A plastic package flat wire long motor for a mine wide-body self-unloading truck

Abstract

A kind of plastic package flat long motor for mining wide-body self-unloading truck, rotor structure includes motor casing, rotor assembly, stator assembly and rotating shaft;The middle position of the inner wall of motor casing is provided with annular stator positioning stopper, two stator assemblies are positioned and installed on the two sides of stator positioning stopper;Rotor assembly includes rotor core, and two rotor cores are arranged side by side along the axis of the rotating shaft;Stator assembly includes stator core and stator winding, two stator cores are arranged on the two sides of stator positioning stopper, and two stator windings are arranged in two stator cores respectively.The scheme greatly reduces the axial space occupation, so that the power density is improved, and has high-efficiency cooling capacity and the ability to effectively reduce temperature rise.

Description

Technical Field

[0001] This utility model relates to the field of motor structure technology, and in particular to a plastic-encapsulated flat wire long motor for use in mining wide-body dump trucks, which is used in the field of electric drive technology for special vehicles. Background Technology

[0002] The statements in this section are merely background information related to this application and do not necessarily constitute prior art.

[0003] In some practical application scenarios of electric vehicles, in order to meet the power requirements of electric vehicles, it is necessary to use a dual-motor or coaxial dual-motor drive assembly to provide more driving force. For example, a coaxial dual-motor drive assembly and vehicle disclosed in Chinese Patent CN202111262884.4 integrates the dual-motor inverter and the two motor drive structures into a single housing, and adopts a plug-in connection between the output end of the drive motor and the input end of the reduction mechanism. It uses magnetic gears to directly output power, eliminating the reduction structure and eliminating the intermediate shaft to reduce the axial dimension.

[0004] While the aforementioned patents have achieved reductions in the height and axial dimensions of the coaxial dual-motor drive assembly, lowering overall vehicle weight and cost, and improving the flexibility of vehicle layout and power performance, some technical challenges exist when used in special environments such as mines. For example, the high dust environment of mines can easily cause radiator blockage, leading to excessively high motor winding temperatures, frequent temperature-related faults, and severely impacting equipment availability. Traditional impregnating varnish is prone to aging and cracking under the thermal cycling conditions of frequent motor start-stop cycles, resulting in increased winding displacement and vibration, which can then lead to fatal insulation faults such as inter-turn short circuits. Moreover, the installation and positioning of the rotor and stator in existing coaxial dual motors are relatively complex, with high assembly difficulty and long assembly time, and there is still significant room for optimization in terms of spatial layout and structural design.

[0005] In view of this, how to solve the problems of frequent heat dissipation failures and complex installation and positioning of existing coaxial dual-motor drive assemblies has become the research topic to be addressed by this utility model. Utility Model Content

[0006] The purpose of this invention is to provide a plastic-sealed flat wire long motor for use in wide-body mining dump trucks.

[0007] To achieve the above objectives, the present invention provides a plastic-sealed flat wire long motor for mining wide-body dump trucks, comprising a motor housing, a rotor assembly, a stator assembly, and a rotating shaft. The rotor assembly and stator assembly are assembled within the cavity space of the motor housing, and the rotating shaft is rotatably mounted on the motor housing along its own axial direction. Its innovation lies in: An annular stator positioning stop is provided in the middle of the inner wall of the motor housing, and two stator assemblies are positioned and installed on both sides of the stator positioning stop; cooling water channels are provided on the motor housing.

[0008] The rotor assembly includes rotor cores, two rotor cores are arranged side by side along the shaft along the axial direction, and a positioning sleeve and a rotor pressure sleeve are fixedly sleeved on the shaft at the position corresponding to the stator positioning stop between the two rotor cores. The two rotor pressure sleeves are respectively fixed on both sides of the positioning sleeve, and a rotor pressure plate is also provided on the radial outer side of each rotor pressure sleeve.

[0009] The stator assembly includes a stator core and a stator winding. The two stator cores are respectively located on both sides of the stator positioning stop, and the two stator windings are respectively located on the two stator cores. The stator windings are flat wire windings and have winding ends extending towards both ends of the axial direction. The winding ends at both ends are potted to form an insulating part.

[0010] The plastic-sealed flat wire long motor for wide-body dump trucks in mining is configured such that: the positioning sleeve provides axial positioning for the rotor assemblies on both sides simultaneously, and the corresponding arrangement between the positioning sleeve and the stator positioning stop forms an isolation space shared by the two rotor cores and the two stator cores on the same axial segment, with the ends of two adjacent stator windings located in the isolation space, and the insulation formed by the potting of the ends of the two adjacent windings connected.

[0011] The design principle and technical concept of this utility model are as follows: In this invention, some problems existing in the existing coaxial dual-motor drive assembly are studied, such as the frequent heat dissipation failures and the complexity and difficulty of installation and positioning. Specifically for the use scenario of mining wide-body dump trucks, this invention innovatively designs a plastic-encapsulated flat wire long motor for mining wide-body dump trucks. This motor meets the heat dissipation requirements in the high dust environment of mines, adapts to the narrow space constraints of mining trucks, and meets the high torque requirements of mining wide-body dump trucks.

[0012] To meet the specific scenarios and requirements mentioned above, this utility model designs the encapsulated flat wire long motor as a coaxial dual-motor integrated drive system. The motor body of this drive system adopts a modular coaxial integrated design, in which the two rotor assemblies and two stator assemblies are coaxially integrated and share a single shaft as the output shaft. Furthermore, the method of coaxial integration and positioning of the two rotor assemblies and two stator assemblies has been improved. An annular stator positioning stop is set in the middle position of the inner wall of the motor housing for positioning and connecting the stator assemblies. This stator positioning stop forms the necessary isolation space between the two stator cores. Furthermore, a positioning sleeve, rotor pressure sleeve, and rotor pressure plate are installed at the middle position of the rotating shaft to position and connect the two rotor assemblies. The positioning sleeve simultaneously provides axial positioning for the rotor assemblies on both sides and forms an isolation space between the two stator cores between the positioning sleeve, rotor pressure sleeve, and rotor pressure plate. The isolation space between the two rotor cores and the two stator cores is located on the same axial segment. The positioning sleeve between the two rotor assemblies serves a dual purpose: its axial positioning provides axial positioning for the rotor assembly on its adjacent side, and its spatial isolation creates the necessary gap between the two rotor assemblies. This improvement in the coaxial integrated positioning method of the two rotor assemblies and two stator assemblies not only further optimizes the layout of the coaxial compact structure but also further optimizes the motor's efficiency, performance, and reliability, making it more suitable for mining scenarios.

[0013] In addition to the improvements in coaxial integrated positioning, this invention also includes coordinated improvements to the stator winding method and the motor housing cooling method. The stator winding of the base assembly adopts a flat wire winding process, significantly improving slot fill factor and laying the foundation for overcoming power density bottlenecks. High-strength insulation material is used to encapsulate the winding ends, forming a reinforced structure. Furthermore, the insulation portions formed by the encapsulation of adjacent winding ends are integrally connected, resulting in higher overall strength and stronger temperature rise suppression. This solution significantly suppresses temperature rise at the winding ends and fundamentally solves the core fault hazards caused by insulation aging failure, inter-turn short circuits, and coil loosening and vibration in this area, thereby ensuring the long-term high reliability and service life of the motor in the harsh environment of mining. Moreover, an optimized water channel design is integrated into the motor housing, providing efficient cooling capacity. Combined with end-encapsulation heat dissipation, this effectively reduces the overall motor operating temperature and enhances thermal stability.

[0014] The relevant contents of this utility model are explained as follows: 1. In the description of this application, it should be understood that the terms "front", "rear", "inner", "outer", "axial", "radial", "circumferential", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0015] 2. In the description of this application, the terms "installation," "connection," "linking," "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; 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 explicitly defined. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0016] 3. In the description of this application, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. 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.

[0017] 4. In the above technical solution of this utility model, the stator positioning stop is an annular structure protruding from the inner wall of the motor housing. This stator positioning stop completely covers the radial projection of the positioning sleeve on the radial projection of the rotating shaft. Using the annular structure protruding from the inner wall of the motor housing at the axial center as the stator positioning stop results in high machining accuracy, improves the positioning accuracy of the stator assembly, and facilitates assembly. The fact that the stator positioning stop completely covers the radial projection of the positioning sleeve on the radial projection of the rotating shaft allows the two sides of the positioning sleeve to have space for mating with the rotor pressure sleeve, ensuring that the axial length and orientation of the isolation space between the two rotor cores and the two stator cores are consistent.

[0018] 5. In the above technical solution of this utility model, the axial length L1 of the two stator windings extending towards the middle of the winding ends is L2, the axial length of the isolation space is L1, L1 is 15% to 30% of L2, and the gap distance between the ends of two adjacent windings is D, D is 40% to 70% of L2. This dimensional design balances and optimizes the electrical insulation reliability, heat dissipation efficiency, electromagnetic performance, and mechanical stability between the ends of two adjacent windings, balancing the proportions of these parameters within a limited space, and avoiding a decrease in motor performance or heat dissipation efficiency.

[0019] 6. In the above technical solution of this utility model, the positioning sleeve has an annular positioning body, and the two ends of the positioning body are provided with protruding first positioning steps; the rotor pressure plate has an annular pressure plate body, and the inner circular wall of the pressure plate body is provided with a second positioning step; the rotor pressure sleeve has a Z-shaped annular structure, the inner side of the rotor pressure sleeve is positioned and engaged with the first positioning step of the positioning sleeve, the outer side of the rotor pressure sleeve is positioned and engaged with the second positioning step of the rotor pressure plate located in the middle, and the inner wall of the rotor pressure sleeve is positioned and connected to the rotating shaft. This design makes the assembly and positioning of the rotor assembly more reasonable, its structure is optimized, the rotor assembly is more stable, and the positioning sleeve can better play its dual role.

[0020] 7. In the above technical solution of this utility model, the rotor pressure plate is divided into a left rotor pressure plate and a right rotor pressure plate. A positioning shoulder is provided on the left side of the rotating shaft within the cavity space of the motor housing and near the rotor core. The positioning shoulder engages with a second positioning step on the left rotor pressure plate, and a keyway is provided on the left rotor pressure plate. This design makes the positioning of the rotor assembly more reliable and allows for quick positioning and assembly onto the rotating shaft with the positioning shoulder.

[0021] 8. In the above technical solution of this utility model, the rotor pressure plate between the two rotor assemblies and at the right end of the right rotor assembly is a rotor right pressure plate. This makes it easier to assemble as the same rotor right pressure plate is used between the two rotor assemblies and at the right end of the right rotor assembly.

[0022] 9. In the above technical solution of this utility model, both the left rotor pressure plate at the left end and the right rotor pressure plate at the right end have end gaps between themselves and the cavity space of the motor housing. The rotor pressure plate has an annular groove near the rotor core, and the annular groove has vent holes that communicate with the end gaps and the space between them to balance the pressure difference between the inside and outside of the rotor core during motor operation. By designing the annular groove and vent holes, the pressure difference between the inside and outside of the rotor core is balanced, improving the overall performance of the motor in complex working environments.

[0023] 10. In the above technical solution of this utility model, the rotor pressure plate is made of aluminum alloy to reduce the influence of strong magnetic fields in the rotor assembly on the assembly process; the rotor pressure sleeve and positioning sleeve are made of steel for positioning and bearing force. By optimizing the material selection in conjunction with the optimization of the structure, the structural design of this set of structures for positioning and assembling the rotor assembly is more reasonable, satisfying compactness while taking into account electromagnetic performance and structural strength.

[0024] 11. In the above technical solution of this utility model, the motor housing is provided with two cooling water channels, and an isolation part is provided on the motor housing at the position corresponding to the stator positioning stop to isolate the two cooling water channels. The axial length of the isolation part is less than the axial length of the stator positioning stop, and both cooling water channels partially extend to the isolation space position corresponding to the positioning stop. By providing two cooling water channels in the motor housing, each cooling water channel can effectively cool the heat source emitted by one set of rotor assembly and stator assembly. The isolation part on the motor housing at the position corresponding to the stator positioning stop to isolate the two cooling water channels not only serves to isolate the two cooling water channels but also as a structural reinforcement. Furthermore, by extending both cooling water channels partially to the isolation space position corresponding to the positioning stop, the cooling water channels can also exchange heat with the ends of two adjacent windings in a timely manner, preventing the ends of two adjacent windings from becoming too hot.

[0025] 13. In the above technical solution of this utility model, Due to the application of the above solution, this utility model has the following advantages and effects compared with the prior art: 1. The above-mentioned solution of this utility model studies some problems existing in the existing coaxial dual motor drive assembly, such as the frequent heat dissipation failures and the complexity and difficulty of installation and positioning of the existing coaxial dual motor drive assembly. In particular, for the use scenario of mining wide-body dump trucks, this utility model innovatively designs a plastic-encapsulated flat wire long motor for mining wide-body dump trucks, which meets the heat dissipation requirements in the high dust environment in the mine, adapts to the narrow space constraints of mining trucks, and meets the high torque requirements of mining wide-body dump trucks.

[0026] 2. In the above-described solution of this utility model, the encapsulated flat wire long motor is designed as a coaxial dual-motor integrated drive system. The motor body of this drive system adopts a modular coaxial integrated design, in which the two rotor assemblies and two stator assemblies are coaxially integrated and share a single shaft as the output shaft. Furthermore, the method of coaxially integrating and positioning the two rotor assemblies and two stator assemblies has been improved. Specifically, an annular stator positioning stop is provided in the middle position of the inner wall of the motor housing for positioning and connecting the stator assemblies. This stator positioning stop forms the necessary isolation space between the two stator cores. Furthermore, a positioning sleeve, rotor pressure sleeve, and rotor pressure plate are installed at the middle position of the rotating shaft to position and connect the two rotor assemblies. The positioning sleeve simultaneously provides axial positioning for the rotor assemblies on both sides and forms an isolation space between the two stator cores between the positioning sleeve, rotor pressure sleeve, and rotor pressure plate. The isolation space between the two rotor cores and the two stator cores is located on the same axial segment. The positioning sleeve between the two rotor assemblies serves a dual purpose: its axial positioning provides axial positioning for the rotor assembly on its adjacent side, and its spatial isolation creates the necessary gap between the two rotor assemblies. This improvement in the coaxial integrated positioning method of the two rotor assemblies and two stator assemblies not only further optimizes the layout of the coaxial compact structure but also further optimizes the motor's efficiency, performance, and reliability, making it more suitable for mining scenarios.

[0027] 3. In the above-mentioned solution of this utility model, the winding method of the stator assembly and the cooling method of the motor housing are also improved in a coordinated manner. The stator winding of the base assembly adopts a flat wire winding process, significantly improving the slot fill factor and laying the foundation for breaking through the power density bottleneck. High-strength insulation material is used to encapsulate the winding ends, forming a reinforced structure. Furthermore, the insulation formed by the encapsulation of adjacent winding ends is integrally connected, resulting in higher overall strength and stronger ability to suppress temperature rise. This effectively reduces temperature rise, with a difference of approximately 17K compared to unencapsulated windings, extending the motor life by at least three times. This solution significantly suppresses the temperature rise at the winding ends and fundamentally solves the core fault hazards caused by insulation aging failure, inter-turn short circuits, and coil loosening and vibration in this area, thereby ensuring the long-term high reliability and service life of the motor in the harsh environment of mining. In addition, an optimized water channel design is integrated into the motor housing, providing efficient cooling capacity. Combined with the end encapsulation heat dissipation, the overall motor operating temperature is effectively reduced, enhancing thermal stability. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of the present utility model; Figure 2 for Figure 2 Enlarged diagram of part A in the diagram; Figure 3 This is a schematic diagram of the positioning sleeve in Embodiment 1 of this utility model; Figure 4 This is a schematic diagram of the rotor pressure sleeve in Embodiment 1 of this utility model; Figure 5 This is a schematic diagram of the structure of the left pressure plate of the rotor in Embodiment 1 of this utility model; Figure 6 This is a schematic diagram of the rotor right pressure plate in Embodiment 1 of this utility model.

[0029] The parts shown in the above attached diagram are illustrated below: 1. Motor housing; 10. Cavity space; 11. Stator positioning stop; 12. Cooling water channel; 13. Isolation section; 2. Rotor assembly; 21. Rotor core; 22. Positioning sleeve; 221. Positioning body; 222. First positioning step; 23. Rotor pressure sleeve; 24. Rotor pressure plate; 241. Left rotor pressure plate; 242. Right rotor pressure plate; 243. Second positioning step; 244. Annular groove; 245. Vent hole; 3. Stator assembly; 31. Stator core; 32. Stator winding; 321. Winding end; 322. Insulation part; 4. Rotary shaft; 41. Locating shoulder; 50. Isolation space; 60. End clearance; 7. Bearing; 8. End cap. Detailed Implementation

[0030] The present invention will be clearly described below with illustrations and detailed description. Any person skilled in the art who understands the embodiments of the present invention can make changes and modifications based on the technology taught in the present invention without departing from the spirit and scope of the present invention.

[0031] This invention aims to address some problems existing in the current coaxial dual-motor drive assembly, such as frequent heat dissipation failures and complex installation and positioning. Specifically designed for the use of wide-body mining dump trucks, this invention innovatively designs a plastic-encapsulated flat-wire long motor for wide-body mining dump trucks. This motor meets the heat dissipation requirements in the high-dust environment of mines, adapts to the narrow space constraints of mining trucks, and meets the high torque requirements of wide-body mining dump trucks.

[0032] Example 1, as Figures 1 to 6As shown, Embodiment 1 of this utility model discloses a plastic-sealed flat wire long motor for a wide-body dump truck in mining, including a motor housing 1, a rotor assembly 2, a stator assembly 3, and a rotating shaft 4. The rotor assembly 2 and the stator assembly 3 are assembled within the cavity space 10 of the motor housing 1, and the rotating shaft 4 is rotatably mounted on the motor housing 1 along its own axial direction. Its innovation lies in: An annular stator positioning stop 11 is provided in the middle of the inner wall of the motor housing 1, and two stator assemblies 3 are positioned on both sides of the stator positioning stop 11; a cooling water channel 12 is provided on the motor housing 1.

[0033] The rotor assembly 2 includes a rotor core 21. Two rotor cores 21 are arranged side by side along the axial direction on the rotating shaft 4. A positioning sleeve 22 and a rotor pressure sleeve 23 are fixedly sleeved on the rotating shaft 4 at the position corresponding to the stator positioning stop 11 between the two rotor cores 21. The two rotor pressure sleeves 23 are respectively fixed on both sides of the positioning sleeve 22. A rotor pressure plate 24 is also provided on the radial outer side of each rotor pressure sleeve 23.

[0034] The stator assembly 3 includes a stator core 31 and a stator winding 32. The two stator cores 31 are respectively disposed on both sides of the stator positioning stop 11, and the two stator windings 32 are respectively disposed on the two stator cores 31. The stator windings 32 adopt flat wire windings and have winding ends 321 extending towards both ends of the axial direction. The winding ends 321 at both ends are potted to form an insulating part 322.

[0035] The plastic-sealed flat wire long motor for mining wide-body dump truck is configured such that: the positioning sleeve 22 simultaneously provides axial positioning for the rotor assemblies 2 on both sides, and the corresponding arrangement between the positioning sleeve 22 and the stator positioning stop 11 forms two rotor cores 21 and a common isolation space 50 located on the same axial segment between the two stator cores, and the ends 321 of two adjacent windings 32 in the middle of the two stator windings 32 are located in the isolation space 50, and the insulation portion 322 formed by the potting of the two adjacent winding ends 321 is connected.

[0036] In the above-mentioned plastic-sealed flat wire long motor used in wide-body mining dump trucks, the various parts will be described.

[0037] This utility model embodiment 1 designs a plastic-encapsulated flat wire long motor as a coaxial dual-motor integrated drive system. The motor body of this drive system adopts a modular coaxial integrated design, in which the two rotor assemblies 2 and two stator assemblies 3 are coaxially integrated and share a single rotating shaft 4 as the output shaft. Furthermore, the method of coaxially integrating and positioning the two rotor assemblies 2 and two stator assemblies 3 has been improved. Specifically, an annular stator positioning stop 11 is provided in the middle position of the inner wall of the motor housing 1 for positioning and connecting the stator assemblies 3. This stator positioning stop 11 forms a necessary isolation space 50 between the two stator cores 31. Additionally, a [missing information - likely a design element] is provided in the middle position of the rotating shaft 4. A positioning sleeve 22, a rotor pressure sleeve 23, and a rotor pressure plate 24 are provided to position and connect the two rotor assemblies 2. The positioning sleeve 22 provides axial positioning for the rotor assemblies 2 on both sides, and forms an isolation space 50 between the two stator cores between the positioning sleeve 22, the rotor pressure sleeve 23, and the rotor pressure plate 24. The isolation space 50 between the two rotor cores 21 and the two stator cores is located on the same axial segment. The positioning sleeve 22 between the two rotor assemblies 2 has a dual function: its axial positioning function provides axial positioning for the rotor assembly 2 located on its adjacent side, and its spatial isolation function forms a necessary gap between the two rotor assemblies 2.

[0038] In Embodiment 1 of this utility model, the winding method of the stator assembly 3 and the cooling method of the motor housing 1 are also improved in a coordinated manner. The stator winding 32 of the base assembly adopts a flat wire winding process, significantly improving the slot fill factor and laying the foundation for overcoming the power density bottleneck. The winding ends 321 are encapsulated with high-strength insulating material to form a reinforced structure. Furthermore, the insulation portions 322 formed by the encapsulation of two adjacent winding ends 321 are integrally connected, resulting in higher overall strength and stronger ability to suppress temperature rise. This solution significantly suppresses the temperature rise of the winding ends 321 and fundamentally solves the core fault hazards caused by this area, such as insulation aging failure, inter-turn short circuits, and coil loosening and vibration, thereby ensuring the long-term high reliability and service life of the motor in the harsh environment of mining. In addition, an optimized water channel design is integrated into the motor housing 1, providing efficient cooling capacity. Combined with the end encapsulation heat dissipation, the overall operating temperature of the motor is effectively reduced, enhancing thermal stability.

[0039] In one embodiment of this utility model, the stator positioning stop 11 is an annular structure protruding from the inner wall of the motor housing 1. The stator positioning stop 11 completely covers the radial projection of the positioning sleeve 22 on the radial projection of the rotating shaft 4. Using the annular structure protruding from the inner wall of the motor housing 1 at the axial center as the stator positioning stop 11 results in high machining accuracy, improves the positioning accuracy of the stator assembly 3, and facilitates assembly. The fact that the stator positioning stop 11 completely covers the radial projection of the positioning sleeve 22 on the radial projection of the rotating shaft 4 allows the positioning sleeve 22 to have space on both sides for mating with the rotor pressure sleeve 23, ensuring that the axial length and orientation of the isolation space 50 between the two rotor cores 21 and the two stator cores are consistent.

[0040] In another embodiment of the first embodiment of this utility model, such as Figure 2 As shown, the axial length L1 of the two stator windings 32 extending towards the middle winding end 321, and the axial length L2 of the isolation space 50, are both 15% to 30% of L2, specifically 15%, 20%, 25%, 30%, etc.; the gap distance between two adjacent winding ends 321 is D, which is 40% to 70% of L2, specifically 40%, 50%, 60%, 70%, etc. This dimensional design balances and optimizes the electrical insulation reliability, heat dissipation efficiency, electromagnetic performance, and mechanical stability between two adjacent winding ends 321, balancing the proportions of these parameters within a limited space, and avoiding a decrease in motor performance or heat dissipation efficiency.

[0041] In another embodiment of the first embodiment of this utility model, such as Figure 3 As shown, the positioning sleeve 22 has an annular positioning body 221, and both ends of the positioning body 221 are provided with protruding first positioning steps 222; as Figure 5 , Figure 6 As shown, the rotor pressure plate 24 has an annular pressure plate body, and a second positioning step 243 is provided on the inner circular wall of the pressure plate body; as Figure 4 As shown, the rotor sleeve 23 has a Z-shaped annular structure. The inner side of the rotor sleeve 23 is positioned and engaged with the first positioning step 222 of the positioning sleeve 22, and the outer side of the rotor sleeve 23 is positioned and engaged with the second positioning step 243 of the rotor pressure plate 24 located in the middle. The inner wall of the rotor sleeve 23 is positioned and connected to the rotating shaft 4. This design makes the assembly and positioning of the rotor assembly 2 more reasonable, optimizes its structure, makes the rotor assembly 2 more stable, and allows the positioning sleeve 22 to better perform its dual functions.

[0042] In one embodiment of the first embodiment of this utility model, such as Figure 5 , Figure 6As shown, the rotor pressure plate 24 is divided into a left rotor pressure plate 241 and a right rotor pressure plate 242. A positioning shoulder 41 is provided on the left side of the rotating shaft 4 within the cavity space 10 of the motor housing 1, near the rotor core 21. The positioning shoulder 41 engages with the second positioning step 243 on the left rotor pressure plate 241. A keyway is provided on the left rotor pressure plate 241. This design ensures more reliable positioning of the rotor assembly 2, allowing for quick and easy assembly onto the rotating shaft 4 with the positioning shoulder 41.

[0043] Specifically, such as Figure 1 As shown, the rotor pressure plate 24 between the two rotor assemblies 2 and at the right end of the right rotor assembly 2 is a rotor right pressure plate 242. This makes assembly easier by using the same rotor right pressure plate 242 between the two rotor assemblies 2 and at the right end of the right rotor assembly 2.

[0044] More specifically, such as Figure 1 As shown, both the left rotor pressure plate 241 at the left end and the right rotor pressure plate 242 at the right end have end gaps 60 between them and the cavity space 10 of the motor housing 1. The rotor pressure plate 24 has an annular groove 244 located close to the rotor core 21. The annular groove 244 has vent holes 245 that communicate with the end gaps 60 and the space between the rotor and the core, used to balance the pressure difference between the inside and outside of the rotor core 21 during motor operation. By designing the annular groove 244 and the vent holes 245, the pressure difference between the inside and outside of the rotor core 21 is balanced, improving the overall performance of the motor in complex working environments.

[0045] In another embodiment of the present invention, the rotor pressure plate 24 is made of aluminum alloy to reduce the influence of the strong magnetic field in the rotor assembly 2 on the assembly process; the rotor pressure sleeve 23 and the positioning sleeve 22 are made of steel for positioning and bearing forces. By optimizing the material selection in conjunction with the optimization of the structure, the structural design of this set of structures for positioning and assembling the rotor assembly 2 is more reasonable, satisfying the requirements of compactness while taking into account electromagnetic performance and structural strength.

[0046] In one embodiment of the first embodiment of this utility model, such as Figure 1 , Figure 2As shown, the motor housing 1 is provided with two cooling water channels 12. An isolation part 13 is provided on the motor housing 1 at the position corresponding to the stator positioning stop 11 to isolate the two cooling water channels 12. The axial length of the isolation part 13 is less than the axial length of the stator positioning stop 11. Both cooling water channels 12 extend partially to the isolation space 50 position corresponding to the positioning stop. By providing two cooling water channels 12 on the motor housing 1, each cooling water channel 12 can effectively cool the heat source emitted by one set of rotor assembly 2 and stator assembly 3. The isolation part 13 on the motor housing 1 at the position corresponding to the stator positioning stop 11 to isolate the two cooling water channels 12 not only serves to isolate the two cooling water channels 12, but also serves as structural reinforcement. Furthermore, by extending both cooling water channels 12 partially to the isolation space 50 position corresponding to the positioning stop, the cooling water channels 12 can also exchange heat with the heat emitted by the two adjacent winding ends 321 in a timely manner, preventing the temperature of the two adjacent winding ends 321 from becoming too high.

[0047] The following detailed embodiment will further illustrate the structure of the plastic-encapsulated flat wire long motor of this utility model.

[0048] refer to Figure 1 In this detailed embodiment, the motor housing 1, rotor assembly 2, stator assembly 3 and shaft 4 are included. The rotor assembly 2 and stator assembly 3 are assembled in the cavity space 10 of the motor housing 1, and the shaft 4 is rotatably mounted on the motor housing 1 along its own axis.

[0049] The motor housing 1 has an annular stator positioning stop 11 located in the middle of its inner wall. Two stator assemblies 3 are positioned on both sides of the stator positioning stop 11. The stator positioning stop 11 is an annular structure protruding from the inner wall of the motor housing 1. The motor housing 1 has two cooling water channels 12. An isolation part 13 is provided on the motor housing 1 at the position corresponding to the stator positioning stop 11 to isolate the two cooling water channels 12. The axial length of the isolation part 13 is less than the axial length of the stator positioning stop 11. Both cooling water channels 12 partially extend to the isolation space 50 corresponding to the positioning stop.

[0050] The rotor assembly 2 includes a rotor core 21, a positioning sleeve 22, and a rotor pressure sleeve 23. Two rotor cores 21 are arranged side by side along the axial direction on the rotating shaft 4. A positioning sleeve 22 and a rotor pressure sleeve 23, which are fixedly sleeved on the rotating shaft 4, are provided between the two rotor cores 21 at the position corresponding to the stator positioning stop 11. The two rotor pressure sleeves 23 are respectively fixed on both sides of the positioning sleeve 22. A rotor pressure plate 24 is also provided on the radial outer side of each rotor pressure sleeve 23. The positioning sleeve 22 has an annular positioning body 221, with protruding first positioning steps 222 at both ends of the positioning body 221; the rotor pressure plate 24 has an annular pressure plate body, with a second positioning step 243 on the inner circular wall of the pressure plate body; the rotor pressure sleeve 23 has a Z-shaped annular structure, with the inner side of the rotor pressure sleeve 23 positioning and engaging with the first positioning step 222 of the positioning sleeve 22, and the outer side of the rotor pressure sleeve 23 positioning and engaging with the second positioning step 243 of the rotor pressure plate 24 located in the middle, and the inner wall of the rotor pressure sleeve 23 positioningly connected to the rotating shaft 4. The rotor pressure plate 24 is divided into a left rotor pressure plate 241 and a right rotor pressure plate 242. A positioning shoulder 41 is provided on the left side of the rotating shaft 4 in the cavity space 10 of the motor housing 1 and near the rotor core 21, with the positioning shoulder 41 positioning and engaging with the second positioning step 243 on the left rotor pressure plate 241, and a keyway is provided on the left rotor pressure plate 241. The rotor pressure plate 24 located between the two rotor assemblies 2 and at the right end of the right rotor assembly 2 is a right rotor pressure plate 242. The left rotor pressure plate 241 at the left end and the right rotor pressure plate 242 at the right end both have end gaps 60 between themselves and the cavity space 10 of the motor housing 1. The rotor pressure plate 24 has an annular groove 244 near the rotor core 21, and the annular groove 244 has vent holes 245 that communicate with the end gaps 60 and the space to balance the internal and external air pressure difference during motor operation. The rotor pressure plate 24 is made of aluminum alloy to reduce the influence of the strong magnetic field in the rotor assembly 2 on the assembly process; the rotor pressure sleeve 23 and the positioning sleeve 22 are made of steel for positioning and bearing force.

[0051] The stator assembly 3 includes a stator core 31 and stator windings 32. Two stator cores 31 are respectively disposed on both sides of the stator positioning stop 11. Two stator windings 32 are respectively disposed on the two stator cores 31. The stator windings 32 are flat wire windings and have winding ends 321 extending axially towards both ends. The winding ends 321 at both ends are encapsulated to form insulating portions 322. The axial length L1 of the winding ends 321 extending towards the middle of the two stator windings 32 is equal to the axial length L2 of the isolation space 50, where L1 is 25% of L2. The gap distance between two adjacent winding ends 321 is D, where D is 50% of L2.

[0052] Through the implementation of the above embodiments, the axial space occupancy is greatly reduced by optimizing the layout of the coaxial compact structure, the flat wire winding and end reinforcement structure, and the efficient thermal management design, thereby increasing the power density. At the same time, it has efficient cooling capacity and the ability to effectively reduce temperature rise, which will extend the motor life by at least 3 times, thus achieving the purpose of this utility model.

[0053] The above embodiments are only for illustrating the technical concept and features of this utility model, and are intended to enable those skilled in the art to understand the content of this utility model and implement it accordingly. They should not be construed as limiting the scope of protection of this utility model. All equivalent changes or modifications made in accordance with the spirit and essence of this utility model should be included within the scope of protection of this utility model.

Claims

1. A plastic-encapsulated flat-wire long motor for a wide-body dump truck used in mining, comprising a motor housing, a rotor assembly, a stator assembly, and a rotating shaft, wherein the rotor assembly and stator assembly are assembled within the cavity space of the motor housing, and the rotating shaft is rotatably mounted on the motor housing along its own axial direction, characterized in that: An annular stator positioning stop is provided in the middle of the inner wall of the motor housing, and two stator assemblies are positioned and installed on both sides of the stator positioning stop; cooling water channels are provided on the motor housing; The rotor assembly includes a rotor core, with two rotor cores arranged side by side along the axial direction on the rotating shaft. A positioning sleeve and a rotor pressure sleeve are fixedly sleeved on the rotating shaft at the position corresponding to the stator positioning stop between the two rotor cores. The two rotor pressure sleeves are respectively fixed on both sides of the positioning sleeve. A rotor pressure plate is also provided on the radial outer side of each rotor pressure sleeve. The stator assembly includes a stator core and a stator winding. The two stator cores are respectively located on both sides of the stator positioning stop. The two stator windings are respectively located on the two stator cores. The stator windings are flat wire windings. The stator windings have winding ends extending towards both ends of the axial direction. The winding ends at both ends are potted to form an insulating part. The plastic-sealed flat wire long motor for wide-body dump trucks in mining is configured such that: the positioning sleeve provides axial positioning for the rotor assemblies on both sides simultaneously, and the corresponding arrangement between the positioning sleeve and the stator positioning stop forms an isolation space shared by the two rotor cores and the two stator cores on the same axial segment, with the ends of two adjacent stator windings located in the isolation space, and the insulation formed by the potting of the ends of the two adjacent windings being integrally connected.

2. The plastic-sealed flat wire long motor for a wide-body mining dump truck according to claim 1, characterized in that: The stator positioning stop is a ring-shaped structure protruding from the inner wall of the motor housing, and the stator positioning stop completely covers the radial projection of the positioning sleeve on the radial projection of the rotating shaft.

3. A plastic-sealed flat wire long motor for a wide-body mining dump truck according to claim 2, characterized in that: The axial length L1 of the two stator windings extending toward the middle of the winding ends, the axial length of the isolation space L2, L1 being 15% to 30% of L2, and the gap distance between the ends of two adjacent windings being D, D being 40% to 70% of L2.

4. A plastic-sealed flat wire long motor for a wide-body mining dump truck according to claim 1, characterized in that: The positioning sleeve has an annular positioning body, with protruding first positioning steps at both ends; the rotor pressure plate has an annular pressure plate body, with a second positioning step on the inner circular wall of the pressure plate body; the rotor pressure sleeve has a Z-shaped annular structure, with the inner side of the rotor pressure sleeve engaging with the first positioning step of the positioning sleeve, the outer side of the rotor pressure sleeve engaging with the second positioning step of the rotor pressure plate located in the middle, and the inner wall of the rotor pressure sleeve being positioned and connected to the rotating shaft.

5. A plastic-sealed flat wire long motor for a wide-body mining dump truck according to claim 1, characterized in that: The rotor pressure plate is divided into a left rotor pressure plate and a right rotor pressure plate. The left side of the rotating shaft is provided with a positioning shoulder in the cavity space of the motor housing and close to the rotor core. The positioning shoulder is positioned and engaged with the second positioning step on the left rotor pressure plate. The left rotor pressure plate is provided with a keyway.

6. A plastic-sealed flat wire long motor for a wide-body mining dump truck according to claim 5, characterized in that: The rotor pressure plate between the two rotor assemblies and at the right end of the right rotor assembly is a right rotor pressure plate.

7. A plastic-sealed flat wire long motor for a wide-body mining dump truck according to claim 5, characterized in that: The rotor left pressure plate located at the left end and the rotor right pressure plate located at the right end both have end gaps between them and the cavity space of the motor housing. The rotor pressure plate has an annular groove at a position close to the rotor core. The annular groove has a vent hole that is connected to the end gap and the space interval to balance the pressure difference between the inside and outside of the motor during operation.

8. A plastic-sealed flat wire long motor for a wide-body mining dump truck according to claim 1, characterized in that: The rotor pressure plate is made of aluminum alloy to reduce the influence of strong magnetic fields in the rotor assembly on the assembly process; the rotor pressure sleeve and positioning sleeve are made of steel for positioning and bearing force.

9. A plastic-sealed flat wire long motor for a wide-body mining dump truck according to claim 1, characterized in that: The motor housing is provided with two cooling water channels. An isolation part is provided on the motor housing at the position corresponding to the stator positioning stop to isolate the two cooling water channels. The axial length of the isolation part is less than the axial length of the stator positioning stop. Both cooling water channels extend partially to the isolation space position corresponding to the positioning stop.

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