031] Figure 10 This is a schematic diagram of the rotor and output shaft of an axial flux motor provided in an embodiment of the present invention;

[0032] Figure 11 This is a front view of the rotor and output shaft of an axial flux motor provided in an embodiment of the present invention.

[0033] In the diagram: 101, end cap; 102, outer casing; 104, output shaft; 105, three-phase power supply; 106, magnetic block; 108, inlet pipe; 109, outlet pipe; 200, iron core; 201, coil; 212, dividing plate; 213, heat-spreading ring; 214, soft washer; 215, rotating rod; 216, inlet channel; 217, connecting channel; 218, outlet channel; 220, arc groove. Detailed Implementation

[0034] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Reference Figures 1 to 11As shown, an axial flux motor provided in this embodiment of the invention includes a housing 102, an output shaft 104, a stator, an adjustment mechanism, and two rotors. The output shaft 104 is rotatably disposed within the housing 102. The rotors and the output shaft 104 are fixedly connected, and the two rotors are spaced apart along the axial direction of the output shaft 104.

[0036] A stator is disposed between two rotors and includes multiple iron cores 200 distributed circumferentially along the output shaft 104. Each iron core 200 has a mounting channel in its center, and the mounting channel contains coolant. A baffle is provided in the mounting channel, which divides the mounting channel into a coolant inlet channel 216 and a coolant outlet channel 218 distributed circumferentially along the output shaft 104. The baffle includes multiple partition plates 212 distributed radially along the output shaft 104, and a connecting channel 217 is formed between two adjacent partition plates 212, which connects the coolant inlet channel 216 and the coolant outlet channel 218.

[0037] The regulating mechanism includes multiple regulating components, each disposed within a communicating channel 217. Each regulating component includes a heat-spreading ring 213, the axial direction of which is radially arranged along the output shaft 104. The heat-spreading ring 213 can rotate about its own axial direction and move along the axial direction of the output shaft 104. The heat-spreading ring 213 is used to contact the iron core 200 to achieve a cooling effect on the iron core 200. A wire mesh is disposed inside the heat-spreading ring 213, and its interior is filled with a working fluid. The working fluid circulates within the heat-spreading ring 213 under capillary action. The area where the heat-spreading ring 213 contacts the iron core 200 along the output shaft 104 constitutes the evaporation end, and the middle part of the heat-spreading ring 213 is the condensation end. After absorbing heat at the evaporation end, the working fluid vaporizes. The vapor flows to the condensation end through the pressure difference within the heat-spreading ring 213, condenses into liquid upon contact with the condenser, and releases latent heat. The liquid then returns to the evaporation end through capillary force, forming a closed-loop circulation. The overall density of the heat-spreading ring 213 is less than that of the coolant, so that the heat-spreading ring 213 can float in the coolant.

[0038] When the output shaft 104 is in a vertical direction, the working fluid inside the heat exchange ring 213 is affected by gravity, and the intensity of capillary action at the lower part of the heat exchange ring 213 is greater than that at the upper part. Since the overall density of the heat exchange ring 213 is less than that of the coolant, the heat exchange ring 213 floats upward under the action of buoyancy. This results in the contact area between the heat exchange ring 213 and the upper part of the iron core 200 being greater than the contact area between the heat exchange ring 213 and the lower part of the iron core 200. Consequently, the heat dissipation effect of the heat exchange ring 213 on the upper and lower parts of the iron core 200 tends to be consistent.

[0039] Furthermore, after the heat spreader ring 213 floats to the surface, the coolant flows over its lower part, generating a rotational torque that causes it to rotate. This rotation continuously refreshes the contact area between the heat spreader ring 213 and the upper and lower parts of the iron core 200, further ensuring uniform heat dissipation. Simultaneously, under centrifugal force, the overall capillary action intensity within the heat spreader ring 213 is enhanced, further improving heat dissipation efficiency.

[0040] In this embodiment, the iron core 200 includes multiple iron plates, which are distributed sequentially along the radial direction of the output shaft 104. The iron plates are insulated from each other, thereby reducing eddy current losses.

[0041] In this embodiment, along the direction gradually moving away from the output shaft 104, the length of multiple iron plates along the tangential direction of the output shaft 104 gradually increases, and the diameter of multiple heat dissipation rings 213 gradually increases to adapt to the shape of the iron plates, thereby making the heat dissipation of the coolant to the iron core 200 more uniform.

[0042] In this embodiment, each iron sheet includes a first plate, a second plate, and an intermediate plate. The first plate and the second plate are distributed sequentially along the axial direction of the output shaft 104, and the intermediate plate connects the first plate and the second plate. When the output shaft 104 is vertically arranged, the first plate is above the second plate. Each iron core 200 is provided with two coils 201. The two coils 201 on each iron core 200 are wound on the entire iron core 200 composed of multiple iron sheets stacked together. The two coils 201 are respectively located between the first plate and the intermediate plate, and between the second plate and the intermediate plate.

[0043] The installation channel is located within the intermediate plate. The first plate and the second plate are respectively provided with concave-facing arc grooves 220. Both arc grooves 220 are connected to the connecting channel 217. The heat dissipation ring 213 is located within the two arc grooves 220. The two arc grooves 220 are used to restrict the movement of the heat dissipation ring 213 in a direction perpendicular to the axial direction of the output shaft 104.

[0044] In this embodiment, the adjustment mechanism further includes a rotating rod 215, which is arranged radially along the output shaft 104. Each rotating rod 215 is disposed in an installation channel and is located in the middle of the intermediate plate. Multiple heat-spreading rings 213 in each installation channel are rotatably disposed on a rotating rod 215.

[0045] In this embodiment, each adjustment component further includes a soft washer 214, which is coaxially arranged with the heat-spreading ring 213 and located inside the heat-spreading ring 213. The soft washer 214 is used to abut against the rotating rod 215 and is capable of deformation.

[0046] In this embodiment, each rotor includes a plurality of magnetic blocks 106, which are sequentially distributed along the circumference of the output shaft 104. Within the same rotor, adjacent magnetic blocks 106 have opposite magnetic properties. The magnetic blocks 106 of the two rotors are staggered, such that any magnetic block 106 in one rotor corresponds circumferentially to a position between two adjacent magnetic blocks 106 in the other rotor.

[0047] The magnetic force between each iron core 200 and a magnetic block 106 is greatest when they are directly opposite each other. However, when the iron core 200 is positioned between two adjacent magnetic blocks 106, the force is significantly reduced. This results in noticeable torque pulsations during rotor rotation, especially at low speeds. Therefore, the design ensures that the positions of the magnetic blocks 106 in one rotor correspond to those of adjacent magnetic blocks 106 in another rotor. This makes the stator forces acting on the iron core 200 at different positions roughly balanced, effectively reducing the jerking sensation during rotor rotation and achieving smooth operation.

[0048] In this embodiment, the housing 102 is provided with an inlet pipe 108, an outlet pipe 109, and a water pump. The inlet pipe 108 is connected to multiple inlet channels 216, and the outlet pipe 109 is connected to multiple outlet channels 218. The water pump is used to pump coolant into the inlet channels 216.

[0049] In this embodiment, an axial flux motor further includes a drive mechanism, which includes a three-phase power supply 105. The three-phase power supply 105 is connected to the stator and is used to supply power to the stator. After the stator is energized, it can drive the rotor to rotate.

[0050] In this embodiment, the drive mechanism further includes two end caps 101, which are disposed inside the housing 102, and each end cap 101 is disposed on the side of one rotor away from the other rotor.

[0051] Working process: In the initial state, supported by the soft washer 214, the heat dissipation ring 213 and the output shaft 104 are coaxially positioned. The heat dissipation ring 213 is in contact with both the first plate and the second plate simultaneously, and the contact areas are equal.

[0052] When the three-phase power supply 105 is started, the stator is energized and drives the rotor to rotate. The rotor drives the output shaft 104 to rotate, and an axial flux motor starts to work.

[0053] After the water pump is started, the coolant is pumped into the inlet channel 216, then through the connecting channel 217 into the outlet channel 218, and finally into the outlet pipe 109. The coolant in the inlet channel 216 and the outlet channel 218 mainly cools the middle plate and the middle part of the heat exchanger ring 213. The heat exchanger ring 213 keeps in contact with the first plate and the second plate. The working fluid inside it absorbs heat at the evaporation end (the part in contact with the heat source) and then vaporizes. The vapor flows to the condensation end under the action of pressure difference, condenses into liquid upon contact with the condenser and releases latent heat. The liquid then returns to the evaporation end by capillary action, forming a closed loop, thereby achieving uniform cooling of the first plate and the second plate, and further improving the overall heat dissipation uniformity of all iron cores 200.

[0054] The cooling efficiency of the heat exchanger ring 213 depends on its contact area with the first plate and the second plate, as well as the intensity of the internal capillary action.

[0055] When the output shaft 104 is in a vertical direction, the working fluid inside the heat exchange ring 213 is affected by gravity, and the intensity of capillary action at the lower part of the heat exchange ring 213 is greater than that at the upper part. Since the overall density of the heat exchange ring 213 is less than that of the coolant, the heat exchange ring 213 floats upward under the action of buoyancy, causing the soft gasket 214 to deform. This results in the contact area between the heat exchange ring 213 and the first plate being greater than the contact area between the heat exchange ring 213 and the second plate, thereby making the heat dissipation effect of the heat exchange ring 213 on the first and second plates more consistent.

[0056] Furthermore, after the heat spreader ring 213 floats to the surface, the coolant flows over its lower part, generating a rotational torque that causes it to rotate. This rotation continuously refreshes the contact area between the heat spreader ring 213 and the first and second plates, further ensuring uniform heat dissipation. Simultaneously, under centrifugal force, the overall capillary action intensity within the heat spreader ring 213 is enhanced, further improving heat dissipation efficiency.

[0057] When the output shaft 104 is tilted, that is, along the radial direction of the output shaft 104, one side of the iron core 200 is higher than the other side. At this time, the height difference between the first plate and the second plate is reduced compared with the vertical state, and the difference in capillary action between the upper and lower parts of the heat dissipation ring 213 is also weakened.

[0058] In this situation, the heat dissipation ring 213 abuts against the dividing plate 212. The friction between the dividing plate 212 and the heat dissipation ring 213 will inhibit the heat dissipation ring 213 from floating up, thereby reducing the difference in the contact area between the heat dissipation ring 213 and the first plate and the second plate. This makes the heat dissipation effect of the heat dissipation ring 213 and the first plate and the second plate more consistent, avoiding the problem that the heat dissipation effect of the upper part is greater than that of the lower part due to the excessive contact area between the upper part of the heat dissipation ring 213 and the first plate.

[0059] When the output shaft 104 is set horizontally (parallel to the ground), the heat dissipation ring 213 and the rotating rod 215 are concentrically set under the action of the soft washer 214. The capillary action in the heat dissipation ring 213 is not affected by gravity, and the cooling effect of the heat dissipation ring 213 on the first plate and the second plate is the same.

[0060] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An axial flux motor, characterized in that: It includes a housing, an output shaft, a stator, an adjustment mechanism, and two rotors; the output shaft is rotatably mounted inside the housing; the rotors and the output shaft are fixedly connected, and the two rotors are spaced apart along the axial direction of the output shaft; The stator is disposed between two rotors and includes multiple iron cores distributed circumferentially along the output shaft. Each iron core has an installation channel in the middle, and the installation channel contains coolant. A baffle is provided in the installation channel, which divides the installation channel into an inlet channel and an outlet channel distributed circumferentially along the output shaft. The baffle includes multiple partition plates distributed radially along the output shaft, and a connecting channel is formed between two adjacent partition plates, which connects the inlet channel and the outlet channel. The regulating mechanism includes multiple regulating components, each disposed within a connecting channel. Each regulating component includes a heat-spreading ring, the axial direction of which is radially aligned with the output shaft. The heat-spreading ring can rotate around its own axis and move axially along the output shaft. The heat-spreading ring is used to contact the iron core to achieve cooling of the iron core. A wire mesh is installed inside the heat-spreading ring, and its interior is filled with working fluid. The working fluid circulates within the heat-spreading ring under capillary action. The area where the heat-spreading ring contacts the iron core along the output shaft constitutes the evaporation end, and the middle of the heat-spreading ring is the condensation end. After absorbing heat at the evaporation end, the working fluid vaporizes. The vapor flows to the condensation end through the pressure difference within the heat-spreading ring, condenses into liquid upon contact with the condenser, and releases latent heat. The liquid then returns to the evaporation end through capillary force, forming a closed-loop circulation. The overall density of the heat-spreading ring is less than the density of the coolant. When the output shaft is set vertically, the heat dissipation ring increases its contact area with the upper part of the iron core by floating upwards, so as to compensate for the effect of gravity on capillary action.

2. An axial flux motor according to claim 1, characterized in that: The iron core consists of multiple iron plates, which are distributed sequentially along the radial direction of the output shaft.

3. An axial flux motor according to claim 2, characterized in that: Along the direction that gradually moves away from the output shaft, the length of multiple iron plates along the tangential direction of the output shaft gradually increases, and the diameter of multiple heat-spreading rings gradually increases to adapt to the shape of the iron plates.

4. An axial flux motor according to claim 2, characterized in that: Each iron sheet includes a first plate, a second plate, and an intermediate plate. The first plate and the second plate are distributed sequentially along the axial direction of the output shaft, and the intermediate plate connects the first plate and the second plate. When the output shaft is set vertically, the first plate is above the second plate. Each iron core is provided with two coils. The two coils on each iron core are wound on the iron core as a whole composed of multiple iron sheets. The two coils are respectively located between the first plate and the intermediate plate, and between the second plate and the intermediate plate.

5. An axial flux motor according to claim 4, characterized in that: The adjustment mechanism also includes a rotating rod, which is arranged radially along the output shaft. Each rotating rod is located in a mounting channel and is situated in the center of the intermediate plate. Multiple heat-spreading rings in each mounting channel are rotatably mounted on a rotating rod.

6. An axial flux motor according to claim 5, characterized in that: Each adjustment assembly also includes a soft washer, which is coaxially arranged with the heat spreader and located inside the heat spreader; the soft washer is used to abut against the rotating rod and is capable of deformation.

7. An axial flux motor according to claim 1, characterized in that: Each rotor includes multiple magnetic blocks, which are distributed sequentially along the circumference of the output shaft; in the same rotor, the magnetic properties of two adjacent magnetic blocks are opposite; the magnetic blocks of the two rotors are staggered, such that any magnetic block in one rotor corresponds to the position between two adjacent magnetic blocks in the other rotor in the circumferential direction.

8. An axial flux motor according to claim 1, characterized in that: The outer casing contains an inlet pipe, an outlet pipe, and a water pump. The inlet pipe is connected to multiple inlet channels, and the outlet pipe is connected to multiple outlet channels. The water pump is used to pump coolant into the inlet channels.

9. An axial flux motor according to claim 1, characterized in that: It also includes a drive mechanism, which includes a three-phase power supply connected to the stator to supply power to the stator. When the stator is energized, it can drive the rotor to rotate.

10. An axial flux motor according to claim 9, characterized in that: The drive mechanism also includes two end caps, which are disposed inside the housing, with each end cap located on the side of one rotor away from the other rotor.

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