Axial flux pulley motor

Abstract

This invention belongs to the field of motor technology and discloses an axial flux pulley motor. The invention comprises a main shaft system, a drive system, a detection system, and connecting and fastening components. This structure simplifies the power transmission path and reduces intermediate transmission links by coaxially integrating a disc-type permanent magnet motor with the main shaft system, thereby improving transmission efficiency and reducing energy loss. Simultaneously, the keyed connection structure ensures reliable torque transmission between the motor and the main shaft, preventing slippage or failure. The double-sleeve structure provides effective support for the main shaft, enabling it to maintain good stability and coaxiality during high-speed operation, helping to reduce vibration and noise and improve the smoothness of equipment operation.

Description

Technical Field

[0001] This invention belongs to, but is not limited to, the field of motor technology, and particularly relates to an axial flux pulley motor. Background Technology

[0002] Quay cranes (shore-side container cranes) and yard cranes (rail-mounted / rubber-mounted container gantry cranes) are core equipment in port loading and unloading operations, with their lifting mechanisms responsible for raising and lowering containers. During container lowering, the lifting mechanism's braking system needs to convert a significant amount of gravitational potential energy into heat energy for dissipation. Traditional solutions typically employ resistance braking or mechanical braking, resulting in extremely low energy utilization. This not only leads to substantial energy waste but also causes problems such as overheating of the braking resistors and frequent maintenance. Statistics show that energy waste during the lowering braking process of container terminal lifting mechanisms accounts for 30% to 40% of the total energy consumption of the machine, indicating significant potential for energy saving.

[0003] In recent years, the requirements for energy conservation and emission reduction in port equipment have been increasing. Utilizing the gravitational potential energy generated during the descent of the hoisting mechanism for power generation has become an important technological development direction. In existing technologies, energy feedback schemes mainly achieve this by adding an external generator and frequency conversion feedback device to the transmission system. However, this scheme requires additional generators, couplings, reducers, and other equipment, resulting in long transmission chains, complex systems, large space requirements, and additional efficiency losses and failure risks introduced by intermediate transmission links.

[0004] Axial flux motors / generators offer significant advantages in direct-drive applications due to their flat disc structure, high power density, high torque density, and excellent heat dissipation characteristics. Compared to traditional radial flux motors, the disc geometry of axial flux motors is naturally well-suited for structural integration with disc-shaped or ring-shaped components of rotating machinery. However, current technologies have not yet achieved deep structural integration of axial flux generators with container terminal lifting pulleys, and there is a lack of specialized magnetic circuit designs and heat dissipation optimization schemes for the power generation operation mode under port lifting conditions.

[0005] Therefore, there is an urgent need for a technical solution that deeply integrates axial flux generators with container terminal lifting pulleys, so as to directly utilize the rotation of pulleys to generate electricity and feed it back without adding additional transmission links, thereby improving the energy efficiency of port lifting equipment and reducing operating costs and carbon emissions.

[0006] Based on the above analysis, the problems and shortcomings of the existing technology are as follows:

[0007] Existing technologies have not yet achieved deep structural integration of axial flux generators with container terminal lifting pulleys, and also lack specialized magnetic circuit design and heat dissipation optimization schemes for power generation operation modes under port lifting conditions. Summary of the Invention

[0008] To address the problems existing in the prior art, the present invention provides an axial flux pulley motor.

[0009] This invention is implemented as follows: an axial flux pulley motor, comprising:

[0010] The spindle is configured to be stationary;

[0011] The pulley assembly is rotatably mounted on the main shaft for receiving external power to rotate;

[0012] A disc-type permanent magnet motor includes an outer rotor and a stator. The outer rotor is fixedly connected to the pulley assembly so as to rotate synchronously with the pulley assembly. The stator is fixedly arranged relative to the main shaft.

[0013] A detection system is used to detect the rotational state of the pulley assembly, the detection system comprising:

[0014] The first encoder gear is fixed on the main shaft and remains stationary;

[0015] The second encoder gear is associated with the encoder connection plate;

[0016] The first encoder gear meshes with the second encoder gear;

[0017] The encoder connecting plate is configured to rotate driven by the pulley assembly, so that the second encoder gear simultaneously rotates on its own axis and revolves around the first encoder gear, thereby transmitting the angular displacement of the pulley assembly to the encoder mounted on the encoder connecting plate.

[0018] Furthermore, it also includes a pulley assembly, which is assembled with the pulley to transmit power to external equipment and / or adjust the output speed or change the transmission direction.

[0019] Furthermore, it also includes a first bushing and a second bushing, which are respectively disposed on the main shaft to constrain the axial and radial positions of the main shaft.

[0020] Furthermore, it also includes bolts for fastening, pins for positioning, and screws for securing accessories.

[0021] Furthermore, it also includes an grease nipple and a steel wire, the grease nipple being used to apply grease to the bearing and the moving mating surfaces, and the steel wire being used to fasten the fasteners to prevent loosening.

[0022] The present invention also provides an angular displacement detection device for a device in which the main shaft is stationary and a rotating component rotates around the main shaft, comprising:

[0023] The first gear is used to fix it on the stationary main shaft;

[0024] Second gear;

[0025] An encoder connection plate, associated with the second gear, is configured to rotate with the rotating member;

[0026] The first gear and the second gear mesh with each other. When the encoder connecting plate is driven to rotate by the rotating component, the second gear simultaneously rotates on its own axis and revolves around the first gear to transmit the angular displacement of the rotating component to the encoder mounted on the encoder connecting plate.

[0027] Furthermore, the second gear is rotatably mounted on the encoder connection plate.

[0028] Furthermore, an encoder is fixed on the encoder connection plate.

[0029] Furthermore, both the first gear and the second gear are encoder gears.

[0030] Furthermore, the device is an axial flux pulley motor, and the rotating component is a pulley assembly.

[0031] Based on the above technical solutions and the technical problems solved, the advantages and positive effects of the technical solution to be protected by this invention are as follows:

[0032] The structure of this invention simplifies the power transmission path and reduces intermediate transmission links by coaxially integrating the disc-type permanent magnet motor with the spindle system, thereby improving transmission efficiency and reducing energy loss. Simultaneously, the keyed connection structure ensures reliable torque transmission between the motor and the spindle, preventing slippage or failure.

[0033] This invention provides effective support for the main shaft by setting up a double-sleeve structure, enabling it to maintain good stability and coaxiality during high-speed operation, which helps to reduce vibration and noise and improve the smoothness of equipment operation.

[0034] The combined design of the first and second encoder gears in this invention allows the spindle motion to be directly transmitted to the detection system, enabling precise measurement of rotational speed and position, which helps improve the system's control accuracy. The encoder connection plate further enhances the installation reliability and adjustment convenience of the detection element.

[0035] The pulley assembly and configuration of the present invention enable the structure to have a certain transmission expansion capability, and can be connected with other mechanical systems as needed to enhance the applicability of the equipment.

[0036] This invention improves the assembly reliability and operational safety of the overall structure by using a variety of standard fasteners in combination with anti-loosening structures; the oil nozzles facilitate maintenance and lubrication, which helps to extend service life.

[0037] The structure of this invention achieves a comprehensive effect of compact structure, stable transmission and accurate detection while ensuring transmission and detection functions.

[0038] (1) The technical solution of this invention fills a technical gap in the domestic and international industry: The invention of this motor is mainly for use in quay cranes as a generator, allowing it to generate electricity during the trolley or hoisting process. After passing through an energy conversion device, it generates three-phase AC power to supply the trolley. The purpose of the entire system is to replace the crane trolley towing system, solving the problem of difficult maintenance of the crane trolley towing system. It changes the uncontrollable maintenance to real-time monitoring of system operation, enabling early maintenance and early troubleshooting.

[0039] (2) The technical solution of the present invention solves a technical problem that people have long wanted to solve but have never been able to solve successfully: how to combine pulleys and motors in a limited space to make the power generation structure more compact and efficient. Existing structural methods are based on this specific space and require special motor design.

[0040] (3) The technical solution of the present invention overcomes the technical prejudices: firstly, pulleys cannot generate electricity, and the electricity they generate is waste electricity and cannot be used; secondly, the torque generated by the electricity is uncontrollable. This motor solves all of the above problems. Attached Figure Description

[0041] Figure 1 This is a front view of the axial flux pulley motor provided in an embodiment of the present invention;

[0042] Figure 2 This is an axial cross-sectional view of the axial flux pulley motor provided in an embodiment of the present invention;

[0043] Figure 3 This is a rear view of the axial flux pulley motor provided in an embodiment of the present invention;

[0044] Figure 4 This is an internal view of the axial flux pulley motor provided in an embodiment of the present invention;

[0045] Figure 5 This is a front view of the disc-type permanent magnet motor provided in an embodiment of the present invention;

[0046] Figure 6 This is a rear view of the disc-type permanent magnet motor provided in an embodiment of the present invention;

[0047] Figure 7 This is an axial sectional view of the disc-type permanent magnet motor provided in an embodiment of the present invention;

[0048] Figure 8 This is the wireless power supply system for shore bridges provided in the embodiments of the present invention;

[0049] Figure 9 This is provided by the embodiments of the present invention. Figure 8 The cross-sectional view shown in the red box above;

[0050] In the diagram: 1. First encoder gear; 2. Second encoder gear; 3. Main shaft end cover; 4. Bushing (106); 5. Main shaft (motor); 6. Pulley assembly (900); 7. Bushing (59); 8. Disc permanent magnet motor (18.5); 9. Key 40*22*63; 10. Pulley assembly (motor); 11. Encoder connecting plate; B1. Screw M6*35; B2. Pin 6*20-B; B3. Oil nozzle PT1 / 4; B4. Bolt M20*45; B5. Steel wire φ2; B6. Pin M20*45-B; B7. Bolt M20*1.5*40; B8. Steel wire φ2; B9. Screw M6*30; B10. Bolt M10*25. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0052] The axial flux pulley motor provided in this invention is an integrated device that converts the mechanical energy of a pulley into electrical energy and also functions as a power transmission and status detection system. The entire system consists of a spindle system, a drive system, a detection system, and connecting and fastening components working together. It has the ability to adapt and adjust the speed and direction of rotation. Its working process is described in detail below.

[0053] External power, such as a steel wire rope, directly drives the pulley assembly to rotate. During this process, the main shaft remains stationary and does not rotate. The outer rotor of the disc-type permanent magnet motor is rigidly connected to the pulley assembly, so when the pulley assembly is driven, the outer rotor rotates synchronously. The outer rotor itself carries permanent magnets, and its rotation constitutes the driving force of the power generation process. The stationary and stable state of the main shaft is due to the bushings arranged before and after it. These bushings tightly constrain the axial and radial degrees of freedom of the main shaft, ensuring extremely high stability and transmission accuracy in the rotational motion of the entire rotor assembly and preventing eccentric wobbling.

[0054] Meanwhile, the pulley assembly works in conjunction with the pulley system to output a portion of the rotational power. Whether driving other mechanisms within the system or providing mechanical energy to external equipment, this assembly can achieve this by switching connection methods. More importantly, by using different specifications of pulleys or belt pulley combinations, the output speed can be flexibly adjusted, and even the transmission direction can be changed, allowing the same device to adapt to different operating conditions without frequent replacements of the entire machine.

[0055] The generation of electrical energy relies entirely on a disc-type permanent magnet motor operating in generator mode. The motor's outer rotor contains permanent magnets with a high magnetic energy product, while the stator windings are integrated into a structure fixed relative to the stationary main shaft. When the pulley drives the outer rotor to rotate, a continuous relative motion occurs between the magnetic field established by the permanent magnets and the stator windings. According to the law of electromagnetic induction, the effective conductors of the stator windings continuously cut magnetic lines of force, causing periodic changes in the internal magnetic flux, thereby inducing an electromotive force (EMF) in the windings. As the rotor speed increases, the frequency and amplitude of the induced EMF also change accordingly. Throughout the entire power generation process, the main shaft remains stationary, ensuring no rotational displacement on the stator side. This provides a stable support environment for the winding leads and insulation structure, and also guarantees the reliability of power transmission. The generated alternating current can be rectified and regulated by subsequent power electronic devices for use by downstream loads or storage.

[0056] To achieve precise condition monitoring and closed-loop control, the device incorporates a gear-based detection system, primarily consisting of a first encoder gear, a second encoder gear, and an encoder connecting plate. The first encoder gear is directly mounted on the stationary main shaft, thus remaining absolutely stationary and serving as the reference end of the entire detection chain. The second encoder gear is connected to the encoder connecting plate and can be driven by the rotation of the pulley. The two gears mesh precisely, forming a differential or planetary gear train-like angular displacement transmission relationship.

[0057] As the pulley rotates, the encoder connecting plate is driven, forcing the second encoder gear to both rotate on its own axis and revolve around the fixed first encoder gear. This combined motion accurately and without slippage converts the pulley's angular displacement into a relative rotation signal that the encoder on the encoder connecting plate can sense. The encoder thus reads the pulley's speed, direction of rotation, and specific angular position in real time and outputs these signals to the control unit. This system does not rely on a separate coupling or additional drive shaft, has a compact structure, strong anti-interference capabilities, and is ideally suited for providing high-precision speed and position feedback in vibrating environments.

[0058] The long-term reliability of the entire machine under heavy load or alternating operating conditions relies on a comprehensive support and fastening system. The bushing not only supports the main shaft but also provides a definite center of rotation for the rotor and withstands radial and axial loads. Multiple fasteners of various sizes perform their specific functions: M20×45 bolts withstand tensile and shear forces between the main structural components, ensuring rigid connections; M20×45-B pins provide precise positioning and prevent relative misalignment; M6×35 screws and other fasteners secure small accessories or covers, preventing loosening. Furthermore, the system is equipped with PT1 / 4″ grease fittings for periodic grease application to bearings and moving surfaces, reducing friction and wear. A φ2 steel wire acts as an anti-loosening element, passing through the bolt head or threaded hole to lock multiple fasteners in series, while also providing sealing and anti-loosening functions at certain mating surfaces. Even under continuous vibration, all connections remain firm and reliable. The synergy of these components ensures that the entire motor can operate safely and smoothly continuously, regardless of frequent start-stop cycles, sudden load changes, or environmental vibrations.

[0059] Through close collaboration in the above four aspects, this axial flux pulley motor fully realizes the conversion from mechanical energy input to electrical energy output, while also possessing the capabilities of flexible power distribution, free adaptation of speed and direction, and high-precision status detection.

[0060] like Figure 1 As shown in the figure, the embodiment of the present invention provides an axial flux pulley motor and a transmission structure integrating disc permanent magnet motor drive and encoder measurement functions. The whole structure is coaxially arranged along the main shaft axis and mainly consists of a main shaft system, a drive system, a detection system and connecting fastening components.

[0061] like Figure 2 , Figure 3 , Figure 4 The spindle system includes a spindle (motor) 5, a spindle end cover 3, and two bushings, namely bushing (106) 4 and bushing (59) 7. The spindle 5 is the core transmission component of the whole machine, which undertakes the functions of power output and torque transmission. Its two ends are supported and positioned by bushings 4 and 7 to ensure the coaxiality and stability of the spindle during rotation. The spindle end cover 3 is set at one end of the spindle to enclose the structure and protect the bearings and internal components, while providing an installation reference for external components.

[0062] like Figure 5 , Figure 6 , Figure 7The drive system mainly includes a disc permanent magnet motor (18.5) 8 and associated pulley assembly (900) 6 and pulley assembly (motor) 10. The disc permanent magnet motor 8 is mounted on one side of the main shaft and is reliably torque-connected to the main shaft 5 via key 40*22*63 (9), so that the rotational power output by the motor is directly transmitted to the main shaft. The pulley assembly 6 and pulley assembly 10 are respectively arranged on the main shaft and the motor side, and are used to realize auxiliary power transmission or linkage with external systems. Their structure is fixed by axial fit and fasteners to ensure the stability of the transmission process.

[0063] The detection system includes a first encoder gear 1, a second encoder gear 2, and an encoder connecting plate 11. The first encoder gear and the second encoder gear are meshed or engaged with each other, with one gear connected to the main shaft 5 and the other gear associated with the encoder connecting plate 11, thereby transmitting the rotational motion of the main shaft to the encoder detection unit. The encoder connecting plate 11 is used to mount and fix the encoder elements, enabling them to accurately acquire displacement or angular change information during gear transmission.

[0064] The connection and fastening components include various standard parts: M6*35 screws (B1), 6*20-B pins (B2), PT1 / 4 grease fittings (B3), M20*45 bolts (B4), φ2 steel wires (B5, B8), M20*45-B pins (B6), M20*1.5*40 bolts (B7), M6*30 screws (B9), and M10*25 bolts (B10). These fasteners are used for connection, positioning, and anti-loosening between various components. Pins are used for positioning, bolts and screws for structural connection, steel wires for anti-loosening measures, and grease fittings for lubrication and maintenance.

[0065] Magnets are mounted on the front and rear housings, which together form the rotor of the motor.

[0066] The cast coil, upper fixing ring, and lower fixing ring together form the stator of the motor;

[0067] The rotor and stator are connected by bearings;

[0068] The stator is fixed on the central axis.

[0069] This structure uses a disc-type permanent magnet motor 8 as the power source, and it is an external rotor motor. When the wire rope drives the pulley to rotate, the pulley directly drives the external rotor of the disc-type permanent magnet motor 8 to rotate, thereby generating electrical energy. The main shaft maintains stable rotation under the support and guidance of the bushings 4 and 7, and its axial and radial positions are effectively constrained, thus ensuring the overall transmission accuracy.

[0070] During the operation of the pulley, the main shaft remains stationary, with only the steel wire rope driving the pulley to rotate, which in turn drives the outer rotor of the disc permanent magnet motor 8 to rotate and generate electricity. Simultaneously, the pulley assembly 6, connected to the pulley, rotates synchronously and, through its cooperation with the pulley assembly 10, transmits power to internal or external equipment. This pulley structure can also be used to adjust the speed or change the transmission direction, giving the entire system good transmission adaptability. Meanwhile, power is transmitted from the first encoder gear to the second encoder gear; the meshing relationship between the two converts the angular displacement of the main shaft into synchronous gear motion. The encoder mounted on the encoder connection plate 11 detects the gear motion state, enabling real-time acquisition of the main shaft's speed, position, or angle information. This detection signal can be used in the control system to monitor the motor's operating status or achieve closed-loop control.

[0071] During operation, all connecting parts are fastened and positioned using bolts, pins, etc., to ensure the stability of each component.

[0072] The relative positions between them are stable; the wire structure is used to prevent fasteners from loosening; the oil nozzle B3 is used to periodically replenish lubricating oil to the internal transmission parts, reduce friction and wear, and ensure long-term stable operation.

[0073] Specific implementation of the present invention:

[0074] The main technical parameters of the generator in this embodiment are shown in Table 1:

[0075] Table 1 Motor Parameter Table

[0076]

[0077] 1. Unique pulley motor structure: It uses a special disc motor combined with a pulley, allowing the pulley to generate electricity as it is driven by a steel wire rope. It can generate electricity whether rotating forward or backward.

[0078] 2. Current Application Cases of Motors

[0079] like Figure 8 , Figure 9 Wireless power system

[0080] As the wire rope moves, it drives the pulley motor to generate electricity, which is then supplied to the energy storage system. The electricity is then converted into sinusoidal AC380 through a conversion device to power the load on the trolley.

[0081] Under heavy load conditions of up to 27T, the motor performed exceptionally well. In 24 sets of ascending and descending movements, the output power (GEN1 / GEN2) repeatedly showed significant negative values ​​(e.g., -46W for descending in the second row, and -49W for descending in the fourth row). This directly proves that the disc permanent magnet motor, driven by the pulley, successfully achieves efficient and active recovery of mechanical kinetic energy into electrical energy. Especially during heavy-load descent, the motor's power generation is significant, completely solving the problem of energy waste in traditional systems under heavy loads.

[0082] The comprehensive measurement data strongly supports the energy-saving effect. Within a test period of approximately 14.14 minutes (11 MOV cycles):

[0083] The average energy consumption is 0.4224 kWh / MOV.

[0084] *The total average energy saving is as high as 0.6658 kWh / MOV.

[0085] **Key Point:** The energy savings far exceed the energy consumption! This means that the system's energy recovery not only completely offsets its own operating losses but also achieves positive net energy savings, feeding back energy to the equipment and the power grid. Combined with the non-operating current of 6.4A and power consumption, this demonstrates extremely excellent energy management under both no-load and heavy-load conditions.

[0086] The encoder detects gear movement and grease nipple lubrication / fastening structure, ensuring that the system can accurately maintain spindle speed and position even under the huge impact torque brought by heavy load (27T). The neat and repetitive shaft current and voltage data in the attached figure prove the transmission accuracy, stability and extremely low wear rate of the system under harsh heavy load environment, effectively extending the equipment maintenance cycle and service life.

[0087] In the description of this invention, unless otherwise stated, "multiple" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," and "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0088] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions, and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention, and within the spirit and principles of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An axial flux pulley motor, characterised in that, include: The spindle is configured to be stationary; The pulley assembly is rotatably mounted on the main shaft for receiving external power to rotate; A disc-type permanent magnet motor includes an outer rotor and a stator. The outer rotor is fixedly connected to the pulley assembly so as to rotate synchronously with the pulley assembly. The stator is fixedly arranged relative to the main shaft. A detection system is used to detect the rotational state of the pulley assembly, the detection system comprising: The first encoder gear is fixed on the main shaft and remains stationary; The second encoder gear is associated with the encoder connection plate; The first encoder gear meshes with the second encoder gear; The encoder connecting plate is configured to rotate driven by the pulley assembly, so that the second encoder gear simultaneously rotates on its own axis and revolves around the first encoder gear, thereby transmitting the angular displacement of the pulley assembly to the encoder mounted on the encoder connecting plate.

2. The axial flux pulley motor of claim 1, wherein, It also includes a pulley assembly, which is assembled with the pulley to transmit power to external equipment and / or adjust the output speed or change the transmission direction.

3. The axial flux pulley motor of claim 1, wherein, It also includes a first bushing and a second bushing, which are respectively disposed on the main shaft to constrain the axial and radial positions of the main shaft.

4. The axial flux pulley motor of claim 1, wherein, It also includes bolts for fastening, pins for positioning, and screws for securing accessories.

5. The axial flux pulley motor of claim 1, wherein, It also includes grease fittings and steel wires, the grease fittings being used to apply grease to bearings and moving mating surfaces, and the steel wires being used to fasten fasteners to prevent loosening.

6. An angular displacement detection device for a device in which the main shaft is stationary and a rotating component rotates around the main shaft, characterized in that, include: The first gear is used to fix it on the stationary spindle; Second gear; An encoder connection plate, associated with the second gear, is configured to rotate with the rotating member; The first gear and the second gear mesh with each other. When the encoder connecting plate is driven to rotate by the rotating component, the second gear simultaneously rotates on its own axis and revolves around the first gear to transmit the angular displacement of the rotating component to the encoder mounted on the encoder connecting plate.

7. The angular displacement sensing device of claim 6, wherein The second gear is rotatably mounted on the encoder connection plate.

8. The angular displacement detection device according to claim 6, characterized in that, An encoder is fixed on the encoder connection plate.

9. The angular displacement detection device according to claim 6, characterized in that, Both the first gear and the second gear are encoder gears.

10. The angular displacement sensing device of claim 6, wherein, The device is an axial flux pulley motor, and the rotating component is a pulley assembly.

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