Stator assembly and axial magnetic field motor

Abstract

The present invention provides a stator assembly and an axial magnetic field motor. The stator assembly comprises a housing which comprises two end plates which are provided opposite to each other, and a stator core provided between the two end plates, and is characterized in that a plurality of magnetizers are provided on the end surface of at least one of the end plates, and at least some of the magnetizers are fitted into open slots of the stator core. The magnetizers are pre-mounted on the end plate, and when an end plate sealing process of the stator assembly is executed, the magnetizers provided on the end plate can be exactly fitted into the open slots of the stator core. Thus, in the process of assembling the end plates, mounting and fixation of the magnetizers on the open slots of the stator core are completed. Compared with the manner in the prior art that a magnetic conductive adhesive is used to bond and fix magnetizers, the winding mounting efficiency is higher, and magnetic circuit connectivity of the stator core can also be ensured.

Description

Stator assembly and axial magnetic field motor Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a stator assembly and an axial magnetic field motor. Background Art

[0002] The cores of most current disc motors are typically made of silicon steel sheets, amorphous alloys, powder metallurgy, and other magnetically conductive alloys, using stamping and winding processes. The slot configuration of disc cores is similar to that of conventional radial-field motors, including open slots, semi-open slots, and closed slots. Open slots facilitate production, but they also compromise electromagnetic performance and increase air-gap harmonics, leading to greater cogging torque and torque ripple. This increases motor losses and reduces performance and efficiency.

[0003] In the prior art, in order to reduce the negative impact of the open slots, a magnet is usually set at the open slots and fixed with magnetic glue to form a magnetic circuit between the stator teeth and the magnet, thereby reducing the degree of drastic changes in the magnetic field at various positions around the air gap and reducing the harmonic magnetic field in the air gap. However, although the magnet has a significant effect in solving the magnetic circuit problem, debonding the magnets one by one seriously reduces the winding offline efficiency.

[0004] Therefore, how to improve the winding offline efficiency while taking into account the stator core magnetic circuit has become a technical problem that needs to be solved urgently by those skilled in the art.

[0005] Summary of the Invention

[0006] Based on this, the purpose of the present invention is to provide a stator assembly and an axial magnetic field motor to solve the technical problems mentioned in the above background technology.

[0007] On the one hand, the present invention provides a stator assembly, including a shell, the shell including two end plates arranged opposite to each other, and a stator core arranged between the two end plates, characterized in that a plurality of magnetic conductors are provided on the end surface of at least one of the end plates, and at least a portion of the magnetic conductors are fitted in the open slots of the stator core.

[0008] Furthermore, in the stator assembly, the magnetic conductor is magnetically connected to the open slot of the stator core.

[0009] Furthermore, in the stator assembly, the end plate is made of high-strength fiber composite material, and the magnetic conductor is formed on the end plate by injection molding or integral compression molding.

[0010] Furthermore, in the stator assembly, the magnetic conductor includes a plurality of stacked fiber cloths and a magnetic material disposed between two adjacent fiber cloths.

[0011] Furthermore, the stator assembly, wherein a plurality of the magnetic conductors are provided on the end faces of the two end plates, the stator core includes a plurality of independently arranged stator teeth, an axially penetrating open slot is formed between two adjacent stator teeth, and the magnetic conductors on the two end plates are respectively embedded in the axial ends of the open slot.

[0012] Furthermore, in the stator assembly, the magnetic conductor is in the shape of an elongated strip, and the length of the magnetic conductor is greater than or equal to the radial length of the stator teeth.

[0013] Furthermore, the stator assembly has an annular groove recessed on the end plate, the magnetic conductor is integrally formed in the annular groove and arranged in an annular array, thereby dividing the annular groove into a plurality of slots, and one axial end of the stator tooth is clamped and fixed in the slot.

[0014] Furthermore, the stator assembly, wherein the outer edge of the annular groove is provided with a plurality of first limit blocks at intervals, the inner edge of the annular groove is provided with a plurality of second limit blocks corresponding to the first limit blocks, and the first limit blocks and the second limit blocks are both embedded between two adjacent magnetic conductors.

[0015] Furthermore, in the stator assembly, the thickness of the magnetic conductor is lower than the depth of the annular groove, and the end face of the magnetic conductor is flush with the end faces of the first limit block and the second limit block.

[0016] Furthermore, in the stator assembly, a plurality of the magnets are provided on the end face of only one of the end plates, the stator core is a yoke stator structure, the yoke portion of the yoke stator structure is installed on the end plate in which there is no magnet, and the open slot portion of the yoke stator structure cooperates with the magnet on the other end plate.

[0017] Furthermore, the stator assembly, wherein the magnetic conductor includes a magnetic section and an insulating section, the magnetic section is arranged on one side or two opposite sides of the insulating section, wherein one side of the magnetic section is connected to the slot wall of the open slot and the other side is connected to the insulating section, so that the insulating section cuts off the magnetic connection between the magnetic section and the open slot.

[0018] Furthermore, in the stator assembly, the end plate and the insulating segment are integrally made of high-strength fiber composite material, and the magnetic conductive segment is formed on the end plate by injection molding or integral compression molding.

[0019] Furthermore, in the stator assembly, the magnetic conductive segment is formed by axially stacking silicon steel sheets or soft magnetic composite materials.

[0020] Furthermore, in the stator assembly, the magnetic conductive section and the insulating section have the same thickness, and their sizes along the radial direction of the end plate are equal.

[0021] Furthermore, the stator assembly, wherein the magnetic conductive segment is provided on one side of the insulating segment, the side of the insulating segment facing away from the magnetic conductive segment is connected to one side slot wall of the open slot, and the side of the magnetic conductive segment facing away from the insulating segment is connected to the other side slot wall opposite to the open slot.

[0022] Furthermore, in the stator assembly, the magnetic conductive segments are arranged on opposite sides of the insulating segment, the sides of the two magnetic conductive segments facing away from the insulating segment are respectively connected to the opposite side slot walls of the open slot, and the insulating segment is connected between the two magnetic conductive segments.

[0023] Furthermore, another aspect of the present invention provides an axial magnetic field motor, comprising the stator assembly described in the above technical solution.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] The magnet is pre-installed on the end plate. When the end plate sealing process of the stator assembly is performed, the magnet arranged on the end plate can fit into the open slot of the stator core. It can be seen that the installation and fixation of the magnet on the open slot of the stator core is completed during the assembly of the end plate. Compared with the method of using magnetic glue to bond and fix the magnet in the prior art, the winding offline efficiency is higher and the magnetic circuit connectivity of the stator core can be taken into account. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG1 is an exploded view of a stator assembly in a first embodiment of the present invention;

[0027] FIG2 is an assembly diagram between the end plate and the stator teeth in the first embodiment of the present invention;

[0028] FIG3 is a schematic diagram of the specific structure of an end plate in the first embodiment of the present invention;

[0029] FIG4 is a schematic diagram of the specific structure of another end plate in the first embodiment of the present invention;

[0030] FIG5 is an assembly diagram of the stator teeth and the magnetic conductor according to the first embodiment of the present invention;

[0031] FIG6 is an exploded view of a stator assembly in a third embodiment of the present invention;

[0032] FIG7 is a schematic diagram of the end plate after the magnetic conductive section is removed in accordance with an embodiment of the third embodiment of the present invention;

[0033] FIG8 is a schematic diagram of an end plate after loading a magnetic conductive segment in an embodiment of the third embodiment of the present invention;

[0034] FIG9 is a schematic diagram of an end plate after removing the magnetic conductive section in another embodiment of the second embodiment of the present invention;

[0035] FIG10 is a schematic diagram of an end plate after loading a magnetic conductive segment in another embodiment of the second embodiment of the present invention;

[0036] Description of main component symbols:

[0037] 10. End plate; 11. Stator surface; 12. Rotor surface; 20. Magnetizer; 30. Stator teeth; 41. Slot; 42. First limit block; 43. Second limit block; 51. Coil; 52. Bridge line; 53. Wire outlet hole; 54. Terminal; 61. Outer retaining ring; 62. Inner retaining ring; 71. Outer shell; 72. Inner shell; 73. Outer ring flow channel; 74. Inner ring flow channel; 75. Inter-tooth flow channel; 81. Threaded hole; 82. Mounting hole; 83. Bolt.

[0038] The following specific embodiments will further illustrate the present invention in conjunction with the above-mentioned drawings. DETAILED DESCRIPTION

[0039] To facilitate understanding of the present invention, the present invention will be described more fully below with reference to the accompanying drawings. The drawings illustrate several embodiments of the present invention. However, the present invention may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the present invention.

[0040] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may be an intermediate element. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be an intermediate element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terms used in this specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0042] First embodiment

[0043] Referring to Figures 1 and 2, the stator assembly in the first embodiment of the present invention includes a housing, which includes two oppositely disposed end plates 10 and a stator core disposed between the two end plates 10. A plurality of magnetic conductors 20 are provided on the end surface of at least one of the end plates 10, and at least a portion of the magnetic conductors 20 fits into an open slot of the stator core.

[0044] In actual applications, when performing the sealing process of the end plate 10 of the stator assembly, the magnetizer 20 provided on the end plate 10 is just embedded in the open slot of the stator core. It can be seen that the installation and fixation of the magnetizer 20 on the open slot of the stator core is completed during the assembly of the end plate 10. Therefore, compared with the existing technology of using magnetic glue to de-bond and fix the magnetizers 20 one by one, this solution has a higher winding offline efficiency and can take into account the magnetic circuit connectivity of the stator core.

[0045] It should be noted that in this embodiment, the end plate 10 is made of a high-strength fiber-reinforced composite material, and the magnetizer 20 can be used as an insert, integrally molded or injection-molded with the composite material. This process is simple and efficient, and the bond strength between the magnetizer 20 and the end plate 10 is higher than that achieved by traditional mechanical fastening or gluing methods, effectively reducing the risk of the stator magnetizer 20 falling off. Furthermore, the magnetizer 20 can be designed as a finished part, placed in a specific mold, and integrally molded or injection-molded with the end plate 10 material. This is low-cost and suitable for mass production.

[0046] Specifically, the magnetic conductor 20 is a structure of multiple layers of glass fiber cloth, with magnetic material evenly dispersed between every two layers of glass fiber cloth, and is filled and shaped by resin. The magnetic material can be iron powder.

[0047] In this embodiment, the magnetizer 20 is primarily composed of resin, iron powder, and glass fiber cloth. When inserted into the open slots of the stator core, it magnetically connects to the open slots. The ratio of the first three components determines its magnetic conductivity and mechanical properties. The ratio is determined based on specific application requirements, such as 60% to 80% iron powder, 15% to 30% resin, and 5% to 15% glass fiber.

[0048] The preparation method of the magnetic conductor 20 in this embodiment is as follows:

[0049] (1) Preparing resin glue: mixing the resin matrix and the curing agent evenly to prepare a resin glue or a resin film;

[0050] (2) Preparation of prepreg: impregnate the glass fiber cloth with resin glue or compound impregnate it with resin glue film through the equipment to obtain the resin-impregnated glass fiber cloth (prepreg);

[0051] (3) Dispersing magnetic materials: spreading a layer of magnetic material evenly on a layer of prepreg according to a certain proportion by hand or machine to obtain a prepreg with evenly dispersed magnetic material;

[0052] (4) Prepreg stacking: Lay another layer of prepreg on the prepreg with evenly spread magnetic material, and continue to spread a layer of magnetic material; repeat the above steps until the required thickness is reached;

[0053] (5) Lamination and curing: The laminated prepreg of the dispersed magnetic material is placed on a press, and is cured by heating to obtain the desired magnetic conductor 20.

[0054] As shown in Figures 1, 2, and 5, in this embodiment, a plurality of magnetizers 20 are provided on the end surfaces of the two end plates 10. The stator core includes a plurality of independently arranged stator teeth 30, forming a yokeless stator structure. An axially extending open slot is formed between two adjacent stator teeth 30. The magnetizers 20 on the two end plates 10 are respectively embedded in the axial ends of the open slot, forming a closed slot stator structure, and the coils 51 provided on the stator teeth 30 are located between the two axially arranged magnetizers 20. It can be understood that the stator core is assembled from a plurality of stator teeth 30, and the design scheme combining a split structure and embedded assembly is adopted to avoid the delamination and interlayer sliding of the silicon steel sheets of the stator core, and prevent the formation of silicon steel sheet faults, thereby ensuring the performance of the stator core. Secondly, the magnetizers 20 on the two end plates 10 are embedded in the axial ends of the open slot and connect the magnetic circuit. Compared with the magnetic circuit connected by an iron yoke, it can provide better magnetic circuit connectivity, reduce magnetic field leakage and loss, and thus improve the efficiency and stability of the motor or generator.

[0055] At the same time, the coil 51 on each stator tooth 30 can be wound individually, solving the common problem of winding the stator core coil 51 of the semi-closed slot disc motor. The coil 51 on a single core unit can be wound mechanically and automatically, which improves the winding production efficiency and greatly increases the slot fill rate, thereby improving the power density of the motor.

[0056] Specifically, in this embodiment, the coils 51 on each of the stator teeth 30 are connected by a bridge wire 52 to form a three-phase winding, so three wire outlet holes 53 are provided on one of the end plates 10 to correspond to the lead-out of the U, V, and W phase terminals 54 in the winding assembly. Of course, in other embodiments, the winding can also be two-phase or six-phase. This embodiment is only an example and not a limitation.

[0057] In this embodiment, each phase winding is composed of several coils 51 and bridge wires 52. The number of coils 51 is equal to the number of stator teeth 30. An integrated structure is adopted. Each phase winding has no welding points, avoiding the risks caused by welding. The winding can be directly installed on the stator core. One end of each phase winding is welded to the terminal 54 through a copper sleeve, and the other end is welded together to form a neutral point, forming a star connection of the three-phase winding of the motor.

[0058] As shown in Figures 3 and 4 , an annular groove is recessed in the end plate 10. The magnetizers 20 are integrally formed within the annular groove and arranged in an annular array, thereby dividing the annular groove into a plurality of slots 41. One axial end of the stator teeth 30 is secured in the slots 41. Specifically, a stator surface 11 and a rotor surface 12 are provided on either axial side of the end plate 10, respectively. The rotor surface 12 is horizontally disposed, and the annular groove is recessed in the stator surface 11. The magnetizers 20 are integrally formed within the annular groove, thereby dividing the annular groove into a plurality of slots 41. When the stator tooth 30 is assembled in the slot 41, the tooth end face of the stator tooth 30 is located between the stator surface 11 and the rotor surface 12. The distance between the tooth end face of the stator tooth 30 and the rotor surface 12 is small, which effectively reduces the length of the electromagnetic air gap, can reduce the magnetic resistance between the motor rotor and stator, thereby reducing the hysteresis loss and iron loss. Under small and medium loads, the ability to generate torque per unit current can be improved, thereby improving the motor efficiency.

[0059] Thanks to the slowdown in the degree of drastic changes in the magnetic field at various circumferential positions of the air gap, the amplitude of the low-order electromagnetic force waves inside the motor is also reduced, improving its NVH characteristics.

[0060] In this embodiment, the three-phase winding is assembled as follows: first, a plurality of stator teeth 30 are assembled together in the slots 41 of an end plate 10. The plurality of stator teeth 30 are separated one by one by the magnetic conductor 20, so that an open slot for arranging the coil 51 is formed between two adjacent stator teeth 30. The coil 51 can be arranged around the circumference of the stator tooth 30 through the open slot. After the winding is arranged, another end plate 10 is assembled to complete the installation of the entire stator assembly.

[0061] Thanks to the one-piece molding between the magnet 20 and the end plate 10, when the stator teeth 30 are assembled on the end plate 10, the installation and fixation of the magnet 20 on the stator core opening slot is completed. Specifically, as shown in Figures 2 and 5, after the end plate 10 is assembled, the magnet 20 on the end plate 10 is just embedded between two adjacent stator teeth 30. Compared with the method of fixing the magnet 20 by bonding with magnetic adhesive, the assembly is simpler and more efficient. The magnet 20 is fixed on the end plate 10 in an one-piece molding manner, which is a simple and efficient process. The bonding strength between the magnet 20 and the end plate 10 is higher than that of traditional mechanical fastening or gluing methods, which effectively reduces the risk of the stator magnet 20 falling off.

[0062] In this embodiment, the shape of the slots 41 matches the profile of the stator teeth 30. The stator teeth 30 are trapezoidal, with their width increasing radially from the inside to the outside. Accordingly, the slots 41 also have a trapezoidal shape. When the stator teeth 30 are inserted into the slots 41, the magnetizers 20 fit snugly into the open slots between adjacent stator teeth 30, forming a closed-slot stator structure. Furthermore, the slots 41 formed between adjacent magnetizers 20 facilitate the installation and positioning of the stator teeth 30 on the end plate 10, improving assembly efficiency.

[0063] Furthermore, as shown in Figures 3 and 4, a plurality of first limit blocks 42 are provided at intervals on the outer edge of the annular groove, and a plurality of second limit blocks 43 corresponding to the first limit blocks 42 are provided on the inner edge of the annular groove. The first limit blocks 42 and the second limit blocks 43 are both embedded between two adjacent magnetizers 20. The first limit blocks 42 and the second limit blocks 43 are integrally provided with the end plate 10, and both are made of the same material, namely, high-strength fiber-reinforced composite material. The first limit blocks 42 and the second limit blocks 43 are used to limit the magnetizer 20, so that the integral fixing effect of the magnetizer 20 on the end plate 10 is more stable, making it less likely to deviate, thereby ensuring that the magnetizer 20 can be tightly attached to both axial sides of the stator teeth 30 and ensuring the connectivity of the magnetic circuit. Secondly, the first limit block 42 and the second limit block 43 are tightly attached to the outer edge and the inner edge of the stator tooth 30, so that the installation position of the stator tooth 30 in the circumferential direction can be effectively fixed, so that the stator tooth 30 installed on one of the end plates 10 corresponds one-to-one with the slot 41 on the other end plate 10, avoiding misalignment and affecting the assembly efficiency.

[0064] Furthermore, the thickness of the magnetizer 20 is less than the depth of the annular groove, and the end surface of the magnetizer 20 is flush with the end surfaces of the first and second stoppers 42, 43. In other words, the magnetizer 20 replaces the existing reinforcing ribs on the end plate 10, helping to increase the structural strength of the end plate 10 and ensure its flatness, without changing the assembly process or difficulty of the original stator components.

[0065] As shown in FIG2 , since the open slot between two adjacent stator teeth 30 has a certain length, the magnetizer 20 in this embodiment is in the shape of an elongated strip, and the length of the magnetizer 20 is greater than or equal to the radial length of the stator teeth 30 to ensure the magnetic conductivity between two adjacent stator teeth 30 .

[0066] As shown in Figure 1, an outer shell 71 and an inner shell 72 are provided between the two end plates 10, wherein the end plates 10 are annular, the outer shell 71 is connected to the outer edge between the two end plates 10, and the inner shell 72 is connected to the inner edge between the two end plates 10, so that a closed stator cavity is formed between the outer shell 71 and the inner shell 72, and the stator core is installed in the stator cavity.

[0067] Furthermore, referring to Figure 2, since the stator cavity is a closed cavity, an outer ring flow channel 73 is formed between the outer shell 71 and the stator tooth 30, an inner ring flow channel 74 is formed between the inner shell 72 and the stator tooth 30, and an inter-tooth flow channel 75 is formed between two adjacent stator teeth 30. The outer ring flow channel 73 is connected to the inner ring flow channel 74 through the inter-tooth flow channel 75 to form a flow gap. Cooling oil can be introduced into the flow gap, so that the cooling oil flows through the outer ring flow channel 73, the inter-tooth flow channel 75 and the inner ring flow channel 74, directly contacting the stator teeth 30 and the winding, which can effectively reduce the heat generated by the winding and the stator teeth 30.

[0068] In other embodiments, a liquid inlet (not shown) and a liquid outlet (not shown) communicating with the stator cavity may be provided on one of the end plates 10. The liquid inlet is used to introduce cooling oil into the stator cavity, while the liquid outlet is used to draw the cooling oil from the flow gap to the outside. It will be appreciated that when the motor is operating, cooling oil is introduced into the flow gap through one of the liquid inlets, while the other liquid outlet is used to draw the cooling oil from the flow gap after heat exchange. The drawn cooling oil is then returned to the housing after cooling. This cycle repeats, and the flow of cooling oil can significantly reduce the heat generated by the stator teeth 30 and coils 51.

[0069] The liquid inlet and outlet can be flexibly arranged on the end plate 10, and the flow rate of the cooling oil can be adjusted as needed. The flow rate is adjusted by the diameter of each inlet / outlet to achieve the best comprehensive heat dissipation effect.

[0070] Continuing to refer to Figure 1, in this embodiment, the end plate 10, the outer shell 71 and the inner shell 72 can be fixed by bolts 83. Specifically, a plurality of threaded holes 81 are provided on the front and back sides of the inner shell 72 and the front and back sides of the outer shell 71. The end plate 10 is provided with mounting holes 82 corresponding to the threaded holes 81. The bolts 83 pass through the mounting holes 82 and are threadedly connected to the threaded holes 81, thereby fixing the end plate 10 to the front and back sides of the outer shell 71 and the inner shell 72.

[0071] Furthermore, in order to improve the installation and positioning accuracy of the inner shell 72 and the outer shell 71 on the end plate 10, in this embodiment, an outer retaining ring 61 that engages with the inner edge of the outer shell 71 and an inner retaining ring 62 that engages with the inner edge of the inner shell 72 are also provided on the end plate 10. By engaging the outer retaining ring 61 with the inner edge of the outer shell 71 and the inner retaining ring 62 with the outer edge of the inner shell 72, displacement and misalignment when installing the end plate 10 are effectively avoided.

[0072] In summary, in the stator assembly of the above-described embodiment of the present invention, the magnetizer 20 is used as an insert, solidified and integrally formed together with the end plate 10. This process is simple and efficient, and the bonding strength between the magnetizer 20 and the end plate 10 is higher than that achieved by traditional mechanical fastening or gluing methods, thereby reducing the risk of the stator magnetizer 20 falling off. Furthermore, the magnetizer 20 is integrally formed on the end plate 10, so that when the stator core is assembled on the end plate 10, the magnetizer 20 is already installed and fixed in the open slots of the stator core. Compared to the prior art method of using magnetic adhesive to glue and fix the magnetizers 20 one by one, assembly is simpler and more efficient.

[0073] Second embodiment

[0074] The stator assembly in the second embodiment differs from the stator assembly in the first embodiment in that the plurality of magnetizers 20 are provided on the end surface of only one of the end plates 10, and the stator core has a yoke stator structure. The yoke portion of the yoke stator structure is mounted to the end plate 10 without a magnetizer, and the open slot portion of the yoke stator structure cooperates with the magnetizers 20 on the other end plate 10. Compared to the first embodiment, which employed a yokeless stator structure for the stator core, this embodiment employs a yoke stator structure, which is simpler to manufacture and install. Furthermore, the magnetizers 20 only need to be provided on one of the two end plates 10, effectively reducing costs.

[0075] Third embodiment

[0076] 6 to 8 , the stator assembly in the third embodiment differs from the stator assembly in the first embodiment in that: the magnetic conductor 20 includes a magnetic conductive segment 21 and an insulating segment 22, wherein the magnetic conductive segment 21 is provided on one side or on two opposite sides of the insulating segment 22, wherein one side of the magnetic conductive segment 21 is connected to the slot wall of the open slot and the other side is connected to the insulating segment 22, thereby the insulating segment 22 cuts off the magnetic connection between the magnetic conductive segment 21 and the open slot.

[0077] It can be understood that in this embodiment, when the magnetic conductor 20 is concave-convexly fitted in the open slot of the stator core, the insulating segment 22 of the magnetic conductor 20 cuts off the magnetic connection between the magnetic segment 21 and the open slot, so that the stator core constitutes a semi-closed slot stator structure, thereby avoiding the formation of a closed circulation path in the open slot, which would lead to an increase in eddy current loss and effectively prevent the stator temperature from rising.

[0078] In this embodiment, the end plate 10 and the insulating segment 22 are made of the same material and are non-magnetic. Specifically, they can be integrally formed of a high-strength fiber-reinforced composite material. The magnetic conductive segment 21 can be used as an insert and integrally molded or injection-molded with the composite material. This process is simple and efficient, and the bonding strength between the magnetic conductive segment 21 and the end plate 10 is higher than that of traditional mechanical fastening or gluing methods, effectively reducing the risk of the magnetic conductive segment 21 falling off the end plate 10. Furthermore, the magnetic conductive segment 21 can be designed as a finished part, placed in a specific mold, and integrally molded or injection-molded with the end plate 10 material. This is low-cost and suitable for mass production.

[0079] Specifically, in some implementations of this embodiment, the magnetic conductive section 21 is made of soft magnetic materials laminated along the axial direction and has good magnetic conductivity, wherein the soft magnetic materials include but are not limited to silicon steel sheets, SMC (soft magnetic composite materials), etc.

[0080] In other implementations of this embodiment, to account for cost, the magnetic conductive segment 21 can also be composed of resin, magnetic material, and glass fiber cloth. Multiple layers of glass fiber cloth are stacked, with the magnetic material evenly dispersed between each layer, and then filled and shaped with resin. The magnetic material can be iron powder. The ratio of the three components, resin, iron powder, and glass fiber cloth, determines its magnetic conductivity and mechanical properties. The ratio is determined based on specific usage requirements, such as an iron powder content of 60% to 80%, a resin content of 15% to 30%, and a glass fiber content of 5% to 15%.

[0081] As shown in FIG6 , in some implementations of this embodiment, there are two end plates 10, and a plurality of magnetizers 20 are provided on the end surfaces of the two end plates 10. The stator core includes a plurality of independently arranged stator teeth 30, and is a yokeless stator structure. An axially extending open slot is formed between two adjacent stator teeth 30. The magnetizers 20 on the two end plates 10 are respectively embedded in the axial ends of the open slot, and the coils 51 on the stator teeth 30 are located between the two axially arranged magnetizers 20. It can be seen that in this embodiment, the stator core is formed by splicing a plurality of stator teeth 30 in combination with the magnetizers 20. The magnetizers 20 can serve as pole shoes to mitigate the degree of drastic changes in the magnetic field at various circumferential positions of the air gap, thereby reducing the AC copper loss of the flat wire of the coil 51, and improving the ability to generate torque per unit current under small and medium load conditions, thereby improving efficiency, and reducing the amplitude of low-order electromagnetic force waves inside the motor, thereby improving its NVH characteristics.

[0082] Secondly, the coil on each stator tooth 30 can be wound individually, solving the common problem of winding the stator core coil of the semi-closed slot disc motor. The coil on a single core unit can be wound mechanically and automatically, improving the winding production efficiency and greatly increasing the slot fill rate, thereby improving the power density of the motor.

[0083] Specifically, in this embodiment, the coils 51 on each of the stator teeth 30 are connected by a bridge line 52 to form a three-phase coil, so three wire outlet holes 53 are provided on one of the end plates 10 to correspond to the lead-out of the U, V, and W phase terminals 54 in the coil 51 assembly. Of course, in other embodiments, the coil 51 can also be two-phase or six-phase. This embodiment is only an example and not a limitation.

[0084] As shown in Figures 7 and 8, in some implementations of this embodiment, each magnetizer 20 is composed of an insulating segment 22 and a magnetic conductive segment 21, the magnetic conductive segment 21 is arranged on one side of the insulating segment 22, the side of the insulating segment 22 facing away from the magnetic conductive segment 21 is connected to the slot wall on one side of the open slot, and the side of the magnetic conductive segment 21 facing away from the insulating segment 22 is connected to the slot wall on the other side opposite to the open slot, and the connecting line between the insulating segment 22 and the magnetic conductive segment 21 is axially collinear with the center line of the open slot, thereby forming an asymmetric semi-closed slot stator structure, wherein the insulating segment 22 not only serves as an insulator, but also serves as a reinforcing rib to improve the structural strength of the end plate 10.

[0085] As shown in Figures 9 and 10, in some other implementations of this embodiment, each magnetic conductor 20 may also be composed of an insulating segment 22 and two magnetic conductive segments 21. The magnetic conductive segments 21 are arranged on opposite sides of the insulating segment 22, and the sides of the two magnetic conductive segments 21 facing away from the insulating segment 22 are respectively connected to the opposite side slot walls of the open slot. The insulating segment 22 is connected between the two magnetic conductive segments 21, and the insulating segment 22 is aligned with the central axis of the open slot, thereby forming a symmetrical semi-closed slot stator structure. Similarly, the insulating segment 22 not only plays an insulating role, but also serves as a reinforcing rib to improve the structural strength of the end plate 10.

[0086] In addition, it should be noted that since the open slot between two adjacent stator teeth 30 extends along the radial direction of the stator tooth 30 and has a certain length, the magnetic conductive segment 21 and the insulating segment 22 in this embodiment are both long strips. When the stator tooth 30 is fixed on the slot 41 of the end plate 10, the insulating segment 22 and the magnetic conductive segment 21 are located in the open slot and extend along the radial direction of the stator tooth 30. Specifically, the magnetic conductive segment 21 and the insulating segment 22 have the same thickness, and the dimensions of the two along the radial direction of the end plate 10 are equal. When the stator tooth 30 is fixed in the slot 41 of the end plate 10, the end face of the magnetic conductive segment 21 is flush with the tooth end face of the stator tooth 30, which can ensure partial closure of the magnetic circuit and effectively guide the magnetic flux to flow through the stator tooth 30.

[0087] Fourth embodiment

[0088] The fourth embodiment of the present invention further provides an axial magnetic field motor, comprising the stator assembly described in the above technical solution.

[0089] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0090] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. A stator assembly, comprising a housing, the housing comprising two oppositely disposed end plates, and a stator core disposed between the two end plates, characterized in that: A plurality of magnetic conductors are arranged on the end surface of at least one of the end plates, and at least a portion of the magnetic conductors fits in the open slots of the stator core.

2. The stator assembly according to claim 1, characterized in that: The magnetic conductor is magnetically connected to the open slot of the stator core.

3. The stator assembly according to claim 2, characterized in that: The end plate is made of high-strength fiber composite material, and the magnetic conductor is formed on the end plate by injection molding or integral compression molding.

4. The stator assembly according to claim 3, characterized in that: The magnetic conductor includes a plurality of fiber cloths stacked in layers and a magnetic material arranged between two adjacent fiber cloths.

5. The stator assembly according to claim 1, characterized in that: A plurality of the magnetic conductors are provided on the end faces of the two end plates, the stator core comprises a plurality of independently arranged stator teeth, an axially penetrating open slot is formed between two adjacent stator teeth, and the magnetic conductors on the two end plates are respectively embedded in the axial ends of the open slot.

6. The stator assembly according to claim 5, characterized in that: The magnetic conductor is in a strip shape, and the length of the magnetic conductor is greater than or equal to the radial length of the stator teeth.

7. The stator assembly according to claim 5, characterized in that: The end plate is recessed with an annular groove, the magnetic conductor is integrally formed in the annular groove and arranged in an annular array, so that the annular groove is divided into a plurality of slots, and one axial end of the stator tooth is fixed in the slot.

8. The stator assembly according to claim 7, characterized in that: The outer edge of the annular groove is provided with a plurality of first limit blocks at intervals, and the inner edge of the annular groove is provided with a plurality of second limit blocks corresponding to the first limit blocks, and the first limit blocks and the second limit blocks are both embedded between two adjacent magnetic conductors.

9. The stator assembly according to claim 8, characterized in that: The thickness of the magnetic conductor is lower than the depth of the annular groove, and the end surface of the magnetic conductor is flush with the end surfaces of the first limiting block and the second limiting block.

10. The stator assembly according to claim 1, characterized in that: A plurality of the magnetizers are provided on the end face of only one of the end plates, the stator core is a yoke stator structure, the iron yoke portion of the yoke stator structure is installed on the end plate where there is no magnetizer, and the open slot portion of the yoke stator structure cooperates with the magnetizer on the other end plate.

11. The stator assembly according to claim 1, characterized in that: The magnetic conductor includes a magnetic conductive section and an insulating section, wherein the magnetic conductive section is arranged on one side or two opposite sides of the insulating section, wherein one side of the magnetic conductive section is connected to the slot wall of the open slot and the other side is connected to the insulating section, so that the insulating section cuts off the magnetic connection between the magnetic conductive section and the open slot.

12. The stator assembly according to claim 11, characterized in that: The end plate and the insulating section are made of high-strength fiber composite material in one piece, and the magnetic conductive section is formed on the end plate by injection molding or integral compression molding.

13. The stator assembly according to claim 12, characterized in that: The magnetic conductive section is formed by axially stacking silicon steel sheets or soft magnetic composite materials.

14. The stator assembly according to claim 11, characterized in that: The magnetic conductive section and the insulating section have the same thickness, and the sizes of the two sections in the radial direction of the end plate are equal.

15. The stator assembly according to claim 11, characterized in that: The magnetic conductive section is arranged on one side of the insulating section, the side of the insulating section facing away from the magnetic conductive section is connected to one side slot wall of the open slot, and the side of the magnetic conductive section facing away from the insulating section is connected to the other side slot wall opposite to the open slot.

16. The stator assembly according to claim 11, characterized in that: The magnetic conductive sections are arranged on opposite sides of the insulating section, and the sides of the two magnetic conductive sections facing away from the insulating section are respectively connected to the opposite side slot walls of the open slot, and the insulating section is connected between the two magnetic conductive sections.

Images