Axial flux motor based on flat copper wire conductor double-layer winding coil structure

Abstract

The utility model discloses an axial magnetic flux motor based on a flat copper wire conductor double-layer winding coil structure, which comprises a stator assembly and two rotors, and the two rotors are respectively arranged on two sides of the stator assembly. Wherein the stator assembly comprises a stator core, a winding coil, a connecting conductor and a motor inlet wire, and the stator core comprises a stator yoke, stator teeth and stator slots; two side surfaces of the stator yoke are respectively provided with a plurality of stator teeth and stator slots, and the stator teeth at corresponding positions are symmetrical about the stator yoke; winding coils are assembled on the stator teeth, and the winding coils on every two adjacent stator teeth are installed in the same stator groove. And the winding coil is formed by winding flat copper wires, is coiled along the radial direction of the stator iron core and is stacked along the axial direction of the stator iron core. According to the utility model, the manufacturing process of the axial flux motor is simplified, the production efficiency is improved, the length of the end conductor is reduced, the utilization rate of the conductor and the utilization rate of the stator slot space are improved, the end copper loss is reduced, and the motor efficiency is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of axial flux permanent magnet motors, in particular to an axial flux motor based on a double-layer winding coil structure of a flat copper wire conductor. Background Art

[0002] In the field of radial-flux and axial-flux motors, stator windings using flat copper wire are becoming increasingly common, compared to traditional round copper wire. Flat wire offers advantages over round wire, such as a large conductor cross-sectional area, low electrical resistance, high slot fill rate, good thermal conductivity, and minimal end windings. These advantages have led to its widespread use in motor winding design. However, the skin effect of current can increase losses and reduce efficiency in motors using flat wire.

[0003] Invention CN 102088226 A discloses a method for winding a double-layer flat copper coil for a motor rotor. The double-layer flat copper coil consists of a rectangular inner flat copper coil and a rectangular outer flat copper coil connected in series. The inner flat copper coil is embedded in the rectangular frame of the outer flat copper coil. During winding, the inner flat copper coil is wound first. The invention is characterized in that after the inner flat copper coil is wound, the outer flat copper coil is wound continuously. This invention reduces the number of solder joints in the winding by 50%, thereby reducing the probability of open welding and improving motor reliability. However, this invention still has the problem of many solder joints and a high risk of open welding. In addition, the heat dissipation channel between the two layers of coils is small, which is not conducive to heat dissipation in the motor and reduces motor efficiency. Utility Model Content

[0004] The purpose of the utility model is to provide an axial flux motor with high conductor utilization and stator slot space utilization, small end copper loss, high motor efficiency, convenient stator assembly, and high industrial production efficiency.

[0005] The technical solution for achieving the purpose of the utility model is: an axial flux motor based on a double-layer winding coil structure with a flat copper wire conductor, comprising a stator assembly and two rotors; wherein the stator assembly comprises a stator core, winding coils, connecting conductors, and motor feed lines; the stator core comprises a stator yoke, stator teeth, and stator slots;

[0006] The stator assembly is arranged in the middle, and a rotor is arranged on each side;

[0007] The stator yoke is provided with a plurality of stator teeth and stator slots on both sides, and the stator teeth at corresponding positions are symmetrical about the stator yoke; winding coils are mounted on the stator teeth, and the winding coils on two adjacent stator teeth are installed in the same stator slot; the winding coils are all wound along the radial direction of the stator core and stacked along the axial direction of the stator core.

[0008] Furthermore, the winding coil is wound with flat copper wire and adopts a centralized winding distribution.

[0009] Furthermore, the winding coil is an inner and outer double-layer coil structure, and the double-layer coil structure is stacked and wound along the radial and axial directions of the stator core by the same flat copper wire conductor. The coil winding method adopted is to start from the stator yoke, first winding the inner layer coil of the winding coil, and then winding the outer layer coil of the winding coil.

[0010] Furthermore, the outer coil of the winding coil is outside the inner coil of the winding coil, and a gap is provided between the outer coil and the inner coil. A flat copper wire conductor starts from the wire input end of the winding coil and is wound from the inner coil along the radial and axial directions of the stator core from bottom to top. When the inner coil is wound, it enters the transition section between the inner coil and the outer coil. The transition section is inclined at a set angle to the axial direction of the stator core. Then the conductor is wound from top to bottom along the inner coil to form the outer coil of the winding coil, and a gap is provided between the outer coil and the inner coil. Finally, the end of the flat copper wire conductor forms the wire output end of the winding coil.

[0011] Furthermore, the flat copper wire conductors of each turn of the inner coil and the outer coil of the winding coil are parallel to each other, and the flat copper wire conductors of the transition section are inclined at a corresponding angle along the axial direction of the stator core.

[0012] Furthermore, the positions of the incoming wire ends and the outgoing wire ends of the winding coils on both sides of the stator core are close to the stator yoke.

[0013] Furthermore, all winding coils in the same phase on both sides of the stator are connected by a connecting conductor, so that all winding coils in the same phase are the same flat wire conductor, and the winding coils on both sides are wave wound as a whole;

[0014] In the winding coils on the same side, the winding coils wound on two adjacent stator teeth constitute one phase of the three phases, and in the same phase, the two winding coil conductors contained in the stator slots between the two stator teeth are in the same direction; in different phases, the two winding coil conductors contained in the stator slots in two adjacent stator teeth are in opposite directions; the winding order and phase sequence of the winding coils on the symmetrical stator teeth on both sides are exactly the same.

[0015] Furthermore, the axial height of the winding coil is smaller than the axial height of the stator teeth, and the winding coil is also at a set height from the stator yoke.

[0016] Furthermore, the connecting conductor is located on the outer circumferential surface of the entire stator assembly, and the connecting conductor adopts a flat copper wire conductor, so that the radial size of the entire stator assembly will not be enlarged due to the presence of the connecting conductor, which is used to complete the assembly of the stator assembly.

[0017] Furthermore, gaps are provided between the inner coil in the winding coil and the stator teeth, between the inner coil and the outer coil of the winding coil, between the outer coil of the winding coil and the stator yoke, and between the outer coils of two adjacent winding coils, so as to realize the assembly of the stator assembly and the assembly of the entire axial flux motor.

[0018] Compared with the prior art, the present invention is notable in that: (1) it adopts an inner and outer double-layer coil structure, and the winding coil is formed by winding a flat copper wire as a whole, and only the connection between different winding coils needs to be made, which simplifies the manufacturing process and improves production efficiency; (2) the connection of the winding coils on both sides adopts an overall wave winding form, that is, the windings on both sides are wound by the same flat wire conductor in the form of wave winding, which reduces the length of the end conductor, improves the utilization rate of the conductor and the utilization rate of the stator slot space, reduces the end copper loss, and improves the efficiency of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a structural schematic diagram of an axial flux motor based on a double-layer winding coil structure of a flat copper wire conductor according to the present invention.

[0020] Figure 2 It is a structural schematic diagram of the stator assembly in an embodiment of the present utility model.

[0021] Figure 3 It is a side structural schematic diagram of the stator assembly in an embodiment of the present utility model.

[0022] Figure 4 Schematic diagram of the arrangement of winding coils in an embodiment of the present invention.

[0023] Figure 5 It is a structural diagram of the winding coil in an embodiment of the present utility model.

[0024] Figure 6a This is a schematic diagram of the structure of the connection of the winding coil ends in an embodiment of the present utility model.

[0025] Figure 6b for Figure 6a A partial enlarged view of .

[0026] Figure 7 This is a schematic diagram of the connection principle of the connecting conductors in the winding coil in an embodiment of the present utility model. DETAILED DESCRIPTION

[0027] The following describes the specific embodiments of the present disclosure in detail with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only used to illustrate and explain the present disclosure and are not intended to limit the present disclosure.

[0028] In this disclosure, unless otherwise specified, directional words such as "up, down, left, right" are generally defined by the direction of the drawings, and "inside" and "outside" refer to the inside and outside of the relevant components.

[0029] It should also be noted that, in the description of this disclosure, unless otherwise expressly specified or limited, the term "connection" should be understood in a broad sense. For example, it can mean a fixed connection, a detachable connection, or an integral connection. It can mean a direct connection, an indirect connection through an intermediate medium, or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this disclosure based on specific circumstances.

[0030] The winding coils in traditional flat-wire motors lack a double-layer structure, with inner and outer layers. When the winding coils are wound around the stator teeth 4, their cross-sectional area is too large, generating significant eddy current losses and reducing efficiency. Furthermore, the lack of gaps between the coils in traditional flat-wire windings prevents stator assembly from being fully integrated, reducing production efficiency.

[0031] The utility model provides an axial flux motor based on a double-layer winding coil structure of a flat copper wire conductor. The design of the winding coil in the utility model can reduce the influence of the large eddy current loss generated by the flat copper wire conductor, improve the utilization rate of the conductor, reduce the length and loss of the conductor at the winding end, and improve the operating efficiency of the entire motor. At the same time, the stator assembly composed of the winding coil is more convenient to operate and use in actual engineering applications, improves production efficiency, and provides a basis for subsequent mass production.

[0032] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific implementation methods.

[0033] like Figure 1 As shown, the utility model is an axial flux motor based on a double-layer winding coil structure of a flat copper wire conductor, comprising a stator assembly 1 and two rotors 2; the stator assembly 1 comprises a stator core 3, a winding coil 4, a connecting conductor 5, and a motor feeder 6; the stator core 3 comprises a stator yoke 3-1, stator teeth 3-2, and stator slots 3-3;

[0034] The stator assembly 1 is arranged in the middle, and a rotor 2 is arranged on each side;

[0035] like Figure 2 、 Figure 3As shown, the stator yoke 3-1 is provided with a plurality of stator teeth 3-2 and stator slots 3-3 on both sides, with the stator teeth 3-2 at corresponding positions being symmetrical about the stator yoke 3-1. Winding coils 4 are mounted on the stator teeth 3-2, with the winding coils 4 on two adjacent stator teeth 3-2 installed in the same stator slot 3-3. The winding coils 4 are all wound in the radial direction of the stator core 3 and stacked in the axial direction of the stator core 3. The winding coils 4 wound on all stator teeth 3-2 have the same structure.

[0036] As a specific example, the winding coil 4 is wound with flat copper wire and adopts a centralized winding distribution.

[0037] As a specific example, the winding coil 4 is an inner and outer double-layer coil structure, which is stacked and wound by the same flat copper wire conductor along the radial and axial directions of the stator core. The coil winding method adopted is to start from the stator yoke 3-1, first winding the inner layer coil of the winding coil 4, and then winding the outer layer coil of the winding coil 4.

[0038] like Figure 4 、 Figure 5 The outer coil 4-1 of the winding coil 4 is outside the inner coil 4-2 of the winding coil 4, and a gap 3-4 is set between the outer coil 4-1 and the inner coil 4-2. A flat copper wire conductor starts from the inlet end 4-4 of the winding coil 4 and is wound from the inner coil 4-2 along the radial and axial directions of the stator core from bottom to top. When the inner coil 4-2 is wound, it enters the transition section 4-5 between the inner coil 4-2 and the outer coil 4-1. The transition section 4-5 is inclined at a certain angle to the axial direction of the stator core. Then the conductor is wound from top to bottom along the inner coil 4-2 to form the outer coil 4-1 of the winding coil 4, and a gap 3-4 is set between the outer coil 4-1 and the inner coil 4-2. Finally, the end of the flat copper wire conductor forms the outlet end 4-3 of the winding coil 4.

[0039] As a specific example, the flat copper wire conductors of each turn of the inner coil 4 - 2 and the outer coil 4 - 1 of the winding coil 4 are parallel to each other, and the flat copper wire conductors of the transition section 4 - 5 are tilted at a corresponding angle along the axial direction of the stator core 3 .

[0040] As a specific example, the positions of the inlet terminal 4 - 4 and the outlet terminal 4 - 3 of the winding coils 4 on both sides of the stator core 3 symmetrically are both close to the stator yoke 3 - 1 .

[0041] As a specific example, all winding coils 4 in the same phase on both sides of the stator are connected by a connecting conductor 5, so that all winding coils 4 in the same phase are the same flat wire conductor, and the winding coils 4 on both sides are generally wave-wound, that is, in the same phase, the connection between the winding coils 4 on one side and the winding coils 4 on the other side is similar to the wave-wound form;

[0042] In the winding coils 4 on the same side, the winding coils 4 wound on two adjacent stator teeth 3-2 constitute one phase of the three phases, and in the same phase, the conductor directions of the two winding coils 4 contained in the stator slots 3-3 between the two stator teeth 3-2 are consistent; in different phases, the conductor directions of the two winding coils 4 contained in the stator slots 3-3 between two adjacent stator teeth 3-2 are opposite; the winding order and phase sequence of the winding coils 4 on the symmetrical stator teeth 3-2 on both sides are exactly the same.

[0043] As a specific example, the axial height of the winding coil 4 is less than the axial height of the stator tooth 3-2, and the winding coil 4 is also at a certain height from the stator yoke 3-1, and the connecting conductor 5 is also made of flat copper wire. Therefore, the radial size of the entire stator assembly 1 does not become larger due to the presence of the connecting conductor 5, which is very friendly to the assembly of the stator assembly 1 and the assembly of the axial flux motor, and has sufficient assembly space, which facilitates the actual operation of the project.

[0044] As a specific example, the connecting conductor 5 is located on the outer circumferential surface of the entire stator assembly 1, and the connecting conductor 5 adopts a flat copper wire conductor, so that the radial size of the entire stator assembly 1 will not be enlarged due to the presence of the connecting conductor 5, which facilitates the assembly of the stator assembly 1.

[0045] As a specific example, gaps 3-4 are provided between the inner coil of the winding coil 4 and the stator tooth 3-2, between the inner coil and the outer coil of the winding coil 4, between the outer coil of the winding coil 4 and the stator yoke 3-1, and between the outer coils of two adjacent winding coils 4, to facilitate the assembly of the stator assembly 1 and the assembly of the entire axial flux motor.

[0046] like Figure 6a As shown, it is a schematic diagram of the end connection structure of the partial winding coil 4 disclosed in the present invention, from Figure 6bThe locally enlarged view in the figure clearly shows the end connection structure of the winding coils 4 on both sides, wherein the incoming line 10 of a certain phase is connected to the left wiring port 24-1 of the 24th winding coil 4-24 on the lower side, the right wiring port 24-2 of the 24th winding coil 4-24 on the lower side is connected to the right wiring port 23-2 of the 23rd winding coil 4-23 on the lower side, the left wiring port 23-1 of the 23rd winding coil 4-23 on the lower side is connected to the left port 24'-1 of the 24th winding coil 4-24' on the upper side, the right port 24'-2 of the 24th winding coil 4-24' on the upper side is connected to the right port 23'-2 of the 23rd winding coil 4-23' on the upper side, and the left port 23'-1 of the 23rd winding coil 4-23' on the upper side is connected to the outgoing line 11 of the phase. The above connection structure is for connecting the ends of the winding coils 4 on the upper and lower sides in one phase belt of a certain phase, and the connection structure of the winding coils 4 in other phase belts is the same as the above connection structure.

[0047] like Figure 7 As shown, this is a connection principle diagram of the winding coil 4 disclosed in the present invention. From the figure, the connection relationship of the three-phase winding can be seen, and the winding coils 4 on both sides of the stator core 3 are connected by flat wire conductors to form a stator assembly 1.

[0048] The preferred embodiments of the present invention are described in detail above in conjunction with the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the scope of protection of the present invention.

[0049] It should be noted that it is obvious to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, from all perspectives, the embodiments should be regarded as illustrative and non-restrictive. The scope of the present invention is defined by the appended claims, not the foregoing description, and it is intended that all variations within the meaning and range of equivalents of the claims be encompassed within the present invention. Any reference signs in the claims should not be construed as limiting the claim to which they relate.

Claims

1. An axial flux motor based on a double-layer winding coil structure with a flat copper wire conductor, characterized in that: The invention comprises a stator assembly (1) and two rotors (2); wherein the stator assembly (1) comprises a stator core (3), a winding coil (4), a connecting conductor (5), and a motor feeder (6); and the stator core (3) comprises a stator yoke (3-1), stator teeth (3-2), and stator slots (3-3); The stator assembly (1) is arranged in the middle, and a rotor (2) is arranged on each side; A plurality of stator teeth (3-2) and stator slots (3-3) are respectively provided on both side surfaces of the stator yoke (3-1), and the stator teeth (3-2) at corresponding positions are symmetrical with respect to the stator yoke (3-1); winding coils (4) are mounted on the stator teeth (3-2), and the winding coils (4) on two adjacent stator teeth (3-2) are installed in the same stator slot (3-3); the winding coils (4) are all wound along the radial direction of the stator core (3) and stacked along the axial direction of the stator core (3).

2. The axial flux motor based on the double-layer winding coil structure of the flat copper wire conductor according to claim 1 is characterized in that: The winding coil (4) is wound with flat copper wire and adopts a centralized winding distribution.

3. The axial flux motor based on the double-layer winding coil structure of the flat copper wire conductor according to claim 1, characterized in that: The winding coil (4) is an inner and outer double-layer coil structure, and the double-layer coil structure is stacked and wound along the radial and axial directions of the stator core by the same flat copper wire conductor. The coil winding method adopted is to start from the stator yoke (3-1), firstly wind the inner coil of the winding coil (4), and then wind the outer coil of the winding coil (4).

4. The axial flux motor based on the double-layer winding coil structure of the flat copper wire conductor according to claim 3 is characterized in that: The outer coil (4-1) of the winding coil (4) is outside the inner coil (4-2) of the winding coil (4), and a gap (3-4) is provided between the outer coil (4-1) and the inner coil (4-2). A flat copper wire conductor is first wound from the inlet end (4-4) of the winding coil (4) and from the inner coil (4-2) along the radial and axial directions of the stator core from bottom to top. When the inner coil (4-2) is wound, it enters the inner coil (4-1). (4-2) and a transition section (4-5) between the outer coil (4-1), the transition section (4-5) is inclined at a set angle to the axial direction of the stator core, and then the conductor is wound from top to bottom along the inner coil (4-2) to form the outer coil (4-1) of the winding coil (4), and a gap (3-4) is set between the outer coil (4-1) and the inner coil (4-2), and finally the end of the flat copper wire conductor forms the output end (4-3) of the winding coil (4).

5. The axial flux motor based on the double-layer winding coil structure of the flat copper wire conductor according to claim 4, characterized in that: The flat copper wire conductors of each turn of the inner coil (4-2) and the outer coil (4-1) of the winding coil (4) are parallel to each other, and the flat copper wire conductors of the transition section (4-5) are inclined at a corresponding angle along the axial direction of the stator core (3).

6. The axial flux motor based on the double-layer winding coil structure of the flat copper wire conductor according to claim 4, characterized in that: The positions of the incoming wire ends (4-4) and outgoing wire ends (4-3) of the winding coils (4) on both sides of the stator core (3) are both close to the stator yoke (3-1).

7. The axial flux motor based on a double-layer winding coil structure of a flat copper wire conductor according to claim 1, characterized in that: All winding coils (4) in the same phase on both sides of the stator are connected via a connecting conductor (5), so that all winding coils (4) in the same phase are the same flat wire conductor, and the winding coils (4) on both sides are in a wave-wound form as a whole; In the winding coils (4) on the same side, the winding coils (4) wound on two adjacent stator teeth (3-2) constitute one phase of the three phases, and in the same phase, the conductor directions of the two winding coils (4) contained in the stator slots (3-3) between the two stator teeth (3-2) are consistent; in different phases, the conductor directions of the two winding coils (4) contained in the stator slots (3-3) between the two adjacent stator teeth (3-2) are opposite; the winding order and phase sequence of the winding coils (4) on the stator teeth (3-2) on both sides are exactly the same.

8. The axial flux motor based on a double-layer winding coil structure of a flat copper wire conductor according to claim 1, characterized in that: The axial height of the winding coil (4) is less than the axial height of the stator teeth (3-2), and the winding coil (4) also has a set height from the stator yoke (3-1).

9. The axial flux motor based on a double-layer winding coil structure of a flat copper wire conductor according to claim 1, characterized in that: The connecting conductor (5) is located on the outer circumferential surface of the entire stator assembly (1), and the connecting conductor (5) is a flat copper wire conductor, so that the radial size of the entire stator assembly (1) does not increase due to the presence of the connecting conductor (5), and is used to complete the assembly of the stator assembly (1).

10. The axial flux motor based on the double-layer winding coil structure of flat copper wire conductor according to claim 1, characterized in that: Gaps (3-4) are provided between the inner coil of the winding coil (4) and the stator teeth (3-2), between the inner coil and the outer coil of the winding coil (4), between the outer coil of the winding coil (4) and the stator yoke (3-1), and between the outer coils of two adjacent winding coils (4), for assembling the stator assembly (1) and the entire axial flux motor.

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