Disc type motor structure

Abstract

The utility model relates to the technical field of motors, in particular to a disc type motor structure, which comprises a stator assembly (1). A first rotor assembly is arranged on one side of the stator assembly (1); a second rotor assembly is arranged on the other side of the stator assembly (1); the stator assembly (1) comprises a stator bracket (2); a stator iron core structure is arranged in the stator bracket (2); the first rotor assembly and the second rotor assembly are arranged on the two sides of the stator support (2) respectively. A disc type motor double-rotor structure is adopted, the space is fully utilized, and higher power density is achieved; the stator assembly is arranged between the first rotor assembly and the second rotor assembly; a magnetic field generated by the stator assembly can be fully utilized, and the power density is effectively improved; and on the other hand, the axial magnetic pulling forces of the two rotor assemblies are mutually offset, so that the stator assembly is prevented from bearing single-side magnetic pulling forces.

Description

TECHNICAL FIELD

[0001] The utility model relates to motor technical field, specifically, the utility model relates to a disc type motor structure. BACKGROUND

[0002] Motors are widely used in automobiles, such as fans and water pumps in cooling systems, which need to run stably during automobile driving to support the normal operation of related automobile systems. Currently, the widely used traditional radial flux motor has mature technology and principle, but its power density is limited, which restricts the further reduction of motor size and weight, causing inconvenience in automobile system arrangement. The disc type motor, also known as axial flux motor, has a different operating principle from the traditional radial field motor, which allows for higher power density and further reduction in motor size. Moreover, its overall structure is flat, making it more flexible in arrangement. However, the existing disc type motor structure still has problems of insufficient electric power density and large size.

[0003] The applicant found, through retrieval, that the Chinese patent document with publication number CN119030207A disclosed a disc type motor rotor and disc type motor on November 26, 2024. The disc type motor includes a stator and a disc type motor rotor. The disc type motor rotor includes a back plate, multiple magnetic conductive blocks, and multiple permanent magnet assemblies. The back plate is made of a non-magnetic conductive material. The back plate is provided with multiple slots along its circumference. Each magnetic conductive block is inserted into the slot along the radial direction and is limited in the axial direction by the back plate. Limiting grooves are formed between adjacent magnetic conductive blocks. Each permanent magnet assembly is inserted into the limiting groove along the radial direction, so that the magnetic conductive block presses the corresponding permanent magnet assembly on the back plate along the axial direction. This device cannot solve the above technical problems.

[0004] Therefore, in order to improve or solve at least one of the above problems, it is necessary to provide a disc type motor structure with high electric power density. INVENTION CONTENTS

[0005] The purpose of the utility model is to provide a disc type motor structure with high electric power density.

[0006] In order to solve the above technical problems, the technical scheme adopted by the utility model is as follows: a disc type motor structure, including a stator assembly; the stator assembly is provided with a first rotor assembly on one side; the stator assembly is provided with a second rotor assembly on the other side;

[0007] The stator assembly includes a stator support; the stator support is provided with a stator core structure; the first rotor assembly and the second rotor assembly are respectively arranged on both sides of the stator support.

[0008] The stator core structure includes an iron core and an insulation frame; the insulation frame includes an insulation frame and a mounting plate; the iron core is arranged in the insulation frame; the insulation frame is provided with a winding.

[0009] The stator support is provided with a PCB control board; the PCB control board is provided with pins; the mounting plate is provided with mounting holes; the pins are disposed in the mounting holes and are connected to the windings.

[0010] The stator support is provided with a shaft mounting hole; a shaft is provided in the shaft mounting hole; the first rotor assembly includes a first back plate; a first sleeve is provided on the first back plate; the first sleeve is sleeved on the shaft; a first magnet groove and a first back plate mounting groove are provided on one side of the stator support; a first magnet is connected to the first back plate; the first magnet is disposed in the first magnet groove; a first limiting block is provided at the end of the first back plate; the first limiting block is disposed in the first back plate mounting groove.

[0011] The second rotor assembly includes a second back plate; a second sleeve is provided on the second back plate; the second sleeve is sleeved on the rotating shaft; a second magnet slot is provided on the stator support; a second magnet is connected to the second back plate, and the second magnet is disposed in the second magnet slot.

[0012] One end of the rotating shaft mounting hole is provided with a first bearing mounting groove; the other end of the rotating shaft mounting hole is provided with a second bearing mounting groove; a first bearing is provided in the first bearing mounting groove; a second bearing is provided in the second bearing mounting groove; both the first bearing and the second bearing are sleeved on the rotating shaft.

[0013] The first bearing mounting groove is provided with a retaining ring mounting groove; the retaining ring mounting groove is provided with an elastic retaining ring; the rotating shaft is provided with a snap ring groove; the snap ring groove is provided with a snap ring; the first bearing is located between the elastic retaining ring and the snap ring; the second bearing mounting groove is provided with a spring; one end of the second bearing is pressed against the spring; the other end of the second bearing is pressed against the second sleeve.

[0014] The PCB control board is sleeved on the second back plate; the stator bracket has an end cap on the side near the PCB control board.

[0015] The stator support has multiple stator core structures evenly distributed in it; the stator support is a BMC support, and the stator support is injection molded to the stator core structure.

[0016] The insulating frame is an insulating resin frame.

[0017] The beneficial effects of this application are as follows:

[0018] This application adopts a disc motor dual rotor structure, which makes full use of space and has a greater power density; the stator assembly is located between the first rotor assembly and the second rotor assembly; it can make full use of the magnetic field generated by the stator assembly and effectively improve the power density; on the other hand, the axial magnetic pull of the two rotor assemblies cancels each other out, avoiding the stator assembly from bearing unilateral magnetic pull.

[0019] The rotor assembly of this application adopts a Halbach Array structure, which allows the rotor magnetic field to flow inside the magnets without the need for an additional rotor yoke. Therefore, the rotor back plate can be made of non-magnetic material and can be appropriately thinned according to structural strength, which can effectively reduce the size of the motor. At the same time, the axial magnetization of the magnets is effectively reduced by using multi-segment magnets spliced ​​together to reduce the eddy current loss of the magnets.

[0020] The stator core structure of this application adopts a segmented splicing structure and is a centralized winding, which makes winding more convenient. It can be mass-produced and then spliced ​​in subsequent processes, resulting in good manufacturability. The stator assembly uses BMC injection molding to encapsulate the core, which can effectively protect the stator from external contamination and corrosion, resulting in better reliability. BMC encapsulation improves the heat dissipation of the stator, allowing the heat of the stator to be dissipated in a timely manner, achieving better heat dissipation effect. BMC forms the main structure of the bearing and motor, reducing the number of motor parts and processing steps, and lowering manufacturing costs. The overall structure of this device is flat, providing more flexibility in the layout of the application. Attached Figure Description

[0021] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings, wherein:

[0022] Figure 1 This is a schematic diagram of the structure of the disc motor.

[0023] Figure 2 This is a schematic diagram of the iron core of this disc motor structure.

[0024] Figure 3 This is a schematic diagram of the insulation frame of this disc motor structure.

[0025] Figure 4 This is a schematic diagram of the stator core structure of this disc motor.

[0026] Figure 5 This is a schematic diagram of the stator core structure of this disc motor in its assembled state.

[0027] Figure 6 This is a schematic diagram of the PCB control board for this disc motor structure.

[0028] Figure 7This is a schematic diagram of the first and second magnets in the disc motor structure.

[0029] Figure 8 This is a schematic diagram of the magnetic field flow path in this disc motor structure.

[0030] The markings in the above figures are all:

[0031] The diagram is marked as follows:

[0032] 1. Stator assembly,

[0033] 2. Stator support,

[0034] 3. Iron heart,

[0035] 4. Insulating frame; 401. Insulating frame; 402. Mounting plate; 403. Mounting holes.

[0036] 5. Windings

[0037] 6. PCB control board, 601, pins,

[0038] 7. Shaft mounting hole, 701, Shaft,

[0039] 8. First backplate, 801. First magnet, 802. First sleeve.

[0040] 9. First magnet slot; 901. First backplate mounting slot; 902. First limit block.

[0041] 10. Second backplate; 101. Second magnet.

[0042] 11. Second sleeve; 111. Second magnetic groove;

[0043] 12. First bearing mounting groove; 121. First bearing; 122. Retaining ring mounting groove; 123. Elastic retaining ring; 124. Snap ring groove; 125. Snap ring.

[0044] 13. Second bearing mounting slot; 131. Second bearing; 132. Spring.

[0045] 14. End cap. Detailed Implementation

[0046] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of this utility model, and to facilitate its implementation.

[0047] Figure 1The disc motor structure shown includes a stator assembly 1; a first rotor assembly is provided on one side of the stator assembly 1; and a second rotor assembly is provided on the other side of the stator assembly 1.

[0048] The stator assembly 1 includes a stator support 2; the stator support 2 has a stator core structure; the first rotor assembly and the second rotor assembly are respectively located on both sides of the stator support 2.

[0049] This application adopts a disc motor dual rotor structure, which makes full use of space and has a greater power density; the stator assembly 1 is located between the first rotor assembly and the second rotor assembly; it can make full use of the magnetic field generated by the stator assembly 1 and effectively improve the power density; on the other hand, the axial magnetic pull of the two rotor assemblies cancels each other out, avoiding the stator assembly 1 from bearing unilateral magnetic pull.

[0050] Stator bracket 2 is a BMC bracket; the stator core structure is injection molded and connected in stator bracket 2; BMC (Bulk Molding Compound) is a bulk molding compound. As a thermosetting composite material, BMC is composed of unsaturated polyester resin, chopped glass fiber, filler, curing agent, thickener and other components. It has good molding performance, high mechanical strength, excellent electrical insulation, chemical corrosion resistance and good dimensional stability. Stator bracket 2 completely encapsulates the stator core structure, which can effectively protect the stator core structure from external pollution and corrosion, and has better reliability. BMC encapsulation improves the heat dissipation of the stator core structure, which can dissipate the heat of the stator core structure in a timely manner and obtain better heat dissipation effect.

[0051] like Figures 2-5 As shown, the stator core structure includes a core 3 and an insulating frame 4; the insulating frame 4 includes an insulating frame 401 and a mounting plate 402; the core 3 is disposed in the insulating frame 401; and the insulating frame 401 is provided with a winding 5.

[0052] The core 3 adopts a segmented structure, and the core 3 is made of silicon steel sheets or cold-rolled steel sheets of different widths stacked together; the sheets are connected together by snap-fit ​​points or adhesive to form a single stator core 3; the insulating frame 4 is injection molded from insulating resin material, and two insulating frames 4 wrap one segment of core 3 to insulate and isolate it from the winding 5; the lamination width of the core 3 varies according to the shape and size of the core 3; this application adopts a concentrated winding 5, that is, the coil pitch is 1, and each coil is wound on one segment of core 3; when the stator assembly 1 is manufactured, the three segments of the wound core are assembled into a complete stator core, and BMC injection molding is performed in the mold. After the BMC is cured, the stator core 3 and the winding 5 are sealed inside to form the stator assembly 1.

[0053] like Figure 6As shown, a PCB control board 6 is provided on the stator bracket 2; a pin 601 is provided on the PCB control board 6; a mounting hole 403 is provided on the mounting plate 402; the pin 601 is located in the mounting hole 403 and is connected to the winding 5.

[0054] Each insulating frame 4 has a mounting hole 403 to fix the pin 601; each insulating frame 4 facing the outgoing wire side is equipped with two pins 601, which are made of conductive material; each core 3 can be wound with coil after being wrapped with the insulating frame 4, and the coil lead is wound on the pin 601 and reinforced by soldering; the PCB control board 6 has solder points corresponding to the pins 601, and the winding 5 is connected to the PCB control board 6 by soldering through the pins 601; the internal circuit of the PCB control board 6 connects the three-phase windings into the required number of parallel branches and connection method (Y / ▲), and the PCB control board 6 has relevant control chips and control circuits;

[0055] In this embodiment, the motor is a three-phase eight-pole motor, including a 12-lobed iron core 3, with a set of coils wound on each lobe of the iron core 3. According to the phase sequence UVWUVWUVWUVW, the end of each coil is connected to the PCB control board 6 through a pin 601. The internal circuit of the PCB control board 6 connects each coil into Y / ▲ and the required parallel branches. When current is applied to the stator assembly 1, a magnetic field is generated. The magnetic field flow path is: starting from the iron core 3 → air gap → one side magnet → air gap → iron core 3 → the other side air gap → the other side magnet → air gap → iron core 3. The magnetic field flow path generated by the rotor magnet is the same as the path of the stator iron core 3. By detecting the back EMF phase or the winding flux linkage and other sensorless control methods, the controller detects the rotor position and controls the stator current phase, so that the stator and rotor magnetic fields maintain a certain relative positional relationship in space, and torque is generated under the interaction of the stator and rotor magnetic fields.

[0056] like Figures 7-8 As shown, the stator support 2 is provided with a shaft mounting hole 7; a shaft 701 is provided in the shaft mounting hole 7; the first rotor assembly includes a first back plate 8; a first sleeve 802 is provided on the first back plate 8; the first sleeve 802 is sleeved on the shaft 701; a first magnet groove 9 and a first back plate mounting groove 901 are provided on one side of the stator support 2; the first back plate 8 is connected to the first magnet 801; the first magnet 801 is located in the first magnet groove 9; a first limiting block 902 is provided at the end of the first back plate 8; the first limiting block 902 is located in the first back plate mounting groove 901.

[0057] The first magnet 801 adopts a Halbach array structure and is fixed on the first back plate 8. The first back plate 8 is connected to the rotating shaft 701 by an interference fit. The external load can be connected to the motor through the first back plate 8 and the rotating shaft 701.

[0058] The first rotor assembly adopts a Halbach array structure, which allows the rotor magnetic field to flow inside the first magnet 801 without the need for an additional rotor yoke. Therefore, the first back plate 8 can be made of non-magnetic material and its thickness can be appropriately reduced according to the structural strength. The axially magnetized first magnet 801 adopts multi-segment magnets spliced ​​together to reduce magnet eddy current losses.

[0059] The first back plate 8 is interference-fitted with the rotating shaft 701, and can be assembled by cold pressing.

[0060] The second rotor assembly includes a second back plate 10; a second sleeve 11 is provided on the second back plate 10; the second sleeve 11 is sleeved on the rotating shaft 701; a second magnet groove 111 is provided on the stator bracket 2; a second magnet 101 is connected to the second back plate 10, and the second magnet 101 is located in the second magnet groove 111.

[0061] The second magnet 101 adopts a Halbach array structure and is fixed on the second back plate 10. The second back plate 10 is connected to the rotating shaft 701 by an interference fit.

[0062] The second rotor assembly adopts a Halbach array structure, which allows the rotor magnetic field to flow inside the second magnet 101 without the need for an additional rotor yoke. Therefore, the second back plate 10 can use non-magnetic materials and can be appropriately thinned according to structural strength. The axially magnetized second magnet 101 adopts multi-segment magnets spliced ​​together to reduce magnet eddy current losses.

[0063] The second back plate 10 is interference-fitted with the rotating shaft 701, and can be assembled by cold pressing.

[0064] One end of the rotating shaft mounting hole 7 is provided with a first bearing mounting groove 12; the other end of the rotating shaft mounting hole 7 is provided with a second bearing mounting groove 13; a first bearing 121 is provided in the first bearing mounting groove 12; a second bearing 131 is provided in the second bearing mounting groove 13; the first bearing 121 and the second bearing 131 are both sleeved on the rotating shaft 701.

[0065] During BMC injection molding, a first bearing mounting groove 12 and a second bearing mounting groove 13 are formed. The first bearing 121 and the second bearing 131 are respectively located in the first bearing mounting groove 12 and the second bearing mounting groove 13. The first bearing 121 and the second bearing 131 are respectively connected to the two ends of the rotating shaft 701, thereby enabling the rotating shaft 701 to rotate flexibly in the rotating shaft mounting hole 7.

[0066] The first bearing mounting groove 12 is provided with a retaining ring mounting groove 122; the retaining ring mounting groove 122 is provided with an elastic retaining ring 123; the rotating shaft 701 is provided with a snap ring groove 124; the snap ring groove 124 is provided with a snap ring 125; the first bearing 121 is located between the elastic retaining ring 123 and the snap ring 125; the second bearing mounting groove 13 is provided with a spring 132; one end of the second bearing 131 is pressed against the spring 132; the other end of the second bearing 131 is pressed against the second sleeve 11.

[0067] The elastic retaining ring 123 and the snap ring 125 can limit the first bearing 121; the elastic retaining ring 123 limits the first bearing 121 in the first bearing mounting groove 12, permanently offsetting the axial dimension changes caused by assembly tolerances and thermal expansion and contraction; the snap ring 125 and the first back plate 8 achieve position locking, and the first bearing 121 can position the relative position of the rotor and stator to ensure the size of the air gap on both sides of the motor; there is no retaining ring in the second bearing mounting groove 13, and the second bearing 131 can float in its position. The spring 132 is a wave spring, which is used to provide bearing preload and reduce noise and vibration.

[0068] The PCB control board 6 is fitted onto the second back plate 10; the stator bracket 2 has an end cap 14 on the side near the PCB control board 6.

[0069] Multiple stator core structures are evenly distributed in the stator support 2; the stator support 2 is a BMC support, and the stator support 2 is injection molded to the stator core structure.

[0070] The insulating frame 4 is an insulating resin frame.

[0071] The specific workflow of this utility model is as follows:

[0072] During the manufacturing of stator assembly 1, the three segments of the wound iron core are assembled into a complete stator iron core. BMC injection molding is performed in the mold. After the BMC is cured, the stator iron core 3 and the winding 5 are encapsulated inside to form stator assembly 1. The winding 5 is connected to the PCB control board 6 by soldering through the pin 601. A rotating shaft 701 is connected to the stator assembly 1.

[0073] The first magnet 801 adopts a Halbach array structure and is fixed on the first back plate 8. The first back plate 8 is connected to the rotating shaft 701 by an interference fit. The external load can be connected to the stator assembly 1 through the first back plate 8 and the rotating shaft 701.

[0074] The second magnet 101 adopts a Halbach array structure and is fixed on the second back plate 10. The second back plate 10 is connected to the rotating shaft 701 by an interference fit.

[0075] An end cap 14 is installed on one side of the second rotor assembly.

[0076] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A disc motor structure, characterized in that: It includes a stator assembly (1); a first rotor assembly is provided on one side of the stator assembly (1); and a second rotor assembly is provided on the other side of the stator assembly (1); The stator assembly (1) includes a stator support (2); the stator support (2) is provided with a stator core structure; the first rotor assembly and the second rotor assembly are respectively provided on both sides of the stator support (2); The stator core structure includes a core (3) and an insulating frame (4); the insulating frame (4) includes an insulating frame (401) and a mounting plate (402); the core (3) is disposed in the insulating frame (401); and the insulating frame (401) is provided with a winding (5). The stator support (2) is provided with a PCB control board (6); the PCB control board (6) is provided with a pin (601); the mounting plate (402) is provided with a mounting hole (403); the pin (601) is located in the mounting hole (403), and the pin (601) is connected to the winding (5); The stator support (2) is provided with a shaft mounting hole (7); the shaft mounting hole (7) is provided with a shaft (701); the first rotor assembly includes a first back plate (8); the first back plate (8) is provided with a first sleeve (802); the first sleeve (802) is sleeved on the shaft (701); the stator support (2) is provided with a first magnet groove (9) and a first back plate mounting groove (901) on one side; the first back plate (8) is connected to a first magnet (801); the first magnet (801) is located in the first magnet groove (9); the end of the first back plate (8) is provided with a first limiting block (902); the first limiting block (902) is located in the first back plate mounting groove (901); The second rotor assembly includes a second back plate (10); a second sleeve (11) is provided on the second back plate (10); the second sleeve (11) is sleeved on the rotating shaft (701); a second magnet slot (111) is provided on the stator support (2); a second magnet (101) is connected to the second back plate (10), and the second magnet (101) is disposed in the second magnet slot (111); One end of the rotating shaft mounting hole (7) is provided with a first bearing mounting groove (12); the other end of the rotating shaft mounting hole (7) is provided with a second bearing mounting groove (13); a first bearing (121) is provided in the first bearing mounting groove (12); a second bearing (131) is provided in the second bearing mounting groove (13); the first bearing (121) and the second bearing (131) are both sleeved on the rotating shaft (701); The first bearing mounting groove (12) is provided with a retaining ring mounting groove (122); the retaining ring mounting groove (122) is provided with an elastic retaining ring (123); the rotating shaft (701) is provided with a snap ring groove (124); the snap ring groove (124) is provided with a snap ring (125); the first bearing (121) is located between the elastic retaining ring (123) and the snap ring (125); the second bearing mounting groove (13) is provided with a spring (132); one end of the second bearing (131) abuts against the spring (132); the other end of the second bearing (131) abuts against the second sleeve (11).

2. The disc motor structure according to claim 1, characterized in that: The PCB control board (6) is sleeved on the second back plate (10); the stator bracket (2) has an end cap (14) on the side near the PCB control board (6).

3. A disc motor structure according to claim 2, characterized in that: The stator support (2) has multiple stator core structures evenly distributed in it; the stator support (2) is a BMC support, and the stator support (2) is injection molded to the stator core structure.

4. A disc motor structure according to claim 3, characterized in that: The insulating frame (4) is an insulating resin frame.

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