Axle-through hub electric drive assembly

Abstract

This utility model discloses a configuration of a through-shaft hub electric drive assembly, which includes a motor rotor assembly, a motor stator assembly, an output flange, a controller, a speed sensor, a fixed shaft assembly, a driven component, and bearings. The motor stator assembly includes a motor stator, heat sinks, and a stator housing. Multiple heat dissipation through holes are arranged radially on the motor stator, which, together with the grooves and through holes on the outer ring of the stator housing, form a cooling channel. Heat sinks are also arranged on the stator to enhance heat dissipation. The controller is located within the cavity of the stator housing. The motor stator assembly and the controller are connected to the fixed shaft assembly through the inner ring of the stator housing. The motor rotor assembly connects the output shaft flange and the driven component, transmitting motor torque. The fixed shaft assembly is fixed at one end to the landing gear or fuselage structure, and at the other end to the motor stator assembly and the controller. Its outer surface is connected to the driven component via bearings, forming the core configuration of this utility model. This utility model is more compact than existing product configurations, especially in terms of axial space. The fixed shaft assembly connects the driven component and the motor stator and rotor assembly respectively, minimizing interference from vibrations and reverse loads from the driven component on the motor and electromagnetic air gap. This utility model configuration has a wide range of applications and can be extended to other fields; for example, the driven component can be a vehicle wheel, aircraft wheel, aircraft rotor, or marine propeller.

Description

Technical Field

[0001] This utility model relates to an electric drive power system for new energy vehicles, particularly hub drive, and can also be applied to wind turbine power generation, aircraft rotor drive, propeller drive, etc. Background Technology

[0002] Currently, due to the gradual popularization of new energy electrification, aircraft, special vehicles, water and underwater transportation tools are gradually becoming electrified, and electrification is also being greatly promoted in fields such as industrial equipment.

[0003] Driven by aviation electrification, the development of electric taxiing systems for aircraft has gradually begun. This system is installed on the landing gear hubs of the aircraft and can replace the engine to drive the aircraft to the runway and assist takeoff during taxiing, or drive the aircraft to the parking position after landing. It can also realize the function of generating electricity during landing and taxiing. This system saves energy consumption of the main engine, increases the range, and saves costs.

[0004] Generally, aircraft landing gear wheel hubs are typically mounted on a fixed main shaft and connected by bearings. The inner cavity of the hub houses a complex braking system, leaving no space for an electric drive system. Therefore, an electric drive system needs to be mounted on the outside of the hub. Furthermore, due to the limitations of the landing gear bay, there are strict requirements on the axial dimensions of the electric drive system, necessitating the development of a compact electric drive system that can be externally mounted on the hub.

[0005] Currently, similar wheel-electric drive assemblies generally consist of a reducer, motor, controller, etc., and are located on the outside of the wheel hub. They are heavy and have large axial dimensions.

[0006] Figure 1 This describes an existing electric drive system structure. It mainly consists of an electric drive housing assembly 1', a reducer 2', a motor 3', a controller 4', a landing gear main shaft 5', a reducer output shaft 6', a wheel hub 7', and a wheel hub bearing 8'. The reducer 2', motor 3', and controller 4' are sequentially arranged axially within the electric drive housing assembly 1', which is connected and fixed to the landing gear main shaft 5' via a central hole. The reducer output shaft 6' is fixed to the outside of the wheel hub 7' and transmits torque. The wheel hub 7' is connected to the landing gear main shaft 5' via the wheel hub bearing 8' and rotates around the landing gear main shaft 5'. When the motor 3' starts, the torque is output to the wheel hub 7' through the reducer 2' and reducer output shaft 6', driving it to rotate around the landing gear main shaft 5' and propelling the aircraft taxiing. Overall, the structure has a reducer 2', motor 3', and controller 4' arranged axially. Its axial length is relatively long, which cannot be adapted to the narrow landing gear bay space. At the same time, the structure is complex, with large shafts, bearings, oil seals, sun gears, etc. arranged in the middle, resulting in a large overall weight and a high risk of oil leakage, and low system reliability. Utility Model Content

[0007] The technical problem to be solved by this utility model is to make the axial arrangement structure of the hub electric drive assembly more compact to reduce the axial length, while reducing weight through system optimization and component optimization.

[0008] To solve the above-mentioned technical problems, this utility model provides a through-shaft hub electric drive assembly, which includes a motor rotor assembly, a motor stator assembly, an output flange, a controller, a speed sensor, a fixed shaft assembly, a driven component, and bearings. The fixed shaft assembly connects the motor stator assembly, the stator part of the speed sensor, and the controller, together forming a fixed assembly; the motor rotor assembly connects the output flange, the driven component, and the rotor part of the speed sensor, together forming a rotating assembly; the fixed assembly and the rotating assembly are connected by bearings.

[0009] The motor rotor assembly includes an outer ring, a magnet, and a fan. The outer ring has a cylindrical structure, and the magnet is fixed to the inner wall of the outer ring. A fan is fixed to one end of the outer ring. When the rotor rotates, the fan rotates accordingly, conveying airflow radially outward from the center. The other end of the outer ring is connected to an output flange to transmit torque.

[0010] Optionally, the fan can be centrifugal or axial.

[0011] The motor stator assembly includes a motor stator, heat sinks, and a stator base. The motor stator has multiple heat dissipation holes arranged in the radial direction, which can allow airflow to partially dissipate heat from the stator. Heat sinks are also arranged on the stator to transfer some heat to the outside of the assembly.

[0012] Optionally, the heat sink can be made of a high thermal conductivity material or a phase change material, and the heat-absorbing part of the heat sink can extend into the gaps of the inner ring of the stator.

[0013] The stator base has a wheel-shaped structure, including an outer ring, spokes, and an inner ring; the outer surface of the outer ring is connected to the stator and has multiple axial grooves; one end of the outer ring has multiple through holes that communicate with the grooves to allow airflow to be introduced.

[0014] Optional, the groove or through hole can be any shape, as long as it can guide airflow to form an airflow channel.

[0015] Under the action of the fan, cooler air is drawn in through the through holes in the outer ring, and then discharged through the grooves and heat dissipation holes on the stator, thus cooling the stator. The through holes and grooves on the outer ring of the stator base, as well as the through holes on the stator, form a cooling channel under the drive of the fan.

[0016] In addition to supporting the motor stator and transmitting the reverse load generated by the motor stator, the spokes of the stator base also serve as the stator portion of the speed sensor, which is connected to the spokes of the stator base.

[0017] The inner ring of the stator base is connected to the fixed shaft assembly to transmit reverse loads.

[0018] The output flange is a disc-shaped mechanism. Its outer edge is connected to the motor rotor assembly; the inner ring is connected to the driven component, transmitting motor torque; the inner ring is also connected to the speed sensor rotor part.

[0019] Optionally, the output flange can be connected to the motor rotor assembly, and is not limited to a certain fixing method. Options include threads, fasteners, keys, interference fits, pins, friction fittings, tapered sleeves, etc.

[0020] Even better, in addition to the above connection methods, a flexible connection is preferred when connecting the output flange to the driven component. A flexible connection can isolate the load, deformation, and vibration of the driven component from being transmitted to the motor rotor assembly, preventing electromagnetic air gap instability and thus affecting motor performance and durability. Flexible connections can employ splines, rubber sleeves, springs, etc.

[0021] The controller is located inside the stator base and consists of a core, a controller cover, and a heat sink. The core is the main part of the controller and contains various control and drive circuit components. The controller cover and the stator base form a sealed cavity, which serves to prevent water and dust. One side of the heat sink is connected to the power devices of the controller, and the other side has heat dissipation fins that penetrate the controller cover to dissipate heat outward.

[0022] The fixed shaft assembly is connected at one end to the landing gear or other structures on the fuselage, and at the other end to the motor stator assembly and controller. Its outer surface is also connected to the driven components via bearings. The advantage is that adverse effects such as axial force, radial force, bending moment, vibration, shock, and deformation of the driven components are directly transmitted to the fixed shaft assembly through the bearings, thus minimizing interference to the motor rotor assembly, motor stator assembly, and controller, achieving mechanical decoupling of adverse effects.

[0023] Optionally, the fixed shaft assembly can be connected at one or both ends to the fuselage structure of a vehicle or machine, such as the wheel support axle of a vehicle, the landing gear of an aircraft, the fuselage arm of an aircraft, or the support arm of a propeller used on water or underwater.

[0024] Optionally, the driven component may be a vehicle wheel, an aircraft wheel, an aircraft rotor, a marine propeller, etc.

[0025] The motor rotor assembly, motor stator assembly, controller, etc., together constitute the power source, which transmits power to the driven components.

[0026] The advantages of this utility model are: It has a more compact structure compared to existing products, especially in terms of axial space.

[0027] By making full use of the fixed shaft assembly to connect the driven component and the motor stator and rotor assembly and controller respectively, mechanical isolation from adverse effects is achieved.

[0028] It has a wide range of applications, including vehicles, aircraft, water and underwater transportation, and even wind power generation. Attached Figure Description

[0029] To more clearly illustrate the technical solution of this utility model, the drawings used in this utility model will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of an existing electric drive system structure; Figure 2 It is a cross-sectional structural diagram of the configuration; Figure 3 This is a schematic diagram of the motor rotor assembly structure; Figure 4 This is a schematic diagram of the motor stator assembly structure; Figure 5 This is a schematic diagram of the motor stator housing structure; Figure 6 This is a diagram of the cooling channels for the motor stator assembly; Figure 7 This is a schematic diagram of the output flange connection structure; Figure 8 This is a controller structure diagram; Figure 9 This is a schematic diagram of the connection structure of the fixed shaft assembly; Figure 10 This is a schematic diagram of the structure of the present invention applied to the rotor drive of aircraft and the propeller drive of ships. Detailed Implementation

[0031] The technical solutions of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model. Example 1

[0032] like Figure 2The through-shaft hub electric drive assembly includes a motor rotor assembly 1, a motor stator assembly 2, an output flange 3, a controller 4, a fixed shaft assembly 5, a speed sensor 6, a driven component 7, and a bearing 8. The fixed shaft assembly 5 connects the motor stator assembly 2, the stator portion of the speed sensor 6, and the controller 4, together forming a fixed assembly; the motor rotor assembly 1 connects the output flange 3, the driven component 7, and the rotor portion of the speed sensor 6, together forming a rotating assembly; the fixed assembly and the rotating assembly are connected by the bearing 8. Example 2

[0033] like Figure 3 The motor rotor assembly 1 includes an outer ring 11, a magnet 12, and a fan 13. The outer ring 11 has a cylindrical structure, and the magnet 12 is fixed to the inner wall of the outer ring 11. A fan 13 is fixed at one end of the outer ring 11 to deliver airflow radially outward from the center; the other end of the outer ring 11 is connected to an output flange 3.

[0034] Optionally, the fan 13 is not limited to a certain form, and is generally centrifugal or axial. Example 3

[0035] like Figure 4 The motor stator assembly 2 includes a motor stator 21, a heat sink 22, and a stator base 23; multiple heat dissipation through holes 211 are arranged radially inside the motor stator 21, and the internal gap of the motor stator 21 is also connected to the heat sink 22.

[0036] Optionally, the heat sink can be made of a material with high thermal conductivity or a phase change material. Example 4

[0037] like Figure 5 , Figure 6 The stator base 23 is a hub-shaped structure, including an outer ring 231, a spoke plate 232, and an inner ring 233. The outer surface of the outer ring 231 is connected to the stator and has multiple axial grooves 2312. One end of the outer ring 231 has multiple through holes 2311 that communicate with the grooves 2312.

[0038] Optional, the groove 2312 and the through hole 2311 are not limited to any shape.

[0039] Figure 6 As shown by the arrow, cooler air is drawn in through the through-hole 2311 of the outer ring 231, and is discharged through the fan 13 through the groove 2312, the heat dissipation through-hole 211 on the stator.

[0040] Figure 5 The spokes 232 and outer ring 231 of the stator base 23 support the motor stator 21, and the stator part 61 of the speed sensor 6 is connected to the spokes 232 of the stator base 23.

[0041] The inner ring 233 of the stator seat 23 is connected to the fixed shaft assembly 5. Example 5

[0042] like Figure 7 The output flange 3 is a disc-shaped mechanism. Its outer edge is connected to the outer ring 11 of the motor rotor assembly 1; its inner ring is connected to the driven component 7; and its inner ring is also connected to the rotor part 62 of the speed sensor 6.

[0043] Optionally, the connection between the output flange 3 and the motor rotor assembly 1 is not limited to a certain fixing method, and can be made of thread, fastener, key, interference fit, pin, friction, tapered sleeve, etc.

[0044] More preferably, the connection between the output flange 3 and the driven component 7 can be either the above-mentioned connection methods or a flexible connection method. The flexible connection can be a spline, a rubber sleeve, a spring, etc., and is not limited to the above methods. Example 6

[0045] like Figure 8 The controller 4 is arranged in the inner cavity of the stator base 23 and is divided into a core 41, a controller cover 42, and a heat sink 43. Example 7

[0046] like Figure 9 The fixed shaft assembly 5 is fixed at one end to the machine body or other structures, and at the other end to the motor stator assembly 2 and the controller 4. Its outer surface is also connected to the driven component 7 via a bearing 8. Example 8

[0047] Extensible, such as Figure 10 The fixed shaft assembly 5 can be connected to the fuselage structure of a vehicle at one or both ends, such as the wheel support axle of a vehicle, the landing gear of an aircraft, the fuselage arm of an aircraft, or the support arm of a propeller used on water or underwater. The driven component 7 can be expanded to include vehicle wheels, aircraft wheels, aircraft rotors, marine propellers, etc. The motor rotor assembly 1, motor stator assembly 2, controller 4, etc., together constitute the power source, transmitting power to the driven component 7.

[0048] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the scope of protection of the present utility model.

Claims

1. A through-axle hub electric drive assembly, characterized in that, The system includes a motor rotor assembly, a motor stator assembly, an output flange, a controller, a speed sensor, a fixed shaft assembly, a driven component, and bearings. The fixed shaft assembly connects the motor stator assembly, the stator portion of the speed sensor, and the controller, forming a fixed assembly. The motor rotor assembly connects the output flange, the driven component, and the rotor portion of the speed sensor, forming a rotating assembly. The fixed shaft assembly and the rotating assembly are connected by bearings. The motor rotor assembly is elastically connected to the driven component via the output flange.

2. The through-axle hub electric drive assembly according to claim 1, characterized in that, The motor rotor assembly includes an outer ring, a magnet, and a fan; a fan, which can be centrifugal or axial, is fixed at the end of the outer ring; the motor stator assembly includes a motor stator, heat sinks, and a stator base; the motor stator has multiple through holes arranged in the radial direction, and heat sinks are arranged in the internal gaps of the stator; the stator base has a hub-shaped structure, including an outer ring, spokes, and an inner ring; multiple axial grooves are arranged on the outer surface of the outer ring; multiple through holes are opened at one end of the outer ring, communicating with the grooves; the grooves and through holes are not limited in shape; the through holes and grooves on the outer ring of the stator base, as well as the through holes on the stator, form a cooling channel under the drive of the fan.

3. The through-axle hub electric drive assembly according to claim 1, characterized in that, The stator portion of the speed sensor is connected to the stator mount in the motor stator assembly; the rotor portion of the speed sensor is connected to the output flange.

4. The through-axle hub electric drive assembly according to claim 1, characterized in that, One or both ends of the fixed shaft assembly are connected to the fuselage structure of a vehicle or machine, and the fixed shaft is connected to the motor stator assembly and the controller, and is also connected to the driven component through bearings; the driven component is a vehicle wheel, an aircraft wheel, an aircraft rotor or a marine propeller.

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