Stator structure of magnetic flux motor in axial direction

Abstract

To provide a stator structure of a magnetic flux motor in an axial direction.SOLUTION: A stator structure of a magnetic flux motor in an axial direction includes a soft magnetic material body, and a plurality of conductors. The soft magnetic material body has a plurality of magnetic poles and a plurality of slots, and each of the plurality of slots includes a plurality of layer positions arrayed in an axial direction. The plurality of conductors penetrate through the plurality of layer positions of the plurality of slots so as to constitute a plurality of coils, respectively. Each of the plurality of conductors penetrates through the undermost layer position of the plurality of layer positions, then moves upward so as to penetrate through a higher layer position of the plurality of layer positions, and moves upward until it penetrates through the uppermost layer position of the plurality of layer positions, each time it advances to the next magnetic pole position. The plurality of conductors include a first conductor and a second conductor, and when the plurality of conductors are wound around the soft magnetic material body, a relative position in a part where the first conductor and the second conductor project to the outside of the soft magnetic material body in all of the slots is constantly retained.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a motor structure, and more particularly to a stator winding structure for an axial flux motor. [Background technology]

[0002] Motors are components that convert electrical energy into mechanical energy and have been widely used in daily life. Traditionally, distributed winding axial motors have been used, in which conductors are arranged in a serpentine pattern along the circumferential slots according to the positions of the corresponding magnetic poles in the stator slots. To effectively fill the slot space and improve the slot fill factor, two conductors in adjacent slots must swap positions axially at their protrusions before proceeding to the next magnetic pole. Thus, each conductor cannot be further assembled into a complete winding after bending; the entire winding must be manufactured using complex forming methods and equipment. Summary of the Invention [Problem to be solved by the invention]

[0003] The present invention proposes a stator structure for an axial flux motor to solve the problems of the prior art. [Means for solving the problem]

[0004] According to some embodiments of the present invention, there is provided a stator structure for an axial flux motor, comprising: a plurality of magnetic poles having a plurality of magnetic pole positions; a plurality of strata; and a plurality of conductors each penetrating the plurality of strata from one magnetic pole position to another magnetic pole position to form a plurality of windings, wherein each of the plurality of conductors, after penetrating a lowest strata of the plurality of strata, rises to penetrate a strata one level higher in the plurality of strata each time it advances to a next magnetic pole position, until it penetrates a top strata of the plurality of strata, wherein the plurality of conductors include at least a first conductor and a second conductor, and all portions of the first conductor maintain the axial relative position invariably with respect to all portions of the second conductor.

[0005] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of inner diameter protrusions located in an internal space surrounding an axis of the stator structure of the axial flux motor, and the axial positions of the two halves of each of the inner diameter protrusions have a difference of one layer.

[0006] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of outer diameter protrusions exposed outside the stator structure of the axial flux motor, and the axial positions of the two halves of each of the outer diameter protrusions have a difference of one layer.

[0007] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of inner diameter protrusions located in an internal space surrounding an axis of a stator structure of the axial flux motor, and half of each of the inner diameter protrusions of the second conductor is located above an adjacent half of the inner diameter protrusion of the first conductor in the axial direction.

[0008] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of outer diameter protrusions exposed outside a stator structure of the axial flux motor, and half of each of the outer diameter protrusions of the second conductor is located above an adjacent half of the outer diameter protrusion of the first conductor in the axial direction.

[0009] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of inner diameter protrusions located in an internal space surrounding the axis of the stator structure of the axial flux motor, and the axial position of each of the inner diameter protrusions of the second conductor is at least partially located above the corresponding inner diameter protrusion of the first conductor.

[0010] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of outer diameter protrusions exposed outside a stator structure of the axial flux motor, and the axial position of each of the outer diameter protrusions of the second conductor is at least partially located above the corresponding outer diameter protrusion of the first conductor.

[0011] According to some embodiments of the present invention, each of the plurality of conductors is formed by bending a continuous linear conductor, or by assembling or welding a plurality of linear conductors.

[0012] According to some embodiments of the present invention, each of the plurality of conductors is wound on a stator structure of the axial flux motor in a spiral or star arrangement.

[0013] According to some embodiments of the present invention, the stator structure of the axial flux motor further comprises a soft magnetic material body having magnetic poles and a plurality of slots, each of the plurality of slots including the plurality of strata arranged along the axial direction.

[0014] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of inner diameter protrusions located in an internal space surrounding the axis of the stator structure of the axial flux motor, a plurality of accommodating portions located within the plurality of slots, and a plurality of outer diameter protrusions exposed outside the stator structure of the axial flux motor.

[0015] According to some embodiments of the present invention, the plurality of conductors are configured to pass through the plurality of slots in the soft magnetic material body and have portions thereof protruding outside the soft magnetic material body, with the portions protruding into the internal space of the axis toward the soft magnetic material body and the portions exposed outside the outer diameter side wall of the soft magnetic material body.

[0016] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of inner diameter protrusions located in the internal space of the soft magnetic material body, and the axial positions of the two halves of each of the inner diameter protrusions differ by one layer.

[0017] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of outer diameter protrusions exposed outside the outer diameter side wall of the soft magnetic material body, and the axial positions of the two halves of each of the outer diameter protrusions differ by one layer.

[0018] According to some embodiments of the present invention, each of the plurality of conductors includes a plurality of inner diameter protrusions located in the internal space of the soft magnetic material body, a plurality of accommodating portions located in the plurality of slots, and a plurality of outer diameter protrusions exposed outside the outer diameter sidewall of the soft magnetic material body.

[0019] In summary, the stator structure of the axial flux motor of the present invention is fabricated by forming each conductor in a spiral or star-shaped configuration, ascending along the circumferential direction. Each time the next magnetic pole position is reached, the conductor in the slot ascends one layer, and in this manner, the conductors ascend continuously to the top layer in the slot in accordance with the magnetic pole. This conductor structure allows the relative positions of different conductors to be maintained when wound around each other, preventing them from crossing over. In this way, after each conductor is formed, it is possible to easily assemble it into a complete winding, and it also solves the problems encountered in various prior art techniques. After each conductor ascends to the top layer of the slot, the current is connected in series with the next conductor through a connecting stage, and the same structure continues, layer by layer, to the top layer. [Effects of the Invention]

[0020] The following embodiments will explain the above description in detail and further explain the technical solution of the present invention. [Brief explanation of the drawings]

[0021] The following description of the accompanying drawings will make the above and other objects, features, advantages and embodiments of the present invention more comprehensible. [Figure 1] 1 is an exploded view showing a stator structure of an axial flux motor according to an embodiment of the present invention; [Figure 2] 2 is an exploded view showing a soft magnetic material body in the stator structure of the axial flux motor of FIG. 1. [Figure 3] FIG. 2 is an exploded view of one conductor according to one embodiment of the present invention. [Figure 4] FIG. 4 is a side view of one conductor of FIG. 3. [Figure 5] FIG. 5 is a top view of one conductor of FIG. 4. [Figure 6] FIG. 1 is a layout diagram showing two conductors according to one embodiment of the present invention. [Figure 7] 1 illustrates in-phase windings according to one embodiment of the present invention. [Figure 8] FIG. 1 is an exploded view showing the stator structure of an iron-coreless axial flux motor. DETAILED DESCRIPTION OF THE INVENTION

[0022] For a more detailed and complete description of the present invention, reference can be made to the accompanying drawings and the following various examples, in which the same reference numerals represent the same or similar elements. Meanwhile, well-known elements and processes are not described in the examples to avoid unnecessary limitations on the present invention. In the embodiments and claims, unless otherwise specified in the text, the words "a" and "the" refer to the singular or the plural.

[0023] 1 and 2, a stator structure 100 for an axial flux motor includes a soft magnetic material body 110 and a plurality of conductors 120. The soft magnetic material body 110 has a plurality of magnetic poles and a plurality of slots 110a. In some embodiments of the present invention, the soft magnetic material body 110 includes 24 slots 110a through which the conductors 120 pass so as to form a plurality of windings, i.e., a plurality of distributed windings. Taking a three-phase magnetic flux motor as an example, dividing the 24 slots 110a by three (phases) results in eight magnetic poles. In other words, one magnetic pole covers three slots. In some embodiments of the present invention, the soft magnetic material body 110 is formed by laminating a plurality of silicon steel plates 110t along the axial direction (AD) or the radial direction. In some embodiments of the present invention, the soft magnetic material body 110 is formed from a soft magnetic composite (SMC). In some embodiments of the present invention, each of the plurality of slots 110a includes a plurality of layers (L1, L2, L3 to Ln) arranged along the axial direction AD, and when a single conductor passes through the slot, it occupies only a single layer.

[0024] 3, 4, and 5, the conductors 121 pass through the slots 110a of the soft magnetic material body 110 to form windings. In some embodiments of the present invention, each of the conductors 121 includes a plurality of inner diameter protrusions 121i, a plurality of receiving portions 121r, and a plurality of outer diameter protrusions 121o, and each of the receiving portions 121r is located in a corresponding slot of the soft magnetic material body 110 so as to be connected between the corresponding inner diameter protrusion 121i and outer diameter protrusion 121o. The soft magnetic material body 110 has a substantially hollow columnar structure, the plurality of inner diameter protrusions 121i are located in an internal space 110b of the soft magnetic material body 110, and the plurality of outer diameter protrusions 121o are exposed to the outside from an outer diameter side wall 110c of the soft magnetic material body 110 (see FIG. 5), the internal space 110b is located between the soft magnetic material body 110 and the axis, that is, the soft magnetic material body 110 surrounds the axis to form the internal space 110b. In some embodiments of the present invention, each of the conductors 121 includes a plurality of inner diameter protrusions 121i located in the internal space 110b surrounding the axis of the soft magnetic material body 110 (see FIG. 5), and the two halves (121i1, 121i2) of each inner diameter protrusion 121i have a difference of one layer along the axial direction AD (see FIG. 3, the half 121i2 is one layer higher than the half 121i1). In some embodiments of the present invention, each of the conductors 121 includes a plurality of outer diameter protrusions 121o exposed to the outside from the outer diameter sidewall 110c of the soft magnetic material body 110 (see FIG. 5), and the two halves (121o1, 121o2) of each of the outer diameter protrusions 121o are different in height by one layer along the axial direction AD (see FIG. 3, the half 121o2 is one layer higher than the half 121o1). In some embodiments of the present invention, after each of the conductors 121 penetrates the lowest layer of the plurality of layers (see FIG. 4, for example, the bottom 121b is at the L1 layer), it rises to penetrate the next higher layer (e.g., L2) of the plurality of layers each time it advances to the next magnetic pole position, until it penetrates the highest layer of the plurality of layers (see FIG. 4, for example, the tip 121t is at the Ln layer). In some embodiments of the present invention, each of the conductors 121 is formed by bending a continuous linear conductor. In another embodiment of the present invention, each of the conductors 121 is formed by assembling or welding together a plurality of linear conductors.

[0025] 6, which shows two conductors (121 / 122) of the plurality of conductors in FIG. 1 passing through adjacent slots in the soft magnetic material body 110, the soft magnetic material body 110 is not shown in the drawing to clearly show the positional relationship of the two conductors (121, 122). After each of the two conductors (121, 122) passes through the lowest level of the plurality of layer levels of the slot (e.g., the bottoms 121b, 122b are at the lowest level), the two conductors (121, 122) rise to pass through the highest level of the plurality of layer levels each time they advance to the next magnetic pole position, and continue to rise until they pass through the highest level of the plurality of layer levels (e.g., the tips 121t, 122t are at the highest level). In some embodiments of the present invention, each of the inner diameter protrusions 122i of the conductor 122 is at least partially located above the corresponding inner diameter protrusion 121i of the conductor 121 in the axial direction AD (e.g., half portion 122i2 of the conductor 122 is located above half portion 122i1 of the conductor 121). In some embodiments of the present invention, each of the outer diameter protrusions 122o of the conductor 122 is at least partially located above the corresponding outer diameter protrusion 121o of the conductor 121 in the axial direction AD (e.g., half portion 122o2 of the conductor 122 is located above half portion 122o1 of the conductor 121). In some embodiments of the present invention, half portion 122i2 of each of the inner diameter protrusions 122i of the conductor 122 is located above half portion 121i1 of the adjacent inner diameter protrusion 121i of the conductor 121 in the axial direction AD. In some embodiments of the present invention, each half portion 122o2 of the outer diameter protrusion 122o of the conductor 122 is located above the half portion 121o1 of the adjacent outer diameter protrusion 121o of the conductor 121 in the axial direction AD. In some embodiments of the present invention, when two conductors (121, 122) are wound around the soft magnetic material body 110, the relative positions in the axial direction AD of all of the portions of the plurality of slots 110a that protrude out of the soft magnetic material body 110 remain unchanged throughout the winding process, i.e., the relative positions of upper and lower layers remain unchanged, for example, the relative positions of the outer diameter protrusions of the two conductors remain unchanged and / or the relative positions of the inner diameter protrusions of the two conductors remain unchanged, or the relative positions of the two conductors within the plurality of slots remain unchanged, so that the relative positions of all portions of the two conductors in the axial direction remain unchanged.In some embodiments of the present invention, the two conductors (121, 122) are arranged and aligned so that when wound around the body of soft magnetic material 110, the contour is spiral or star-shaped.

[0026] Referring to FIG. 7, the winding 120w is formed by connecting a plurality of conductors (121, 123, 125, 127). After the bottom 121b of the conductor 121 passes through the lowest layer (e.g., L1) of the corresponding slot, it rises to pass through a layer one layer higher in the slot each time it advances to the next magnetic pole position, until the tip 121t of the conductor 121 passes through the highest layer in the slot. Similarly, after the bottom 123b of the conductor 123 passes through the lowest layer (e.g., L1) of the corresponding slot, it rises to pass through a layer one layer higher in the slot each time it advances to the next magnetic pole position, until the tip 123t of the conductor 123 passes through the highest layer in the slot. The two conductors (121, 123) are connected in series by a connection step 120cl. Next, after the bottom portion 125b of the conductor 125 has penetrated the lowest layer level (e.g., L1) of the corresponding slot, it rises to penetrate a layer level one layer higher in the slot each time it advances to the next magnetic pole position, until the tip end 125t of the conductor 125 has penetrated the top layer level of the slot. The two conductors (123, 125) are connected in series by the connection step 120cl. Next, after the bottom portion 127b of the conductor 127 has penetrated the lowest layer level (e.g., L1) of the corresponding slot, it rises to penetrate a layer level one layer higher in the slot each time it advances to the next magnetic pole position, until the tip end 127t of the conductor 127 has penetrated the top layer level of the slot. The two conductors (125, 127) are connected in series by the connection step 120cl. The multiple conductors (121, 123, 125, 127) are connected in series by the connection step 120cl to form the winding 120w. Taking a three-phase flux motor as an example, the other two phase windings (e.g., U-phase and V-phase windings) are formed in a similar manner to fill the remaining slots 110a of the soft magnetic material body 110, which will not be described in detail.

[0027] Referring to FIG. 8, this figure shows an ironless stator structure 100a for an axial-flux motor with multiple conductors 120. This ironless stator structure 100a can achieve a simple structure without a soft magnetic material body (e.g., the soft magnetic material body 110 in FIGS. 1 and 2). Despite the absence of a soft magnetic material body, the ironless stator structure 100a still has multiple magnetic poles and multiple magnetic pole positions and levels, and the conductors 120 have similar characteristics to the conductors (121, 122, 123, 125, 127) shown in FIGS. 3, 4, 5, 6, and 7. Each conductor 120 penetrates one of the lowest levels, then moves from one magnetic pole position to the next, ascending to higher levels and finally to the top level. The relative positions of each conductor portion remain unchanged in the axial direction. The first conductor and the second conductor defined in the claims may be two of the conductors (120, 121, 122, 123, 125, 127) mentioned above.

[0028] The stator structure of the axial flux motor of the present invention is fabricated by forming each conductor in a spiral or star-shaped configuration, ascending along the circumferential direction. Each time the next magnetic pole position is reached, the conductor in the slot ascends one layer, and in this manner, the conductors ascend continuously to the top layer in the slot in accordance with the magnetic pole. This conductor structure allows the relative positions of the conductors of different strands to remain unchanged when wound around each other, preventing them from crossing over. In this way, after each conductor is formed, it is possible to easily assemble it into a complete winding, and it also solves the problems encountered in various prior art techniques. After each conductor ascends to the top layer of the slot, a current is connected to the next conductor in series through a connecting step, and the conductors ascend successively layer by layer while maintaining this same structure.

[0029] The present invention has been disclosed in the above embodiments, but the above embodiments are not intended to limit the present invention, and any person skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and the protection scope of the present invention should be based on what is defined by the appended claims. [Explanation of symbols]

[0030] 100: Stator structure of axial flux motor 100a: Coreless stator structure 110: Soft magnetic material body 110a: Slot 110b: Internal space 110c: Outer diameter side wall 110t: silicon steel plate L1, L2, L3, Ln: Stratigraphy 120: conductor 120w:Wound 120cl: Connection stage 121: conductor 121b: Bottom 121t:Tip 121o: Outer diameter protrusion 121o1:half 121o2:half 121i: Inner diameter protrusion 121i1: Half 121i2: Half 121r: Storage area 122: conductor 122b: Bottom 122t:Tip 122o: Outer diameter protrusion 122o1:half 122o2:half 122i: Inner diameter protrusion 122i1:Half part 122i2:Half part 123: conductor 123b: Bottom 123t:Tip 125: conductor 125b: Bottom 125t: Tip 127: Conductor 127b: Bottom 127t:Tip AD: Axial direction

Claims

1. a plurality of magnetic poles having a plurality of magnetic pole positions; Multiple strata and a plurality of conductors each passing through the plurality of layers from one pole position to another of the plurality of pole positions to form a plurality of windings; Equipped with each of the plurality of conductors, after penetrating the lowest level of the plurality of levels, rises to penetrate a level one level higher of the plurality of levels each time it advances to the next magnetic pole position, and rises until it penetrates the highest level of the plurality of levels; The plurality of conductors includes at least a first conductor and a second conductor, and all portions of the first conductor maintain an invariable axial relative position with respect to all portions of the second conductor.

2. 2. The stator structure of claim 1, wherein each of the plurality of conductors includes a plurality of inner diameter protrusions positioned in an internal space surrounding an axis of the stator structure of the axial flux motor, and the positions of the two halves of each of the inner diameter protrusions in the axial direction differ by one layer.

3. 2. The stator structure of an axial flux motor according to claim 1, wherein each of the plurality of conductors includes a plurality of outer diameter protrusions exposed outside the stator structure of the axial flux motor, and the axial positions of the two halves of each of the outer diameter protrusions are different by one layer.

4. 2. The stator structure of claim 1, wherein each of the plurality of conductors includes a plurality of inner diameter protrusions located in an internal space surrounding an axis of the stator structure of the axial flux motor, and half of each of the inner diameter protrusions of the second conductors is located above half of an adjacent inner diameter protrusion of the first conductor in the axial direction.

5. 2. The stator structure of an axial flux motor according to claim 1, wherein each of the plurality of conductors includes a plurality of outer diameter protrusions exposed outside the stator structure of the axial flux motor, and half of each of the outer diameter protrusions of the second conductors is located above an adjacent half of the outer diameter protrusion of the first conductor in the axial direction.

6. 2. The stator structure of an axial flux motor according to claim 1, wherein each of the plurality of conductors includes a plurality of inner diameter protrusions located in an internal space surrounding an axis of the stator structure of the axial flux motor, and the axial position of each of the inner diameter protrusions of the second conductor is at least partially located above the corresponding inner diameter protrusion of the first conductor.

7. 2. The stator structure of an axial flux motor according to claim 1, wherein each of the plurality of conductors includes a plurality of outer diameter protrusions exposed outside the stator structure of the axial flux motor, and the axial position of each of the outer diameter protrusions of the second conductor is at least partially located above the corresponding outer diameter protrusion of the first conductor.

8. 2. The stator structure of an axial flux motor according to claim 1, wherein each of the plurality of conductors is formed by bending a continuous linear conductor, or by assembling or welding a plurality of linear conductors.

9. The stator structure of an axial flux motor according to claim 1 , wherein each of the plurality of conductors is wound around the stator structure of the axial flux motor in a spiral or star-like arrangement.

10. 2. The stator structure of claim 1, further comprising a soft magnetic material body having magnetic poles and a plurality of slots, each of the plurality of slots including the plurality of strata arranged along the axial direction.

11. Each of the plurality of conductors is a plurality of inner diameter protrusions located in an interior space surrounding an axis of a stator structure of the axial flux motor; a plurality of receptacles located within the plurality of slots; a plurality of outer diameter protrusions exposed outside the stator structure of the axial flux motor; 11. The axial flux motor stator structure of claim 10, comprising:

12. 11. The stator structure of an axial flux motor according to claim 10, wherein the plurality of conductors are configured to pass through the plurality of slots in the soft magnetic material body and have portions that protrude outside the soft magnetic material body, with some of the conductors protruding toward the soft magnetic material body into an internal space of the axis and some that are exposed outside an outer diameter side wall of the soft magnetic material body.

13. 13. The stator structure of an axial flux motor according to claim 12, wherein each of the plurality of conductors includes a plurality of inner diameter protrusions positioned in the internal space of the soft magnetic material body, and the positions of the two halves of each of the inner diameter protrusions in the axial direction are different by one layer.

14. 13. The stator structure of an axial flux motor according to claim 12, wherein each of the plurality of conductors includes a plurality of outer diameter protrusions exposed outside the outer diameter side wall of the soft magnetic material body, and the positions of the two halves of each of the outer diameter protrusions in the axial direction are different by one layer.

15. Each of the plurality of conductors is a plurality of inner diameter protrusions located in the internal space of the soft magnetic material body; a plurality of receptacles located within the plurality of slots; a plurality of outer diameter protrusions exposed outside the outer diameter side wall of the soft magnetic material body; 13. The axial flux motor stator structure of claim 12, comprising:

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