Axial flux motor

Abstract

The utility model relates to an axial flux motor, including motor casing, first and second stator assembly. Motor casing includes mirror image symmetry arrangement and is connected with each other first and second casing, first and second casing are respectively arranged with along the axial extension multiple first and second passages along the circumferential interval, and first passage includes first through -hole and first radial groove, and second passage includes second through -hole and second radial groove, and the winding end portion of the second stator winding of second stator assembly is inserted first and second through -hole through second radial groove, and with the winding end portion of the first stator winding of first stator assembly is fixed with each other in first radial groove, and from first radial groove stretch out. The axial flux motor of the utility model adopts split type casing design, has reduced the difficulty of processing manufacture, has reduced manufacturing cost, and the overall motor structure is simple and compact, and has solved the problem of air gap uneven, has improved NVH performance, and has realized the efficient cooling of rotor and stator.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and in particular to an axial flux motor. Background Technology

[0002] Axial flux motors (AFMs) are increasingly valued by the new energy vehicle industry due to their compact axial dimensions, smaller size, lighter weight, and ability to provide greater torque and power. They can deliver stronger drive torque in a smaller and lighter structure.

[0003] Existing axial flux motors include a stator and a rotor. The stator includes a stator core and stator windings wound on the stator core. The rotor includes a rotor core with magnets mounted thereon. However, due to the axial magnetic pull during motor operation, the air gap between the rotor and stator becomes uneven, affecting the overall NVH performance of the axial flux motor and thus limiting its application. Furthermore, the cooling issues for the stator and rotor of axial flux motors, as well as the overall manufacturing cost, are also major factors limiting their mass production and widespread adoption. Utility Model Content

[0004] The purpose of this utility model is to solve at least one of the above-mentioned problems and / or other problems existing in the prior art.

[0005] To achieve the above objectives, this utility model provides an axial flux motor, comprising: a motor housing, the motor housing including a first housing and a second housing that are cylindrical and arranged mirror-symmetrically along the axial direction, the first housing and the second housing being connected to each other; a first stator assembly and a second stator assembly respectively disposed within the first housing and the second housing; and a rotor assembly disposed between the first stator assembly and the second stator assembly; wherein the first stator assembly and the second stator assembly each include a plurality of first stator windings and a plurality of second stator windings that correspond one-to-one with each other; wherein the first housing and the second housing are respectively provided with axially spaced circumferentially spaced axial ... The device comprises a plurality of first channels and a plurality of second channels extending inward, wherein the first channel includes a first through hole and a first radial groove that communicates with the first through hole and opens radially inward toward the first housing; the second channel includes a second through hole and a second radial groove that communicates with the second through hole and opens radially inward toward the second housing; a winding end of the first stator winding is inserted into the first radial groove, and a corresponding winding end of the second stator winding is inserted through the second radial groove, passing through the second through hole and the first through hole, and merges with the corresponding winding end of the first stator winding in the first radial groove and is fixed to each other, and extends out from the first radial groove.

[0006] In one embodiment, a first insulating sleeve and a second insulating sleeve are respectively provided in the first through hole and the second through hole, and the winding end of the second stator winding is inserted through the first insulating sleeve and the second insulating sleeve.

[0007] In one embodiment, insulating adhesive is filled inside the first insulating sleeve and the second insulating sleeve to fix the winding ends of the second stator winding therein.

[0008] In one embodiment, the first housing and the second housing are respectively provided with at least two first pin holes and at least two second pin holes arranged circumferentially at their axial ends that abut each other, wherein the first pin holes and the corresponding second pin holes are aligned with each other in the axial direction so as to position the first housing and the second housing in the circumferential direction by engaging a first pin in the aligned first pin holes and second pin holes.

[0009] In one embodiment, the first stator assembly includes a first stator side plate connected to the first housing on a side opposite to the second housing, and the second stator assembly includes a second stator side plate connected to the second housing on a side opposite to the first housing.

[0010] In one embodiment, a plurality of winding holes are arranged circumferentially on the first stator side plate, and the winding end of the second stator winding engages with the winding end of the first stator winding and extends out of the motor housing through the winding holes from the first radial groove.

[0011] In one embodiment, the first housing and the second housing are respectively provided with at least two third pin holes and at least two fourth pin holes arranged circumferentially at their axial ends facing away from each other; the first stator side plate and the second stator side plate are respectively provided with at least two first positioning holes and at least two second positioning holes, wherein the first positioning holes and the corresponding third pin holes and the second positioning holes and the corresponding fourth pin holes are respectively aligned with each other in the axial direction, so as to position the first housing and the first stator side plate and the second housing and the second stator side plate circumferentially by engaging second pins in the aligned first positioning holes and third pin holes and engaging third pins in the aligned second positioning holes and fourth pin holes.

[0012] In one embodiment, an adjusting shim is provided between the first housing and the first stator side plate or between the second housing and the second stator side plate, so that the air gap values ​​between the rotor assembly and the first stator assembly and the second stator assembly are equal, respectively.

[0013] In one embodiment, the first housing and the second housing are respectively provided with a plurality of first U-shaped notches and a plurality of second U-shaped notches that are circumferentially spaced and recessed axially toward the corresponding housing interiors at their axial ends where they abut each other, so that when the first housing and the second housing are joined together, the first U-shaped notches and the second U-shaped notches are joined together to form a first heat dissipation hole for heat dissipation of the rotor assembly.

[0014] In one embodiment, both the first stator side plate and the second stator side plate are provided with a plurality of second heat dissipation holes arranged circumferentially for heat dissipation of the rotor assembly; wherein, the rotor assembly forms a cavity between itself and the first stator assembly and the second stator assembly respectively, and the cavity is in fluid communication with the first heat dissipation holes and the second heat dissipation holes to utilize air to dissipate heat from the rotor assembly.

[0015] In one embodiment, each of the first stator side plate and the second stator side plate is provided with a plurality of liquid inlet holes spaced apart along a first circumferential direction near its radial inner periphery and a plurality of liquid outlet holes spaced apart along a second circumferential direction near its radial outer periphery.

[0016] In one embodiment, the first stator assembly and the second stator assembly each include a stator core and a stator cover. The stator cover is connected to a corresponding stator side plate to jointly define a stator cavity for mounting the corresponding stator core and stator winding. A cooling channel is formed in the stator cavity, communicating with the plurality of liquid inlets and the plurality of liquid outlets, so that the coolant enters the cooling channel from the liquid inlet and flows out from the liquid outlet.

[0017] In one embodiment, the stator core includes a main body and a plurality of extensions spaced circumferentially along the main body, the plurality of extensions extending axially to one side from the main body to wind a corresponding stator winding; the cooling channel includes: an inner annular flow section defined by the main body, the stator cover and the corresponding stator side plate, surrounding the radially inner side of the main body of the corresponding stator core; an outer annular flow section defined by the main body, the stator cover and the corresponding stator side plate, surrounding the radially outer side of the main body of the corresponding stator core; and a plurality of intermediate flow sections connecting the inner annular flow section and the outer annular flow section and spaced circumferentially.

[0018] In one implementation, the intermediate flow section extends radially and is formed between two adjacent stator windings.

[0019] The axial flux motor of this invention achieves at least one of the following technical effects: by dividing the motor housing of the axial flux motor into two interconnected housings (first and second housings), manufacturing is facilitated and costs are reduced; by adopting a dual-stator, single-rotor structure, axial magnetic pull balance is achieved, effectively solving the problem of uneven air gap; and by arranging first and second channels on the first and second housings respectively for receiving the winding ends of the first and second stator windings, and by installing insulating sleeves within the channels and filling them with insulating glue as needed to fix the position of the copper wires within the sleeves, the overall NVH performance is greatly improved; by setting a structure between each stator assembly and the corresponding housing for adjusting the air gap between the rotor assembly and the stator assembly, the air gap uniformity is further improved, enhancing NVH performance; and by designing air-cooling channels for the rotor assembly and oil-cooling channels for the stator assembly in the motor structure, the cooling and heat dissipation of the stator and rotor assemblies are effectively improved. Attached Figure Description

[0020] The features and advantages of this utility model will become clear from the following detailed description provided with reference to the accompanying drawings. It should be understood that the following drawings are merely schematic and not necessarily drawn to scale, and therefore should not be considered as limitations on this utility model, wherein:

[0021] Figure 1 A perspective view of an axial flux motor according to an embodiment of the present invention is shown.

[0022] Figure 2 Show Figure 1 The diagram shown is an exploded view of an axial flux motor.

[0023] Figure 3 Show Figure 1 The front view of the axial flux motor is shown.

[0024] Figure 4 Shown in the form of a partial 3D view Figure 3 The cross-sectional structure of the axial flux motor along line AA is shown.

[0025] Figure 5 Presented in the form of partial 3D images and color renderings Figure 3 The cross-sectional structure of the axial flux motor along line AA is shown.

[0026] Figure 6 Shown in the form of a partial 3D view Figure 3 The cross-sectional structure of the axial flux motor along line BB is shown.

[0027] Figure 7 Shown in the form of a partial 3D view Figure 3The cross-sectional structure of the axial flux motor along line CC is shown.

[0028] Figure 8 Shown in the form of a partial 3D view Figure 3 The cross-sectional structure of the axial flux motor along line DD is shown. Detailed Implementation

[0029] Embodiments of the present invention are described below with reference to the accompanying drawings. In the following description, numerous specific details are set forth to enable those skilled in the art to more fully understand and implement the present invention. However, it will be apparent to those skilled in the art that implementations of the present invention may not include some of these specific details. Furthermore, it should be understood that the present invention is not limited to the specific embodiments described. Rather, the present invention can be conceived to be implemented with any combination of the features and elements described below, regardless of whether they relate to different embodiments. Therefore, the following aspects, features, embodiments, and advantages are for illustrative purposes only and should not be construed as elements or limitations of the claims unless expressly set forth in the claims.

[0030] The terms "first" and "second" are used below to describe the elements of this application. These terms are used only to distinguish the individual elements and not to limit the nature, order, or number of these elements. The terms "comprising" and "having" are used to indicate an open-ended inclusion and mean that there may be additional elements / components besides those listed.

[0031] Figure 1-3 An axial flux motor according to one embodiment of the present invention is shown. For example... Figures 1 to 3 As shown, the axial flux motor according to this embodiment may include a motor housing 1, a first stator assembly 2 and a second stator assembly 3, and a rotor assembly 9 disposed between the first stator assembly 2 and the second stator assembly 3. (See reference...) Figures 1 to 3 As shown, the motor housing 1 may include a first housing 11 and a second housing 12, which are respectively cylindrical. The first housing 11 and the second housing 12 are arranged side by side along the axial direction and are mirror symmetrical and connected to each other to form the outer peripheral housing of the axial flux motor.

[0032] Reference Figure 2 as well as Figure 4 and Figure 5The first stator assembly 2 may include a first stator side plate 23, which is generally annular in shape and connected to the side of the first housing 11 opposite to the second housing 12 via a plurality of fasteners arranged circumferentially spaced. Similarly, the second stator assembly 3 may also include a second stator side plate 33. The second stator side plate 33 is also generally annular in shape and connected to the side of the second housing 12 opposite to the first housing 11 via a plurality of fasteners arranged circumferentially spaced.

[0033] The first stator assembly 2 includes a first stator core 21 and a plurality of first stator windings 22. Specifically, the first stator core 21 may include a main body 211 and a plurality of extensions 212. The main body 211 is generally a cylindrical structure with a circular cross-section, and the plurality of extensions 212 are arranged circumferentially around the main body and extend axially to one side from the main body 211. The plurality of first stator windings 22 are wound one-to-one on the corresponding extensions 212. The second stator assembly 3 may include a second stator core 31 and a second stator winding 32. The second stator core 31 may include a main body 311 and a plurality of extensions 312. The main body 311 is generally a cylindrical structure with a circular cross-section, and the plurality of extensions 312 are arranged circumferentially around the main body and extend axially to one side from the main body 311. The plurality of second stator windings 32 are wound one-to-one on the corresponding extensions 312. The plurality of first stator windings 22 correspond one-to-one with the plurality of second stator windings 32. Each stator winding includes two winding ends (referred to below as "first winding end" and "second winding end").

[0034] like Figure 4 and Figure 5 As shown, the first housing 11 has a plurality of first channels 111 arranged circumferentially and axially through each other (see...). Figure 2 The first channel 111 may include a first through hole 1111 and a first radial groove 1112 communicating with each other, wherein the first radial groove 1112 opens towards the radially inward side of the first housing 11. Similarly, the second housing 12 has second channels 121 arranged circumferentially spaced and extending axially (see...). Figure 2The second channel 121 may include a second through hole 1211 and a second radial groove 1212 communicating with each other. The second radial groove 1212 opens radially inward toward the second housing 12. In this way, one of the winding ends (or "first winding end") of the first stator winding 22 is allowed to extend radially and be inserted into the first radial groove 1212, and the corresponding winding end of the second stator winding 32 extends radially and is inserted into the second radial groove 1212, and then sequentially inserted through the second through hole 1211 and the first through hole 1111 axially aligned with the second through hole via the second radial groove 1212, and then merges with and is fixed to each other in the first radial groove 1112, and then extends out of the first radial groove 1112.

[0035] In addition, see especially Figure 4 and Figure 5 The first stator side plate 23 covers the axial end face of the first housing 11, thereby covering the first radial groove 1112. Correspondingly, a plurality of winding holes 231 are arranged circumferentially along the first stator side plate 23, such that the two first winding ends of the second stator winding 32 and the first stator winding 22, which are engaged and fixed to each other, extend out of the first radial groove 1112 and then out of the motor housing 1 through the corresponding winding holes 231. In addition, the second stator side plate 33 covers the corresponding entire axial end face of the second housing 12, thereby covering the second radial groove 1212.

[0036] It can be seen that by dividing the motor housing of the axial flux motor into two interconnected housings (a first housing and a second housing) and connecting each housing to a corresponding stator assembly, the difficulty of processing and manufacturing is greatly reduced, thereby advantageously reducing manufacturing costs. Furthermore, by providing aligned channels on the first and second housings for the winding ends of the first and second stator windings to pass through, and by ensuring that the two winding ends converge and are fixed within the same channel, reliable winding output and stability are ensured. The overall motor structure is simple, with compact axial dimensions, facilitating overall layout by the client.

[0037] In a preferred embodiment, a first insulating sleeve 4 may be arranged in the first through hole 1111, and a second insulating sleeve 5 may be arranged in the second through hole 1211. When the first winding end of the second stator winding 22 passes through the first through hole 1111 and the second through hole 1211, the insulating sleeves prevent damage to the outer periphery of the first winding end due to friction with the first housing 11 and the second housing 12 made of metal material. This further strengthens the insulation performance between the motor housing 1 and the stator assembly, improving reliability.

[0038] To provide a stop and limit for the insulating sleeves when the first insulating sleeve 4 and the second insulating sleeve 5 are installed in the first through hole 1111 and the second through hole 1211, the radial width of the first radial groove 1112 is designed to be larger than the diameter of the first through hole 1111, thereby forming a stepped surface at the connection between the first radial groove 1112 and the first through hole 1111. One end of the first insulating sleeve 4 is provided with an annular protrusion that can abut against the stepped surface. Similarly, the radial width of the second radial groove 1212 is designed to be larger than the diameter of the second through hole 1211, so that a stepped surface is formed at the connection between the second radial groove 1212 and the second through hole 1211, and one end of the second insulating sleeve 5 is also provided with an annular protrusion that can abut against the stepped surface.

[0039] Optionally, insulating glue is filled inside the first insulating sleeve 4 and the second insulating sleeve 5 to fix the winding ends of the second stator winding 32 therein, which can improve the NVH performance of the entire motor.

[0040] It should be understood that the air gaps between the rotor assembly 9 and the two stator assemblies 2 and 3 directly affect the symmetry of the magnetic circuit and the balance of magnetic pull. Therefore, balancing the air gaps between the rotor assembly 9 and the stator assemblies is very important, and a uniform air gap is also a crucial aspect for improving NVH performance. To this end, adjusting shims (not specifically shown in the figure) can be provided between the first housing 11 and the first stator side plate 23, or between the second housing 12 and the second stator side plate 33, to adjust the air gap values ​​between the rotor assembly 9 and the first stator assembly 2 and the second stator assembly 3, respectively, so that the air gap values ​​on both sides are equal, resulting in a uniform air gap, thereby further improving the overall NVH performance of the motor.

[0041] Continue to refer to Figure 2 and Figure 6 It shows the positioning structure between the motor housing 1, the first stator assembly 2, and the second stator assembly 3. For example... Figure 6 As shown, the first housing 11 and the second housing 12 are respectively provided with at least two first pin holes 112 and at least two second pin holes 122 arranged circumferentially at their axial ends that meet each other. Each first pin hole 112 is aligned with a corresponding second pin hole 122 and is provided with a first pin 6. A portion of the cylindrical first pin 6 is inserted into the first pin hole 112, and the other portion of the first pin 6 is inserted into the second pin hole 122, thereby positioning the first housing 11 and the second housing 12 in the circumferential direction.

[0042] Still referencing Figure 6As shown, the first housing 11 has at least two third pin holes 113 arranged circumferentially at its axial end opposite to the second housing 12, and the first stator side plate 23 has at least two first positioning holes 232 arranged circumferentially at a position covering the axial end. Each third pin hole 113 is aligned with a corresponding first positioning hole 232 and is provided with a second pin 7. A portion of the cylindrical second pin 7 is inserted into the third pin hole 113, and the other portion of the second pin 7 is inserted into the first positioning hole 232, thereby positioning the first housing 11 and the first stator side plate 23 of the first stator assembly in the circumferential direction.

[0043] Correspondingly, the second housing 12 has at least two fourth pin holes 123 arranged circumferentially at its axial end opposite to the first housing 11, and the second stator side plate 33 has at least two second positioning holes 331 arranged circumferentially at a position covering the axial end. Each fourth pin hole 123 is aligned with a corresponding second positioning hole 331 and is provided with a third pin 8. A portion of the cylindrical third pin 8 is inserted into the fourth pin hole 123, and another portion of the third pin 8 is inserted into the second positioning hole 331, thereby positioning the second housing 12 and the second stator side plate 33 of the second stator assembly circumferentially.

[0044] Figure 7 A heat dissipation structure for the rotor assembly 9 of an axial flux motor according to this embodiment is shown. In this embodiment, the rotor assembly 9 can be cooled by air cooling. (Referring to the reference...) Figure 2 and Figure 7 The first housing 11 has a plurality of first U-shaped recesses 114, which are circumferentially spaced and recessed axially toward the interior of the first housing, at its axial end where it mates with the second housing 12. The second housing 12 has a plurality of second U-shaped recesses 124, which are circumferentially spaced and recessed axially toward the interior of the second housing, at its axial end where it mates with the first housing 11. The plurality of first U-shaped recesses 114 and the plurality of second U-shaped recesses 124 are engaged one-to-one, thereby forming a plurality of first heat dissipation holes 13 arranged circumferentially around the motor housing 1.

[0045] refer to Figure 1 and Figure 7 As shown, the first stator side plate 23 has a plurality of second heat dissipation holes 233 spaced circumferentially, and a cavity is formed between the rotor assembly 9 and the first stator assembly 2. The cavity is in fluid communication with the plurality of first heat dissipation holes 13 and the plurality of second heat dissipation holes 233, so that the flowing air can be used to dissipate heat to the first axial end of the rotor assembly 9. Similarly, refer to Figure 3 and Figure 7As shown, the second stator side plate 33 may also have a plurality of second heat dissipation holes 332 arranged circumferentially, and a cavity is formed between the rotor assembly 9 and the second stator assembly 3. The cavity is fluidly connected to a plurality of first heat dissipation holes 13 and a plurality of second heat dissipation holes 332, so that the flowing air can be used to dissipate heat from the second axial end of the rotor assembly 9 that is opposite to the first axial end.

[0046] Figure 8 The heat dissipation structure of the axial flux motor according to this embodiment for the first stator assembly 2 and the second stator assembly 3 is shown. In this embodiment, the first stator assembly 2 and the second stator assembly 3 can be cooled by oil cooling.

[0047] Reference Figure 1 and Figure 8 As shown, the first stator side plate 23 is generally annular in shape. The first stator side plate 23 also has a plurality of liquid inlet holes 234 spaced apart along a first circumferential direction near its radial inner periphery, and a plurality of liquid outlet holes 235 spaced apart along a second circumferential direction near its radial outer periphery (the other winding end of the first stator winding, or "second winding end," extends out of the motor housing from this liquid outlet hole, see...). Figure 8 Preferably, a plurality of liquid inlet holes 234 are arranged at intervals along a first circumferential direction, and a plurality of liquid outlet holes 235 are arranged at intervals along a second circumferential direction. The first stator assembly 2 may further include a stator cover 24. The stator cover 24 is connected to the first stator side plate 23 and together defines a stator cavity for mounting the first stator core 21 and the first stator winding 22. Thus, the first stator core 21, the second stator winding 22, the first stator side plate 23, and the stator cover 24 together define a cooling channel 25 for the flow of cooling medium to cool the first stator assembly 1.

[0048] Specifically, the cooling channel 25 may include an outer annular flow section 251, a plurality of intermediate flow sections 252, and an inner annular flow section 253. The outer annular flow section 251 is defined by the radially outer side of the first stator core 21 (and / or the first stator winding 22), the stator cover 24, and the first stator side plate 23, and is in fluid communication with a plurality of liquid outlet holes 235, thereby allowing the outer annular flow section 251 to be formed around the radially outer side of the first stator core 21 (and / or the first stator winding 22). The inner annular flow section 253 is defined by the radially inner side of the first stator core 21 (and / or the first stator winding 22), the stator cover 24, and the first stator side plate 23, and is in fluid communication with a plurality of liquid inlet holes 234, thereby allowing the inner annular flow section 253 to be formed around the radially inner side of the first stator core 21 (and / or the first stator winding 22). Multiple intermediate flow sections 252 are arranged circumferentially between two adjacent first stator windings 22 and extend radially along the stator cavity to connect the inner annular flow section 253 and the outer annular flow section 251, so that the coolant can enter the cooling channel 25 from the inlet hole 234 and then flow out from the outlet hole 235 to achieve cooling of the first stator assembly 3.

[0049] Reference Figure 3 and Figure 8 As shown, the second stator side plate 33 is generally annular in shape. The second stator side plate 33 also has a plurality of liquid inlet holes 333 spaced apart along a first circumferential direction near its radial inner periphery, and a plurality of liquid outlet holes 334 spaced apart along a second circumferential direction near its radial outer periphery. Preferably, the plurality of liquid inlet holes 333 are spaced apart along the first circumferential direction, and the plurality of liquid outlet holes 334 are spaced apart along the second circumferential direction. The second stator assembly 3 may also include a stator cover 34. The stator cover 34 is connected to the second stator side plate 33 and together defines a stator cavity for mounting the second stator core 31 and the second stator winding 32. Thus, the second stator core 31, the second stator winding 32, the second stator side plate 33, and the stator cover 34 together define a cooling channel 35 for the flow of cooling medium to cool the second stator assembly 3.

[0050] Specifically, the cooling channel 35 may include an outer annular section 351, a plurality of intermediate sections 352, and an inner annular section 353. The outer annular section 351 is defined by the radially outer side of the second stator core 31 (and / or the second stator winding 32), the stator cover 34, and the second stator side plate 33, and is in fluid communication with a plurality of liquid outlet holes 334, thereby allowing the outer annular section 351 to be formed around the radially outer side of the second stator core 31 (and / or the second stator winding 32). The inner annular section 353 is defined by the radially inner side of the second stator core 31 (and / or the second stator winding 32), the stator cover 34, and the second stator side plate 33, and is in fluid communication with a plurality of liquid inlet holes 333, thereby allowing the inner annular section 353 to be formed around the radially inner side of the second stator core 31 (and / or the second stator winding 32). Multiple intermediate flow sections 352 are arranged circumferentially between two adjacent second stator windings 32 and extend radially along the stator cavity to connect the inner annular flow section 353 and the outer annular flow section 351, so that the coolant can enter the cooling channel 35 from the inlet hole 333 and flow out from the outlet hole 334 to achieve cooling of the second stator assembly 3.

[0051] In the field of motor technology, the overall architecture of axial flux motors typically includes single-stator single-rotor, double-stator single-rotor, and double-rotor single-stator structures. Especially for the single-stator single-rotor and double-rotor single-stator structures, the axial magnetic pull during motor operation can lead to uneven air gaps between the rotor and stator, affecting the NVH performance of the axial flux motor. This utility model patent adopts a dual-stator single-rotor scheme, which balances the axial magnetic pull of the intermediate rotor on both sides, effectively solving the problem of uneven air gap and improving NVH performance. By dividing the motor housing of the axial flux motor into two interconnected housings, it facilitates processing and manufacturing and reduces manufacturing costs. By arranging first and second channels on the first and second housings respectively to receive the winding ends of the first and second stator windings, and by setting insulating sleeves in the channels and filling them with insulating glue as needed to fix the position of the copper wires in the sleeves, the overall NVH performance is improved. By setting a structure between each stator assembly and the corresponding housing to adjust the air gap between the rotor assembly and the stator assembly, the air gap uniformity is further improved, enhancing NVH performance. Finally, by introducing air-cooling channels for the rotor assembly and oil-cooling channels for the stator assembly into the motor structure, the cooling and heat dissipation of the stator and rotor assemblies are effectively improved.

[0052] Various modifications and variations can be made to the embodiments disclosed above without departing from the scope or spirit of this invention. Other embodiments of this invention will be apparent to those skilled in the art based on the practice of this invention disclosed in this specification. This specification and the examples disclosed herein should be considered illustrative only, and the true scope of this invention is defined by the appended claims and their equivalents.

Claims

1. An axial flux motor, characterized in that, The axial flux motor includes: The motor housing (1) includes a first housing (11) and a second housing (12) that are respectively cylindrical and arranged in a mirror-symmetric manner along the axial direction, and the first housing and the second housing are connected to each other; The first stator assembly (2) and the second stator assembly (3) are respectively disposed in the first housing and the second housing, and A rotor assembly (9) disposed between the first stator assembly (2) and the second stator assembly (3); The first stator assembly and the second stator assembly each include a plurality of first stator windings (22) and a plurality of second stator windings (32) that correspond one-to-one with each other; The first housing and the second housing are respectively provided with a plurality of first channels (111) and a plurality of second channels (121) extending axially at intervals along the circumferential direction. The first channel includes a first through hole (1111) and a first radial groove (1112) that communicates with the first through hole and opens radially inward toward the first housing. The second channel includes a second through hole (1211) and a second radial groove (1212) that communicates with the second through hole and opens radially inward toward the second housing. One end of the first stator winding is inserted into the first radial groove, and the corresponding end of the second stator winding is inserted through the second radial groove, passing through the second through hole and the first through hole, and merges with the corresponding end of the first stator winding in the first radial groove and is fixed to each other, and extends out from the first radial groove.

2. The axial flux motor according to claim 1, characterized in that, A first insulating sleeve (4) and a second insulating sleeve (5) are respectively provided in the first through hole and the second through hole, and the winding end of the second stator winding is inserted through the first insulating sleeve (4) and the second insulating sleeve (5).

3. The axial flux motor according to claim 2, characterized in that, Insulating adhesive is filled in the first insulating sleeve (4) and the second insulating sleeve (5) to fix the winding ends of the second stator winding (32) therein.

4. The axial flux motor according to any one of claims 1 to 3, characterized in that, The first housing (11) and the second housing (12) are respectively provided with at least two first pin holes (112) and at least two second pin holes (122) arranged circumferentially at their axial ends that abut each other, wherein the first pin holes and the corresponding second pin holes are aligned with each other in the axial direction to position the first housing and the second housing in the circumferential direction by engaging a first pin (6) in the aligned first pin holes and second pin holes.

5. The axial flux motor according to any one of claims 1 to 3, characterized in that, The first stator assembly (2) includes a first stator side plate (23) connected to the first housing on the side opposite to the second housing, and the second stator assembly (3) includes a second stator side plate (33) connected to the second housing on the side opposite to the first housing.

6. The axial flux motor according to claim 5, characterized in that, The first stator side plate has a plurality of winding holes (231) arranged circumferentially. The winding end of the second stator winding engages with the winding end of the first stator winding and extends out of the motor housing through the winding holes from the first radial groove.

7. The axial flux motor according to claim 5, characterized in that, The first housing (11) and the second housing (12) are respectively provided with at least two third pin holes (113) and at least two fourth pin holes (123) arranged circumferentially at their axial ends facing away from each other; the first stator side plate (23) and the second stator side plate (33) are respectively provided with at least two first positioning holes (232) and at least two second positioning holes (331), wherein the first positioning holes and the corresponding third pin holes and the second positioning holes and the corresponding fourth pin holes are respectively aligned with each other in the axial direction, so as to position the first housing and the first stator side plate and the second housing and the second stator side plate in the circumferential direction by engaging the second pin (7) in the aligned first positioning holes and the third pin holes and engaging the third pin (8) in the aligned second positioning holes and the fourth pin holes.

8. The axial flux motor according to claim 5, characterized in that, An adjusting shim is provided between the first housing (11) and the first stator side plate or between the second housing (12) and the second stator side plate, so that the air gap values ​​between the rotor assembly and the first stator assembly and the second stator assembly are equal respectively.

9. The axial flux motor according to claim 5, characterized in that, The first housing (11) and the second housing (12) are respectively provided with a plurality of first U-shaped notches (114) and a plurality of second U-shaped notches (124) that are circumferentially spaced and recessed into the corresponding housing interiors along the axial direction at their abutting axial ends, so that when the first housing and the second housing are joined together, the first U-shaped notches and the second U-shaped notches are joined together to form a first heat dissipation hole (13) for heat dissipation of the rotor assembly.

10. The axial flux motor according to claim 9, characterized in that, Both the first stator side plate (23) and the second stator side plate (33) are provided with a plurality of second heat dissipation holes for heat dissipation of the rotor assembly at intervals along the circumference; The rotor assembly forms cavities between itself and the first stator assembly and the second stator assembly, respectively. The cavities are in fluid communication with the first heat dissipation hole and the second heat dissipation hole to dissipate heat from the rotor assembly using air.

11. The axial flux motor according to claim 5, characterized in that, Each of the first stator side plate and the second stator side plate is provided with a plurality of liquid inlet holes spaced apart along a first circumferential direction near its radial inner periphery and a plurality of liquid outlet holes spaced apart along a second circumferential direction near its radial outer periphery.

12. The axial flux motor according to claim 11, characterized in that, The first stator assembly and the second stator assembly each include a stator core and a stator cover. The stator cover is connected to the corresponding stator side plate to jointly define a stator cavity for mounting the corresponding stator core and stator winding. A cooling channel is formed in the stator cavity, which communicates with the plurality of liquid inlets and the plurality of liquid outlets, so that the coolant enters the cooling channel from the liquid inlet and flows out from the liquid outlet.

13. The axial flux motor according to claim 12, characterized in that, The stator core includes a main body and a plurality of extensions arranged circumferentially along the main body. The plurality of extensions extend axially to one side from the main body to wind corresponding stator windings. The cooling channel includes: an inner annular flow section defined by the main body, the stator cover, and the corresponding stator side plate on the radially inner side of the main body of the corresponding stator core; an outer annular flow section defined by the main body, the stator cover, and the corresponding stator side plate on the radially outer side of the main body of the corresponding stator core; and a plurality of intermediate flow sections connecting the inner annular flow section and the outer annular flow section and arranged at intervals in the circumferential direction.

14. The axial flux motor according to claim 13, characterized in that, The intermediate flow section extends radially and is formed between two adjacent stator windings.

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