Stator and electric machine comprising same

Abstract

This application provides a stator including multiple winding tooth blocks spaced circumferentially, the multiple winding tooth blocks being integrally encapsulated together, and multiple fixing portions forming on the outer periphery of the encapsulated stator. This application also provides a motor including a housing and the aforementioned stator; wherein the housing has multiple fixing slots along its circumference, and multiple fixing portions of the stator are detachably embedded and installed within the multiple fixing slots, the fixing slots being grooves corresponding to the fixing portions. Through improvements and designs to the stator and related mounting structures, the motor achieves higher power density and stronger performance, while also simplifying assembly and maintenance, resulting in lower assembly and maintenance costs.

Description

Technical Field

[0001] This application relates to the field of electric motors, and more particularly to stators and electric motors including those stators. Background Technology

[0002] Torque density and power density are two important indicators for measuring motor performance. With the development of the manufacturing industry, the demand for highly integrated products in various fields, especially in the rapidly developing intelligent manufacturing industry, is becoming increasingly urgent. In other words, compared with motors of the same volume and weight, axial flux motors with high torque density and high power density are one of the core technologies for the development of highly integrated products in intelligent manufacturing.

[0003] Currently, mainstream axial flux motors have two stator configurations: yoke-type and yoke-less stator. Axial flux motors based on these two stator configurations exhibit significant performance differences. This is because the presence of the yoke in the stator increases its weight and volume. Improper design can easily lead to increased magnetic reluctance, and under high load or high current conditions, magnetic saturation can easily occur, reducing the magnetic field strength. Since motor torque and power are positively correlated with magnetic field strength and inversely correlated with motor size and weight, the presence of the stator yoke not only reduces magnetic field strength but also increases motor size and weight, severely limiting torque and power density, and consequently restricting the motor's operating scenarios. Therefore, to overcome this limitation, the industry has proposed axial flux motors based on yoke-less stators.

[0004] For axial flux motors with yokeless stators, the torque density and power density are significantly improved compared to yoke-based designs because the yokeless design is no longer constrained by the stator yoke. However, the applicant discovered the following during the implementation of this axial flux motor based on a yokeless stator: Since the stator core yoke itself is used to support the teeth or connect the teeth, removing the stator core yoke and then fixing the teeth of the stator core to form a stable stator core is a difficult problem.

[0005] Currently, to facilitate winding, stator assembly, and rotor assembly, the industry commonly uses two fixed cover plates or support frames along the stator axis to clamp the tooth blocks, or employs a tooth block receiving box / slot to hold the fixed tooth blocks, thus fixing multiple tooth blocks together. However, adding cover plates increases the motor size and significantly increases magnetic leakage. It also reduces the air gap magnetic flux density due to the increased stator-rotor air gap, resulting in a loss of electromagnetic conversion efficiency. In this case, the waveform of the air gap magnetic flux density line is more dispersed, increasing torque fluctuations and affecting motor performance. Therefore, within the same design requirements, the motor's torque and power density must be sacrificed, especially when applied to the power mechanisms of highly integrated equipment. In confined design spaces, it is necessary to achieve the maximum torque and power density with the smallest possible size or weight. Therefore, the solution of clamping the fixed tooth blocks with two fixed cover plates or support frames is not feasible. Summary of the Invention

[0006] To address the problem that the torque and power densities of motors with yokeless stators in the prior art are not high and therefore insufficient in miniaturized equipment, this application proposes a stator comprising multiple winding tooth blocks spaced along the circumference, the multiple winding tooth blocks being integrally encapsulated together, and the outer periphery of the encapsulated stator having multiple fixing parts.

[0007] The above-mentioned solution in this application, through the integrated stator potting design, reduces the fixed cover plate required for conventional yokeless stators. Under the same motor size design requirements, it indirectly increases the size of the stator and rotor, thereby improving the power density of the motor. Furthermore, the stator is obtained by integrated potting of the tooth blocks, which optimizes the air gap and improves the electromagnetic conversion efficiency of the motor. On the other hand, the outer periphery of the stator forms a fixing part through potting. By simply matching the shape of the fixing part with a corresponding mounting structure (such as the subsequent housing), a new stator fixing method can be provided, which can stably fix the stator to the corresponding structural components. Since the fixing part of the stator is integrated with the tooth blocks through potting, this fixing method simplifies the stator installation / removal process compared to existing technologies, facilitating subsequent detachable installation of the stator. When applied to motors, this significantly reduces production assembly and maintenance costs.

[0008] In some embodiments, the stator leads extend radially outward from the end of one of the fixing portions. The applicant considered that when using integrated potting, the design of the leads needs to balance overall compactness, circuit rationality, and maximum strength. It is appropriate to use the end of the fixing portion of the stator for lead-out, so that it can extend through the bayonet of the mounting structure receiving fixing portion without the need to make holes in other parts of the mounting structure that mates with the stator, thus maintaining the strength of the mounting structure.

[0009] In some embodiments, each winding block includes a tooth block with a cross-section resembling an I-shape and a coil winding wound on the tooth block. The I-shaped tooth block design can accommodate more windings. According to the Ampere force formula F=NBIL (where N is the number of turns, B is the magnetic flux density, I is the winding current, and L is the winding length), with B, L, and I remaining constant, the more turns N there are, the greater the output Ampere force, and thus the greater the stator torque density.

[0010] In some embodiments, the tooth block includes a tooth body and tooth shoes located at the upper and lower ends of the tooth body, each tooth shoe at the upper and lower ends having at least one positioning groove. The opening of the upper and lower positioning grooves plays a positive role in fixing a single tooth block during winding fixtures and in the assembly fixtures for multiple winding tooth blocks after winding is completed, facilitating the implementation of winding fixtures and stator assembly fixtures.

[0011] Preferably, the positioning groove is linear, and the extension direction of the linear positioning groove is consistent with the extension direction of the radius of the stator circumference. This structural and directional design of the linear positioning groove makes the flatness and roundness of the tooth block better, thereby increasing the magnetic field utilization rate and reducing torque fluctuation. It is beneficial to the distribution of air gap magnetic flux density between the stator and rotor of the motor, which increases the torque density to a certain extent, and at the same time makes the motor less noisy when it rotates.

[0012] Preferably, the tooth blocks are sintered from soft magnetic composite (SMC). Due to the compact structure and small size of the motor, the magnetic flux density of the iron core formed by multiple tooth blocks in the motor stator is relatively high. When the motor is operating at high frequencies, it will generate significant iron losses. Using SMC material to make the tooth blocks can reduce the high-frequency stator iron losses of the motor, thereby improving the motor's operating efficiency. Preferably, the tooth block is integrally formed from the tooth body and tooth shoe.

[0013] In some embodiments, the potting material is, for example, a high thermal conductivity and high strength resin made from resin as a raw material, wherein the thermal conductivity of the potted resin is between 1.8 and 2.0 W / m*K, and / or the tensile strength is between 90 and 100 N / mm. 2 The high strength achieved after potting provides excellent "fixation," while the high thermal conductivity allows the heat generated by the stator to be transferred outward through the casing, resulting in good heat conduction. This, in turn, improves motor performance, allowing for greater power output and increasing the motor's torque density.

[0014] In some embodiments, the fixing part is an annular support body or a protrusion radially arranged on the annular support body. When an annular support body is used, the stator assembly and fixing are more stable; when multiple protrusions radially arranged on the annular support body are used, the stator assembly is stable while simplifying the assembly process.

[0015] On the other hand, this application also proposes a motor that, in addition to the stator described above, includes a housing. The housing has multiple fixing slots along its circumference, and multiple fixing parts of the stator are detachably embedded in these fixing slots. Each fixing slot is a corresponding groove to one of the fixing parts. By providing a housing with fixing slots, the stator can be fixed in an economical and effective manner, reducing production, installation, and subsequent maintenance costs.

[0016] As a typical embodiment, multiple fixing slots are circumferentially distributed along one side edge of the housing; multiple fixing parts of the stator are axially embedded in the multiple fixing slots.

[0017] In another typical embodiment, multiple fixing slots are distributed circumferentially along the radial inner edge of the housing; multiple fixing parts of the stator are radially embedded in the multiple fixing slots. To reduce the difficulty of radial installation between the stator and the housing, in some embodiments, the housing is divided into at least two sections, each section including a portion of the fixing slots. During assembly, the fixing parts of the stator can be embedded into the fixing slots of each section of the housing, and then the sections of the housing are spliced ​​and fixed together to complete the overall installation.

[0018] In some embodiments, the motor further includes an end cover, which is detachably fixed to the housing by fasteners, securing multiple fixing parts of the stator within multiple fixing slots in the housing. The end cover and the housing together form a complete motor housing. During assembly and maintenance, only the fasteners need to be removed and reinstalled to quickly insert and remove the stator from the housing.

[0019] As a typical embodiment, the end caps include a left end cap and a right end cap located on both sides of the housing.

[0020] In some embodiments, the motor further includes a motor shaft, the axial shaft of which is movably connected to the left end cover and the right end cover via bearings; the axial shaft of the motor shaft passes through the central shaft hole of the left end cover, the stator, the housing, and the central shaft hole of the right end cover, and is coaxial with the left end cover, the stator, the housing, and the right end cover.

[0021] In some embodiments, both the left and right end covers have a central shaft hole through which the axial shaft of the motor passes. A bearing, such as an angular contact bearing, a thrust ball bearing, or a tapered roller bearing, is disposed within the central shaft hole. The bearing design facilitates motor rotation and reduces the occurrence of stalling.

[0022] In some embodiments, the motor shaft further includes a radial flange that protrudes radially from the center of the axial shaft. The radial flange can serve as a limiting and positioning part during axial installation. For example, the radial flange can be fixed together with the rotor disc by fasteners, which facilitates the positioning of the rotor during installation and its fixation after installation.

[0023] In some embodiments, the end of the axial shaft is provided with a threaded mounting hole, which facilitates the attachment of assembly and disassembly tooling during motor assembly, and assists in the quick positioning and installation of components; and can also be used to attach other sensors, such as magnetic encoders, after the motor is assembled, making one hole a multi-purpose tool.

[0024] In some embodiments, the motor further includes a rotor; the rotor is located between the left end cover and the stator, or between the right end cover and the stator. This embodiment is mainly designed to accommodate single-rotor cases, i.e., using one rotor and one stator to constitute the power generation mechanism of the motor.

[0025] In a typical embodiment, the rotor includes at least a first rotor and a second rotor, which are located on opposite sides of the stator; the first rotor is located between the left end cover and the stator; and the second rotor is located between the right end cover and the stator.

[0026] Furthermore, this application improves the ease of disassembly and assembly of the rotor; specifically, the rotor includes: A rotor core having a first row of positioning slots along its outer circumference; A rotor disk having a second row of positioning grooves along its outer circumference, the second row being the same as the first row, wherein the arrangement includes a preset number and spacing. Multiple magnets are distributed circumferentially corresponding to the rotor core.

[0027] By designing the rotor's positioning slots, the alignment of the first and second rows of positioning slots during rotor assembly facilitates the relative positioning between the rotor disc and the rotor core. After positioning, the assembly position of the magnet relative to the rotor core can be determined.

[0028] As a typical embodiment, the rotor's positioning slot is a square slot. The square slot design allows for use with square keys during actual assembly, which not only facilitates positioning but also reduces the risk of displacement between the rotor disc and the rotor core after positioning.

[0029] In some embodiments, the rotor disk has at least a third row of outer positioning holes and a fourth row of inner positioning holes along its circumference. Each outer positioning hole and each inner positioning hole is located radially along the extension line of one of the magnets. This design of the outer and inner positioning holes facilitates the assembly of the two rotors. First, the first rotor is assembled, and the positioning pin hole (i.e., outer positioning hole 231) is measured to be either N or S polarity relative to the magnet, and marked with a marker. Then, a pin is inserted into the pin hole. Similarly, after determining the N / S polarity of the magnet on the other rotor, a position opposite to the polarity of the first rotor is selected, and the rotor disk is assembled into place using the pin hole (i.e., outer positioning hole 231) along the pin. This determines the relative positions of the rotor core and rotor disk when assembling the two rotors in the dual-rotor motor.

[0030] In one typical embodiment, the outer positioning holes in the third row and the inner positioning holes in the fourth row are geometrically symmetrically distributed relative to each other. This geometrical symmetry facilitates accurate identification of positioning positions by assembly personnel, making adjustment and installation work easier.

[0031] In a typical embodiment, the fourth row of inner positioning holes has eight holes, and the third row of outer positioning holes has four holes. The four outer positioning holes correspond to various different magnetic pole distributions when the deflection is 90 degrees, while the eight inner positioning holes correspond to various different magnetic pole distributions when the deflection is 45 degrees.

[0032] As a typical embodiment, the first row is the same as the third row, which further facilitates the determination of the position of the magnets as soon as the rotor disk and rotor core are relatively positioned.

[0033] In some embodiments, adjusting shims are arranged axially between the rotor and the motor shaft. The adjusting shims facilitate adjustment of the flux gap according to actual operating conditions.

[0034] In summary, the motor of this application improves and designs the relevant structures of the stator and rotor, resulting in higher torque density and power density. At the same time, its assembly and maintenance are simple, and the assembly and maintenance costs are reduced. Attached Figure Description

[0035] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1A This is a plan view of the stator according to an embodiment of this application; Figure 1B yes Figure 1A The diagram shows a cross-sectional view of the stator. Figure 2A This is a schematic diagram of a stator tooth block according to an embodiment of this application; Figure 2B yes Figure 2A A schematic diagram of a single winding tooth block after the tooth block is wound with enameled wire; Figure 3A This is a plan view of a rotor according to an embodiment of this application; Figure 3B yes Figure 3A A schematic cross-sectional view of the rotor is shown. Figure 4A For the application of one embodiment of this application Figure 1A The stator shown and Figure 3A An exploded schematic diagram of a dual-rotor axial flux motor with the rotor shown. Figure 4B for Figure 4A A schematic cross-sectional view of the axial flux motor shown. Figure 5 This is a schematic diagram of another variant embodiment of the housing of this application; Figure 6A and Figure 6B It was adopted Figure 4A and Figure 4B The diagram shows the relationship between torque and current of a dual-rotor axial flux motor under different operating conditions. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0038] In the description of this specification, it should be understood that the orientation or positional relationship indicated by center, longitudinal, transverse, length, width, up, down, left, right, vertical, horizontal, inner, outer, axial, radial, circumferential, etc., is based on the orientation or positional relationship shown in the accompanying drawings, and is for the purpose of facilitating the description of this application and simplifying the text description.

[0039] stator Reference Figure 1A and Figure 1BThe figure shows a stator 10, with reference to axis a. The stator 10 is an axially hollow disc stator, comprising multiple winding tooth blocks 101 spaced circumferentially. These winding tooth blocks 101 are integrally encapsulated with a resin-based material, achieving high strength and / or high thermal conductivity. The white annular area shown in the figure represents the shape after resin encapsulation molding. It can be seen that the encapsulated stator 10 has an annular support body 102a and four fixing portions 102b formed on its outer periphery. The stator 10's lead wires 103 extend radially outward from the outer end of one of the fixing portions 102b (located at the top in the figure).

[0040] The aforementioned resin potting can be rapidly molded using a mold. The annular support body 102a formed by potting fixes multiple winding tooth blocks together, eliminating the need for left and right tooth block fixing frames, fixing discs, cover plates, and other components. The potting mold shapes multiple fixing parts (four identical protrusions in the figure), solving subsequent stator assembly and positioning issues and enabling rapid mass production, providing effective assurance for motor mass production. The excellent thermal conductivity and / or tensile strength of the potted resin allow for higher torque and power densities without the need for an additional "cover plate," while also balancing mechanical strength and / or high heat dissipation, which helps extend the motor's service life.

[0041] Continue to refer to Figure 1B , showed Figure 1A A cross-sectional view of the stator. The winding tooth block 101 is wound with enameled wire 104. Due to... Figure 1B The cutting position is exactly located on the fixed part where the lead wire is located, so Figure 1B The annular support body 102a and the fixing part 102b shown in the figure are combined together. Because they are formed by potting with the same resin material, there is no clear dividing line between the annular support body 102a and the fixing part 102b in the figure. As a specific application, various operating status monitoring sensors, such as temperature sensors (not shown), can be wound around the enameled wire 104. Correspondingly, the leads can be divided into power lines 103a and sensor signal lines 103b.

[0042] As Figure 1A and Figure 1B The application example of stator 10 shown is as follows. Figure 4AThis diagram illustrates the stator and housing of an axial flux motor in use. As shown, the stator 10 includes four protrusions 102b evenly distributed along its outer circumference. The housing 11 has four matching mounting slots 110 evenly distributed along its circumference on one axial side (either left or right). The mounting slots are groove-shaped. The four protrusions 102b are detachably axially embedded within the mounting slots 110. After embedding, the stator 10's lead wires 103 extend beyond one of the corresponding mounting slots 110. The motor also includes a left end cover 12 and a right end cover 13 located on the left and right sides of the housing 11. The left end cover 12 has a central shaft hole 120, and the right end cover 13 has a central shaft hole 130. The axial shaft 302 of the motor shaft passes through the central shaft hole 120 of the left end cover 12, the stator 10, the housing 11, and the central shaft hole 130 of the right end cover 13, and is coaxial with the left end cover 12, the stator 10, the housing 11, and the right end cover 13. The left end cover 12 and the right end cover 13 are fixedly connected to the housing 11 by fasteners through corresponding fixing holes provided on each other. The four protrusions 102b of the stator 10 are reinforced in the four fixing slots 110 of the housing 11 to keep the stator 10 fixedly in place within the housing 11.

[0043] Figure 5 Another variation of the housing is shown, in which four mounting slots 110' are circumferentially distributed along the radially inner end edge of the housing 11' (three mounting slots are not shown due to viewing angle). When this variation of the housing is used, multiple fixing parts of the stator can be adaptively radially embedded and installed within multiple mounting slots 110'. Figure 5 In the middle, the housing 11' is divided into two sections, including housing section 11a' and housing section 11b'. Each housing section includes two fixing slots. During assembly, the fixing part of the stator can be inserted into the fixing slots included in housing section 11a' and housing section 11b' respectively, and then housing section 11a' and housing section 11b' are spliced ​​and fixed together to complete the installation of the stator and housing.

[0044] Clearly, the matching and embedding installation of the fixing part and the fixing bayonet, the design position and extension position of the lead wire, and the detachable auxiliary fixing of the side (left) end cover all simplify assembly and maintenance and reduce production costs in various aspects.

[0045] Continue to refer to Figure 2A and Figure 2B The diagram shows the structure of a single tooth block and the winding tooth block after winding. It can be seen that the cross-section of the winding tooth block 1010 is I-shaped, including a vertical tooth body 1010a and transverse tooth shoes 1010b located at the upper and lower ends of the tooth body 1010a.

[0046] To meet the requirements of positioning and high motor performance, each toothed shoe 1010b has a positioning groove 1010c along its longitudinal length, forming a pair of positioning grooves. The introduction of the positioning groove 1010c facilitates the clamping and positioning of individual toothed blocks for winding fixtures. For small batches of prototypes, it enables rapid manual unwinding of toothed blocks for winding enameled wire 104, while for mass production, it allows direct winding of enameled wire 104 onto a winding machine. For multiple circumferentially arranged toothed blocks, the multiple positioning grooves of multiple toothed blocks facilitate matching with disc-mounted positioning fixtures, assembling all toothed blocks into a flat circle. Furthermore, the positioning groove 1010c adopts a linear shape, with its direction aligned with the radial extension direction of the stator's circumference. Compared to other shapes of positioning grooves (such as cylindrical and square grooves) and their directional designs, this is beneficial for the distribution of air gap magnetic flux between the motor's stator and rotor, resulting in smaller torque fluctuations and lower noise during motor rotation. In a preferred embodiment, the tooth block 1010 is sintered from SMC material, and the iron core is treated with an insulating coating process before winding. It is known that sintering, coating, and winding are all mature, cost-effective, and mass-producible processes, effectively reducing and controlling the processing cost of a single tooth block.

[0047] rotor Figure 3A and Figure 3B The image shows a rotor 20 according to an embodiment of this application. The rotor 20 includes: A rotor core 21 having a first row of positioning slots 210 along its outer circumference; Rotor disk 23 having the same second row of positioning grooves 230 along its outer circumference, the arrangement including a number of four and corner intervals of 90 degrees; Multiple magnets 22 are distributed circumferentially relative to the rotor core 21.

[0048] As shown in the figure, positioning slot 210 is a positioning slot on rotor core 21. Positioning slot 230 is a positioning slot on rotor disk 23. Both positioning slots 210 and 230 are square slots. During the positioning of rotor core 21 and rotor disk 23, square keys (not shown) are used for positioning during assembly using pairs of square slots. This square slot design ensures the relative position of rotor core 21 and rotor disk 23, thereby determining the position of the subsequent magnet 22 assembly.

[0049] Continue to refer to Figure 3AThe rotor disk 23 has a third row of outer positioning holes 231 and a fourth row of inner positioning holes 232 arranged along its circumference. Each outer positioning hole 231 and each inner positioning hole 232 is located radially along the extension line of one of the magnets. In the embodiment shown in the figure, the third row of outer positioning holes 231 and the fourth row of inner positioning holes 232 are geometrically symmetrical with respect to each other. There are eight inner positioning holes 232 in the fourth row and four outer positioning holes 231 in the third row. The four outer positioning holes 231 correspond to various different magnetic pole distributions when deflected by 90 degrees, and the eight inner positioning holes 232 correspond to various different magnetic pole distributions when deflected by 45 degrees. The rotor disk 23 also has a number of screw holes 233 for disassembly and assembly, used to temporarily fix tooling to the rotor disk 23, facilitating the fixing of the rotor disk 23 to the radial flange 301 of the motor shaft (see, for example). Figure 4A The corresponding mounting holes on the left or right end cap are aligned and then secured with fasteners.

[0050] Typically, the outer positioning hole 231 and the inner positioning hole 232 are pin holes.

[0051] The outer positioning hole 231 and the inner positioning hole 232 are designed to fix the rotor disk 23 onto the radial flange 301 of the motor shaft 30, while the outer positioning hole 231 is used to position the magnets. Specifically, during the assembly of the dual-rotor axial flux motor, the first rotor is assembled first. The positioning pin hole (i.e., the outer positioning hole 231) is measured to ensure that the magnet is N or S polarity, and this is marked with a marker. Then, a pin is inserted into the pin hole. The same method is used to determine the N / S polarity of the magnet on the other rotor. After determining the N / S polarity, a position opposite to the polarity of the first rotor is selected, and the rotor disk is assembled into place using the pin hole (i.e., the outer positioning hole 231) along the pin. This determines the relative positions of the rotor core and rotor disk when assembling the two rotors in the dual-rotor axial flux motor.

[0052] Further reference Figure 3A It can be observed that the first row of positioning slots 210 is the same as the third row of external positioning holes 231. This further facilitates the determination of the position of the magnet 22 immediately after the rotor disk 23 and rotor core 21 are relatively positioned.

[0053] The rotor 20 with the above structure, in conjunction with the stator 10, makes the magnetic performance and control performance of the motor better. Through the design of the positioning slot 210 and the matching of the positioning slot 210, the design of the outer positioning hole 231 and its distribution, the design of the inner positioning hole 232 and its distribution, and the design of the screw hole 233 and its distribution, the assembly process of the rotor 20 and the rotor 20 with the stator 10 and the rotor with the motor shaft 30 is optimized, and the labor efficiency is improved.

[0054] motor Reference Figure 4A and Figure 4B This is an application of one embodiment of this application. Figure 1A The stator shown and Figure 3A The diagram shows a schematic of an axial flux motor with a rotor. The axial flux motor 1 shown is a dual-rotor axial flux motor with a rotor-stator-rotor structure. Both the first rotor 20 and the second rotor 20' include a rotor core 21, magnets 22, and a rotor disk 23. The motor shaft 30 also includes a radial flange 301 that protrudes radially from the center of the axial shaft 302. An adjusting shim 19 is arranged between the rotor disk 23 and the radial flange 301. When the rotor disk 23 and the radial flange 301 are fastened together by fasteners 100, the shim 19 can adjust the flux gap.

[0055] The first rotor 20 is located between the left end cover 12 and the stator 10; the second rotor 20' is located between the right end cover 13 and the stator 10. The stator 10 is assembled in the fixing buckle 110 of the housing 11 via the protrusion 102b. The left end cover 12 and the right end cover 13 are both fixed to the housing 11 by fasteners 1000, which hold the stator 10 in the housing 11. The axial shaft 302 of the motor shaft 30 passes through the central shaft hole 120 of the left end cover 12, the first rotor 20, the stator 10, the housing 11, the second rotor 20', and the central shaft hole 130 of the right end cover 13, and is coaxial with the left end cover 12, the first rotor 20, the stator 10, the housing 11, the second rotor 20', and the right end cover 13.

[0056] The axial shaft 302 has threaded holes 303 at both ends for attaching assembly and disassembly fixtures. The fixtures are screwed in, for example, through bolts via the threaded holes 303. After being screwed close to the rotor disk 23 for positioning, the fixtures can be fixed to the rotor disk 23 using fasteners via the screw holes 233. Through continuous screwing of the fixtures, the rotor, including the rotor disk 23, is pressed against the radial flange 301 of the motor shaft 30. Subsequently, the rotor disk 23 is fixed to the radial flange 301 of the motor shaft 30 using fasteners 100 and inner positioning holes 232, completing the installation of the rotor on the motor shaft 30. The threaded holes 303, used for attaching the assembly and disassembly fixtures, overcome the difficulty of the rotor magnets strongly adhering to the stator during stator and rotor assembly, facilitating air gap adjustment and disassembly. As an additional use, after assembly, the fixtures can be removed from the threaded holes 303. The threaded holes 303 can also be used to assemble and fix the magnetic encoder 17 and the code disk bracket 170, offering multiple uses from a single hole. After assembly, the right end of the axial rotating shaft 302 is the output end.

[0057] Further reference Figure 4A and Figure 4BBearings, such as angular contact bearings 18, are installed in the central shaft holes 120 and 130. As a variation, thrust ball bearings and tapered roller bearings can also be selected to replace the angular contact bearings depending on the load size. The axial rotating shaft 302 of the motor shaft is movably connected to the left end cover 12 and the right end cover 13 through the bearings 18. The bearing design helps the motor to rotate and reduces the occurrence of stalling.

[0058] exist Figure 4A In the embodiment shown, air gaps can be formed between the stator 10 and the first rotor 20, and between the stator 10 and the second rotor 20', respectively. The axial magnetic pull generated by the two air gaps can cancel each other out, ensuring the balance of axial forces. The resulting axial flux motor has higher working stability.

[0059] exist Figure 4A and Figure 4B Inspired by this, it can be understood that axial flux motors can also consist of two or more rotors and two or more stators, which can be configured according to actual needs.

[0060] Figure 6A and Figure 6B It was adopted Figure 4A and Figure 4B The diagram shows the relationship between torque and current under different operating conditions for a dual-rotor axial flux motor with the structure shown, provided that the design dimensions of the axial flux motor are met for the equipment or application scenario, such as when it is used in the joints of a humanoid robot.

[0061] After the dual-rotor axial flux motor is powered on, the electrons in the motor control circuit generate a rotating magnetic field in the stator, which drives the motor rotor to rotate synchronously. The motor rotor 20 transmits the corresponding torque through the motor shaft 30 and bearing 18.

[0062] Figure 6A References are shown Figure 4A and Figure 4B The structure and the measured TI (torque-current) curve of the motor prototype (excluding the housing and screws) made according to the working requirements of the humanoid robot's joints were analyzed. Figure 6A It can be seen that when the phase current is around 180A, the motor torque reaches the peak value of 30Nm in the dynamometer test range. At this time, the T-I curve shows that the motor is far from saturated when the dynamometer peak value is reached. The actual measured mass of the motor sample is 0.9kg, and the torque density can reach 33.3Nm / kg in the peak range of the dynamometer.

[0063] Further, by applying Maxwell's theory of electromagnetic induction, the study of forces in a magnetic field of a current-carrying conductor, and the design principles of permanent magnet synchronous motors, and combining this with simulation and debugging using the magnetic circuit method (RMxprt) in the professional motor simulation software ANSYS Maxwell, the TI (torque-current) curve was obtained. Figure 6B .from Figure 6B It can be seen that when the phase current is 360A, the peak torque of the motor can reach 50.4Nm, and gradually approaches saturation.

[0064] In the simulation software ANSYS Maxwell, due to the limited selection of potting materials, housing, screws, etc., the theoretical mass of the motor in the software is slightly larger, at 1.2kg. The theoretical torque density of the motor measured by the simulation software is = peak torque / motor mass = 50.4Nm / 1.2kg = 42Nm / kg.

[0065] Obviously, from Figure 6A and Figure 6B The graphs and analysis show that the performance of this type of motor is very promising when applied to robot joints. In other words, the dual-rotor axial flux motor of this application not only achieves small size and high power density, but also saves on manufacturing costs.

[0066] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A stator, characterized in that, include: Multiple winding tooth blocks are distributed at intervals along the circumference, and the multiple winding tooth blocks are integrally encapsulated together. After encapsulation, multiple fixing parts are formed on the outer periphery of the stator.

2. The stator according to claim 1, characterized in that, The stator leads extend radially outward from the end of one of the fixed parts.

3. The stator according to claim 1, characterized in that, Each winding tooth block includes a tooth block with an I-shaped cross-section and a coil winding wound on the tooth block.

4. The stator according to claim 1, characterized in that, The tooth block includes: a tooth body and toothed shoes located at the upper and lower ends of the tooth body, wherein each toothed shoe has at least one positioning groove.

5. The stator according to claim 4, characterized in that, The positioning groove is linear in shape, and its extension direction is consistent with the radial extension direction of the stator's circumference.

6. The stator according to claim 1, characterized in that, Each tooth block is sintered from a soft magnetic composite material.

7. The stator according to claim 1, characterized in that, The multiple winding tooth blocks are encapsulated together with resin. The thermal conductivity of the encapsulated resin is between 1.8 and 2.0 W / m*K, and / or the tensile strength is between 90 and 100 N / mm. 2 between.

8. The stator according to claim 1, characterized in that, The fixing part is a ring-shaped support body or multiple protrusions radially arranged on the ring-shaped support body.

9. An electric motor, characterized in that, The stator includes a housing and a stator according to any one of claims 1-8; the housing has a plurality of fixing slots along its circumference, and a plurality of fixing parts of the stator are detachably embedded in the plurality of fixing slots, wherein the fixing slots are grooves corresponding to the fixing parts.

10. The motor according to claim 9, characterized in that, The plurality of fixing slots are distributed circumferentially along one side edge of the housing; the plurality of fixing parts of the stator are axially embedded in the plurality of fixing slots.

11. The motor according to claim 9, characterized in that, The plurality of fixing slots are distributed circumferentially along the radial inner edge of the housing; the plurality of fixing parts of the stator are radially embedded in the plurality of fixing slots.

12. The motor according to claim 11, characterized in that, The casing is composed of at least two sections joined together.

13. The motor according to claim 9, characterized in that, It also includes an end cap, wherein the end cap is detachably fixed to the housing by fasteners, thereby securing multiple fixing parts of the stator in multiple fixing slots of the housing.

14. The motor according to claim 13, characterized in that, The end caps include a left end cap and a right end cap located on both sides of the housing.

15. The motor according to claim 13, characterized in that, Also includes: Motor shaft; the axial shaft of the motor shaft is movably connected to the end cover.

16. The motor according to claim 15, characterized in that, The motor shaft also includes a radial flange that protrudes radially from the center of the axial shaft.

17. The motor according to claim 16, characterized in that, The end of the axial shaft is provided with a threaded mounting hole.

18. The motor according to claim 14, characterized in that, Also includes: Rotor; the rotor is located between the left end cover and the stator, or between the right end cover and the stator.

19. The motor according to claim 18, characterized in that, The rotor includes at least a first rotor and a second rotor, which are located on opposite sides of the stator; the first rotor is located between the left end cover and the stator; and the second rotor is located between the right end cover and the stator.

20. The motor according to claim 18, characterized in that, The rotor includes: A rotor core having a first row of positioning slots along its outer circumference; A rotor disk having a second row of positioning slots along its outer circumference, the second row being identical to the first row, wherein the arrangement includes a predetermined number and spacing. Multiple magnets are distributed circumferentially corresponding to the rotor core.

21. The motor according to claim 20, characterized in that, The positioning slot of the rotor is a square slot.

22. The motor according to claim 20, characterized in that, The rotor disk has at least a third row of outer positioning holes and a fourth row of inner positioning holes along its circumference. Each outer positioning hole and each inner positioning hole is located on the extension line of one of the magnets along the radial direction of the circumference.

23. The motor according to claim 22, characterized in that, The outer positioning holes in the third row and the inner positioning holes in the fourth row are geometrically symmetrical with respect to each other.

24. The motor according to claim 22 or 23, characterized in that, The first row is the same as the third row.

25. The motor according to claim 18, characterized in that, Adjustment shims are arranged axially between the rotor and the motor shaft.

Images