Low cost energy conversion device and method of assembly

Abstract

The application relates to a low-cost energy conversion device, which comprises a main shaft, a rotor mechanism, a stator mechanism, a plurality of coil layers arranged in axial overlap, a plurality of coil layers sleeved and fixed on the main shaft, each coil layer comprising three groups of winding groups arranged in circumferential alternation, each winding group comprising a plurality of conductor coils connected in sequence, the conductor coil being a double-layer structure formed by bending a flat copper wire, each conductor coil comprising an upper layer, a lower layer and a folding part connecting the upper layer and the lower layer, the upper layer of each conductor coil being arranged in a ring array along the main shaft, the lower layer of each conductor coil being arranged in a ring array along the main shaft, and the head and tail of each conductor coil being connected in sequence. The application can realize the ring array of the plurality of bent flat copper wires by the conductor coil bending process, the head and tail of which are connected in sequence, the tolerance of the stamping or carving process is small, the cost is low, the processing efficiency is high, and the consumption of copper material is extremely small.

Description

Technical Field

[0001] This invention relates to an axial magnetic flux energy conversion device, and more particularly to a low-cost 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] For example, since stators are usually processed from a whole sheet or strip, a lot of scrap is generated, resulting in low material utilization and serious waste. At the same time, the overall production process is cumbersome and complicated, and it is difficult to accurately control the dimensional tolerances and flatness of the finished product. Especially when using stamping or engraving processes to make copper wire windings, not only are the processes lengthy and the production efficiency low, but it is also very inconvenient to achieve high-efficiency mass automated production, and it is also quite wasteful of copper materials.

[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 low-cost energy conversion device that can convert copper materials into energy through a conductor coil bending process. This device utilizes a ring array of multiple bent flat copper wires connected end to end, resulting in smaller tolerances, lower costs, higher processing efficiency, and minimal copper consumption compared to stamping or engraving processes.

[0007] To achieve the above objectives, the present invention discloses a low-cost energy conversion device for use in an axial flux motor or axial flux generator, wherein the low-cost 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 overlappingly along the axial direction. The multiple sets of coil layers are sleeved and fixed on the main shaft. Each coil layer includes three sets of windings arranged alternately along the circumference. Each winding includes multiple conductor coils connected end to end along the circumference. The conductor coils are double-layered structures formed by bending flat copper wire. Each conductor coil includes an upper layer, a lower layer, and a folded portion connecting the upper layer and the lower layer. The upper layers of each conductor coil are arranged in a circular array along the main shaft, and the lower layers of each conductor coil are arranged in a circular array along the main shaft. Each conductor coil has a head and a tail located on the inner side, and the heads and tails of each conductor coil are connected in sequence.

[0008] As a further description of the above technical solution, the folded portion of the conductor coil is disposed on the outer side away from the main shaft.

[0009] 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.

[0010] 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.

[0011] As a further description of the above technical solution, the upper layer formed by bending each of the conductor coils overlaps with the lower layer of another set of conductor coils spaced two sets apart along the vertical projection plane to form a three-phase alternating arrangement.

[0012] As a further description of the above technical solution, the connection between the two sets of connected conductor coils is achieved by welding.

[0013] As a further description of the above technical solution, the low-cost 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.

[0014] As a further description of the above technical solution, the number of coil layers is set to six groups, and the projection surfaces of each group of coil layers overlap along the vertical direction.

[0015] As a further description of the above technical solution, the main shaft is configured as a hollow structure, and the cavity formed by the main shaft is used to pass through the wiring for connecting the stator mechanism.

[0016] A method for assembling a low-cost energy conversion device, comprising the following steps: Multiple sets of flat copper wires are bonded together with adhesive to form a conductor coil. The conductor coil is folded into a double layer by bending it horizontally along the narrow side at the same angle and then bending it vertically along the wide side. The multiple sets of conductor coils are connected end to end and arranged in a ring along the main axis to form a coil layer; Multiple coil layers are stacked and nested on the main shaft in a vertical direction to form a stator mechanism; The rotor mechanism is installed on one or both sides of the stator mechanism along the vertical direction.

[0017] By employing the above technical solutions, the beneficial effects of the present invention are as follows: The low-cost energy conversion device of this invention utilizes a conductor coil bending process, employing a ring array of multiple bent flat copper wires connected end-to-end. This method offers advantages over stamping or engraving processes, including smaller tolerances, lower costs, higher processing efficiency, and minimal copper consumption. Specifically, the main body of its stator mechanism is entirely composed of basic conductor coils, which can be made from low-cost metal materials such as flat copper wire. Through bending, connecting, and stacking methods, a disc-shaped stator mechanism is ultimately formed, resulting in minimal material waste. The process is simple, frameless, and easy for mass production.

[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 an exploded schematic diagram of a low-cost energy conversion device provided in the embodiments of this specification; Figure 2 This is a three-dimensional schematic diagram of a low-cost energy conversion device provided in the embodiments of this specification; Figure 3 This is a schematic diagram of a single flat copper wire of a low-cost energy conversion device provided in the embodiments of this specification; Figure 4 This is a schematic diagram of a conductor coil assembly of a low-cost energy conversion device provided in the embodiments of this specification; Figure 5This is a schematic diagram of a single-layer coil of a low-cost energy conversion device provided in the embodiments of this specification; Figure 6 This is a schematic diagram of a set of windings in a single-layer coil of a low-cost 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. 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 1-6 This embodiment provides a low-cost energy conversion device for use in an axial flux motor or axial flux generator. The low-cost 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 overlappingly along the axial direction. The multiple sets of coil layers 31 are sleeved and fixed on the main shaft 1. Each coil layer 31 includes three sets of windings arranged alternately along the circumference. Each winding includes multiple conductor coils 311 connected end to end along the circumference. The conductor coils 311 are double-layered structures formed by bending flat copper wire. Each conductor coil 311 includes an upper layer 3111, a lower layer 3112, and a folded portion connecting the upper layer 3111 and the lower layer 3112. The upper layers 3111 of each conductor coil 311 are arranged in a circular array along the main shaft 1, and the lower layers 3112 of each conductor coil 311 are arranged in a circular array along the main shaft 1. Each conductor coil 311 has a head and a tail located on the inner side, and the heads and tails of each conductor coil 311 are connected in sequence.

[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 winding cross-sectional area, material strength, and cost in a three-phase motor.

[0026] Based on the above-mentioned process of the present invention, the installation can be achieved by the following low-cost energy conversion device assembly method, which specifically includes the following steps: bonding multiple sets of flat copper wires together with a fixing adhesive to form conductor coils 311; bending them horizontally at the same angle along the narrow side, and then bending them vertically along the wide side, so that the conductor coils 311 are folded into double layers; 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; 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 4 The 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] In other words, in the solution of this invention, the conductor coil 311 can be bent using a circular array of multiple bent flat copper wires connected end to end, achieving a smaller tolerance, lower cost, and higher processing efficiency compared to stamping or engraving processes, while minimizing copper consumption. Specifically, the main body of the stator mechanism 3 is entirely composed of basic conductor coils 311, which can be made of low-tolerance, low-cost metal materials such as flat copper wire. Through bending, connecting, and stacking methods, a disc-shaped stator mechanism 3 is finally formed, resulting in minimal material waste, a simple process, no frame, and easy mass production.

[0033] The stator mechanism 3 can be fixed in various ways, such as fixing the coil layer 31 to the main shaft 1 along the radial inner side, or fixing the coil layer 31 to the inner wall of the corresponding motor or generator along the radial outer side.

[0034] During installation, in the conductor coil 311, which consists of multiple flat copper wires arranged in parallel, three sets of flat copper wires can be arranged side by side and fixed with adhesive. Then, bending, welding, and other operations are performed to form a complete coil layer 31. Furthermore, by using the bending process of the conductor coil 311, and through the use of multiple sets of bent flat copper wires in a ring array connected end to end, a filling gap for filling thermal adhesive is formed between the upper layer 3111 and the lower layer 3112 of the conductor coil 311, which can significantly improve the heat dissipation level.

[0035] In terms of the specific connection process, the connection between the two sets of connected conductor coils 311 is achieved by welding. Depending on the needs and for ease of processing, the welding points 3113 connecting the ends can be optionally located at the edge of the coil layer 31. For example, in one embodiment, the welding point 3113 is located on the outermost side of the coil layer 31 away from the main shaft 1; in another embodiment, conversely, the welding point 3113 is located on the innermost side closest to the main shaft 1. See [link to relevant documentation] for details. Figure 5 .

[0036] In terms of overall structural layout, the low-cost 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, 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.

[0037] 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.

[0038] 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.

[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] 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.

[0042] 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.

[0043] 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 low-cost energy conversion device for use in an axial flux motor or axial flux generator, characterized in that, The low-cost 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 overlappingly along the axial direction. The multiple sets of coil layers are sleeved and fixed on the main shaft. Each coil layer includes three sets of windings arranged alternately along the circumference. Each winding includes multiple conductor coils connected end to end along the circumference. The conductor coils are double-layered structures formed by bending flat copper wire. Each conductor coil includes an upper layer, a lower layer, and a folded portion connecting the upper layer and the lower layer. The upper layers of each conductor coil are arranged in a circular array along the main shaft, and the lower layers of each conductor coil are arranged in a circular array along the main shaft. Each conductor coil has a head and a tail located on the inner side, and the heads and tails of each conductor coil are connected in sequence.

2. The low-cost energy conversion device according to claim 1, characterized in that: The folded portion of the conductor coil is located on the outside away from the main shaft.

3. The low-cost energy conversion device according to claim 1, 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.

4. The low-cost energy conversion device according to claim 1, 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.

5. The low-cost energy conversion device according to claim 1, characterized in that: Each of the conductor coils, when bent, forms an upper layer that overlaps with the lower layer of another set of conductor coils, which is spaced two sets apart, along the vertical projection plane to form a three-phase alternating arrangement.

6. The low-cost energy conversion device according to claim 1, characterized in that: The connection between the two sets of connected conductor coils is achieved by welding.

7. The low-cost energy conversion device according to claim 1, characterized in that: The low-cost 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.

8. The low-cost energy conversion device according to claim 1, characterized in that: The number of coil layers is set to six groups, and the coil layers in each group overlap in the vertical direction.

9. The low-cost energy conversion device according to claim 1, characterized in that: The main shaft is configured as a hollow structure, and the cavity formed by the main shaft is used to carry the wiring for connecting the stator mechanism.

10. A method for assembling a low-cost energy conversion device, characterized in that, Includes the following steps: Multiple sets of flat copper wires are bonded together with adhesive to form a conductor coil. The conductor coil is folded into a double layer by bending it horizontally along the narrow side at the same angle and then bending it vertically along the wide side. The multiple sets of conductor coils are connected end to end and arranged in a ring along the main axis to form a coil layer; Multiple coil layers are stacked and nested on the main shaft in a vertical direction to form a stator mechanism; The rotor mechanism is installed on one or both sides of the stator mechanism along the vertical direction.

Images