Axial flux motor stator assembly and axial flux motor

Abstract

The axial flux motor stator assembly comprises a stator end cover, a stator iron core, a stator winding and a packaging body, the stator end cover comprises a bottom plate and a bearing seat axially protruding towards two sides from the middle of the bottom plate, and the packaging body packages the bottom plate and the stator iron core wound with the stator winding into a whole. A cavity is formed between the outer side of the bearing seat and the packaging body, a plurality of radiating ribs distributed at intervals in the circumferential direction are arranged on the outer side face of the bearing seat and connected with the bottom plate, ventilation holes are defined by the bottom plate and the two adjacent radiating ribs, part of the radiating ribs are located in the cavity, and the cavity is communicated with the outside through the ventilation holes. The stator end cover adopts a frame type design, the internal stress characteristics of the axial magnetic flux motor are fully utilized, the structural strength is ensured, the material consumption of the stator end cover is reduced as much as possible, the material cost is reduced, the processing efficiency is improved, and the heat dissipation and NVH performance is improved.

Description

Technical field:

[0001] The utility model relates to an axial flux motor stator component and an axial flux motor. Background technology:

[0002] The existing axial flux motors are similar in the form of stator components, which are mainly composed of end covers and stator cores with windings. In order to improve the protection level, the end covers can often cooperate with the end covers on the other side to form a sealing mechanism, but the outer diameter of the axial flux motor is often large. When the outer diameter increases, the surface area of ​​the casing increases rapidly, which means higher costs. In the existing solutions, the windings are not directly in contact with the outermost structure of the motor (the casing), and in the process of heat being transferred to the outside of the casing, the thermal conductivity of other intermediate materials will affect the heat dissipation effect. From the perspective of structural strength, the structural strength of the traditional design is expected to be relatively stable, but it does not mean that there are no other better solutions that can improve processing efficiency. In the current conventional stator end cover design, the end cover is often made of cast aluminum or stretched end cover: the production efficiency of larger and more complex cast aluminum end covers is not high, and the mold cost of larger stretched end covers is not low. The main source of electromagnetic noise of the axial flux motor is the resonance in the axial direction. At present, the damping of each solution system is low, and electromagnetic resonance is prone to generate large noise. For details, see Patent No.: 201822111507.0 Name: Utility model patent for an axial magnetic field motor.

[0003] In conventional designs, axial flux motors often use cast aluminum, stretched or other forms of end covers to cover the stator part of the motor as a whole, and cooperate with the end cover (or end cover) on the other side to improve the protection level, but axial flux motors often have a larger outer diameter, which means that the cost of the casing material that can cover the motor is relatively high, which is not conducive to saving materials or costs, and is prone to waste of resources. In terms of heat dissipation, the stator winding and the outermost structure of the motor are not directly connected. When heat is transferred in the intermediate material, it will affect the heat dissipation efficiency. Even if the winding is potted or filled with other media, its heat dissipation efficiency will be affected by these dielectric materials. See patent number: 202120878426.2, patent name: Utility model patent for motor end cover, motor and electrical equipment. This patent adopts potting or filling of other dielectric structures, but the structure of the motor end cover is also too complicated, the mold opening cost is high, and it does not reduce the manufacturing cost. In addition, the heat dissipation is poor and the noise is high. Summary of the invention:

[0004] The utility model aims to provide an axial flux motor stator assembly and an axial flux motor, which can solve the technical problems of the axial flux motor stator assembly in the prior art, such as complex stator end cover structure, high processing cost, low processing efficiency and poor heat dissipation.

[0005] The purpose of this utility model is achieved through the following technical solutions:

[0006] An axial flux motor stator assembly comprises a stator end cover, a stator core, a stator winding and a packaging body, wherein the stator end cover comprises a bottom plate and a bearing seat protruding axially from the middle of the bottom plate to both sides, a bearing chamber for mounting a bearing is arranged inside the bearing seat, the packaging body packages the bottom plate and the stator core wound with the stator winding into one body, a cavity is formed between the outer side of the bearing seat and the packaging body, a plurality of circumferentially spaced heat dissipation ribs are arranged on the outer side of the bearing seat and connected to the bottom plate, a ventilation hole is formed between the bottom plate and two adjacent heat dissipation ribs, part of the heat dissipation ribs are located inside the cavity, and the cavity is connected to the outside through the ventilation hole.

[0007] The other part of the heat dissipation ribs extends out of the cavity and protrudes out of the bottom of the bottom plate.

[0008] The bottom plate is provided with a plurality of circumferentially spaced weight-reducing holes, the packaging body is filled in the weight-reducing holes, and the bottom plate is a flat plate.

[0009] A plurality of mounting feet are extended from the bottom plate, the mounting feet protrude from the packaging body, and mounting holes are arranged on the mounting feet.

[0010] The top periphery of the bearing seat is wrapped by the packaging body to seal the top of the cavity; or there is a gap between the top periphery of the bearing seat and the packaging body, and the gap is blocked by a sealing plug to seal the top of the cavity.

[0011] The above-mentioned package is formed by potting or plastic sealing process, and the package is made of BMC material, resin or composite material; the stator end cover is made of aluminum, iron or alloy material.

[0012] An axial flux motor stator assembly comprises a stator end cover, a stator core, a stator winding and a packaging body, wherein the stator end cover comprises a bottom plate, a bearing seat protruding axially from the middle of the bottom plate to both sides, a plurality of circumferentially spaced heat dissipation ribs are arranged on the outer side of the bearing seat, a mounting ring is connected to the periphery of the heat dissipation ribs, a bearing chamber for mounting bearings is arranged inside the bearing seat, the packaging body packages the bottom plate and the stator core wound with the stator winding into one body, a cavity is formed between the outer side of the bearing seat and the packaging body, and is connected to the bottom plate by screws passing through the mounting ring, ventilation holes are arranged on the bottom plate, part of the heat dissipation ribs are located inside the cavity, and the cavity is connected to the outside through the ventilation holes.

[0013] The top periphery of the bearing seat is wrapped by the packaging body to seal the top of the cavity; or there is a gap between the top periphery of the bearing seat and the packaging body, and the gap is blocked by a sealing plug to seal the top of the cavity.

[0014] The bottom plate is provided with a plurality of circumferentially spaced weight-reducing holes, and the packaging body is filled in the weight-reducing holes.

[0015] A plurality of mounting feet are extended from the bottom plate, the mounting feet protrude from the packaging body, and mounting holes are arranged on the mounting feet.

[0016] The above-mentioned package is formed by potting or plastic sealing process, and the package is made of BMC material, resin or composite material; the stator end cover is made of aluminum, iron or alloy material.

[0017] An axial flux motor comprises a stator assembly and a rotor assembly, wherein the stator assembly and the rotor assembly are axially magnetically coupled, and is characterized in that the stator assembly is the above-mentioned stator assembly of the axial flux motor.

[0018] Compared with the prior art, the utility model has the following effects:

[0019] Effect 1: The stator end cover of the utility model includes a bottom plate and a bearing seat protruding axially from the middle of the bottom plate to both sides. A bearing chamber for installing the bearing is arranged inside the bearing seat. The packaging body wraps the bottom plate and the stator core with the stator winding wrapped around it into one body. The stator end cover adopts a "frame-type" design, which fully utilizes the internal force characteristics of the axial flux motor to ensure its structural strength. At the same time, it minimizes the amount of material used for the stator end cover to reduce material costs, improve processing efficiency, and enhance its heat dissipation and NVH performance;

[0020] Effect 2: The bottom plate and the bearing seat protruding axially to both sides in the middle of the bottom plate can be manufactured separately and then welded together to form a component, which has a simple structure, high processing efficiency, high material utilization rate, and can significantly reduce costs;

[0021] Effect 3: The stator core wound with the stator winding is wrapped and packaged into one body. The heat generated by the stator core wound with the stator winding is transferred to the air through the package. The heat exchange is completed twice, which reduces the number of heat exchanges and improves the heat dissipation efficiency.

[0022] Effect 4: A cavity is formed between the outer side of the bearing seat and the packaging body. The outer side of the bearing seat is provided with a number of circumferentially spaced heat dissipation ribs connected to the bottom plate. Ventilation holes are formed between the bottom plate and two adjacent heat dissipation ribs. Some of the heat dissipation ribs are located inside the cavity, and the cavity is connected to the outside through the ventilation holes. In this structure, the air in the cavity isolates the heat generated by the stator core wound with the stator winding, ensuring that the operating temperature of the bearing is not too high. At the same time, the outer side of the bearing seat is provided with a number of circumferentially spaced heat dissipation ribs to accelerate heat dissipation; the function of the ventilation holes is to accelerate heat transfer with the outside air.

[0023] Effect 5: The stator end cover of the utility model includes a bottom plate, a bearing seat protruding axially from the middle of the bottom plate to both sides, a plurality of circumferentially spaced heat dissipation ribs are arranged on the outer side of the bearing seat, a mounting ring is connected to the periphery of the heat dissipation ribs, a bearing chamber for mounting the bearing is arranged inside the bearing seat, and the packaging body packages the bottom plate and the stator core wound with the stator winding into one body, and is connected to the bottom plate through the mounting ring by screws. In this structure, the bearing seat and the bottom plate are manufactured separately, the stator end cover structure is simplified, the mold structure becomes simple, the installation is flexible and convenient, suitable for large-scale production, and high production efficiency. Description of the drawings:

[0024] Figure 1 It is a three-dimensional view of the stator assembly of the axial flux motor of the first embodiment of the utility model at one angle;

[0025] Figure 2 It is a front view of the stator assembly of the axial flux motor according to the first embodiment of the utility model;

[0026] Figure 3 yes Figure 2 AA section view;

[0027] Figure 4 yes Figure 2 BB cross-sectional view;

[0028] Figure 5 It is an exploded view of the stator assembly of the axial flux motor of the first embodiment of the utility model;

[0029] Figure 6 It is a three-dimensional view of a stator end cover of the first embodiment of the utility model at one angle;

[0030] Figure 7 It is a three-dimensional view of the stator end cover of the first embodiment of the utility model from another angle;

[0031] Figure 8 This is a front view of the stator end cover of the first embodiment of the utility model;

[0032] Fig. 9 yes Figure 8 CC section view;

[0033] Fig.10 It is a bottom view of the stator assembly of the axial flux motor according to the first embodiment of the utility model;

[0034] Fig.11 yes Fig.10 DD cross-sectional view;

[0035] Fig.12 It is a schematic diagram of heat exchange of a conventional axial flux motor stator assembly;

[0036] Fig.13It is a schematic diagram of heat exchange of the stator assembly of the axial flux motor of the utility model;

[0037] Fig.14 It is a schematic diagram of using a sealing rubber plug to block the gap of the stator assembly of the axial flux motor of the utility model.

[0038] Fig.15 is a three-dimensional diagram of a stator assembly of an axial flux motor according to a second embodiment of the present utility model;

[0039] Fig.16 It is a bottom view of the stator assembly of the axial flux motor of the second embodiment of the utility model;

[0040] Fig.17 yes Fig.16 EE cross-sectional view;

[0041] Fig.18 It is a three-dimensional diagram of the stator assembly of the axial flux motor of the second embodiment of the present invention with the packaging body omitted. Specific implementation method:

[0042] The present invention will be further described in detail below through specific embodiments in conjunction with the accompanying drawings.

[0043] Embodiment 1: Figures 1 to 11 As shown, the present embodiment provides an axial flux motor stator assembly, comprising a stator end cover 1, a stator core 2, a stator winding 3 and a packaging body 4, characterized in that: the stator end cover 1 comprises a base plate 11 and a bearing seat 12 protruding axially from the middle of the base plate 11 to both sides, a bearing chamber 121 for mounting a bearing is arranged inside the bearing seat 12, the packaging body 4 packages the base plate 11 and the stator core 2 wound with the stator winding 3 into one body, a cavity 41 is formed between the outer side of the bearing seat 12 and the packaging body 4, a plurality of circumferentially spaced heat dissipation ribs 123 are arranged on the outer side of the bearing seat 12 and connected to the base plate 11, a ventilation hole 122 is formed between the base plate 11 and two adjacent heat dissipation ribs 123, part of the heat dissipation ribs 123 are located inside the cavity 41, and the cavity 41 is connected to the outside through the ventilation hole 122. The stator end cover 1 adopts a "frame-type" design, which fully utilizes the internal force characteristics of the axial flux motor to ensure its structural strength while minimizing the amount of stator end cover material to reduce material costs, improve processing efficiency, and enhance its heat dissipation and NVH performance; a steel sleeve can be added to the inside of the bearing chamber when necessary to further increase strength and fatigue resistance.

[0044] The bottom plate 11 and the bearing seat 12 axially protruding on both sides in the middle of the bottom plate 11 can be manufactured separately and then welded together to form a component, which has a simple structure, high processing efficiency, high material utilization rate, and can significantly reduce costs; a cavity 41 is formed between the outer side of the bearing seat 12 and the packaging body 4 and is filled with air, so that the heat generated by the stator core 2 wound with the stator winding 3 cannot be directly transferred to the bearing seat 12, ensuring that the operating temperature of the bearing in the bearing chamber 121 is not too high; the working heat of the bearing in the bearing chamber 121 is transferred to the air in the cavity 41 through the bearing seat 12, the heat dissipation ribs 123 can accelerate the heat dissipation of the bearing seat 12, and the ventilation holes 122 can accelerate the heat transfer of the air in the cavity 41.

[0045] The package body 4 is formed by potting or plastic encapsulation process. The package body 4 encapsulates the bottom plate 11 and the stator core 2 wound with the stator winding 3 into one body, ensuring the insulation performance of the stator; at the same time, the stator is potted as a whole to improve the protection level of the stator core.

[0046] The package body 4 encapsulates the bottom plate 11 and the stator core 2 wound with the stator winding 3 into one body, and the mold needs to be designed in a certain way so that the injection molding or potting material can cover the bottom plate 11, so as to reduce the amplitude of the transfer function of the entire stator assembly. The heat dissipation performance is excellent, and the NVH performance can be effectively improved and the noise can be reduced.

[0047] Fig.11 The top periphery of the bearing seat 12 is wrapped by the packaging body 4 to close the top of the cavity 41, which can improve the protection level of the motor.

[0048] The bottom plate 11 is provided with a plurality of circumferentially spaced weight-reducing holes 111, and the packaging body 4 is filled in the weight-reducing holes 111. The bottom plate 11 is a flat plate, which can reduce the material usage of the stator end cover 1 and reduce the cost.

[0049] A plurality of mounting feet 112 are extended from the bottom plate 11, the mounting feet 112 protrude from the package body 4, and mounting holes 1120 are arranged on the mounting feet 112. The structure is simple and the installation is convenient.

[0050] The package 4 is made of BMC material, resin or composite material; the stator end cover is made of aluminum, iron or alloy material. The material of the stator core 2 can be various materials, including silicon steel sheet, composite material, SMC material, etc.; the structure of the stator core 2 can be various structures, such as wound core, block core or other structures with similar functions; the stator end cover bearing scheme can be various schemes, including different bearing numbers, different bearing types, etc.

[0051] like Fig.12As shown in FIG. 1 , the heat exchange of the stator assembly of the traditional axial flux motor has three exchanges (i.e., the stator core with stator winding - plastic package - stator end cover - air), and the efficiency is relatively low; Fig.13 As shown, the heat exchange of the stator assembly of the axial flux motor of the utility model only involves two exchanges (i.e., stator core with stator winding - plastic package - air), and the heat transfer requires less medium and has higher transfer efficiency.

[0052] like Fig.14 As shown, when the packaging body 4 packages the base plate 11 and the stator core 2 wound with the stator winding 3 into one body (i.e., during injection molding or potting), there is a gap between the top periphery of the bearing seat 12 and the packaging body 4, and the gap is blocked with a sealing plug 5 to close the top of the cavity 41.

[0053] Embodiment 2:

[0054] like Figures 15 to 18 As shown, the present embodiment provides an axial flux motor stator assembly, comprising a stator end cover 1, a stator core 2, a stator winding 3 and a packaging body 4, characterized in that: the stator end cover 1 comprises a bottom plate 11, a bearing seat 12 protruding axially from the middle of the bottom plate 11 to both sides, the outer side of the bearing seat 12 is provided with a plurality of circumferentially spaced heat dissipation ribs 123, a mounting ring 124 is connected to the periphery of the heat dissipation rib 123, a bearing chamber 121 for mounting a bearing is provided inside the bearing seat 12, the packaging body 4 packages the bottom plate 11 and the stator core 2 wound with the stator winding 3 into one body, a cavity 41 is formed between the outer side of the bearing seat 12 and the packaging body 4, and is connected to the bottom plate 11 through the mounting ring 124 by screws 6, a ventilation hole 122 is provided on the bottom plate 11, part of the heat dissipation rib 123 is located inside the cavity 41, and the cavity 41 is connected to the outside through the ventilation hole 122. The stator end cover 1 adopts a "frame-type" design, which fully utilizes the internal force characteristics of the axial flux motor to ensure its structural strength while minimizing the amount of stator end cover material to reduce material costs, improve processing efficiency, and enhance its heat dissipation and NVH performance; a steel sleeve can be added to the inside of the bearing chamber when necessary to further increase strength and fatigue resistance.

[0055] There is a gap between the top periphery of the bearing seat 12 and the packaging body 4, which can be blocked by a sealing plug (not shown) to seal the top of the cavity. Of course, the packaging body can also be used to block the top of the cavity 41 during injection molding or potting.

[0056] The bottom plate 11 is provided with a plurality of circumferentially spaced weight-reducing holes 111 , and the packaging body 4 is filled in the weight-reducing holes 111 .

[0057] A plurality of mounting feet 112 extend from the bottom plate 11, the mounting feet 112 protrude from the package body 4, and mounting holes 1120 are provided on the mounting feet 112. The package body 4 is formed by potting or plastic encapsulation process, and the package body 4 is made of BMC material, resin or composite material; the stator end cover is made of aluminum, iron or alloy material.

[0058] The biggest difference between this embodiment and the first embodiment is that the packaging body 4 packages the bottom plate 11 and the stator core 2 wound with the stator winding 3 into one body, and is connected to the bottom plate 11 through the screw 6 passing through the mounting ring 124. In this structure, the bearing seat 12 and the bottom plate 11 are manufactured separately, the stator end cover structure is simplified, the mold structure becomes simple, the installation is flexible and convenient, suitable for large-scale production, and high production efficiency.

[0059] Embodiment three:

[0060] An axial flux motor comprises a stator assembly and a rotor assembly, wherein the stator assembly and the rotor assembly are axially magnetically coupled, and is characterized in that the stator assembly is an axial flux motor stator assembly as described in Embodiment 1 or Embodiment 2.

[0061] The above embodiments are preferred implementation modes of the present invention, but the implementation modes of the present invention are not limited thereto. Any other changes, modifications, substitutions, combinations, and simplifications made without departing from the spirit and principle of the present invention are equivalent replacement methods and are included in the protection scope of the present invention.

Claims

1. An axial flux motor stator assembly, comprising a stator end cover (1), a stator core (2), a stator winding (3) and a packaging body (4), characterized in that: The stator end cover (1) comprises a bottom plate (11) and a bearing seat (12) protruding axially from the middle of the bottom plate (11) to both sides. A bearing chamber (121) for mounting a bearing is arranged inside the bearing seat (12). The packaging body (4) packages the bottom plate (11) and the stator core (2) wound with a stator winding (3) into one body. A cavity (41) is formed between the outer side of the bearing seat (12) and the packaging body (4). A plurality of heat dissipation ribs (123) distributed at intervals in the circumferential direction are arranged on the outer side of the bearing seat (12) and connected to the bottom plate (11). A ventilation hole (122) is formed between the bottom plate (11) and two adjacent heat dissipation ribs (123). Part of the heat dissipation ribs (123) are located inside the cavity (41). The cavity (41) is connected to the outside through the ventilation hole (122).

2. An axial flux motor stator assembly according to claim 1, characterized in that: Another portion of the heat dissipation ribs (123) extends out of the cavity (41) and protrudes from the bottom of the bottom plate (11).

3. An axial flux motor stator assembly according to claim 1 or 2, characterized in that: A plurality of weight-reducing holes (111) are arranged on the bottom plate (11) and are spaced apart from each other in the circumferential direction. The packaging body (4) is filled in the weight-reducing holes (111). The bottom plate (11) is a flat plate.

4. The axial flux motor stator assembly according to claim 3, characterized in that: A plurality of mounting feet (112) extend from the bottom plate (11), the mounting feet (112) protrude from the packaging body (4), and mounting holes (1120) are provided on the mounting feet (112).

5. The axial flux motor stator assembly according to claim 1, characterized in that: The top periphery of the bearing seat (12) is wrapped by the encapsulation body (4) to seal the top of the cavity (41); or there is a gap between the top periphery of the bearing seat (12) and the encapsulation body (4), and the gap is blocked by a sealing plug (5) to seal the top of the cavity (41).

6. An axial flux motor stator assembly according to claim 5, characterized in that: The package (4) is formed by potting or plastic sealing process, and the package (4) is made of BMC material, resin or composite material; the stator end cover is made of aluminum, iron or alloy material.

7. An axial flux motor stator assembly, comprising a stator end cover (1), a stator core (2), a stator winding (3) and a packaging body (4), characterized in that: The stator end cover (1) comprises a bottom plate (11), a bearing seat (12) protruding axially from the middle of the bottom plate (11) to both sides, a plurality of heat dissipation ribs (123) distributed circumferentially at intervals are arranged on the outer side of the bearing seat (12), a mounting ring (124) is connected to the periphery of the heat dissipation ribs (123), a bearing chamber (121) for mounting a bearing is arranged inside the bearing seat (12), a packaging body (4) packages the bottom plate (11) and a stator core (2) wound with a stator winding (3) into one body, a cavity (41) is formed between the outer side of the bearing seat (12) and the packaging body (4), and the mounting ring (124) is screwed through to connect the bottom plate (11), a ventilation hole (122) is arranged on the bottom plate (11), part of the heat dissipation ribs (123) is located inside the cavity (41), and the cavity (41) is connected to the outside through the ventilation hole (122).

8. An axial flux motor stator assembly according to claim 7, characterized in that: The top periphery of the bearing seat (12) is wrapped by the encapsulation body (4) to seal the top of the cavity (41); or there is a gap between the top periphery of the bearing seat (12) and the encapsulation body (4), and the gap is blocked by a sealing plug (5) to seal the top of the cavity (41).

9. An axial flux motor stator assembly according to claim 7 or 8, characterized in that: A plurality of weight-reducing holes (111) are arranged on the bottom plate (11) and are spaced apart from each other in the circumferential direction, and the packaging body (4) is filled in the weight-reducing holes (111).

10. An axial flux motor stator assembly according to claim 9, characterized in that: A plurality of mounting feet (112) extend from the bottom plate (11), the mounting feet (112) protrude from the packaging body (4), and mounting holes (1120) are provided on the mounting feet (112).

11. An axial flux motor stator assembly according to claim 10, characterized in that: The package (4) is formed by potting or plastic sealing process, and the package (4) is made of BMC material, resin or composite material; the stator end cover is made of aluminum, iron or alloy material.

12. An axial flux motor, comprising a stator assembly and a rotor assembly, wherein the stator assembly and the rotor assembly are axially magnetically coupled, characterized in that: The stator assembly is an axial flux motor stator assembly as claimed in any one of claims 1 to 11.

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