Axial flux motor

Abstract

The utility model relates to the field of motors, and discloses an axial magnetic flux motor which comprises a machine shell, a rotor structure and a stator structure, the rotor structure and the stator structure are arranged in the machine shell, the stator structure and the rotor structure are oppositely arranged in the axial direction, the stator structure comprises an annular stator iron core, and the stator iron core is fixedly installed in the machine shell. Winding parts are evenly arranged on the stator core in the circumferential direction of the stator core, each winding part is wound with a coil winding, the rotor structure comprises a rotating shaft rotationally installed in the stator core, a rotor back plate is installed on the rotating shaft, an annular first groove is formed in the rotor back plate around the rotating shaft, a rotor core is installed in the first groove, and the first groove is communicated with the first groove. A plurality of magnetic steels are uniformly arranged on the rotor iron core along the circumferential direction of the rotor iron core; and the plurality of magnetic steels are arranged in one-to-one correspondence with the coil windings along the axial direction. According to the motor structure, the rotor and the stator are axially arranged, so that the axial size can be greatly reduced, and the arrangement of an electric friction side-hung motor can be better met.

Description

Technical Field

[0001] This application belongs to the field of electrical machinery, and specifically relates to an axial flux motor. Background Technology

[0002] Traditional radial flux motors are the most common type of rotating motor. The stator is usually cylindrical with slots on the inside containing three-phase windings that form electromagnetic poles. The rotor is located inside the stator and can be a permanent magnet, wound-rotor, or squirrel-cage structure. The magnetic poles are distributed circumferentially and radially coupled to the stator's magnetic field. This type of motor has the advantages of mature structure and simple manufacturing process.

[0003] With the rapid development of new energy vehicle technology, the performance requirements for drive motors used in electric motorcycles are becoming increasingly stringent, demanding high continuous power and torque. Currently, the industry widely uses flat-wire radial motors to improve the continuous power and torque of the motors. However, due to the large axial dimension of radial motors, they are generally only suitable for mid-drive configurations and not for side-mounted drives. Furthermore, their transmission components are complex, costly, have low transmission efficiency, and consume more electricity. Utility Model Content

[0004] To overcome the problem that existing flat-wire radial motors are too large and unsuitable for side-mounted drives, this application provides an axial flux motor with a compact structure and small size, suitable for side-mounted drives.

[0005] To achieve the above objectives, this application provides an axial flux motor, including a housing, and a rotor structure and a stator structure disposed within the housing, wherein the stator structure and the rotor structure are disposed opposite to each other along the axial direction;

[0006] The stator structure includes an annular stator core, which is fixedly installed inside the housing. The stator core has winding sections evenly arranged along its circumference, and each winding section is wound with a coil winding.

[0007] The rotor structure includes a rotating shaft rotatably mounted inside the stator core. A rotor back plate is mounted on the rotating shaft. An annular first groove is formed around the rotating shaft on the rotor back plate. The rotor core is installed in the first groove. Multiple magnets are evenly arranged on the rotor core along its circumference. The multiple magnets are arranged in a one-to-one correspondence with each of the coil windings along the axial direction.

[0008] This application improves upon the traditional radial stator and rotor design by arranging them axially. The stator and rotor can then be flattened, significantly reducing the motor's axial dimensions and better accommodating the side-mounted motor layout for electric motorcycles. When the rotor and stator are axially arranged, the rotor core, typically made of wound silicon steel sheets, has poor self-support. By installing the rotor core in slots on the rotor back plate, effective support is provided. Furthermore, installing the rotor core within the corresponding slots on the rotor back plate further reduces the motor's axial dimensions.

[0009] The motor provided in this application can be arranged next to the wheel hub. It uses axial magnetic flux, has a simple structure, and high motor efficiency.

[0010] Preferably, the end of the magnet near the rotating shaft is chamfered, and both the rotor core and the magnet are fixed to the rotor back plate using epoxy resin. The chamfered end of the magnet, combined with the thicker epoxy resin sealant, facilitates compression of the magnet, resulting in a more secure and reliable fixation. The epoxy resin sealant serves both to fix the rotor core and magnet and to provide insulation.

[0011] Preferably, the first groove is an open groove, and its open end is flush with the outer edge of the rotor back plate;

[0012] An annular baffle is provided on the outer edge of the rotor back plate, perpendicular to the rotor back plate. One end of the rotor core is tightly attached to the baffle. In the axial direction, the sum of the thicknesses of the rotor core and its corresponding magnet does not exceed the axial length of the baffle along the shaft. The first slot is designed as an open slot to facilitate the installation of the rotor core, while the baffle protects the magnets, rotor core, and other structures inside.

[0013] Preferably, the housing includes a first end cover, on which a second end cover is fastened;

[0014] A portion of the first end cap extends toward the second end cap to form a cylindrical stator mounting portion, and the stator core is fixedly mounted on the outer circle of the stator mounting portion;

[0015] A bearing is installed inside the inner cavity of the stator mounting part, and the rotating shaft is inserted into the bearing. The rotor back plate is fixedly installed on the rotating shaft between the stator structure and the second end cover. A first annular limiting step is provided on the rotating shaft corresponding to the rotor back plate. The rotor back plate abuts against the second limiting step, and one end of the rotating shaft freely passes through the second end cover.

[0016] By adopting the above structure, the stator core is installed on the stator mounting part formed on the first end cover, and the bearing for mounting the shaft is fixed in the inner cavity of the stator mounting part, thereby further reducing the axial structure of the entire motor.

[0017] Preferably, the rotating shaft is provided with an annular second limiting step, the other end of the rotating shaft is inserted into the bearing, and the corresponding end of the rotating shaft extends out of the bearing and is threadedly connected to a locking nut. An adjusting shim is sleeved on the rotating shaft between the bearing and the second limiting step, and the second limiting step presses the adjusting shim against the bearing.

[0018] With the above structure, the gap between the stator structure and the rotor structure is the air gap. The air gap can be adjusted by adjusting the shims to ensure consistent performance.

[0019] Preferably, the rotor back plate has an annular second groove around the rotating shaft, the second groove is located inside the first groove, and the second limiting step falls in the second groove.

[0020] Preferably, a steel bearing housing is installed inside the stator mounting section, and the bearing is fixedly installed in the bearing housing. By using an independent steel bearing housing, the fixing plate of the bearing outer ring and the bearing housing are combined into one piece, eliminating the need for an embedded steel sleeve in the stator housing and simplifying the structure.

[0021] Preferably, a cover plate is installed on the surface of the stator mounting portion away from the second end cover. This structure seals the inner cavity of the stator mounting portion with the cover plate, keeping the entire motor in a sealed state and preventing dust from entering.

[0022] Compared with the prior art, the present invention has the following advantages:

[0023] (1) The rotor and stator adopt an axial layout, which can significantly reduce the axial dimension and better meet the requirements of the side-mounted motor layout of electric motorcycles;

[0024] (2) The bearings are arranged inside the stator, which reduces the axial dimension occupied;

[0025] (3) By using an independent steel bearing housing, the steel sleeve embedded in the stator housing was eliminated, simplifying the structure;

[0026] (4) The air gap can be adjusted by adjusting the shims, which ensures consistent performance.

[0027] Other features and advantages of the embodiments of this application will be described in detail in the following detailed description section. Attached Figure Description

[0028] The accompanying drawings are provided to further illustrate the embodiments of this application and form part of the specification. They are used together with the following detailed description to explain the embodiments of this application, but do not constitute a limitation on the embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without any inventive effort. In the drawings:

[0029] Figure 1 This is an exploded view of an axial flux motor.

[0030] Figure 2 This is a schematic diagram of the internal structure of an axial flux motor.

[0031] Figure 3 This is a schematic diagram of the rotor backplate.

[0032] Figure 4 This is an exploded view of the rotor structure. Detailed Implementation

[0033] The specific embodiments of this application will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit this application.

[0034] In the description of this application, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0035] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between components; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0036] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0037] In this application, "multiple" means two or more.

[0038] The following description is based on the accompanying drawings.

[0039] like Figure 1-4 As shown, this application provides an axial flux motor, including a housing, and a rotor structure 9 and a stator structure 3 disposed within the housing, wherein the stator structure 3 and the rotor structure 9 are disposed opposite each other along the axial direction;

[0040] The stator structure 3 includes an annular stator core 3a, which is fixedly installed inside the housing. The stator core 3a is uniformly provided with winding portions 3b along its circumference, and each winding portion 3b is wound with a coil winding 4.

[0041] The rotor structure 9 includes a rotating shaft 9a rotatably mounted inside the stator core 3a. A rotor back plate 9b is mounted on the rotating shaft 9a. An annular first groove 16 is formed around the rotating shaft 9a on the side of the rotor back plate 9b facing the stator structure 3. A rotor core 9c is installed in the first groove 16. A plurality of magnets 9d are evenly arranged on the rotor core 9c along its circumference. The plurality of magnets 9d are arranged one-to-one with each of the coil windings 4 along the axial direction.

[0042] As can be seen from the figure, the winding part 3b is disposed on the side of the stator core 3a facing the rotor core 9c and extends along the axial direction of the stator core 3a. The magnet 9d is disposed on the side of the rotor core 9c facing the stator core 3a. In the axial direction, each winding part 3b and its coil winding 4 are disposed in a one-to-one correspondence with each magnet 9d.

[0043] The side of the magnet 9d facing the corresponding coil winding 4 is the south pole or the north pole, and the side of the magnet 9d away from the corresponding coil winding 4 along the axial direction is the north pole or the south pole (i.e., the north and south poles of a single magnet 9d are distributed along the axial direction). The south and north poles of all the sides of the magnet 9d facing the corresponding coil winding 4 are alternately distributed along the circumference.

[0044] In some embodiments, the end of the magnet 9d near the rotating shaft 9a is chamfered. Both the rotor core 9c and the magnet 9d are fixed to the rotor back plate 9b using epoxy resin 9e. The specific material of the epoxy resin 9e used is prior art and not the focus of this application, so it will not be described further here. During fabrication, the rotor back plate 9b can be placed horizontally first, and the rotor core 9c and magnet 9d can be installed in the first groove 16 as required. Then, the epoxy resin 9e is poured, thereby fixing both the rotor core 9c and the magnet 9d to the rotor back plate 9b using the epoxy resin 9e.

[0045] In some embodiments, the first groove 16 is an open groove, the open end of which is flush with the outer edge of the rotor back plate 9b. The outer edge of the rotor back plate 9b is connected to an annular baffle 15, which is perpendicular to the rotor back plate 9b. The inner end of the rotor core 9c (the end near the rotating shaft 9a) abuts against the groove wall of the first groove 16, and its outer end is in close contact with the baffle 15. In the axial direction, the sum of the thicknesses of the rotor core 9c and its corresponding magnet 9d does not exceed the length of the baffle 15 along the axial direction of the rotating shaft 9a. The baffle 15 and the rotor back plate 9b are integrally formed.

[0046] More specifically, the first groove 16 includes an inner groove 16a and an outer groove 16b, which are stacked together along the axial direction and connected to each other. The rotor core 9c is installed in the inner groove 16a, and the magnet 9d is installed in the outer groove 16b.

[0047] In some embodiments, the housing includes a first end cover 2, on which a second end cover 10 is fastened and the two are fixedly connected by bolts. A portion of the first end cover 2 extends toward the second end cover 10 to form a cylindrical stator mounting portion 14 with openings at both ends. The stator core 3a is fixedly mounted on the outer circle of the stator mounting portion 14. A steel bearing chamber 7 is installed in the inner cavity of the stator mounting portion 14. The bearing 6 is fixedly mounted in the bearing chamber 7. The rotating shaft 9a is inserted into the bearing 6. The stator core 3a and the winding portion 3b are integrally formed.

[0048] The rotor back plate 9b is fixedly installed on the rotating shaft 9a between the stator core 3a and the second end cover 10 of the stator structure 3. The rotating shaft 9a is provided with an annular first limiting step 12 corresponding to the rotor back plate 9b. The rotor back plate 9b is provided with an annular second groove 13 around the rotating shaft 9a. The second groove 13 is located in the inner circle of the first groove 16. The second groove 13 and the first groove 16 are located on the same side of the rotor back plate 9b, and the second groove 13 communicates with the hole on the rotor back plate 9b through which the rotating shaft 9a passes. The first limiting step 12 falls in the second groove 13, and the rotor back plate 9b abuts against the first limiting step 12. One end of the rotating shaft 9a freely passes through the second end cover 10.

[0049] In some embodiments, the rotating shaft 9a is provided with an annular second limiting step 11, which is located between the first limiting step 12 and the stator structure 3. The other end of the rotating shaft 9a is inserted into the bearing 6, and its corresponding end extends out of the bearing 6 and is threadedly connected to a locking nut 5. Further, in order to facilitate the adjustment of the air gap between the stator structure and the rotor structure, an adjusting shim 8 is sleeved on the rotating shaft 9a between the bearing 6 and the second limiting step 11, and the second limiting step 11 presses the adjusting shim 8 against the bearing 6.

[0050] In some embodiments, a cover plate 1 is mounted on the surface of the stator mounting portion 14 away from the second end cover 10.

[0051] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. An axial flux motor, comprising a housing, and a rotor structure and a stator structure disposed within the housing, characterized in that, The stator structure and rotor structure are arranged opposite each other along the axial direction; The stator structure includes an annular stator core, which is fixedly installed inside the housing. The stator core has winding sections evenly arranged along its circumference, and each winding section is wound with a coil winding. The rotor structure includes a rotating shaft rotatably mounted inside the stator core. A rotor back plate is mounted on the rotating shaft. An annular first groove is formed around the rotating shaft on the rotor back plate. The rotor core is installed in the first groove. Multiple magnets are evenly arranged on the rotor core along its circumference. The multiple magnets are arranged in a one-to-one correspondence with each of the coil windings along the axial direction.

2. The axial flux motor according to claim 1, characterized in that, The magnet has a chamfer at one end near the rotating shaft; The rotor core and the magnet are both fixed to the rotor back plate by epoxy resin.

3. The axial flux motor according to claim 1 or 2, characterized in that, The first slot is an open slot, and its open end is flush with the outer edge of the rotor back plate; An annular baffle is provided on the outer edge of the rotor back plate. The baffle is perpendicular to the rotor back plate. One end of the rotor core is tightly attached to the baffle. In the axial direction, the sum of the thickness of the rotor core and the corresponding magnet does not exceed the axial length of the baffle along the shaft.

4. The axial flux motor according to claim 3, characterized in that, The housing includes a first end cover, on which a second end cover is fastened; A portion of the first end cap extends toward the second end cap to form a cylindrical stator mounting portion, and the stator core is fixedly mounted on the outer circumference of the stator mounting portion; A bearing is installed inside the inner cavity of the stator mounting part, and the rotating shaft is inserted into the bearing. The rotor back plate is fixedly installed on the rotating shaft between the stator structure and the second end cover. A first annular limiting step is provided on the rotating shaft corresponding to the rotor back plate. The rotor back plate abuts against the first limiting step, and one end of the rotating shaft freely passes through the second end cover.

5. The axial flux motor according to claim 4, characterized in that, The rotating shaft is provided with an annular second limiting step. The other end of the rotating shaft is inserted into the bearing, and the corresponding end of the shaft extends out of the bearing and is threaded with a locking nut. An adjusting shim is sleeved on the rotating shaft between the bearing and the second limiting step, and the second limiting step presses the adjusting shim against the bearing.

6. The axial flux motor according to claim 5, characterized in that, A steel bearing chamber is installed inside the stator mounting section, and the bearing is fixedly installed inside the bearing chamber.

7. The axial flux motor according to any one of claims 4-6, characterized in that, A cover plate is installed on the surface of the stator mounting section away from the second end cover.

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