A small volume energy conversion device

Abstract

This invention relates to a small-volume energy conversion device, comprising a main shaft; a rotor mechanism mounted on a rotating bearing of the main shaft; and a stator mechanism comprising multiple sets of axially overlapping coil layers fixed to the main shaft. Each coil layer comprises multiple sets of conductor coils, wherein each conductor coil has a first end and a second end that are oppositely arranged and bent at different layers. The first end and the second end are both located on a side adjacent to the main shaft, and the first end of each conductor coil has a bend of not 0 degrees or 180 degrees, forming a raised bend portion. This bend portion is used for welding to the end face of the second end of another adjacent conductor coil. This invention reduces the overall volume by locating the welding points of the conductor coils in the stator mechanism on the inner side adjacent to the main shaft and utilizing the raised bend portion of the conductor coils for welding.

Description

Technical Field

[0001] This invention relates to an axial magnetic flux energy conversion device, and more particularly to a small-volume energy conversion device. Background Technology

[0002] The description in this section provides only background information related to the disclosure of this invention and does not constitute prior art.

[0003] Axial flux motors / generators, with their high power density, compact axial dimensions, and excellent torque performance, have a significantly better application prospect than traditional radial flux motors in the fields of new energy vehicles and high-end industrial drives. However, the characteristics of axial flux make its basic structural design inherently difficult in terms of manufacturing processes, especially in the stator structure.

[0004] In some existing axial flux devices, the stator is composed of bent linear conductor coils. To form a complete circuit, each set of conductor coils needs to be physically connected to another set. To facilitate welding, in welding connection schemes, the welding point is generally located on the outermost part of the stator furthest from the main shaft. This structure results in the stator generally having a reserved outer edge without magnetic flux, which cannot keep the edge flush with the rotor, leading to an increase in the size of the motor or generator.

[0005] It should be noted that the above description of the technical background is only for the purpose of providing a clear and complete explanation of the technical solutions of the present invention and facilitating understanding by those skilled in the art. It should not be assumed that the above technical solutions are known to those skilled in the art simply because they have been described in the background section of this invention. Summary of the Invention

[0006] The purpose of this invention is to provide a small-volume energy conversion device that reduces the overall volume by setting the welding points of the conductor coils in the stator mechanism on the inner side near the main shaft and welding them using the bent and raised parts of the conductor coils.

[0007] To achieve the above objectives, the present invention discloses a small-volume energy conversion device for assembly in an axial flux motor or axial flux generator, wherein the small-volume energy conversion device comprises: spindle; A rotor mechanism, wherein the rotor mechanism is sleeved and mounted on the rotary bearing of the main shaft; A stator mechanism includes multiple sets of coil layers arranged axially overlapping each other. The multiple sets of coil layers are sleeved and fixed on the main shaft. Each coil layer includes multiple sets of conductor coils. Each conductor coil has a first end and a second end that are arranged opposite to each other and bent in different layers. The first end and the second end are both located on the side adjacent to the main shaft. The first end of each conductor coil has a bend that is not 0 degrees or 180 degrees and forms a raised bend. The bend is used to weld with the end face of the second end of another adjacent conductor coil.

[0008] As a further description of the above technical solution, the bent portion of the conductor coil is configured to be bent at 90 degrees along the axial direction, so that the second end face of the conductor coil is radially bonded to the side wall of the other bent portion.

[0009] As a further description of the above technical solution, the length of the bent portion is greater than the thickness of the second end face of the conductor coil.

[0010] As a further description of the above technical solution, the second end face of the conductor coil is welded to the middle position of the side wall of the bent portion.

[0011] As a further description of the above technical solution, the conductor coil is configured as three parallel flat copper wires.

[0012] As a further description of the above technical solution, each of the flat copper wires has at least one vertical flat bend along the wide surface, such that the flat copper wire is folded into a double layer.

[0013] As a further description of the above technical solution, each of the flat copper wires has at least one horizontal vertical bend along the narrow face, so that the upper and lower layers of the flat copper wires are staggered.

[0014] As a further description of the above technical solution, the flat copper wire has one and only one vertical flat bend, and the bend is located at the end away from the main shaft.

[0015] As a further description of the above technical solution, the fold is aligned with the outer edge of the rotor along the axial direction.

[0016] As a further description of the above technical solution, the energy conversion device has a first end and a second end arranged opposite to each other along the axial direction, and the number of rotor mechanisms is set to two sets, one set of rotor mechanisms is arranged on one side of the first end of the stator mechanism, and the other set of rotor mechanisms is arranged on one side of the second end of the stator mechanism, and the gap size between the two sets of rotor mechanisms and the stator mechanism is equal.

[0017] By employing the above technical solutions, the beneficial effects of the present invention are as follows: The small-volume energy conversion device of the present invention reduces the overall volume by placing the welding points of the conductor coils in the stator mechanism on the inner side adjacent to the main shaft and welding them using the bent and raised portions of the conductor coils. Specifically, the coil layer of the stator mechanism in the present invention can be composed of multiple sets of conductor coils welded together. The first end of each conductor coil is bent to form a raised portion, and the bent portion is located on the inner side adjacent to the main shaft. Therefore, the outer side of the coil layer away from the main shaft is the main body, which can achieve a perfect fit between the projection surface of the outer edge of the stator mechanism and the rotor mechanism. By placing the welding points of the functional parts on the inner main shaft where the impact is relatively small, the overall volume is significantly reduced while ensuring magnetic flux performance. Indirectly, the outer diameter of the main shaft can be made larger, and the structure is more stable.

[0018] To further understand the features and technical content of the present invention, please refer to the following detailed description and drawings of the present invention. However, the drawings provided are for reference and illustration only and are not intended to limit the present invention. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments or prior art of this specification, the drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this specification. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the welding connection of a small-volume energy conversion device provided in the embodiments of this specification; Figure 2 This is a schematic diagram of the conductor coil of a small-volume energy conversion device provided in the embodiments of this specification; Figure 3 This is a schematic diagram of the coil layer of a small-volume energy conversion device provided in the embodiments of this specification; Figure 4 This is an exploded schematic diagram of a small-volume energy conversion device provided in the embodiments of this specification; Figure 5 This is a three-dimensional schematic diagram of a small-volume energy conversion device provided in the embodiments of this specification; In the picture: 1. Spindle; 11. Rotary bearing; 2. Rotor mechanism; 3. Stator mechanism; 31. Coil layer; 311. Conductor coil; 3111. Upper layer; 3112. Lower layer; 3113. Welding point; 3114. Bending section. Detailed Implementation

[0021] To enable those skilled in the art to better understand the technical solutions in this specification, the technical solutions in the embodiments of this specification will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this specification, and not all embodiments. Based on the embodiments in this specification, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this specification.

[0022] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of the present invention. Furthermore, the accompanying drawings of the present invention are for simple illustrative purposes only and are not depictions of actual dimensions; this is stated in advance. The following embodiments will further describe the relevant technical content of the present invention in detail, but the disclosed content is not intended to limit the scope of protection of the present invention.

[0023] It should be understood that while terms such as "first," "second," and "third" may be used in this document to describe various components or signals, these components or signals should not be limited by these terms. These terms are primarily used to distinguish one component from another, or one signal from another. Furthermore, the term "or" as used herein should, as appropriate, include any combination of one or more of the related listed items.

[0024] Please see Figure 1-5 This embodiment provides a small-volume energy conversion device for use in an axial flux motor or axial flux generator. The small-volume energy conversion device includes: Spindle 1; Rotor mechanism 2, which is sleeved and mounted on the rotary bearing 11 of the main shaft 1; The stator mechanism 3 includes multiple sets of coil layers 31 arranged axially overlapping each other. The multiple sets of coil layers 31 are sleeved and fixed on the main shaft 1. Each coil layer 31 includes multiple sets of conductor coils 311. Each conductor coil 311 has a first end and a second end that are arranged opposite to each other and bent in different layers. The first end and the second end are both located on the side adjacent to the main shaft 1. The first end of each conductor coil 311 has a bend that is not 0 degrees or 180 degrees, forming a raised bend portion 3114. The bend portion 3114 is used to weld and cooperate with the end face of the second end of another adjacent conductor coil 311.

[0025] In the above scheme, the conductor coil 311 is configured as three parallel flat copper wires, or other conductors as needed. Considering that the stator in existing general axial flux motors and generators is generally configured as a flat disk with a large radial dimension, choosing flat copper wires for bending and connecting has the advantage of improving slot fill factor, and the thicker, wider surface of the flat copper wires can occupy radial space. The three parallel configuration can better balance the cross-sectional area and material strength in a three-phase motor.

[0026] Based on the above-mentioned process of the present invention, the installation can be achieved by the following assembly method of the energy conversion device, which specifically includes the following steps: bending multiple sets of flat copper wires horizontally at the same angle along the narrow side, and then bending them vertically along the wide side, so that the flat copper wires are folded into double layers to form conductor coils 311; connecting the multiple sets of conductor coils 311 end to end and arranging them in a ring along the main shaft 1 to form coil layers 31, wherein the first end and the second end of each conductor coil 311 are both set facing one side of the main shaft 1, and the corresponding second end face and the bent portion 3114 of the first end are attached, and after applying flux, welding is performed so that the second end face of the corresponding conductor coil 311 and the side wall of the bent portion 3114 of the first end form a welded connection; stacking multiple sets of coil layers 31 along the vertical direction on the main shaft 1 to form a stator mechanism 3; and installing a rotor mechanism 2 on one / both sides of the stator mechanism 3 along the vertical direction.

[0027] In the above-described scheme of the present invention, the main steps of the stator mechanism 3 production are to uniformly bend and connect the finished flat copper wires and assemble them at the corresponding position of the main shaft 1. In the bending step, multiple sets of flat copper wires are bent horizontally along the narrow surface at the same angle and then bent vertically along the wide surface, so that the flat copper wires are folded into double layers.

[0028] Among them, horizontal vertical bending along a narrow face refers to bending at a small angle in the horizontal direction between 0 degrees and 180 degrees. Considering the physical characteristics of flat copper wire, in order to avoid material stress damage, the horizontal bending angle can be set between 0 degrees and 90 degrees.

[0029] A vertical flat bend along the wide face refers to having at least one vertical flat bend along the wide face in each of the flat copper wires, such that the flat copper wire is folded into a double layer, comprising an upper layer 3111 and a lower layer 3112. Because a horizontal bend has been performed beforehand, after the vertical fold, the upper layer 3111 and the lower layer 3112 do not overlap vertically in a single set of conductor coils 311.

[0030] Considering that the upper layer 3111 and the lower layer 3112 do not overlap vertically, they can be connected and combined in an alternating manner. See [link to documentation] for details. Figure 4The coils can be wound around the center of the main axis 1 at equal angles in the circumferential direction. The upper layer 3111 of all conductor coils 311 is located above the lower layer 3112 of any conductor coil 311. The upper and lower layers of different conductor coils 311 will alternate along the axial projection until one group can achieve the overlap of the upper layer 3111 of the first group of conductor coils 311 and the lower layer 3112 of the second group of conductor coils along the axial projection, forming a cyclic topology. They are arranged alternately one by one to complete a complete circumference around the main axis 1, forming coil layer 31.

[0031] In the present invention, the energy conversion device can be used in an electric motor, wherein the motor energizes the stator mechanism 3, and drives the rotor mechanism 2 to rotate around the axis through electromagnetic effect to output power. Alternatively, it can be used in a generator, wherein external wind power, water power, etc. drive the blades of the rotating bearing 11 connected to the main shaft 1 to rotate, causing the rotor mechanism 2 to rotate, and generating electricity by cutting the magnetic field through the stator mechanism 3 via electromagnetic effect.

[0032] Based on the above-described process of the present invention, during installation, the welding points 3113 of the conductor coils 311 in the stator mechanism 3 can be located on the inner side adjacent to the main shaft 1, and welding can be performed using the bent portion 3114 of the conductor coils 311, thereby reducing the overall volume. Specifically, in the present invention, the coil layer 31 of the stator mechanism 3 can be formed by welding and connecting multiple sets of conductor coils 311 together. The first end of each conductor coil 311 is bent to form a bent portion 3114, and the bent portion 3114 is located on the inner side adjacent to the main shaft 1. Therefore, the outer side of the coil layer 31 away from the main shaft 1 is the pure main body, which can achieve perfect fit of the outer edge projection surface of the stator mechanism 3 with the rotor mechanism 2. By placing the welding points 3113 of the functional parts on the inner main shaft 1 where the impact is relatively small, the overall volume is significantly reduced while ensuring magnetic flux performance. Indirectly, the outer diameter of the main shaft 1 can be made larger, and the structure is more stable.

[0033] In the specific design of the bending section 3114 node, the bending section 3114 of the conductor coil 311 is set to be bent at 90 degrees along the axial direction, so that the second end face of the conductor coil 311 is radially bonded to the side wall of the other bending section 3114. That is to say, the lower layer 3112 main body of the conductor coil 311 is set to be parallel to the radial direction, while the bent section 3114 is set to be parallel to the axial direction. The actual angle between the two is a right angle. The right angle structure has stronger stress and is less prone to bending phenomenon with angle change during subsequent welding.

[0034] Furthermore, in terms of the bonding method, the length of the bent portion 3114 is greater than the thickness of the second end face of the conductor coil 311. Therefore, the sidewall of the bent portion 3114 can at least cover the entire second end face of the other conductor coil 311, so that the welding strength reaches the optimal level. The second end face of the conductor coil 311 is welded to the middle position of the sidewall of the bent portion, so that even if there is slight shaking during the welding process, the sidewall of the bent portion 3114 can still easily cover the entire second end face of the other conductor coil 311.

[0035] In terms of overall structural layout, the energy conversion device has a first end and a second end arranged opposite each other along the axial direction. The number of rotor mechanisms 2 is set to two sets, one set located on one side of the first end of the stator mechanism 3, and the other set located on one side of the second end of the stator mechanism 3. The gap between the two sets of rotor mechanisms 2 and the stator mechanism 3 is equal. That is to say, this embodiment is a classic single-stator dual-rotor structure, which has relatively stable balance and a small axial thickness. The two sets of rotor mechanisms 2 are actually arranged symmetrically, and their thickness is comparable to that of the stator mechanism 3.

[0036] In another embodiment, the number of coil layers 31 is set to six groups, with each group of coil layers 31 overlapping in the vertical direction. In the above structure, each group of coil layers 31 can be connected by potting adhesive, which can be a curing adhesive with a certain heat dissipation capacity. The axial thickness of the stator mechanism 3 can be further increased as needed.

[0037] In terms of pipeline connection, the main shaft 1 is configured as a hollow structure, and the cavity formed by the main shaft 1 is used to pass through the wiring for connecting the stator mechanism 3. Specifically, the conductor coil 311 can be inserted through the corresponding hole opened on the main shaft 1 and electrically connected to the controller side along the axial direction.

[0038] Since the welding point 3113 of the conductor coil 311 in this invention is designed to be located on the inner side close to the main shaft 1, the outer edge of the conductor coil 311 can be made flush with the outer edge 2 of the rotor mechanism without having to consider the external welding process requirements. The overlapping surfaces of the stator mechanism 3 and the rotor mechanism 2 are also flush. The main welding, fixing, and wiring are all set in one circle of the main shaft 1. The outer circle has a larger area, which maximizes the magnetic flux and reduces the overall volume under the same power requirements.

[0039] In this scheme, each coil layer 31 is actually composed of three windings, generally referring to the U, V and W three-phase windings. The three-phase windings are arranged in a staggered and alternating manner so that the U, V and W three-phase windings are adjacent to each other and form a cycle.

[0040] Furthermore, in the upper layer 3111 of each individual conductor coil 311, the horizontal bending tendency is to make multiple stepped bends in the corresponding direction along the circumference (such as clockwise), so that there is a tendency to bend in a clockwise direction from the inside to the outside. In the lower layer 3112, the opposite is true, with multiple stepped bends, so that there is also a tendency to bend in a clockwise direction from the outside to the inside.

[0041] Furthermore, similarly, in practice, if there is ample space, the outer diameter of spindle 1 can be made larger to ensure the strength of spindle 1, or to make it easier to thread wires and lay out pipelines from one side of spindle 1.

[0042] The content disclosed above is only a preferred and feasible embodiment of the present invention, and is not intended to limit the scope of the patent application of the present invention. Therefore, all equivalent technical changes made based on the content of the present invention specification and drawings are included in the scope of the patent application of the present invention.

[0043] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

[0044] Although this application has been described by way of examples, those skilled in the art will know that this application has many modifications and variations without departing from the spirit of this application, and it is intended that the appended embodiments include these modifications and variations without departing from this application.

Claims

1. A small-volume energy conversion device for assembly in an axial flux motor or axial flux generator, characterized in that, The small-volume energy conversion device includes: spindle; A rotor mechanism, wherein the rotor mechanism is sleeved and mounted on the rotary bearing of the main shaft; A stator mechanism includes multiple sets of coil layers arranged axially overlapping each other. The multiple sets of coil layers are sleeved and fixed on the main shaft. Each coil layer includes multiple sets of conductor coils. Each conductor coil has a first end and a second end that are arranged opposite to each other and bent in different layers. The first end and the second end are both located on the side adjacent to the main shaft. The first end of each conductor coil has a bend that is not 0 degrees or 180 degrees and forms a raised bend. The bend is used to weld with the end face of the second end of another adjacent conductor coil.

2. The small-volume energy conversion device according to claim 1, characterized in that: The bending portion of the conductor coil is configured to be bent 90 degrees axially, so that the second end face of the conductor coil is radially bonded to the sidewall of the other bending portion.

3. The small-volume energy conversion device according to claim 1, characterized in that: The length of the bent portion is greater than the thickness of the second end face of the conductor coil.

4. The small-volume energy conversion device according to claim 3, characterized in that: The second end face of the conductor coil is welded to the middle position of the side wall of the bent portion.

5. The small-volume energy conversion device according to claim 1, characterized in that: The conductor coil is configured as multiple parallel flat copper wires.

6. The small-volume energy conversion device according to claim 5, characterized in that: Each of the flat copper wires has at least one vertical flat bend along the wide surface, such that the flat copper wire is folded into a double layer.

7. The small-volume energy conversion device according to claim 6, characterized in that: Each of the flat copper wires has at least one horizontal vertical bend along the narrow face, resulting in a staggered design between the upper and lower layers of the flat copper wire.

8. The small-volume energy conversion device according to claim 6, characterized in that: The flat copper wire has one and only one vertical flat bend, and the bend is located at the end away from the main shaft.

9. The small-volume energy conversion device according to claim 8, characterized in that: The fold is aligned axially with the outer edge of the rotor.

10. The small-volume energy conversion device according to claim 1, characterized in that: The energy conversion device has a first end and a second end arranged opposite to each other along the axial direction. The number of rotor mechanisms is set to two sets, one set of rotor mechanisms is set on one side of the first end of the stator mechanism, and the other set of rotor mechanisms is set on one side of the second end of the stator mechanism. The gap size between the two sets of rotor mechanisms and the stator mechanism is equal.

Images