Motor stator assembly, motor and power system for vehicle

Abstract

The utility model provides a motor stator assembly, a motor and a power system for a vehicle. The motor stator assembly comprises a first stator, a second stator and a supporting sleeve which are assembled together. The supporting sleeve is located between the first iron core and the second iron core in the radial direction of the motor stator assembly, the supporting sleeve, the first iron core and the second iron core are coaxially arranged, and the first stator and the second stator are fixed together through the supporting sleeve and are spaced in the radial direction. Thus, since the first stator and the second stator are integrated in the radial direction in a laminated arrangement manner, the motor stator assembly can have better performance under the condition of saving space, and the first stator and the second stator are integrated through the supporting sleeve after being respectively assembled, so that the motor stator assembly is more compact in structure. This reduces the complexity of the assembly process and reduces the corresponding costs.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of electric machines, in particular to an electric machine stator assembly, an electric machine comprising the electric machine stator assembly, and a vehicle power system comprising the electric machine. BACKGROUND

[0002] Nowadays, an electric machine can be used as a motor to output torque and power, and the electric machine can also be used as a generator to charge a battery, so the electric machine can be applied to a power system of a pure electric vehicle or a hybrid electric vehicle. In order to meet the requirements of cost and performance of the vehicle, it is necessary to reduce the cost of the electric machine while improving the power density of the electric machine, and it is also necessary for the electric machine to have a smaller size while maintaining the performance. For this purpose, there is a scheme in the prior art to integrate two sets of stators and rotors together to form an electric machine, so as to meet the above requirements.

[0003] For example, in German Patent Application DE 10 2022 107 665 A1, an electric machine is disclosed. In the electric machine, one winding is installed at the outer peripheral portion of the core and another winding is installed at the inner peripheral portion of the core, so that the two windings are arranged in a stacked manner in the radial direction of the electric machine on the same core. However, in the electric machine, the scheme of installing two windings on the same core results in a complex assembly process and a high corresponding cost. UTILITY MODEL CONTENT

[0004] The present application is made in view of the above state of the art. One object of the present application is to provide an electric machine stator assembly which, while achieving the integration of two stators arranged in a stacked manner in the radial direction, reduces the complexity of the assembly process and the corresponding cost. Other objects of the present application are to provide an electric machine comprising the above electric machine stator assembly and a vehicle power system comprising the electric machine.

[0005] In order to achieve the above objects, the present application can adopt the following technical solutions.

[0006] The present application provides an electric machine stator assembly, comprising:

[0007] a first stator comprising a first core and a first winding, the first core being formed with a plurality of first conductor slots, the first winding being installed in the plurality of first conductor slots;

[0008] a second stator comprising a second core and a second winding, the second core being formed with a plurality of second conductor slots, the second winding being installed in the plurality of second conductor slots, the second core being arranged coaxially with the first core and located radially inward of the first core; and

[0009] a support sleeve located between the first core and the second core in a radial direction of the motor stator assembly, the support sleeve being coaxially arranged with the first core and the second core such that the first stator and the second stator are fixed to each other via the support sleeve and spaced apart in the radial direction.

[0010] In an alternative, the support sleeve continuously extends along a whole circumference of the motor stator assembly.

[0011] In another alternative, the support sleeve is interference-fitted with the first core and the second core.

[0012] In another alternative, axial end faces of the support sleeve are flush with axial end faces of the first core, and

[0013] axial end faces of the support sleeve are flush with axial end faces of the second core.

[0014] In another alternative, the plurality of first conductor slots are formed in an outer circumferential portion of the first core, and the plurality of second conductor slots are formed in an inner circumferential portion of the second core.

[0015] In another alternative, the support sleeve is made of non-magnetic metal.

[0016] In another alternative, the support sleeve is made of non-magnetic steel.

[0017] The present application also provides a motor including the motor stator assembly according to any one of the above technical solutions.

[0018] In an alternative, the motor further includes:

[0019] a first rotor located radially outward of the first stator; and

[0020] a second rotor located radially inward of the second stator.

[0021] The present application also provides a vehicle power system including the motor according to any one of the above technical solutions.

[0022] By adopting the above technical solution, this application provides a motor stator assembly. The motor stator assembly includes a first stator, a second stator, and a support sleeve assembled together. The first stator includes a first iron core and a first winding. The first iron core forms a plurality of first conductor slots, and the first winding is mounted in the plurality of first conductor slots. The second stator includes a second iron core and a second winding. The second iron core forms a plurality of second conductor slots. The second winding is mounted in the plurality of second conductor slots. The second iron core is coaxially arranged with the first iron core and located radially inside the first iron core. The support sleeve is located radially between the first and second iron cores of the motor stator assembly. The support sleeve is coaxially arranged with the first and second iron cores and is fixed to the first and second stators, such that the first and second stators are fixed together via the support sleeve and radially spaced apart.

[0023] In this way, because the first and second stators are integrated together in a radially stacked arrangement, the motor stator assembly can achieve better performance while saving space. Furthermore, since the first core of the first stator and the second core of the second stator are fixed together radially spaced by a support sleeve, the first and second stators can be assembled separately and then integrated together by the support sleeve. This reduces the complexity of the assembly process and lowers the corresponding cost. Moreover, in a more advantageous embodiment, if the support sleeve is made of a non-magnetic material such as a non-magnetic metal, it also helps to reduce the coupling between the magnetic fields generated by the two radially stacked windings, thus improving the decoupling effect of the magnetic fields of the first and second stators.

[0024] Furthermore, this application also provides an electric motor including the aforementioned motor stator assembly and a vehicle powertrain including the aforementioned motor, both of which have the same effect of reducing the complexity of the assembly process and lowering the corresponding costs. Moreover, by decoupling the magnetic field generated by the first stator and the magnetic field generated by the second stator of the motor stator assembly, torque fluctuations and NVH problems caused by the coupling of the magnetic fields generated by the two stators in the electric motor and vehicle powertrain according to this application can be mitigated. Attached Figure Description

[0025] Figure 1 This is an exploded structural diagram of a motor stator assembly according to an embodiment of this application.

[0026] Figure 2 It shows Figure 1 A schematic diagram of the motor stator assembly.

[0027] Figure 3 It shows Figure 1 A three-dimensional cross-sectional view of the motor stator assembly.

[0028] Figure 4 is a cross-sectional perspective view showing Figure 1 a motor stator assembly in a non-assembled state.

[0029] Reference Signs List

[0030] 1 first stator; 11 first core; 12 first winding;

[0031] 2 second stator; 21 second core; 22 second winding;

[0032] 3 support sleeve;

[0033] A axial direction; R radial direction; C circumferential direction. DETAILED DESCRIPTION

[0034] Exemplary embodiments of the present application are described herein below with reference to the accompanying drawings. It is to be understood that the specific description is merely illustrative of how to practice the present application, and is not intended to limit the scope of the present application in any way.

[0035] In the present application, unless otherwise specified, "axial direction", "radial direction" and "circumferential direction" refer to the axial direction, the radial direction and the circumferential direction of the motor stator assembly (motor), respectively. "Radially outer side" refers to the side away from the center axis of the motor stator assembly in the radial direction, and "radially inner side" refers to the side approaching the center axis of the motor stator assembly in the radial direction.

[0036] A motor stator assembly according to an embodiment of the present application will be described below with reference to the accompanying drawings.

[0037] As shown in Figures 1 to 4 , the motor stator assembly according to an embodiment of the present application includes a first stator 1, a second stator 2 and a support sleeve 3 assembled together. The first stator 1 and the second stator 2 are arranged in a stacked manner in the radial direction R, and are spaced apart and fixed to the support sleeve 3 in the radial direction R, whereby the first stator 1 and the second stator 2 are integrated together via the support sleeve 3.

[0038] In the present embodiment, as Figures 1 to 4As shown, the first stator 1 includes a first core 11 and a first winding 12 assembled together. The first core 11 may be constructed by stacking multiple silicon steel sheets together in the axial direction A, and the first core 11 may include a first yoke and first teeth fixed to each other. The first yoke has a cylindrical structure, and multiple first teeth protrude radially outward from the first yoke, and the multiple first teeth are evenly distributed at intervals in the circumferential direction C. A first conductor slot is defined between every two adjacent first teeth in the circumferential direction C, and each first conductor slot may penetrate the first core 11 along the axial direction A and each first conductor slot may have an opening that opens radially outward. Thus, the outer periphery of the first core 11 forms a plurality of first conductor slots distributed at intervals in the circumferential direction C. In addition, the first winding 12 may include a plurality of first conductor portions mounted in the plurality of first conductor slots and two first mounting rings located at the axial ends of the first winding 12. The first winding 12 may be interconnected by hairpin units to form a predetermined electrical circuit and integrated into a whole by means of mounting rings. Therefore, when the first winding 12 is energized, the first winding 12, in conjunction with the first iron core 11, enables the first stator 1 to generate the desired magnetic field. Furthermore, the axial ends of the first winding 12 extend from the first iron core 11 towards both axial directions.

[0039] In this embodiment, as Figures 1 to 4 As shown, the second stator 2 includes a second core 21 and a second winding 22 assembled together. The second core 21 may be constructed by stacking multiple silicon steel sheets together in the axial direction A, and the second core 21 may include a second yoke and second teeth fixed to each other. The second yoke has a cylindrical structure, and multiple second teeth protrude radially inward from the second yoke, and the multiple second teeth are evenly distributed at intervals in the circumferential direction C. A second conductor slot is defined between every two adjacent second teeth in the circumferential direction C, and each second conductor slot may penetrate the second core 21 along the axial direction A and each second conductor slot may have an opening that opens radially inward. Thus, the inner circumference of the second core 21 forms a plurality of second conductor slots distributed at intervals in the circumferential direction. In addition, the second winding 22 includes second conductor portions mounted in the plurality of second conductor slots and two second mounting rings located at the axial ends of the second winding 22. The second winding 22 may be interconnected by hairpin units to form a predetermined electrical circuit and integrated into a whole by means of the second mounting rings. Therefore, when the second winding 22 is energized, the second winding 22, in conjunction with the second iron core 21, enables the second stator 2 to generate the desired magnetic field. Furthermore, the axial ends of the second winding 22 extend from the second iron core 21 towards both axial directions. Further, as... Figures 1 to 4As shown, the second iron core 21 is located radially inside the first iron core 11, and the second iron core 21 is coaxially arranged with the first iron core 11. The second iron core 21 and the first iron core 11 may have the same axial dimension, and the two axial end faces of the two iron cores may be flush.

[0040] like Figures 1 to 4 As shown, a radial gap extends continuously along the circumferential direction C between the outer peripheral surface of the second iron core 21 and the inner peripheral surface of the first iron core 11, and the radial dimension of the radial gap is equal at all positions along the circumference. Thus, the second iron core 21 and the first iron core 11 achieve non-direct contact through the radial gap. The support sleeve 3 can be made of a non-magnetic metal material. The support sleeve 3 extends continuously along the circumferential direction and is arranged coaxially with the first iron core 11 and the second iron core 21 at the aforementioned radial gap, thereby positioning the support sleeve 3 radially between the first iron core 11 and the second iron core 21. The support sleeve 3 can be interference-fitted with both the first iron core 11 and the second iron core 21, fixing the support sleeve 3 to the first stator 1 and the second stator 2, thereby radially separating and fixing the first stator 1 and the second stator 2 together via the support sleeve 3. In addition, the axial end faces of the support sleeve 3 are flush with the axial end faces of the first iron core 11, and the axial end faces of the support sleeve 3 are flush with the axial end faces of the second iron core 21.

[0041] By adopting the above-described scheme, a motor stator assembly according to an embodiment of this application integrates the first stator 1 and the second stator 2 in a radially stacked manner. The motor stator assembly with this structure has a compact overall structure and occupies less space. Since the first iron core 11 of the first stator 1 and the second iron core 21 of the second stator 2 are fixed together radially R at a distance by the support sleeve 3, the first stator 1 and the second stator 2 can be assembled separately and then integrated together by the support sleeve 3. This reduces the complexity of the assembly process and lowers the corresponding cost. Moreover, since the support sleeve 3 is made of a non-magnetic metal material, it helps to reduce the mutual coupling of the magnetic fields generated by the first stator 1 and the second stator 2 stacked radially R, that is, it facilitates the decoupling of the magnetic fields generated by the first stator 1 and the second stator 2.

[0042] Further, the application also provides an electric machine which not only comprises the above-mentioned electric machine stator assembly, but also comprises a first rotor and a second rotor assembled with the above-mentioned electric machine stator assembly. The electric machine stator assembly, the first rotor and the second rotor can be arranged in a coaxial manner. The first rotor is located radially outside the electric machine stator assembly and spaced apart from the electric machine stator assembly, and the first rotor can rotate relative to the electric machine stator assembly in the magnetic field generated by the first stator 1 of the electric machine stator assembly. The second rotor is located radially inside the electric machine stator assembly and spaced apart from the electric machine stator assembly, and the second rotor can rotate relative to the electric machine stator assembly in the magnetic field generated by the second stator 2 of the electric machine stator assembly.

[0043] Further, the first rotor can comprise a first rotor core and a rotor support, and the rotor support can be located radially outside the first rotor core and fixed together with the first rotor core. In this way, the first rotor can output torque to the outside or receive torque from the outside via the rotor support. The second rotor can comprise a second rotor core and a rotor shaft, and the rotor shaft can be located radially inside the second rotor core and fixed together with the second rotor core. In this way, the second rotor can output torque to the outside or receive torque from the outside via the rotor shaft. Since the magnetic field generated by the first stator 1 of the electric machine stator assembly and the magnetic field generated by the second stator 2 of the electric machine stator assembly can be decoupled, the electric machine according to the application substantially reduces the torque fluctuation and NVH problem caused by the magnetic fields coupling with each other.

[0044] It should be understood that the above-mentioned embodiments are only exemplary and are not intended to limit the application. Those skilled in the art can make various modifications and changes to the above-mentioned embodiments under the teaching of the application without departing from the scope of the application. The technical solutions of the application are further described below.

[0045] i.It can be understood that the electric machine according to the application can typically be applied to a vehicle, and the electric machine can not only be applied to a pure electric vehicle, but also be applied to a hybrid vehicle. For this purpose, the application provides a vehicle power system. In the case of a pure electric vehicle, the vehicle power system can be an electric axle drive system, which can further comprise a transmission mechanism such as a gearbox, and the electric machine is drivingly coupled to the input shaft of the transmission to realize bidirectional torque transmission. In the case of a hybrid vehicle, the vehicle power system can be a hybrid power system, which can further comprise an engine, and the electric machine according to the application can work in cooperation with the engine.

[0046] ii.It can be understood that in the scheme of the application, the power density of the electric machine and the structural integration of the electric machine are improved, and the space occupied by the electric machine is significantly reduced. Moreover, since the space occupied by the electric machine is reduced, the layout of the corresponding components such as the housing and the bearing can also be more compact.

[0047] iii.It can be understood that in the scheme of the present application, the preliminary decoupling between the magnetic field of the first stator 1 and the magnetic field of the second stator 2 can be achieved by designing other structures, and the scheme of the present application can be used to further improve the decoupling effect.

[0048] iv.In the scheme of the present application, when the plurality of silicon steel sheets are stacked together by welding to form the first core 11 and the second core 21, the welding position (welding seam) can be located at the radial gap between the first core 11 and the second core 21, without welding at the air gap between the stator and the rotor, avoiding additional loss and reducing the overall efficiency of the motor caused by welding at the air gap.

[0049] In addition, welding assistance can also be used to position the first core 11 and the second core 21 relative to the stator in the axial direction A, and in this scheme, the first core 11 and the second core 21 can be welded at the radial gap. Compared with the scheme of two cores sharing a yoke (the yokes of the two cores are integrated), in the scheme of the present application, since two independently manufactured cores are used, the process of installing the windings on the two cores is less difficult, which is conducive to simplifying the assembly process and reducing the assembly difficulty.

Claims

1. An electric machine stator assembly, characterized by, comprises a first core formed with a plurality of first conductor slots and a first winding installed to the plurality of first conductor slots; a second stator comprising a second core formed with a plurality of second conductor slots and a second winding installed to the plurality of second conductor slots, the second core being coaxially arranged with the first core and located radially inward of the first core; and a support sleeve located between the first core and the second core in a radial direction of the motor stator assembly, the support sleeve being coaxially arranged with the first core and the second core such that the first stator and the second stator are fixed to each other via the support sleeve and spaced apart in the radial direction. The support sleeve continuously extends along a whole circumference of the motor stator assembly. The support sleeve is interference-fitted with the first core and the second core.

2. The motor stator assembly of claim 1, wherein, 4. The motor stator assembly according to any one of claims 1 to 3, wherein 3. The motor stator assembly of claim 1, wherein, an axial end surface of the support sleeve is flush with an axial end surface of the first core, and an axial end surface of the support sleeve is flush with an axial end surface of the second core. The plurality of first conductor slots are formed at an outer circumferential portion of the first core, and the plurality of second conductor slots are formed at an inner circumferential portion of the second core. The support sleeve is made of a non-magnetic metal.

5. The motor stator assembly of any one of claims 1 to 3, wherein, The support sleeve is made of a non-magnetic steel.

6. The motor stator assembly of any one of claims 1 to 3, wherein, The motor stator assembly according to any one of claims 1 to 7.

7. The motor stator assembly of claim 6, wherein, Further comprising:

8. An electric machine characterized by a first rotor located radially outward of the first stator; and 9. The electric machine of claim 8, wherein, a second rotor located radially inward of the second stator. The motor according to claim 8 or 9. ​ ​ 10. A powertrain system for a vehicle, characterized by comprising: ​

Images