Axial flux wheel motor for a light electric vehicle

Abstract

The utility model provides a kind of axial flux wheel hub motor of light electric vehicle, it is related to light electric vehicle wheel hub motor technical field, including motor shaft, wheel hub shell, stator assembly and rotor assembly, wheel hub shell is rotatably arranged on motor shaft, multiple magnetic steel grooves are set on the inner end wall of wheel hub shell along the axial direction, and the circumferential of all magnetic steel grooves is evenly distributed relative to motor shaft;Stator assembly is located inside wheel hub shell, and is fixedly sleeved on motor shaft, and stator assembly includes multiple stator windings evenly distributed along the circumferential;Rotor assembly includes multiple magnetic steel fixedly arranged in corresponding magnetic steel groove, and magnetic steel is oppositely arranged with stator winding;The utility model uses axial flux to cooperate single rotor single stator structure, not only high space utilization, overall structure is more compact, meet the light weight, small and exquisite demand of light electric vehicle, and magnetic flux path is short, force arm is big, and driving output is strong, simultaneously dismounting is convenient, it is convenient for production and later maintenance.

Description

Technical Field

[0001] This utility model relates to the field of hub motor technology for lightweight electric vehicles, specifically to an axial flux hub motor for lightweight electric vehicles. Background Technology

[0002] Among existing electric two-wheeled and three-wheeled light electric vehicles, radial hub motors are the most widely used drive components. They achieve electromagnetic induction drive through a radially arranged stator and rotor structure, providing driving power for the vehicle.

[0003] However, such radial hub motors have inherent limitations in practical applications: Because its magnetic circuit is radially distributed, the stator core and windings need to be stacked radially, resulting in a large overall radial dimension of the motor. This not only increases the space occupied by the wheel hub, but also increases the drag coefficient when the vehicle is in motion, indirectly affecting the driving range.

[0004] Meanwhile, the radial flux structure has limited magnetic circuit utilization, and magnetic field energy is easily lost during radial transmission, making it difficult to further increase the power density of the motor and failing to fully meet the development needs of lightweight electric vehicles for "miniaturization and high efficiency" of drive components.

[0005] In addition, the rotor and stator assembly structure of radial hub motors is relatively complex and has a large number of parts, which not only increases the manufacturing cost but also affects the convenience of later maintenance, thus restricting its further optimized application in the field of lightweight electric vehicles. Utility Model Content

[0006] The purpose of this utility model is to provide an axial flux hub motor for a lightweight electric vehicle to solve the aforementioned technical problems in the prior art; the preferred technical solutions among the various technical solutions provided by this utility model can produce many technical effects, as detailed below.

[0007] To achieve the above objectives, the present invention provides the following technical solution: This utility model provides an axial flux hub motor for a lightweight electric vehicle, comprising a motor assembly including a motor shaft, a hub housing, a stator assembly, and a rotor assembly. The hub housing is rotatably mounted on the motor shaft, and its inner end wall has multiple axially oriented magnetic slots evenly distributed circumferentially relative to the motor shaft. The stator assembly is located inside the hub housing and fixedly mounted on the motor shaft, comprising multiple circumferentially evenly distributed stator windings. The rotor assembly comprises multiple magnets fixedly disposed within corresponding magnetic slots, the magnets being positioned opposite the stator windings.

[0008] Preferably, the width of the magnet gradually increases in the direction away from the motor shaft; the magnet slot matches the shape of the magnet.

[0009] Preferably, the stator assembly includes a stator core, the stator core having a plurality of winding slots evenly arranged circumferentially, and the stator windings being wound in the corresponding winding slots; the cross-sectional shape of the stator windings is set to a rectangular flat shape.

[0010] Preferably, the stator assembly includes a stator end plate, which is fixedly sleeved on the motor shaft, and the stator core is fixedly disposed on the end face of the stator end plate.

[0011] Preferably, the axial flux hub motor of the lightweight electric vehicle includes a rim, which is detachably fitted onto the outside of the hub housing via a connecting structure, and the rim rotates synchronously with the hub housing.

[0012] Preferably, multiple rims are provided depending on their specifications; any one of the rims can be connected to the hub shell through the connecting structure.

[0013] Preferably, the connection structure includes a threaded connector, and the hub housing is detachably connected to the rim via the threaded connector.

[0014] Preferably, the wheel hub housing is provided with a plurality of first connecting holes evenly distributed along the circumference, and the wheel rim is provided with a second connecting hole at the position corresponding to the first connecting hole, and the threaded connector passes through the corresponding first connecting hole and the second connecting hole.

[0015] Preferably, a plurality of first ear plates are evenly arranged circumferentially on the outer peripheral wall of the wheel hub shell, and the first connecting hole is disposed through the first ear plate; a plurality of second ear plates are evenly arranged circumferentially on the inner peripheral wall of the wheel rim, and the second connecting hole is disposed through the second ear plate.

[0016] Preferably, a guide groove is provided on the outer peripheral wall of the wheel hub shell corresponding to the position of the first ear plate, and the guide groove is adapted to the second ear plate; when the wheel rim is disassembled or assembled, the wheel rim is pushed and pulled along the axial direction, and the second ear plate slides along the guide groove.

[0017] The axial flux hub motor for a lightweight electric vehicle provided by this utility model has at least the following beneficial effects: I. Significantly optimized spatial layout to meet the needs of lightweight electric vehicles: By axially arranging the magnets and stator windings, the magnetic circuit is transmitted along the axis, eliminating the need for radial stacking structures. This significantly reduces the radial dimension of the motor, making the overall volume of the hub housing more compact. This not only reduces the installation space occupied but also reduces wind resistance during vehicle operation, which helps improve the vehicle's range and better meets the design requirements of "lightweight and compact" for lightweight electric vehicles.

[0018] II. Improving magnetic circuit utilization and power density: The axial flux structure arranges the magnets and stator windings face to face, resulting in a shorter and more concentrated magnetic field transmission path. This effectively reduces magnetic field energy loss, significantly improves magnetic circuit utilization, and increases the lever arm. At the same time, the compact axial structure allows for the arrangement of more effective electromagnetic components within the same installation space, thereby increasing the power density of the motor, making the drive output more powerful, and meeting the power requirements of lightweight electric vehicles.

[0019] III. Simplify assembly structure and reduce production and maintenance costs: The rotor assembly is directly fixed to the hub housing via magnet slots, and the stator assembly is fixedly sleeved on the motor shaft. The overall assembly structure is simple and has fewer parts, which not only reduces the assembly difficulty and cost in the manufacturing process, but also provides convenience for later maintenance and repair, and improves the practicality and economy of the product. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art 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 based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is an exploded view of the present invention. Figure 3 This is a utility model Figure 2 Enlarged view of part A; Figure 4 This is an exploded view of the present invention from another perspective; Figure 5 This is a schematic diagram of the stator assembly of this utility model; Figure 6 This is an exploded view of the motor assembly and wheel rim of this utility model. Figure 7 This is a utility model Figure 6 Enlarged view of part B; Figure 8This is a utility model Figure 6 Enlarged view of part C; Figure 9 This is an exploded view of the motor assembly and rim of this utility model from another perspective.

[0022] Figure Labels 1. Motor assembly; 11. Motor shaft; 12. Hub housing; 121. End cover; 1211. Magnet slot; 122. Housing; 13. Stator assembly; 131. Stator winding; 132. Stator core; 1321. Winding slot; 133. Stator end plate; 14. Rotor assembly; 141. Magnet; 2. Rim; 3. Connection structure; 31. Threaded connector; 32. First lug; 321. First connecting hole; 33. Second lug; 331. Second connecting hole; 34. Guide groove. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be described in detail below. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0024] Example 1: This utility model provides an axial flux hub motor for a lightweight electric vehicle, referenced. Figures 1 to 9 As shown, the axial flux hub motor of the lightweight electric vehicle includes a motor assembly 1, which includes a motor shaft 11, a hub housing 12, a stator assembly 13, and a rotor assembly 14.

[0025] The hub housing 12 is rotatably mounted on the motor shaft 11. Multiple magnetic steel grooves 1211 are provided on the inner end wall of the hub housing 12 along the axial direction. All magnetic steel grooves 1211 are evenly distributed circumferentially relative to the motor shaft 11.

[0026] The stator assembly 13 is located inside the hub housing 12 and is fixedly sleeved on the motor shaft 11. The stator assembly 13 includes a plurality of stator windings 131, which are evenly distributed along the circumference of the motor shaft 11.

[0027] The rotor assembly 14 includes a plurality of magnets 141, the number of which is the same as the number of magnet slots 1211. The magnets 141 are fixedly arranged in the corresponding magnet slots 1211 and are arranged opposite to the stator windings 131.

[0028] During operation, the axially arranged magnet 141 emits magnetic lines of force that pass through the stator assembly 13 in a direction parallel to the motor shaft 11, forming a closed loop.

[0029] This utility model adopts an axial magnetic flux combined with a single rotor and single stator structure, which not only has high space utilization and a more compact overall structure, but also meets the characteristics of lightweight and compact design, which helps to improve the vehicle's range. In addition, the magnetic flux path is short and the force arm is large, which can improve the magnetic circuit utilization and power density, making the drive output more powerful and meeting the needs of frequent start-stop and hill climbing. At the same time, it can effectively simplify the assembly structure, making production and subsequent maintenance easier.

[0030] Example 2: Example 2 is based on Example 1. like Figures 2 to 5 As shown, the width of the magnet 141 gradually increases in the direction away from the motor shaft 11, and the magnet 141 is trapezoidal.

[0031] Compared to traditional square magnets, this configuration optimizes the top edge, top edge width, and side angles, making the distribution of the air gap magnetic field closer to an ideal sine wave. This not only ensures more complete magnetic field coupling between magnet 141 and stator winding 131, reducing magnetic field leakage and further improving magnetic circuit utilization and motor drive efficiency, but also reduces electromagnetic torque pulsation, improves operational stability, and eliminates or weakens harmonic electromagnetic forces, thereby reducing electromagnetic noise and vibration at the source and optimizing the user experience.

[0032] The magnetic slot 1211 and the magnetic steel 141 are shaped to fit each other; not only is the magnetic steel 141 installed firmly, preventing the magnetic steel 141 from shifting due to centrifugal force or vibration when the motor is running, thus improving structural reliability, but it also simplifies the assembly and positioning process of the magnetic steel 141, improving assembly accuracy and efficiency.

[0033] As an optional implementation, the stator assembly 13 includes a stator core 132, the stator core 132 having a plurality of winding slots 1321 uniformly arranged in the circumferential direction, and the stator winding 131 being wound in the corresponding winding slots 1321; the winding cross-sectional shape of the stator winding 131 is set to a rectangular flat shape.

[0034] Compared to traditional circular cross-section windings, the rectangular flat structure can more fully fill the winding slot space, increasing the slot fill factor. More winding wires can be arranged in the same volume, enhancing the electromagnetic induction effect and improving the motor's output power and torque. At the same time, the rectangular flat winding has a larger heat dissipation area and higher heat dissipation efficiency, which can effectively reduce the temperature rise during motor operation and avoid affecting motor performance and service life due to overheating. Furthermore, the setting of winding slot 1321 makes the winding arrangement more regular, reducing mutual interference between windings, reducing copper losses, and further optimizing motor energy efficiency.

[0035] As an optional implementation, the stator assembly 13 includes a stator end plate 133, which is fixedly sleeved on the motor shaft 11, and the stator core 132 is fixedly disposed on the end face of the stator end plate 133.

[0036] The stator end plate 133 provides stable mounting support for the stator core 132, making the connection between the stator core 132 and the motor shaft 11 more secure, preventing the stator core 132 from shaking or shifting when the motor is running at high speed, ensuring the relative positional accuracy of the stator winding 131 and the rotor magnet 141, and improving the stability of motor operation; at the same time, the stator end plate 133 also simplifies the assembly process of the stator assembly 13 and facilitates the positioning and installation of the stator core 132.

[0037] As an optional implementation method, such as Figures 6 to 9 As shown, the axial flux hub motor of the lightweight electric vehicle includes a rim 2, which is detachably mounted on the outside of the hub shell 12 via a connecting structure 3, and the rim 2 rotates synchronously with the hub shell 12.

[0038] The connection structure 3 enables a separate design between the rim 2 and the motor body. When the rim 2 is worn, damaged, or needs to be replaced with a different model, it is not necessary to disassemble the entire motor. Only the rim 2 needs to be disassembled and installed separately, which greatly improves the convenience and flexibility of maintenance.

[0039] As an optional implementation, the rim 2 can be configured in multiple ways depending on the specifications, such as 10-inch, 11-inch, and 12-inch rims; any rim 2 can be connected to the hub shell 12 through the connecting structure 3.

[0040] In practical applications, users can replace rims 2 of different specifications without disassembling the motor assembly 1, which significantly improves the versatility and adaptability of the motor assembly 1.

[0041] As an optional implementation, the connection structure 3 includes a threaded connector 31, and the hub housing 12 is detachably connected to the rim 2 via the threaded connector 31.

[0042] The use of threaded connections not only ensures a robust structure during connection but also facilitates easy assembly and disassembly.

[0043] As an optional implementation, a plurality of first connecting holes 321 are uniformly arranged on the circumferential direction of the hub housing 12, and a second connecting hole 331 is arranged on the rim 2 at the position corresponding to the first connecting holes 321.

[0044] The number of threaded connectors 31, the number of first connecting holes 321, and the number of second connecting holes 331 are the same and correspond one-to-one.

[0045] During installation, the threaded connector 31 passes through the corresponding first connecting hole 321 and second connecting hole 331 to achieve installation.

[0046] As an optional implementation, the hub housing 12 includes a housing 122 with one side open and an end cap 121 provided at the open position of the housing 122 by bolts.

[0047] Multiple first ear plates 32 are evenly arranged circumferentially on the outer peripheral wall of the housing 122, and a first connecting hole 321 is provided through the first ear plate 32. A magnet groove 1211 is provided on the inner end face of the end cover 121.

[0048] Multiple second ear plates 33 are evenly arranged circumferentially on the inner peripheral wall of the rim 2, and the second connecting hole 331 is disposed through the second ear plate 33.

[0049] The ear plate makes the connection part more prominent, which facilitates the installation and removal of the threaded connection 31 during disassembly and assembly, improves maintenance convenience, and the circumferentially distributed ear plate can further optimize the stress distribution, ensure the connection stability between the rim 2 and the hub housing 12, and avoid affecting the structural strength due to the opening of holes in the rim 2 or hub housing 12, thus ensuring the service life of the components.

[0050] As an optional implementation, a guide groove 34 is provided on the outer peripheral wall of the hub housing 12 at the position corresponding to the first ear plate 32, and the guide groove 34 is adapted to the second ear plate 33.

[0051] When disassembling or assembling the rim 2, push or pull the rim 2 along the axial direction, and the second ear plate 33 slides along the guide groove 34.

[0052] The guide groove 34 provides precise guidance for the axial disassembly and assembly of the rim 2, effectively limiting the relative rotation of the rim 2 during disassembly and assembly, avoiding misalignment of holes, and reducing assembly difficulty.

[0053] In the description of this application, it should be understood that the terms "upper", "lower", "inner", "outer", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They 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. Therefore, they should not be construed as limitations on this application.

[0054] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, 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" or "several" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0055] In this application, unless otherwise expressly specified and limited, 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 direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0056] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the protection scope of the claims.

Claims

1. An axial flux hub motor for a lightweight electric vehicle, characterized in that, The motor assembly includes a motor shaft, a hub housing, a stator assembly, and a rotor assembly, wherein: The hub housing is rotatably mounted on the motor shaft. Multiple magnetic slots are provided axially on the inner end wall of the hub housing, and all the magnetic slots are evenly distributed circumferentially relative to the motor shaft. The stator assembly is located inside the hub housing and is fixedly sleeved on the motor shaft. The stator assembly includes a plurality of stator windings evenly distributed along the circumference. The rotor assembly includes a plurality of magnets fixedly disposed in the corresponding magnet slots, and the magnets are disposed opposite to the corresponding stator windings.

2. The axial flux hub motor for a lightweight electric vehicle according to claim 1, characterized in that, The width of the magnet gradually increases in the direction away from the motor shaft; The magnet groove is matched with the shape of the magnet.

3. The axial flux hub motor for a lightweight electric vehicle according to claim 1, characterized in that, The stator assembly includes a stator core, the stator core having a plurality of winding slots evenly arranged circumferentially, and the stator windings being wound in the corresponding winding slots; The cross-sectional shape of the stator winding is set to a rectangular flat shape.

4. The axial flux hub motor for a lightweight electric vehicle according to claim 3, characterized in that, The stator assembly includes a stator end plate, which is fixedly sleeved on the motor shaft, and the stator core is fixedly disposed on the end face of the stator end plate.

5. The axial flux hub motor for a lightweight electric vehicle according to claim 1, characterized in that, The axial flux hub motor of the lightweight electric vehicle includes a rim, which is detachably fitted onto the outside of the hub housing via a connecting structure, and the rim rotates synchronously with the hub housing.

6. The axial flux hub motor for a lightweight electric vehicle according to claim 5, characterized in that, The wheel rims are configured in multiple ways depending on their specifications; Each of the wheel rims can be connected to the wheel hub housing via the connecting structure.

7. The axial flux hub motor for a lightweight electric vehicle according to claim 5, characterized in that, The connection structure includes a threaded connector, and the hub housing is detachably connected to the rim via the threaded connector.

8. The axial flux hub motor for a lightweight electric vehicle according to claim 7, characterized in that, The wheel hub shell is provided with a plurality of first connecting holes evenly arranged circumferentially, and the wheel rim is provided with a second connecting hole at the position corresponding to the first connecting hole. The threaded connector passes through the corresponding first connecting hole and the second connecting hole.

9. The axial flux hub motor for a lightweight electric vehicle according to claim 8, characterized in that, A plurality of first ear plates are evenly arranged circumferentially on the outer peripheral wall of the wheel hub shell, and the first connecting hole is disposed through the first ear plate. Multiple second ear plates are evenly arranged circumferentially on the inner peripheral wall of the rim, and the second connecting hole is disposed through the second ear plate.

10. The axial flux hub motor for a lightweight electric vehicle according to claim 9, characterized in that, A guide groove is provided on the outer peripheral wall of the wheel hub shell corresponding to the position of the first lug plate, and the guide groove is adapted to the second lug plate; When assembling or disassembling the rim, the rim is pushed or pulled axially, and the second ear plate slides along the guide groove.

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