High-power compact hub motor

Abstract

The utility model relates to a high-power compact hub motor, and aims to solve the problem of contradiction between power density and volume in the existing motor design. The motor comprises a left end cover, a right end cover, a steel ring, magnetic steel, an iron core, a motor shaft and the like. The step surface of the outer step of the steel ring is accurately matched with the step surface of the inner step of the end cover, so that the length of the magnetic steel and the iron core can be maximized in a limited space, and the power of the motor is improved without increasing the boundary dimension. The two ends of the motor shaft are provided with oil seals, the sealing performance and stability of the motor are ensured, and the glue injection design enhances the stability and durability of the winding. The outer diameter of the steel ring is matched with the positioning step on the end cover, so that the assembly precision is ensured. According to the utility model, the design of cooperation between the end covers is optimized, so that the power of the motor is improved without increasing the volume of the motor, and the motor is suitable for electric automobiles and the like which need efficient and compact motors. According to the motor, the power is improved, and the stability of the structure and the reliability in long-term use are enhanced.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle power system technology, and in particular to a high-power compact hub motor. Background Technology

[0002] With the development of electric vehicles and intelligent transportation, in-wheel motors, as an important component of electric drive systems, face key technical challenges in achieving high power density and compact design. However, the design of traditional in-wheel motors often faces a trade-off between power and size. Within limited space, the dimensions of the motor's magnets and core are restricted, resulting in the motor's power output failing to meet the demands of high-efficiency electric vehicles.

[0003] Existing technologies typically increase power density by increasing the size of the motor, but this not only increases the weight and size of the motor but also affects the energy efficiency and performance of the entire vehicle. Therefore, how to improve the power output of the motor without increasing its size has become a major challenge in the design of electric drive systems.

[0004] Given the existing frame and fork mounting dimensions, how to increase the height of the magnets and iron core without significantly altering the external dimensions has become a pressing technical challenge. Utility Model Content

[0005] A high-power compact hub motor includes a left end cover and a right end cover. A steel ring is positioned between the opposite end faces of the left and right end covers, and the steel ring is threadedly connected to the left and right end covers by fastening screws. A magnet is provided on the inner wall of the steel ring. A motor shaft is coaxially inserted into the center of the left and right end covers. An iron core is fitted onto the motor shaft at the center position between the left and right end covers, and a winding is embedded inside the iron core, connected to a motor wire. An injection hole is provided on the side wall of the motor shaft for injecting adhesive. A shaft hole is provided inside the motor shaft, and shaft hole adhesive is provided inside the shaft hole. The motor wire passes through the shaft hole adhesive and extends to the outside of the right end cover. A bearing is embedded in the center of the inner wall of both the left and right end covers. Oil seals are fitted on the outer circumference of both ends of the motor shaft, and the oil seals are embedded in the center of the outer wall of both the left and right end covers. Multiple positioning steps are provided on the sides of both the left and right end covers, and the outer diameter of the steel ring cooperates with the positioning steps.

[0006] Furthermore, a rim is fitted onto the outer circumference of the steel ring.

[0007] Furthermore, the winding is a multi-strand winding, using copper wire material, and the number of turns of the winding is designed to match the motor power.

[0008] Furthermore, the oil seals at both ends of the motor shaft adopt a double-lip design.

[0009] This utility model of a high-power compact hub motor includes components such as a left end cover, a right end cover, a steel rim, a magnet, an iron core, windings, a motor shaft, motor wires, shaft hole adhesive, an oil seal, and a wheel rim. The following are the design and functional descriptions of each key component:

[0010] Left end cap and right end cap:

[0011] The left and right end covers are located at opposite ends of the motor, respectively, and secure the motor shaft with bearings, providing structural support. They are connected by steel rings and further secured to the rings with threaded screws, ensuring the stability and precision of the motor assembly.

[0012] Steel rim:

[0013] The steel ring is a crucial structural component of the motor. The fit between the outer stepped surface and the inner stepped surface of the end cover ensures that the magnets and core can utilize their length to the maximum extent within a limited space. Multiple magnets are arranged on the inner wall of the steel ring, with the magnets being the same length as the ring itself, thereby enhancing the motor's magnetic field strength and increasing power output.

[0014] The steel ring, through the fit between the outer stepped surface and the inner stepped surface of the end cover, ensures the assembly precision and structural stability of the motor.

[0015] Magnets and iron cores:

[0016] Magnets are mounted on the inner wall of the steel ring, with the magnets being the same length as the ring. This increases the magnetic field strength of the motor and improves power output. The installation of the magnets ensures that the motor has high magnetic energy conversion efficiency.

[0017] The iron core is located on the motor shaft and works with the windings to form a magnetic field. The length of the iron core is the same as that of the magnet, allowing the magnetic field to flow over a longer path, thereby increasing the motor's output power.

[0018] Motor shaft and windings:

[0019] The motor shaft passes through the left and right end covers and secures the iron core. Oil seals are installed at both ends of the motor shaft to prevent oil leakage and to ensure lubrication and sealing inside the motor.

[0020] The winding is installed inside the iron core and is connected to an external power source through motor wires. When energized, it generates a rotating magnetic field that drives the motor to rotate.

[0021] Shaft hole glue and injection hole:

[0022] The shaft hole adhesive is placed in the inner hole of the motor shaft to fix the motor wires, ensure the stability of the motor wires, and prevent them from loosening during operation.

[0023] The motor shaft sidewall is provided with an injection hole for injecting adhesive to fix the winding, enhance the stability and durability of the winding, and prevent the winding from loosening due to vibration or long-term operation.

[0024] Oil seal:

[0025] Oil seals are installed at both ends of the motor shaft and are made of high-temperature and corrosion-resistant synthetic materials to ensure stable operation of the motor in high-temperature and harsh environments and to prevent lubricating oil leakage.

[0026] Wheel rim:

[0027] The rim, fitted onto the outer circumference of the steel ring, serves as the external connection to the motor. It connects to the wheels of the electric vehicle, providing power output. The rim is made of high-strength aluminum alloy to enhance the overall structural strength and stability of the motor.

[0028] Breakthrough steel ring and end cap mating design: The outer diameter of the steel ring and the outer stepped steps of the end cap mat together, which allows the magnet and iron core to be used to the maximum extent in a limited space, increasing the power output of the motor without changing the external dimensions of the motor.

[0029] Optimized magnet and core design: The length of the magnet is the same as that of the steel ring, and the length of the core is also the same as that of the magnet, which maximizes the magnetic field path of the motor and thus improves the power density of the motor.

[0030] Oil seal and glue injection design: A double oil seal design ensures long-term stable operation of the motor. Meanwhile, the glue injection holes and shaft hole glue effectively secure the windings, preventing loosening and extending the motor's service life.

[0031] Achieving both compact structure and high power output: Through ingenious design of the motor structure, the motor power is increased without increasing the external size of the motor, making it suitable for applications requiring miniaturization and high power.

[0032] This invention achieves an optimal balance between motor power and size through optimized design. Motors using this design not only have high power output but also operate normally under space-constrained conditions, making them suitable for applications in electric vehicles, smart power tools, and other fields.

[0033] Beneficial effects

[0034] Increased power: Compared to traditional designs, this motor offers 20%-30% more power within the same volume, providing more efficient driving force for applications such as electric vehicles.

[0035] Compact structure: The design makes full use of the internal space, making the motor size compact and the installation more flexible.

[0036] Improved stability: The use of high-strength alloy materials, oil seals, and glue injection design improves the durability and stability of the motor.

[0037] The innovative design of this utility model significantly improves the power density of the motor, meeting the application requirements of high power output and miniaturization of electric systems, and has broad market prospects and application value.

[0038] The above description is merely an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this utility model more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the internal cross-sectional structure of the high-power compact hub motor proposed in this utility model.

[0040] Figure 2 The high-power compact hub motor proposed in this utility model Figure 1 A magnified schematic diagram of the local structure at point A in the middle.

[0041] In the diagram: 1. Left end cap; 2. Right end cap; 3. Rim; 4. Magnet; 5. Motor shaft; 6. Iron core; 7. Winding; 8. Motor wire; 9. Shaft hole glue; 10. Oil seal; 11. Bearing; 12. Glue injection hole; 13. Fastening screw; 14. Steel ring; 15. Positioning step; 16. Bearing. Detailed Implementation

[0042] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0043] Example 1, referring to Figures 1 to 2 High-power compact hub motor

[0044] This invention provides a high-power compact hub motor. The purpose is to increase the length of the magnet to be the same as the length of the steel ring by changing the end cover from fitting with the inner wall of the steel ring to fitting with the outer cylindrical surface of the steel ring within a limited space. At the same time, the stator core is also increased to be the same length as the magnet. While keeping the external dimensions of the motor unchanged, the length of the magnet and the core is increased, thereby improving the power of the motor, while maintaining a compact shape to meet different application requirements.

[0045] This invention focuses on overcoming the challenge of increasing the power of a hub motor within a limited space. Its core lies in a unique structural design that, through the mating of the end cap and the outer cylindrical surface of the steel rim, opens up a new path for extending the magnet, thereby achieving a leap in motor performance. The specific implementation method is as follows:

[0046] Overall Motor Architecture

[0047] The high-power compact hub motor mainly consists of key components such as the left end cover 1, the right end cover 2, the steel ring 14, and the motor shaft 5. The left end cover 1 and right end cover 2 are located at opposite ends of the motor, forming the basic structure that supports the motor shaft 5 and numerous internal and external components. Their outer surfaces are meticulously designed with multiple positioning steps 15. The steel ring 14 is firmly connected to the left and right end covers using fastening screws 13. Its fit with the end cover positioning steps 15 is ingenious—it uses an outer diameter fit, unlike the traditional internal positioning step design, thus eliminating the constraints on magnet length caused by internal positioning in the past. Furthermore, the steel ring 14 is not only a structural connector, but its inner ring surface is also a crucial location for the subsequent installation of the magnet 4, and its outer circumference also has reserved space for the wheel rim 3.

[0048] Optimized layout of magnets and iron core

[0049] like Figure 2 As shown, the magnets 4 are arranged sequentially along the inner wall of the steel ring 14. Thanks to the space released by the fit between the end cap and the outer cylindrical surface of the steel ring, the length of the magnets can be extended to be the same as that of the steel ring. In this way, the limited motor space is maximized, the magnetic field strength is significantly enhanced, and a solid foundation is laid for the high-power output of the motor.

[0050] Correspondingly, an iron core 6 is fitted onto the upper part of the motor shaft 5, with windings 7 wound inside. The iron core serves as the main path for the motor's magnetic flux and the closed loop of the magnetic field, and its length is also extended to match that of the magnet. This equal-length design creates the longest effective magnetic field path, which greatly reduces magnetic flux loss during motor operation, thus improving both efficiency and power output.

[0051] Motor shaft and windings work together

[0052] The motor shaft 5 is securely positioned between the left end cover 1 and the right end cover 2, bearing the heavy responsibility of supporting the iron core 6 and the winding 7, and is precisely fixed by the central shaft hole. To prevent lubricating oil leakage, an oil seal 10 is installed at each end of the motor shaft.

[0053] Winding 7, a crucial component for motor power generation, employs a multi-strand winding design and is cleverly housed within the iron core. Current is delivered to winding 7 via motor wire 8, which passes through the shaft hole 9 inside the motor shaft and extends to the outside of the right end cover 2. Once energized, winding 7 generates a rotating magnetic field with the assistance of the iron core 6. Furthermore, the side wall of the motor shaft is equipped with an injection hole 12, allowing for timely injection of adhesive to firmly secure winding 7, resist operational vibrations, and eliminate the risk of winding loosening or damage.

[0054] Careful consideration of bearings and seals

[0055] To ensure smooth and stable motor operation, high-precision bearings 16 are embedded in the center of the inner walls of both the left end cover 1 and the right end cover 2, providing stable support for the motor shaft. In terms of sealing, double-lip oil seals 10 located at the center of the outer walls of the left end cover 1 and the right end cover 2 play a crucial role. They tightly prevent lubricating oil leakage, maintain a clean internal environment for the motor, and safeguard long-term stable operation.

[0056] Rim adapter connection

[0057] The rim 3 is fitted onto the outer circumference of the steel ring 14. As an extension of the motor, it can seamlessly connect with the electric vehicle wheel, successfully coordinating the motor power output with the wheel rotation, and continuously delivering driving force for the vehicle to move forward.

[0058] Explanation of working principle

[0059] When the motor is powered on, the current quickly reaches the winding 7 via the motor wire 8. Relying on the iron core 6, an alternating magnetic field is immediately generated around the winding 7. At this moment, the magnet 4 on the inner wall of the steel ring 14 interacts with this alternating magnetic field, forming a strong driving force that propels the motor shaft 5 to rotate stably around its axis. The bearings 16 at both ends of the motor shaft 5 ensure stable rotation, while the oil seal 10 maintains a tight seal, allowing the entire system to stably output powerful output.

[0060] Working principle

[0061] When the motor is powered on, the current is transmitted to the winding 7 through the motor wire 8. With the iron core 6 present, the winding 7 generates an alternating magnetic field around it. Since the inner wall of the steel ring 14 is equipped with magnets 4, the alternating magnetic field interacts with the magnetic field of the magnets 4, causing the motor shaft 5 to rotate around its axis. The two ends of the motor shaft 5 are supported on the left end cover 1 and the right end cover 2 by bearings 16. The oil seal 10 ensures the sealing during rotation, allowing the entire motor to output power stably.

[0062] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A high-power compact hub motor, comprising a left end cover (1) and a right end cover (2), characterized in that, The left end cap (1) and the right end cap (2) are provided with the same steel ring (14) between their opposite end faces. The steel ring (14) is threadedly connected to the left end cap (1) and the right end cap (2) by fastening screws (13). The inner wall of the steel ring (14) is provided with a magnet (4). The left end cap (1) and the right end cap (2) are coaxially inserted with a motor shaft (5). The motor shaft (5) is fitted with an iron core (6) at the center position between the left end cap (1) and the right end cap (2). The iron core (6) is embedded with a winding (7). The winding (7) is connected to a motor wire (8). The side wall of the motor shaft (5) is provided with an injection hole (12). The injection hole (12) is used to inject adhesive. The motor shaft (5) has a shaft hole inside, and the shaft hole is provided with shaft hole adhesive (9). The motor wire (8) passes through the shaft hole adhesive (9) and extends to the outside of the right end cover (2). The center of the inner wall of the left end cover (1) and the right end cover (2) is provided with a bearing (16). The outer circumference of both ends of the motor shaft (5) is provided with an oil seal (10). The oil seal (10) is embedded in the center of the outer wall of the left end cover (1) and the right end cover (2). The side of the left end cover (1) and the right end cover (2) is provided with multiple positioning steps (15). The outer diameter of the steel ring (14) is matched with the positioning steps (15).

2. The high-power compact hub motor according to claim 1, characterized in that, The outer circumference of the steel ring (14) is fitted with a rim (3).

3. The high-power compact hub motor according to claim 1, characterized in that, The winding (7) is a multi-strand winding made of copper wire, and the number of turns of the winding is designed to match the power of the motor.

4. The high-power compact hub motor according to claim 1, characterized in that, The oil seals (10) at both ends of the motor shaft (5) adopt a double-lip design.

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