In-situ cooling structure of radial micro-channel based hub motor stator

Abstract

This invention discloses an in-situ cooling structure for the stator of a hub motor based on radial microchannels, comprising: a hub motor mechanism, the hub motor mechanism including a fixed outer shell, a stator core fixedly connected to the inner wall of the fixed outer shell, a coil wound on the surface of the stator core, and a rotor disposed inside the stator core. This invention belongs to the field of motor thermal management technology. The purpose of this invention is to solve the problem in the prior art where the cooling channel is far from the stator core and coil, which are the main heat sources, and heat needs to be conducted through the stator core to the outer shell to be carried away, resulting in high thermal resistance and limited heat dissipation efficiency, which makes it difficult to meet the heat dissipation requirements of high power density hub motors. The technical effect achieved is that the spiral cooling channel is directly opened inside the stator core, so that the cooling medium flows through the core heat generation area, realizing zero-distance contact between the cooling channel and the main heat source, and solving the problems of high thermal resistance and low heat dissipation efficiency of traditional shell water cooling methods.

Description

Technical Field

[0001] This invention belongs to the field of motor thermal management technology, and specifically relates to an in-situ cooling structure for the stator of a hub motor based on radial microchannels. Background Technology

[0002] Hub motors are primarily used in the power drive systems of electric vehicles, electric bicycles, and various other electric vehicles. Hub motors integrate the motor directly into the wheel hub, offering advantages such as compact structure, high transmission efficiency, and good space utilization, making them a core component of distributed drive systems. With the continuous increase in the power density of hub motors, the heat generated by the stator core and coils during operation increases dramatically. Therefore, an efficient and reliable cooling structure becomes crucial to ensuring the continuous and stable operation of the motor.

[0003] However, traditional cooling methods mostly involve water cooling or air cooling of the outer casing. The cooling channels are far from the stator core and coils, which are the main heat sources. Heat must be conducted through the stator core to the outer casing to be carried away, resulting in high thermal resistance and limited heat dissipation efficiency, which is difficult to meet the heat dissipation requirements of high power density hub motors. At the same time, traditional channel arrangements are mostly single annular or spiral shapes, which fail to fully consider the geometric characteristics of annular stators. There is a lack of flow uniformity design between parallel channels, which can easily lead to uneven flow distribution due to differences in channel length, resulting in local overheating. In addition, the flow rate of existing cooling systems is fixed or only relies on external pump drive, which cannot adaptively adjust the cooling flow rate according to changes in motor speed and heat generation, resulting in overcooling at low speeds and undercooling at high speeds. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the purpose of this invention is to provide an in-situ cooling structure for the stator of a hub motor based on radial microchannels, so as to solve the problem of poor heat dissipation of hub motors in the prior art.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: The in-situ cooling structure for the stator of a hub motor based on radial microchannels includes: The hub motor mechanism includes a fixed housing, a stator core fixedly connected to the inner wall of the fixed housing, coils wound on the surface of the stator core, a rotor inside the stator core, permanent magnets embedded on the surface of the rotor, a rotating shaft fixedly connected inside the rotor, and a hub fixedly connected to the end of the rotating shaft. A spiral cooling channel is formed inside the stator core. That is, in this invention, the cooling channel is located inside the stator core and is spirally shaped. This allows the cooling medium to directly participate in heat exchange in the core heat-generating area, and the spiral structure increases the heat exchange area, significantly improving the heat dissipation capacity of the hub motor.

[0006] A rear end cover assembly includes a rear end cover plate, the surface of which is fixedly connected to the inner wall of one end of a fixed housing. The rear end cover plate has a liquid inlet chamber that communicates with the inlet of a spiral cooling channel. This invention distributes the cooling medium into the spiral cooling channel of the stator core by creating a liquid inlet chamber on the rear end cover plate.

[0007] A front cover assembly includes a front cover plate whose surface is fixedly connected to the inner wall of the other end of a fixed housing. The front cover plate has radially arranged converging channels that communicate with the outlet of a spiral cooling channel. This invention, by providing radially arranged converging channels in the front cover plate, collects the cooling medium after heat exchange. The path formed by the liquid inlet chamber, the spiral cooling channel, and the radially arranged converging channels allows the cooling medium to flow in multiple parallel cooling channels, greatly improving the heat exchange effect.

[0008] A flow rate adaptive component includes a drive ring, the inner ring wall of which is fixedly connected to the surface of a rotating shaft, and a unidirectional drive tooth fixedly connected to the outer ring surface of the drive ring. This invention, through the unidirectional drive tooth design of the drive ring, enables adaptive flow distribution of the cooling medium, ensuring uniform flow in each flow channel.

[0009] Furthermore, an inlet is provided on one side of the inner cavity of the liquid inlet chamber, and radial microchannels are uniformly opened on the inner wall of the liquid inlet chamber in a circumferential direction. The ends of the radial microchannels are connected to the ends of the spiral cooling channel. One end of the radial manifold is connected to the other end of the spiral cooling channel, and the other end of the radial manifold is connected to a manifold cavity, with a liquid outlet on one side of the manifold cavity. The manifold cavity can equalize the pressure of the medium discharged from each channel and avoid backflow interference.

[0010] Furthermore, the radial microchannels radiate radially and are preferably arranged at equal angles, with their radial distal ends connected to the ends of the spiral cooling channels; correspondingly, the radial confluence channels radiate radially and are preferably arranged at equal angles, with their radial distal ends connected to the other end of the spiral cooling channels; the number of radial microchannels, spiral cooling channels, and radial confluence channels are the same, and they are connected one-to-one to form parallel multi-channel media flow.

[0011] Furthermore, the radial microchannels, spiral cooling channels, and radial confluence channels are all high aspect ratio microchannel arrays with a channel width of 0.1–1 mm, a depth of 1–10 mm, and an aspect ratio of not less than 5, which can effectively ensure heat exchange effect and medium flow rate.

[0012] Furthermore, the inlet chamber constitutes an inlet distribution chamber. After the cooling medium enters the inlet chamber through the inlet port, the flow rate of each radial microchannel is adaptively distributed through the flow resistance matching principle, ensuring uniform flow rate of multiple parallel microchannels. The radial confluence channel and the confluence chamber constitute an outlet collection chamber. The cooling medium flows into the radial confluence channel through the spiral cooling channel and then collects in the confluence chamber, achieving pressure equalization of the cooling medium in each parallel channel. The shape design of the flow channel in this invention matches the geometric characteristics of the annular stator, avoiding localized overheating of the stator.

[0013] Furthermore, the end of the unidirectional drive tooth is arc-shaped, and the surface of the drive ring is rotatably connected to a mounting component. The mounting component is annular and coaxially mounted with the drive ring. A booster blade is fixedly connected to its outer wall surface. Through the booster blade, the cooling medium can be accelerated to flow.

[0014] Furthermore, the inner wall of the mounting component is connected to a one-way locking block. The end of the one-way locking block is arc-shaped and contacts the arc-shaped end of the one-way drive tooth in the opposite direction. This contact means that they can engage, allowing the drive ring to rotate in only one direction. For example, if the arc-shaped end of the one-way drive tooth faces counterclockwise and the arc-shaped end of the one-way locking block faces clockwise, the drive ring can only rotate clockwise. When rotating counterclockwise, the end of the one-way locking block will lock the end of the one-way drive tooth. For example, the number of one-way locking blocks can be multiple, but it does not need to be the same as the number of one-way drive teeth.

[0015] Furthermore, the one-way locking block is connected to the inner wall of the mounting component via a rotating shaft, the rotating shaft being parallel to the central axis of the mounting component. The surface of the one-way locking block is also fixedly connected to the inner wall of the mounting component via a spring. A limit locking block is fixedly connected to the surface of the one-way locking block, and the surface of the limit locking block overlaps with the surface of the mounting component. The function of the limit locking block is to prevent structural damage caused by forced rotation of the drive ring in a non-rotatable direction.

[0016] Furthermore, one end of a spring is connected to the inner side of the arc-shaped end of the one-way block, and the other end of the spring is fixedly connected to the inner wall of the mounting component, so that the one-way block can be reset after being pressed by the rotating one-way drive tooth.

[0017] Furthermore, the flow rate adaptive component is provided in two sets. The unidirectional drive teeth, unidirectional locking blocks and pressurizing blades in the two sets of flow rate adaptive components deflect in opposite directions, so that when the rotating shaft rotates clockwise or counterclockwise, it can drive a set of pressurizing blades to rotate, pushing the cooling medium to flow forward, thereby achieving on-demand cooling without the need for an external pump source.

[0018] Compared with the prior art, the beneficial effects of the present invention are: By directly inserting spiral cooling channels inside the stator core, the cooling medium flows through the core heat-generating area, achieving zero-distance contact between the cooling channels and the main heat source. This solves the problems of high thermal resistance and low heat dissipation efficiency in traditional shell-based water cooling methods. The cooling medium directly absorbs the heat generated by the coils and core inside the stator, resulting in a short heat transfer path and high heat exchange efficiency, significantly improving the heat dissipation capacity of the hub motor under high power density conditions. By setting an inlet chamber and radial microchannels in the rear end cover, and radial confluence channels and confluence cavities in the front end cover, a parallel microchannel network combining an inlet distribution cavity and an outlet collection cavity is constructed. The inlet chamber utilizes the flow resistance matching principle to achieve adaptive flow distribution of the cooling medium when entering each radial microchannel, effectively compensating for flow resistance deviations caused by differences in channel length, and ensuring uniform flow in multiple parallel microchannels. The outlet collection cavity balances the pressure of the medium discharged from each channel, avoiding backflow interference. The combined arrangement of radial, annular, and spiral flow channels fully adapts to the geometric characteristics of the annular stator, fundamentally eliminating the risk of localized overheating. Simultaneously, a bidirectional adaptive flow velocity assembly, consisting of a drive ring, unidirectional drive teeth, unidirectional locking blocks, springs, and booster blades, is incorporated. Utilizing the rotational power of the motor shaft itself to drive the booster blades, this achieves automatic matching of cooling flow rate with motor speed. When the motor operates at high speed and heat generation increases, the shaft speed increases, and the booster blade speed increases synchronously, accelerating the cooling medium flow rate and enhancing heat dissipation. When the motor operates at low speed, the cooling flow rate automatically decreases, avoiding energy waste. The two sets of components with opposite deflection directions ensure effective cooling circulation in both forward and reverse motor rotation, eliminating the need for an external pump source. The compact structure and rapid response enable intelligent heat dissipation management with on-demand cooling. Attached Figure Description

[0019] Figure 1 This is a front view schematic diagram of the in-situ cooling structure for the stator of a hub motor based on radial microchannels provided by the present invention.

[0020] Figure 2 This is a side view of the in-situ cooling structure for the stator of a hub motor based on radial microchannels provided by the present invention.

[0021] Figure 3 This is a schematic diagram of the exploded state of the in-situ cooling structure of the hub motor stator based on radial microchannels provided by the present invention.

[0022] Figure 4 This is a side view of the exploded state of the in-situ cooling structure for the stator of a hub motor based on radial microchannels provided by the present invention.

[0023] Figure 5 A schematic diagram of the rotor structure of the hub motor stator in-situ cooling structure based on radial microchannels provided by the present invention.

[0024] Figure 6 This is a cross-sectional schematic diagram of the in-situ cooling structure of the hub motor stator based on radial microchannels provided by the present invention.

[0025] Figure 7 A schematic diagram of the spiral cooling channel structure of the in-situ cooling structure for the stator of a hub motor based on radial microchannels, provided by the present invention.

[0026] Figure 8 A schematic diagram of the flow rate adaptive component structure of the in-situ cooling structure for the stator of a hub motor based on radial microchannels provided by the present invention.

[0027] Figure 9 A cross-sectional schematic diagram of the flow rate adaptive component of the in-situ cooling structure for the stator of a hub motor based on radial microchannels provided by the present invention.

[0028] Figure 10 A schematic diagram of the radial microchannel structure of the in-situ cooling structure for the stator of a hub motor based on radial microchannels provided by the present invention.

[0029] In the diagram: 11. Fixed outer casing; 12. Stator core; 13. Coil; 14. Rotor; 15. Permanent magnet; 16. Shaft; 17. Hub; 18. Spiral cooling channel; 21. Rear end cover; 22. Liquid inlet chamber; 23. Liquid inlet; 24. Radial microchannels; 31. Front end cover; 32. Radial manifold; 33. Manifold chamber; 34. Liquid outlet; 41. Drive ring; 42. One-way drive tooth; 43. Mounting component; 44. Pressure boosting blade; 45. One-way locking block; 46. Spring; 47. Limiting block. Detailed Implementation

[0030] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. 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.

[0031] Example 1 like Figures 1 to 10As shown, the in-situ cooling structure for the stator of a hub motor based on radial microchannels in the first aspect embodiment of the present invention includes: a hub motor mechanism, the hub motor mechanism including a fixed housing 11, a stator core 12 fixedly connected to the inner wall of the fixed housing 11, a coil 13 wound around the surface of the stator core 12, a rotor 14 disposed inside the stator core 12, a permanent magnet 15 embedded on the surface of the rotor 14, a rotating shaft 16 fixedly connected inside the rotor 14, a hub 17 fixedly connected to the end of the rotating shaft 16, and a spiral cooling channel 18 opened inside the stator core 12; and a rear end cover assembly. The rear cover assembly includes a rear cover plate 21, the surface of which is fixedly connected to the inner wall of one end of the fixed housing 11, and an inlet chamber 22 is provided inside the rear cover plate 21; the front cover assembly includes a front cover plate 31, the surface of which is fixedly connected to the inner wall of the other end of the fixed housing 11, and a radial confluence channel 32 is provided inside the front cover plate 31; the flow rate adaptive assembly includes a drive ring 41, the inner wall of which is fixedly connected to the surface of the rotating shaft 16, and a one-way drive tooth 42 is fixedly connected to the surface of the drive ring 41. In the above embodiments, it should be noted that the stator core 12 is fixedly installed on the inner wall of the fixed housing 11 to provide a magnetic circuit channel for the motor; the coil 13 is wound on the surface of the stator core 12 and generates a rotating magnetic field after being energized; the rotor 14 is located inside the stator core 12, and the permanent magnet 15 embedded on the surface interacts with the rotating magnetic field to generate electromagnetic torque; the rotating shaft 16 is fixedly connected to the rotor 14 and transmits the torque to the hub 17 to drive the wheel to rotate; the spiral cooling channel 18 is opened inside the stator core 12 as a channel for the flow of cooling medium; the rear end cover plate 21 and the front end cover plate 31 respectively close the two ends of the fixed housing 11, and the liquid inlet chamber 22 and the radial confluence channel 32 opened inside constitute the inlet and outlet channels of the cooling medium; the drive ring 41 rotates synchronously with the rotating shaft 16 to provide power input for the flow rate adaptive component; The technical effects achieved by the above embodiments are as follows: the spiral cooling channel 18 is directly opened inside the stator core 12, so that the cooling medium flows through the core heating area, realizing zero-distance contact between the cooling channel and the main heat source, resulting in a short heat transfer path and high heat exchange efficiency; the integrated design of the rear cover plate 21 and the front cover plate 31 integrates the distribution and collection structure of the cooling medium inside the end cover, resulting in a compact structure without the need for additional pipelines; the flow rate adaptive component is linked with the rotating shaft 16, providing a power basis for subsequent adaptive adjustment of cooling flow rate with rotation speed.

[0032] Example 2 like Figures 1 to 10As shown, the in-situ cooling structure for the stator of a hub motor based on radial microchannels includes all the contents of Embodiment 1. Furthermore, a liquid inlet 23 is provided on one side of the inner cavity of the liquid inlet chamber 22. Radial microchannels 24 are uniformly arranged circumferentially on the inner wall of the liquid inlet chamber 22. The ends of the radial microchannels 24 are connected to the ends of the spiral cooling channels 18. The end of the radial confluence channel 32 is connected to the other end of the spiral cooling channels 18. The other end of the radial confluence channel 32 is connected to a confluence cavity 33. A liquid outlet 3 is provided on one side of the confluence cavity 33. 4. The surface of the one-way drive tooth 42 is arc-shaped. The surface of the drive ring 41 is rotatably connected to the mounting part 43. The surface of the mounting part 43 is fixedly connected to the booster blade 44. The inner wall of the mounting part 43 is rotatably connected to the one-way latch 45. The end of the one-way latch 45 is arc-shaped. The surface of the one-way latch 45 is fixedly connected to the spring 46. The end of the spring 46 is fixedly connected to the inner wall of the mounting part 43. The surface of the one-way latch 45 is fixedly connected to the limit latch 47. The surface of the limit latch 47 overlaps with the surface of the mounting part 43. In the above embodiments, it should be noted that the inlet 23 is used to connect to the external cooling medium supply pipeline; the radial microchannels 24 are evenly opened on the inner wall of the inlet cavity 22, and the cooling medium is evenly distributed from the inlet cavity 22 to each spiral cooling channel 18; the radial manifold 32 collects the cooling medium discharged from each spiral cooling channel 18, gathers it into the manifold 33 and then discharges it through the outlet 34; the booster blades 44 push the cooling medium to flow when the mounting part 43 rotates, producing a boosting effect; the one-way locking block 45 engages with the one-way drive tooth 42 under the action of the spring 46, and when the drive ring 41 rotates with the rotating shaft 16, it drives the mounting part 43 and the booster blades 44 to rotate; the arc-shaped surface design makes the one-way drive tooth 42 engage with the one-way locking block 45 when driving in one direction, and slip when rotating in the opposite direction; the limiting locking block 47 limits the rotation angle of the one-way locking block 45 to ensure that it reliably engages with the one-way drive tooth 42; The technical effects achieved by the above embodiments are as follows: the radial microchannels 24 are uniformly arranged circumferentially, and together with the distribution function of the liquid inlet chamber 22, the cooling medium is uniformly introduced into each spiral cooling channel 18, avoiding local overheating caused by uneven flow distribution; the booster blades 44 are driven by the rotational power of the rotating shaft 16 itself, without the need for an external pump source, realizing the self-driving of cooling flow; the cooperation between the one-way locking block 45 and the arc-shaped one-way drive tooth 42 ensures that the booster blades 44 are only driven when the rotating shaft 16 rotates in one direction, avoiding the reverse drive of the booster blades 44 on the cooling medium when rotating in the opposite direction; the structure is compact and efficient, effectively utilizing the rotational kinetic energy of the motor itself.

[0033] Example 3 like Figures 1 to 10As shown, the in-situ cooling structure for the stator of a hub motor based on radial microchannels includes all the contents of Embodiment 2. Furthermore, the flow rate adaptive components are provided in two sets. The unidirectional drive teeth 42, unidirectional locking blocks 45, and booster blades 44 in the two sets of flow rate adaptive components deflect in opposite directions, so that when the rotating shaft 16 rotates clockwise or counterclockwise, it can drive one set of booster blades 44 to rotate, pushing the cooling medium forward. The radial microchannels 24, spiral cooling channels 18, and radial confluence channels 32 are all high aspect ratio microchannel arrays. The width is 0.1-1mm, the depth is 1-10mm, and the aspect ratio is not less than 5. The inlet chamber 22 forms the inlet distribution chamber. After the cooling medium enters the inlet chamber 22 through the inlet port 23, the flow rate of each radial microchannel 24 is adaptively distributed through the flow resistance matching principle to ensure uniform flow rate of multiple parallel microchannels. The radial confluence channel 32 and the confluence chamber 33 form the outlet collection chamber. After the cooling medium flows into the radial confluence channel 32 through the spiral cooling channel 18, it is collected in the confluence chamber 33 to achieve pressure balance of the cooling medium in each parallel channel. In the above embodiments, it should be noted that the two sets of flow rate adaptive components deflect in opposite directions, one set is used for driving when rotating forward and the other set is used for driving when rotating in reverse; the high aspect ratio microchannel array maximizes the heat exchange area in a limited space, and the aspect ratio of not less than 5 ensures good heat exchange efficiency; the liquid inlet chamber 22 serves as the inlet distribution chamber, and the flow resistance matching principle is used to automatically balance the flow of each parallel flow channel; the radial confluence channel 32 and the confluence chamber 33 serve as the outlet collection chamber, so that the cooling medium discharged from each flow channel is discharged after the pressure is balanced.

[0034] The technical effects achieved by the above embodiments are as follows: Two sets of flow rate adaptive components with opposite deflection directions enable the motor to effectively drive the cooling medium circulation regardless of whether it rotates forward or backward, realizing adaptive cooling under all operating conditions; the high aspect ratio microchannel array significantly increases the heat exchange area and improves the heat dissipation capacity per unit volume; the inlet distribution cavity uses the flow resistance matching principle to realize the adaptive distribution of flow of multiple parallel microchannels, effectively compensating for the flow resistance deviation caused by the difference in flow channel length; the outlet collection cavity balances the pressure of the medium discharged from each flow channel, avoiding backflow interference; the combination arrangement of radial and spiral flow channels fully adapts to the geometric characteristics of the annular stator, fundamentally eliminating the hidden danger of local overheating, realizing automatic matching of cooling flow with motor speed, enhancing heat dissipation at high speed and reducing energy consumption at low speed, providing a reliable guarantee for the high power density operation of hub motors.

[0035] Working Principle: During operation, the cooling medium enters the inlet chamber 22 inside the rear cover plate 21 through the inlet port 23. The inlet chamber 22 serves as an inlet distribution chamber, utilizing the flow resistance matching principle to achieve adaptive flow distribution of the cooling medium as it enters each radial microchannel 24. This effectively compensates for flow resistance deviations caused by differences in channel length, ensuring uniform flow across multiple parallel microchannels. The cooling medium flows through the circumferentially uniformly opened radial microchannels 24 into the spiral cooling channels 18 opened inside the stator core 12. The spiral cooling channels 18 are directly opened inside the stator core 12. As the cooling medium flows in the spiral channels, it fully exchanges heat with the heat generated by the coils 13 and the stator core 12, directly removing heat from the core heating area. The spiral channel design increases the contact time and heat exchange area between the cooling medium and the heat source. The high aspect ratio microchannel array maximizes the heat exchange area within a limited space, significantly improving heat dissipation efficiency. After absorbing heat, the cooling medium flows out from the other end of the spiral cooling channel 18 and enters the radial confluence channel 32 inside the front cover plate 31. The radial confluence channel 32 collects the cooling medium discharged from each channel and gathers it into the confluence chamber 33, achieving pressure equalization of the cooling medium in each parallel channel and avoiding backflow interference. Finally, it is discharged through the outlet 34, completing one cooling cycle. The flow rate adaptive component uses the rotational power of the motor to drive the cooling medium circulation. When the rotating shaft 16 rotates, the drive ring 41 fixed on its surface rotates accordingly. The arc-shaped one-way drive teeth 42 on the surface of the drive ring 41 cooperate with the one-way locking block 45 rotatably connected to the inner wall of the mounting part 43. When the shaft 16 rotates clockwise, the one-way drive gear 42 pushes the one-way latch 45 in a set of flow rate adaptive components, causing the mounting part 43 to rotate synchronously with the drive ring 41, driving the booster blades 44 to rotate and pushing the cooling medium forward. At this time, the one-way latch 45 in the other set of flow rate adaptive components with opposite deflection direction slips under the action of the arc surface and does not participate in the drive. When the shaft 16 rotates counterclockwise, the functions of the two sets of components are reversed, and the other set of booster blades 44 starts to work, ensuring that the motor can effectively drive the circulation of cooling medium regardless of whether it rotates forward or backward. Since the speed of the booster blades 44 is proportional to the speed of the shaft 16, when the motor is running at high speed and the heat generation increases, the speed of the booster blades 44 increases synchronously, the flow rate of the cooling medium increases, and the heat dissipation capacity is enhanced; when the motor is running at low speed and the heat generation is small, the cooling flow rate automatically decreases to avoid energy waste. This design achieves adaptive matching of cooling flow rate with motor speed, requires no external pump source, and has a compact structure and rapid response. The entire cooling system achieves full-process optimization from inlet distribution, in-situ heat exchange, to outlet collection: the combination of radial microchannels and spiral cooling channels fully adapts to the geometric characteristics of the annular stator; the inlet distribution cavity and outlet collection cavity ensure uniform flow in each parallel channel; the high aspect ratio microchannel array maximizes the heat exchange area; and the bidirectional flow rate adaptive component enables on-demand cooling.This structure effectively solves the technical problems of high thermal resistance, uneven flow distribution, and inability to adaptively adjust the traditional water-cooled casing, providing a reliable thermal management solution for the high power density operation of hub motors.

Claims

1. A radial microchannel-based in-situ cooling structure for a hub motor stator, characterized in that, include: The hub motor mechanism includes a fixed housing (11), a stator core (12) fixedly connected to the inner wall of the fixed housing (11), a coil (13) wound on its surface, a rotor (14) inside, a permanent magnet (15) embedded on the surface of the rotor (14), a rotating shaft (16) fixedly connected inside, a hub (17) fixedly connected to the end of the rotating shaft (16), and a spiral cooling channel (18) opened inside the stator core (12). The rear end cover assembly includes a rear end cover plate (21), the surface of which is fixedly connected to the inner wall of one end of the fixed housing (11), and an inlet chamber (22) is provided inside, which is connected to the inlet of the spiral cooling channel (18). The front cover assembly includes a front cover plate (31), the surface of which is fixedly connected to the inner wall of the other end of the fixed housing (11), and a radial confluence channel (32) is provided inside, which is connected to the outlet of the spiral cooling channel (18). The flow rate adaptive component includes a drive ring (41), the inner ring wall of the drive ring (41) is fixedly connected to the surface of the rotating shaft (16), and the outer ring surface of the drive ring (41) is fixedly connected with a unidirectional drive tooth (42).

2. The in-situ cooling structure of a radial micro-channel based hub motor stator according to claim 1, characterized in that, The liquid inlet (23) is provided on one side of the inner cavity of the liquid inlet chamber (22), and radial microchannels (24) are uniformly opened on the inner wall of the liquid inlet chamber (22) in the circumferential direction. The end of the radial microchannel (24) is connected to the end of the spiral cooling channel (18). The end of the radial manifold (32) is connected to the other end of the spiral cooling channel (18), and the other end of the radial manifold (32) is connected to the manifold cavity (33), and a liquid outlet (34) is provided on one side of the manifold cavity (33).

3. The radial microchannel-based in-wheel motor stator in-situ cooling structure according to claim 2, characterized by The radial microchannel (24) radiates radially, and its radial distal end is connected to the end of the spiral cooling channel (18); The radial confluence channel (32) radiates radially, and its radial distal end is connected to the other end of the spiral cooling channel (18); The radial microchannels (24), spiral cooling channels (18) and radial confluence channels (32) are of the same number and are connected in a one-to-one correspondence.

4. The radial microchannel-based in-hub motor stator in situ cooling structure of claim 2, wherein, The radial microchannels (24), spiral cooling channels (18) and radial confluence channels (32) are all high aspect ratio microchannel arrays with a channel width of 0.1 to 1 mm, a depth of 1 to 10 mm, and an aspect ratio of not less than 5.

5. The radial microchannel-based in-wheel motor stator in-situ cooling structure according to claim 2 or 3 or 4, characterized by, The liquid inlet chamber (22) constitutes the inlet distribution chamber. After the cooling medium enters the liquid inlet chamber (22) through the liquid inlet (23), the flow rate of each radial microchannel (24) is adaptively distributed through the flow resistance matching principle to ensure that the flow rate of the multi-parallel microchannels is uniform. The radial manifold (32) and the manifold cavity (33) form an outlet collection cavity. The cooling medium flows into the radial manifold (32) through the spiral cooling channel (18) and then gathers into the manifold cavity (33), thereby achieving pressure balance of the cooling medium in each parallel channel.

6. The in-situ cooling structure for the stator of a hub motor based on radial microchannels according to claim 1, characterized in that, The end of the unidirectional drive tooth (42) is arc-shaped, and the surface of the drive ring (41) is rotatably connected to the mounting part (43). The mounting part (43) is ring-shaped and is coaxially installed with the drive ring (41). The outer wall surface of the mounting part is fixedly connected to the booster blade (44).

7. The in-situ cooling structure for the stator of a hub motor based on radial microchannels according to claim 6, characterized in that, The inner wall of the mounting component (43) is connected to a one-way locking block (45). The end of the one-way locking block (45) is arc-shaped and is in the opposite direction to the arc of the end of the one-way drive tooth (42) and in contact with it, so that the drive ring (41) can rotate in only one direction.

8. The in-situ cooling structure for the stator of a hub motor based on radial microchannels according to claim 7, characterized in that, The one-way locking block (45) is connected to the inner wall of the mounting part (43) via a rotating shaft. The rotating shaft is parallel to the central axis of the mounting part (43). The surface of the one-way locking block (45) is fixedly connected to the inner wall of the mounting part (43) via a spring (46). A limit locking block (47) is fixedly connected to the surface of the one-way locking block (45). The surface of the limit locking block (47) overlaps with the surface of the mounting part (43).

9. The in-situ cooling structure for the stator of a hub motor based on radial microchannels according to claim 8, characterized in that, One end of a spring (46) is connected to the inner side of the arc-shaped end of the one-way block (45), and the other end of the spring (46) is fixedly connected to the inner wall of the mounting part (43) so that the one-way block (45) can be reset after being pressed by the rotating one-way drive tooth (42).

10. The in-situ cooling structure for the stator of a hub motor based on radial microchannels according to claim 6, 7, 8, or 9, characterized in that, The flow rate adaptive component is provided in two sets. The unidirectional drive teeth (42), unidirectional locking blocks (45) and booster blades (44) in the two sets of flow rate adaptive components have opposite deflection directions, so that when the rotating shaft (16) rotates clockwise and counterclockwise, it can drive a set of booster blades (44) to rotate, thus pushing the cooling medium to flow forward.

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