Preform axial flux motor process design and manufacturing method

Abstract

This application presents a preformed axial flux motor process design and manufacturing method, further improving upon prior applications by proposing a stamping preformation process. Since the slot windings and end windings of the axial flux motor are essentially on the same plane or common parallel plane, they can be integrally stamped, reducing the flat wire winding forming process, improving production efficiency and forming accuracy, and reducing the length and resistance of the end windings. All phases and slots corresponding to the windings in the same plane can be stamped in one go, and the connecting conductors at the inner and outer ring ends can be removed after overall assembly, greatly improving processing and assembly efficiency. Insulating films are set between layers. Since the end winding mating surfaces of all layers of the axial flux motor are in a stacked relationship, the electrical connection relationship of each circuit can be achieved by pressing them together in one go with the insulating films in place. The mating area is large and the force is uniform, making it suitable for mechanical pressure mating to achieve electrical connection; alternatively, welding can be used.

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